Machine Guarding Training | Machine Safety Training Programs

On-Site Training Overview

In this live, in-person training option, our experts at Machine Safety Specialists (MSS) will properly train your staff on machine safety, conveniently on-location at your site. We offer single or multiple-day classes, as well as workshops and technical breakout sessions. You can customize class size, the content covered based on your team’s skill level, and when and where the training is held. This type of training is typically held at your facility, at a training location of your choosing – even on the plant floor to workshop a particular machine. Our consultants include practical, real examples and illustrations from more than 30 years’ experience inspecting, consulting, and conducting accident investigations in more than 500 plants across the U.S., Canada, Mexico, and Japan.

Learning Objectives

In this training, safety professionals, technical personnel, engineers and managers will develop an understanding of the latest OSHA, ANSI, NFPA, RIA (industrial and collaborative robots) and ISO/EN requirements for industrial machine safety and risk assessment. Upon completion of this training, participants will be able to:

Identify machine-related workplace hazards
Understand applicable U.S. machine safeguarding requirements
Inspect and recommend compliant machine safeguarding
Complete an OSHA/ANSI compliant risk assessment
Understand advanced concepts, such as:
- Control reliability and functional safety
- Alternatives to Lock-out/Tag-out (LOTO – Hazardous Energy Controls)
- Industrial and collaborative robots
- Risk assessment and risk reduction strategies
- Liability and legal concerns

Syllabus Options

Our TÜV certified senior safety engineers can cover a range of advanced machine safeguarding, safety standards, and risk assessment topics, and are able to customize the class syllabus based on your needs. Choose from three core sessions, with the potential to add on a variety of technical breakout sessions. See details on these options, below.

Session 1: Machine Safety Training

✓

Number of Participants: Unlimited (ideal: up to 40 participants, but we collaborate with clients to find the best fit)
Program Length: 4 hours
Client Requirements
- Classroom facility with projector or large monitor
- Lunch and drinks for participants and instructors
MSS Deliverables
- A softcopy training manual is provided for each student (hardcopies available for purchase). This training manual includes the training presentation.
- Optional: One (1) MSS Universal Safety Scale (“Gotcha-Stick”)
Topics Covered:
- Why improve machine safety? (Injury prevention, compliance, the law)
- OSHA basics of machine guarding (abbreviated)
- Hierarchy of controls with examples
- Hazard recognition: Basics, Intermediate, Advanced (embedded in training)
- Functional Safety (Introduction to Control Reliability, Category 3 circuits, and guard interlocks)
- OSHA 1910.147 – OSHA requirements for Alternative Protective Methods and the Minor Servicing Exception to LOTO / ANSI Z244.1
- Safety distances

Session 2: Machine Safety Training

✓

Number of Participants: Unlimited (ideal: up to 40 participants, but we collaborate with clients to find the best fit)
Program Length: 4 hours
Client Requirements:
- Classroom facility with projector or large monitor
- Lunch and drinks for participants and instructors
MSS Deliverables
- A softcopy training manual is provided for each student (hardcopies available for purchase). This training manual includes the training presentation.
- Optional: One (1) MSS Universal Safety Scale (“Gotcha-Stick”)
Topics Covered:
- ANSI B11.19 – Modern machine safeguarding requirements
- NFPA 79 – Stopping Functions / Emergency Stop Requirements
- Comparison of U.S. and ISO/EU machine safety standards (abbreviated)
  - CE marking
- Introduction to Industrial and Collaborative Robot Safety: OSHA / RIA 15.06 / RIA 15.606
- ANSI B11.0 – Risk Assessment
  - Quantifying the risk
- How to perform a Risk Assessment
  - Why do a risk assessment?
  - Risk Assessment System
  - Risk Factors: Severity, Exposure, Probability
  - Risk Assessment spreadsheet tool overview

Session 3: Hands-on Risk Assessment Workshop

✓

Number of Participants: Unlimited (ideal: up to 40 participants, but we collaborate with clients to find the best fit)
Program Length: 4 hours
Client Requirements:
- Prerequisite training: Sessions 1 and 2 are required prior to this session
- Classroom facility with projector or large monitor
- Lunch and drinks for participants and instructors

MSS Deliverables
- A softcopy training manual is provided for each student (hardcopies available for purchase). This training manual includes the training presentation.
- Optional: One (1) MSS Universal Safety Scale (“Gotcha-Stick”)
- Risk Assessment document (spreadsheet) in compliance with ANSI/RIA TR 15.306
Summary:
- The purpose of the Team Based Risk Assessment (RA) is to identify the remediation (safeguarding) required to reduce the risk within tolerable levels and comply with all applicable safety regulations. In a RA, a multi-disciplined team identifies tasks and risks of the machine. The risk is scored (with and without safeguarding) and a safeguarding plan is developed. This RA document is then accepted by the team and forms the basis of the remediation (safeguarding) plan. For complex machinery, a team-based risk assessment is an essential process that is required to develop practical, detailed risk reduction measures.
Topics Covered:
- Risk Assessment Workshop – select a machine in the client’s facility and perform a risk assessment, to the extent feasible within the time allowed.
- MSS to guide discussion and update the Risk Assessment Spreadsheet during this conference. Client to include in the meeting, as a minimum, the following authorized personnel: Operator, Maintenance, Engineering, and EHS.
- Guidance of the Risk Assessment workgroup for a machine/process as needed to:
  - Identify hazards
  - Review drawings and technical details
  - Score in terms of severity, probability, and frequency
  - Guidance in use of spreadsheet tool
  - Checking, correcting, approval
  - Facilitate team discussions and team engagement
- Example safety devices from various manufacturers are displayed on a table in the classroom. As training progresses, these product examples are passed around the class for students to see/handle.

Technical Breakout Sessions

✓

Number of Participants: Unlimited (ideal: up to 40 participants, but we collaborate with clients to find the best fit)
Program Length: Each technical breakout session topic is planned for 1-hour (45 minutes of instruction and 15 minutes of Q&A)
Client Requirements:
- Prerequisite training: Sessions 1 and 2 are required prior to technical breakout sessions
- Classroom facility with projector or large monitor
- Lunch and drinks for participants and instructors
Available technical breakout session topics include:
- Industrial robot safety: Includes an overview of industrial robot safety requirements in accordance with ANSI/RIA 15.06 (ISO 10218) and ANSI/RIA TR 15.306. This presentation goes into more detail than the general safety training course.
- Collaborative robot safety: Includes an overview of collaborative robot safety requirements in accordance with RIA TR R15.606 (ISO/TS 15066). This presentation goes into more detail than the general safety training course.
- Stop-time measurement classroom training: Includes classroom training covering ANSI B11.19 requirements for stop-time measurement. Includes example case study (presentation). Includes live demonstration of a stop-time meter in the classroom.
- Stop-time measurement hands-on exercise: Includes stop-time measurements on one (1) machine in your facility which interactive participation from students. For machines with “wearable” braking mechanisms (such as friction brakes), a stop-time measurement should be performed on an annual basis in order to ensure that the machine’s stop-time has not changed.
- Safety Requirements for Bypassing (Suspending) Guards: This session provides advanced training showing U.S. and ISO requirements for operating powered industrial machinery with exposure to hazards with guards removed or bypassed. Includes detailed instruction and discussion on required engineering controls and administrative measures.
- Advanced functional safety and control reliability: Overview of ANSI B11.26 for technical personnel including engineers, technicians, and senior maintenance personnel. Includes recommendations and requirements for functional safety systems including fluid power safety systems (hydraulics and pneumatics). Typical safety system designs are reviewed and discussed including schematic diagrams for safety control systems, hydraulic systems and pneumatic (air) systems.
- Roller and Conveyor Guarding: This session covers OSHA and ANSI safeguarding recommendations for conveyors and machines with roller hazards. Includes a summary of requirements from OSHA, ANSI and ASME safety standards as they pertain to safeguarding of rotational hazards, conveyors and in running nip hazards. Includes discussion on best practices for safeguarding conveyors and rollers.
- Safe Entry Requirements for Manufacturing Cells: Complex manufacturing systems (such as industrial robot cells) expose employees to high-risk machinery hazards during cell entry if risk reduction methods are inadequate. This technical training session covers a four (4) step safety design process needed to properly apply engineering controls to manufacturing systems with perimeter guarding. This class presents up-to-date guarding and functional safety requirements in consideration of hazardous energy control requirements (LOTO) and OSHA’s minor servicing exception.
- Custom Training Session: This custom session is planned for up to two (2) hours (includes up to 30 minutes of Q&A and discussion). Includes preparation of training material and safety engineering review and approval of content prior to presentation.

Machine Guarding Training | Machine Safety Training Programs | MSS

On-site Training

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