Safe Materials Handling and

Machine Safety
Joe Nail

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Industrial Safety Lecture Four 11/07/21
Introduction
 Handling Materials Safely

 50 tons per one ton shipped.

 Some is moved by machine and some by hand.
 When handling material, technique is everything.

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Industrial Safety Lecture Four 11/07/21
Causes of Injuries
 25% of all injuries are related to material
handling.
 80% are to the lower back.
 Incorrect lifting causes most injuries.
 Incorrect use of equipment.

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Industrial Safety Lecture Four 11/07/21
Carelessness
 Be aware of your environment.

Hey Charlie! Did you see that

game last night?

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Industrial Safety Lecture Four 11/07/21
Avoiding Workplace Injuries

 Stay in shape.

 Consider where you will walk.

 Don’t use your body if you don’t have to.

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Industrial Safety Lecture Four 11/07/21
Rules for Lifting
 Get close to the load.
 Keep feet apart.
 Keep back straight.
 Bend your knees.
 Tuck your chin.

 Grip the load with your palms.

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Industrial Safety Lecture Four 11/07/21
Hazards Associated with
Materials Handling
 Check your environment for sufficient
moving room
 Check for projecting objects, wear gloves.
 Are materials secure?
 Are chemicals to be moved?

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Industrial Safety Lecture Four 11/07/21
 Teamwork and Handling
Various Shapes and Sizes
 If an object seems to heavy to lift, it
probably is.
 When working with others,
communication is critical.
 Your back should be kept straight when
you carry objects.
 Special lifting tools should be sought out
and used for large objects.
 Protect yourself when handling things.

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Industrial Safety Lecture Four 11/07/21
Examples of Lifting Equipment

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 Hand Tools and Accessories

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Industrial Safety Lecture Four 11/07/21
 Power Operated Hand Trucks

 Examples of a “walkie” and a “rider” type

powered hand trucks
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Industrial Safety Lecture Four 11/07/21
Powered Industrial trucks
 Trucks are usually classified by power
source.
 Electric Motors
 Internal Combustion Engine
– Gasoline
– Diesel
– LP Liquefied Petroleum

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Industrial Safety Lecture Four 11/07/21
Standard Powered Industrial
Lift Truck

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Straddle Truck

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Order Picker Truck

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Industrial Truck Safety
Popular Misconceptions
 “Anyone can drive a lift truck.”
 “They handle just like a car.”
 “They are easier to drive than a car.”
 “You don’t need any training to safely
drive a fork lift.”

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Industrial Safety Lecture Four 11/07/21
Industrial Truck Safety
Facts
 The center of gravity of a lift truck
changes.
 Most trucks are “rear steer.”
 Most trucks have no suspension system.
 It is NOT safe to alter the lift truck’s
counterweight!

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Industrial Safety Lecture Four 11/07/21
Industrial Truck Safety

 What does OHSA say about powered

industrial truck training?
 OSHA regulations state that “only
trained and authorized operators shall
be permitted to operate a powered
industrial truck.”
 But why?

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Industrial Safety Lecture Four 11/07/21
 Training helps to Prevent Accidents!

Get the picture?

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Industrial Safety Lecture Four 11/07/21
  Data plate.
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Industrial Safety Lecture Four 11/07/21
Powered Industrial Trucks -
Operator Training

1910.178 (l)
1915.120 (a)
1917.1 (a)(2)(xiv)
1918.1 (b)(10)
1926.602 (d)
Disclaimer
 This presentation is intended as a resource for
providing training on OSHA’s revised powered
industrial truck operator standards. It is not a
substitute for any of the provisions of the
Occupational Safety and Health Act of 1970, or
for any standards issued by the U.S.
Department of Labor’s Occupational Safety
and Health Administration (OSHA). It is also
not a substitute for a powered industrial
truck operator training program.

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Acknowledgment
 OSHA’s Office of Training and Education wishes to
acknowledge the following for contributing some of the
graphics used in this presentation:
– Caterpillar Lift Trucks
– Mason Contractors Association of America
– Industrial Truck Association
– State of Utah Labor Commission - Occupational Safety &
Health Division
– Steamship Trade Association of Baltimore
– Taylor Machine Works, Inc.
– UAW - Ford National Joint Committee on Health and Safety
 Appearance of products does not imply endorsement by
the U.S. Department of Labor.

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Powered Industrial
Truck - Definition
 A mobile, power-propelled truck used to carry,
push, pull, lift, stack or tier materials. [American
Society of Mechanical Engineers (ASME)
definition]
 Excluded are vehicles used for earth moving and
over-the-road hauling.
 Commonly known as forklifts, pallet trucks, rider
trucks, forktrucks, or lifttrucks.
 Can be powered through electric or combustion
engines.
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Scope of Standard
 The scope provisions of 1910.178(a), which are based
on ANSI B56.1 - 1969, remain in effect and cover:
– ... fork trucks, tractors, platform lift trucks,
motorized hand trucks, and other specialized
industrial trucks powered by electric motors or
internal combustion engines.
– It does not apply to compressed air or nonflammable
compressed gas-operated industrial trucks, farm
vehicles, nor vehicles intended primarily for earth
moving or over-the-road hauling.
 This scope covers general industry, construction and
shipyards.

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Scope of Standard (continued)
 For marine terminal and longshoring
industries, all powered industrial trucks are
covered, no matter what specialized name
they are given.
 This includes, but is not limited to, straddle
carriers, hustlers, toploaders, container
reach stackers, and other vehicles that
carry, push, pull, lift, or tier loads.

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Reasons for New Standard
 Powered industrial truck accidents cause
approximately 100 fatalities and 36,340
serious injuries in general industry and
construction annually.
 It is estimated that 20 - 25% of the
accidents are, at least in part, caused by
inadequate training.

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Additional Reasons for New
Standard
 Updated consensus standards have been
published.
 OSHA has been petitioned to improve the
requirements for industrial truck training.
 Advisory Committee on Construction Safety and
Health has recommended improving the standard.
 Resolutions have been introduced in the Senate
and House urging OSHA to revise its outdated
standard.

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 Forklift Fatalities, 1992-1996
120 114

95
86 89

1992 1993 1994 1995 1996

Source: Bureau of Labor Statistics, Job Related Fatalities Involving Forklifts

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Forklift Fatalities by Age Group
1992 -1996
12%
5% Under 20
21% 3%
20 - 24
25 - 34
10% 35 - 44
45 - 54
56 - 64
65 & over

22%
27%

Source: Bureau of Labor Statistics

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Industries Where Powered Industrial
Truck Accidents Occurred

Source: OSHA Fatality/Catastrophe Reports, complied by OSHA Office of Electrical/Electronic and

Mechanical Engineering Safety Standards. 31
Nonfatal Occupational Injuries and
Illnesses by Source, 1996

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Source: Bureau of Labor Statistics, Job Related Fatalities by Selected Characteristics, 1996.
Background

 The previous OSHA standards, while

requiring operator training, did not define
the type of training or authorization
required.
 March 15, 1988 - Industrial Truck
Association (ITA) petitioned OSHA for
specific training requirements.

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Background (continued)
 American National Standards Institute
(ANSI), in cooperation with ASME, has
revised its standard 4 times, including
current lifttruck technology and specific
training topics.

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Background (continued)
 OSHA published a proposed ruling on March 14,
1995 for General Industry, Shipyard, Marine
Terminals, and Longshoring regulations, adding
specific training requirements.
 On January 30, 1996, OSHA proposed a revision
of the construction standards, mandating the
development of an operator training program
based on the prior knowledge and skills of the
trainee and requiring a periodic evaluation.

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Final Rule
 OSHA published the final rule for Powered
Industrial Truck Operator Training on
December 1, 1998.
 The effective date is March 1, 1999. Start-up
dates are included in paragraph (l)(7).
 It applies to all industries except agricultural
operations.
 OSHA estimates that the new rule will prevent
11 deaths and 9,422 injuries per year.

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Fatalities/Injuries Potentially Averted
Annually by New Standard

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Source: U.S. Department of Labor, OSHA, Office of Regulatory Analysis, 1997
Performance-Oriented
Requirements
 The powered industrial truck operator
training requirements are performance-
oriented to permit employers to tailor a
training program to the characteristics of
their workplaces and the particular types
of powered industrial trucks operated.

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Revised Operator Training
Requirements
 General Industry: 1910.178 is amended by revising
paragraph (l) and adding Appendix A.
 Shipyard Employment: New section 1915.120 and
Appendix A are added.
 Marine Terminals: Section 1917.1 is amended by
adding new paragraph (a)(2)(xiv) and Appendix A.
 Longshoring: Section 1918.1 is amended by adding
new paragraph (b)(10) and Appendix A.
 Construction: 1926.602 is amended by adding new
paragraph (d) and Appendix A.

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 Operator Training
 Safe operations
– The employer shall ensure that each powered industrial
truck operator is competent to operate a powered
industrial truck safely, as demonstrated by successful
completion of the training and evaluation specified in
the OSHA standard.
– Prior to permitting an employee to operate a powered
industrial truck (except for training purposes), the
employer shall ensure that each operator has
successfully completed the required training (or
previously received appropriate training).

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Training Program
Implementation
 Trainees may operate a powered industrial
truck only:
– Under direct supervision of a person who
has the knowledge, training, and
experience to train operators and evaluate
their competence; and,
– Where such operation does not endanger
the trainee or other employees.

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Training Program Implementation
(continued)
 Training shall consist of a combination of:
 Formal instruction (e.g., lecture, discussion,
interactive computer learning, written material),
 Practical training (demonstrations and exercises
performed by the trainee), and
 Evaluation of the operator’s performance in the
workplace

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Training Program
Implementation (continued)
 Training and
evaluation shall be
conducted by a person
with the knowledge,
training and
experience to train
powered industrial
truck operators and
evaluate their
competence.

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Training Program Content
 Operators shall receive initial training in
the following topics, except in topics
which the employer can demonstrate are
not applicable to safe operation in the
employer’s workplace.
– Truck-related topics
– Workplace-related topics
– The requirements of the standard

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 Training Program Content
(continued)
 Truck-related topics
– Operating instructions,
warnings and precautions
– Differences from
automobile
– Controls and
instrumentation
– Engine or motor operation
– Steering and maneuvering
– Visibility
– Fork and attachment
adaptation, operation, use
– Vehicle capacity and stability
– Vehicle inspection and
maintenance that the operator
will be required to perform
– Refueling/Charging/
Recharging batteries
– Operating limitations
– Other instructions, etc.
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Training Program Content
(continued)
 Workplace-related topics
– Surface conditions
– Composition and stability
of loads
– Load manipulation,
stacking, unstacking
– Pedestrian traffic
– Narrow aisles and
restricted areas
– Operating in hazardous
(classified) locations
– Operating on ramps and
sloped surfaces
– Potentially hazardous
environmental conditions
– Operating in closed
environments or other areas
where poor ventilation or
maintenance could cause
carbon monoxide or diesel
exhaust buildup
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Training Program Content
(continued)
 The requirements of the OSHA standard
on powered industrial trucks must also be
included in the initial operator training
program.

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Refresher Training and
Evaluation
 Refresher training, including an evaluation of the
effectiveness of that training, shall be conducted to
ensure that the operator has the knowledge and skills
needed to operate the powered industrial truck safely.
 Refresher training required when:
– Unsafe operation
– Accident or near-miss
– Evaluation indicates need
– Different type of equipment introduced
– Workplace condition changes

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Refresher Training and
Evaluation (continued)
 An evaluation of each powered industrial
truck operator’s performance must be
conducted:
– After initial training,
– After refresher training, and
– At least once every three years

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Avoidance of Duplicative
Training
 If an operator has previously received
training in a topic specified in this section,
and the training is appropriate to the truck
and working conditions encountered,
additional training in that topic is not
required if the operator has been evaluated
and found competent to operate the truck
safely.

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Certification

 The employer shall certify that each

operator has been trained and evaluated as
required by the standard.
 Certification shall include:
– Name of operator
– Date of training
– Date of evaluation
– Identity of person(s) performing the training
or evaluation

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Dates
 The employer shall ensure that operators of
powered industrial trucks are trained, as
appropriate, by the dates shown in the following
table.
If the employee was The initial training
hired: and evaluation of
that employee must
be completed:
Before December 1, By December 1, 1999
1999
Before the employee is
After December 1, 1999 assigned to operate a
powered industrial truck.

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Appendix A - Stability of Powered
Industrial Trucks
 Appendix A provides non-mandatory
guidance to assist employers in
implementing the standard.
 This appendix does not add to, alter, or
reduce the requirements of this section.

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Appendix A - Stability of Powered
Industrial Trucks
 Definitions
 General
 Basic Principles
 Stability Triangle
 Longitudinal
Stability
 Lateral Stability
 Dynamic Stability

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 Stability Triangle - Figure 1
Vehicle Center of
B Gravity (Unloaded)

C Center of Gravity
of Vehicle and
Maximum Load
(Theoretical)
Notes:
1. When the vehicle is loaded, the combined center of gravity (CG) shifts toward line B-C.
Theoretically the maximum load will result in the CG at the line B-C. In actual practice, the
combined CG should never be at line B-C.
2. The addition of additional counterweight will cause the truck CG to shift toward point A and
result in a truck that is less stable laterally. 55
Stability Triangle - Figure 2

Load CG
Load CG
Vertical
Stability
Line
Combined CG
(Line of Action)

Combined CG
Vertical
Truck CG Stability
Truck CG Line
(Line of Action)

The vehicle is stable This vehicle is unstable and

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will continue to tip over
Effective Powered Industrial
Truck Operator Training Program
 Four major areas of concern must be
addressed:
– The general hazards that apply to the operation of
all or most powered industrial trucks;
– The hazards associated with the operation of
particular types of trucks;
– The hazards of workplaces generally; and,
– The hazards of the particular workplace where the
vehicle operates.
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Types of Powered Industrial
Trucks
 There are many different types of powered industrial
trucks covered by the OSHA standard.
 Commonly used types include:
– High lift trucks, counterbalanced trucks, cantilever trucks, rider
trucks, forklift trucks, high lift trucks, high lift platform trucks,
low lift trucks, motorized hand trucks, pallet trucks, straddle
trucks, reach rider trucks, high lift order picker trucks, motorized
hand/rider trucks, and counterbalanced front/side loader lift
trucks.
 A single type of truck can only be described by calling
it by all of its characteristics, (e.g., a high lift,
counterbalanced, sit down rider truck).

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Unique Characteristics of
Powered Industrial Trucks
 Each type of powered industrial truck has
its own unique characteristics and some
inherent hazards.
 To be effective, training must address the
unique characteristics of the type of
vehicle the employee is being trained to
operate.

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Components of a Forklift Truck*

*One of the most common types of powered industrial

60 trucks
 Classes of Commonly-Used
Powered Industrial Trucks*
 The Industrial Truck Association has placed powered
industrial trucks into 7 classes.
– Class I - Electric motor rider trucks
– Class II - Electric motor narrow aisle trucks
– Class III - Electric motor hand trucks or hand/rider trucks
– Class IV - Internal combustion engine trucks
(solid/cushion tires)
– Class V - Internal combustion engine trucks (pneumatic
tires)
– Class VI - Electric and internal combustion engine tractors
– Class VII - Rough terrain forklift trucks

* Note that this classification refers to commonly-used vehicles and does

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not include all powered industrial trucks covered by the OSHA standard.
Class I - Electric Motor Rider
Trucks
 Counterbalanced rider type, stand up
 Three wheel electric trucks, sit-down
 Counterbalanced rider type, cushion tires,
sit-down (high and low platform)
 Counterbalanced rider, pneumatic tire, sit-
down (high and low platform)

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Class I - Electric Motor Rider
Trucks

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Class I - Electric Motor Rider
Trucks
 Counterbalanced
Rider Type, Stand-
Up

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Class II - Electric Motor Narrow
Aisle Trucks
 High lift straddle
 Order picker
 Reach type outrigger
 Side loaders, turret trucks, swing mast and
convertible turret/stock pickers
 Low lift pallet and platform (rider)

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Class II - Electric Motor Narrow Aisle
Trucks

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Class II - Narrow Aisle Trucks

67
Class III - Electric Motor Hand or
Hand/Rider Trucks
 Low lift platform
 Low lift walkie pallet
 Reach type outrigger
 High lift straddle
 High lift counterbalanced
 Low lift walkie/rider pallet

68
Class III - Electric Motor Hand
or Hand/Rider Trucks

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Class III - Hand & Hand/Rider
Trucks

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Class IV - Internal Combustion
Engine Trucks - Cushion (Solid)
Tires

Fork, counterbalanced (cushion/solid tires)

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Class IV - Internal Combustion
Engine Trucks - Cushion (Solid)
Tires

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Class V - Internal Combustion
Engine Trucks - Pneumatic Tires

Fork, counterbalanced (pneumatic tires)73

Class V - Internal Combustion
Engine Trucks (Pneumatic Tires)

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Class VI - Electric & Internal
Combustion Engine Tractors

Sit-down rider

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Class VII - Rough Terrain Forklift
Trucks
– Straight-mast forklift – Extended-reach forklift

All rough terrain forklift trucks

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Rough Terrain Straight Mast
Forklifts

77
Rough Terrain Extended-Reach
Forklifts

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Some Types of Powered Industrial
Trucks Used in Maritime
 The following types of vehicles are
covered by the OSHA standard if the
vehicles carry, push, pull, lift, or tier
loads.
– Container top – Sidehandlers
handlers – Combination vacuum
– Container reach lifts
stackers – Yard tractors
– Straddle carriers
– Semi-tractors/ Utility
vehicles 79
Powered Industrial Trucks Used
in Maritime

Container Handlers
80
Powered Industrial Trucks Used in
Maritime

Empty-Container Handler 81
Powered Industrial Trucks Used
in Maritime

Container Reach Stacker

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Powered Industrial Trucks Used
in Maritime

Straddle Carriers
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Powered Industrial Trucks Used
in Maritime

Yard Tractor 84
 Dock Safety

 Painting of area.
 Trailer brakes and securing.
 People in the area.
 Perform daily check of truck.

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Industrial Safety Lecture Four 11/07/21
 Dock Safety

Portable Docking Plate

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 Dock Safety

Dock Restraint Mechanism

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 Conveyors

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Conveyors
 Powered type is most dangerous.
 Most people get hurt while working on
them.
 Most injuries involve fingers, hands,
and arms.
 Accidents can be prevented if workers
are careful to turn off the power and
lock it out.
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Hoists and
Cranes

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Hoists and
Cranes

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Hoists and Cranes
 Hoists and Cranes should be inspected
before use, every time.
 When cranes fail, it usually happens
fast.
fast
 Tension on a sling is relative to total
weight be lifted and angle of sling.
 Never stand under a suspended load.

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Receiving and Storing
Materials

 Does this look safe to you?

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When Storing Materials
 Place large, heavy packages on the bottom
and lighter ones on top.
 Never place materials where they can be
tripped over or where someone could get hurt
attempting to retrieve them.
 When materials are moved to where you are
working, they should be secured so they can’t
fall on anyone.
 Never block a traffic path or prop materials
up against a wall where they might slide over
and cause an accident.
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Industrial Safety Lecture Four 11/07/21
Corrosive and Flammable
Liquids
 Understand what it is that you are about
to move.
 Examine the containers to make sure
they are sealed and properly labeled.
 Make sure you are wearing all required
PPE.

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 Safety Guards

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Safety Guards
 Are required to prevent accidents.
 Protect people, not the machine.
 Hazardous parts include point of
operation components, control
mechanisms, parts that transmit power,
and parts that retain stored energy

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Moving Parts
Make
Guards
Necessary

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Moving Parts
Make Guards
Necessary

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 Point of Operation Guard

 OSHA 29 CFR 1910.217

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 Fixed Guards

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Fixed Guards
 Prevent entry into the point of operation
 Do not move when the machine is in
operation.
 Example: Barrier Guard
 Example: Enclosure Guard

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Interlocking Guards
 Used when a fixed guard cannot be
used.
 Connected to machine controls or power
source.
 Can be mechanical, electrical, or
pneumatic.

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Industrial Safety Lecture Four 11/07/21
 Automatic Guards
 Push, pull, or sweep the operator’s
hands out of the danger zone.
 Example: Automatic Pull Backs

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Presence-sensing Guards

 No physical barrier.Create a sensing

area around the danger zone.
 May use magnetic fields, radio waves, or
light waves.
 Machinery must be able to stop
instantaneously.
instantaneously

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Industrial Safety Lecture Four 11/07/21
Power Transmission Guards
 Prevent pieces from flying out.
 Should be kept in place at all times while the
machine is running.
 Should only be removed for repair work.

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Other Safety Devices
 Machine controls.
 Feeding and extracting tools.
 Ejectors.

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OSHA Lock Out/Tag Out
Procedures 29 CFR 1910.147
 Locking out has to do with the removal or
prevention of hazardous energy.
 Tag out is a communication technique that
warns others of the machines repair work.

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Control of Hazardous Energy
29 CFR 1910.147
The standard covers the servicing and
maintenance of machines and equipment
in which the unexpected energization or
start up of the machines or equipment , or
release of stored energy could cause injury
to employees.

109
Provisions Of The Standard

Requires employers to establish

procedures for isolating machines or
equipment from their source of energy
and affixing appropriate locks or tags to
energy isolating devices

110
Employer Responsibilities
 Establish energy control program
 Establish energy control procedures for
machines and equipment
 Provide employee training
 Conduct periodic inspections of the energy
control program

111
Application Of The Standard
 An employee is required to remove or
bypass a guard or other safety device
 An employee is required to place any part
of their body in contact with the point of
operation of the operational machine or
piece of equipment
 An employee is required to place any part
of their body into a danger zone
associated with a machine operating cycle

112
Exceptions To The Standard
 Work on cord and plug connected
electric equipment controlled by
unplugging of the equipment - the plug
is under exclusive control of the
employee performing maintenance

113
Exceptions To The Standard
 Hot tap operations involving transmission
and distribution systems for substances
such as gas, steam, water, or petroleum
products

114
Minor Servicing Tasks
Employees performing minor tool changes
and adjustments that are routine, repetitive,
and integral to the use of the equipment
and that occur during normal operations
are not covered by the lockout/tagout
standard, provided the work is performed
using alternative measures that provide
effective protection.

115
Definitions
 Authorized employee: A person who locks
out or tags out machines or equipment in
order to perform servicing or maintenance
 Affected employee: A person whose job
requires him to operate or use a machine or
equipment on which servicing or
maintenance is being performed under
lockout or tagout

116
Definitions
 Energy isolating device: The
mechanism that prevents the
transmission or release of energy and to
which locks or tags are attached
 Includes manually operated circuit
breakers, disconnect switches, line
valves, blocks, and others

117
Definitions
 Lockout: The placement of a lockout
device on an energy isolating device to
ensure that the equipment being
controlled cannot be operated until the
lockout device is removed

118
Definitions
 Tagout: The placement of a tagout
device on an energy isolating device to
indicate the equipment being controlled
may not be operated until the tagout
device is removed

119
De-energizing Equipment
 Shut down the machine or equipment
 Isolate the machine or equipment from the
energy sources
 Apply the lockout or tagout device(s) to the
energy isolating device(s)
 Safely release all potentially hazardous
stored or residual energy
 Verify the isolation of the machine or
equipment prior to the start of servicing
work
120
Stored Energy
 If there is a possibility of
reaccumulation of stored energy to a
hazardous level, verification of
isolation shall be continued until the
possibility of such accumulation no
longer exists

121
Re-energizing Equipment
 Ensure that machine or equipment
components are operationally intact
 Ensure that all employees are safely
positioned or removed from equipment
 Ensure that lockout or tagout devices are
removed from each energy isolation
device by the employee who applied the
device

122
Lockout/Tagout Requirements
 If an energy isolating device is not
capable of being locked out, the
employer’s energy control program
shall utilize a tagout system

123
Lockout Requirements
 After January 1990, whenever
replacement, major repair, or
modification of a machine is performed,
or whenever new machines or
equipment are installed, they must be
designed to accept a lockout device

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Device Requirements
 Durable: Lockout and tagout devices must
withstand the environment to which they are
exposed for the maximum duration
 Standardized: Both lockout and tagout
devices must be standardized according to
either color, shape, or size
 Tagout devices must also be standardized
according to print and format

125
Device Requirements
 Substantial: Lockout and tagout
devices must be substantial enough to
minimize early or accidental removal
 Identifiable: Locks and tags must
clearly identify the employee who
applies them.

126
Tag Requirements
 Tags must also include a legend such
as:
– Do not start
– Do not open
– Do not close
– Do not energize
– Do not operate

127
Periodic Inspections
 The employer shall conduct a periodic
inspection of the energy control
procedure at least annually
 Shall be performed by an authorized
employee other than the person(s)
utilizing the energy control procedure
being inspected

128
Periodic Inspections
 Shall be conducted to correct any
deviations or inadequacies identified
 Where lockout is used, the inspection
shall include a review between the
inspector and each authorized
employee

129
Periodic Inspections
 Where tagout is used, the inspection
shall include a review between the
inspector and each authorized and
affected employees

130
Periodic Inspections
 The employer shall:
– Certify that the periodic inspections have been
performed
– Identify the machine or equipment on which
energy control procedures were used
 The employer shall also note:
– The date of the inspection
– The employees included in the inspection
– The person performing the inspection

131
Training and Communication
 Each authorized employee shall receive
training in:
– Recognition of applicable hazardous
energy sources
– Type and magnitude of the energy
available in the workplace
– Methods and means necessary for energy
isolation and control

132
 Training and Communication
 Each affected employee shall be instructed
in the purpose and use of the energy
control procedure
 All other employees shall be instructed
about the prohibition relating to attempts
to restart or reenergize machines or
equipment which are locked out or tagged
out

133
Training and Communication
 The employer shall certify that
employee training has been
accomplished and is being kept up to
date
 Certification shall contain employee
names and dates of training

134
Group Lockout or Tagout
 Primary responsibility is vested in an
authorized employee for a set number
of employees working under the
protection of a group lockout or tagout
device
 Each authorized employee shall affix a
personal lockout or tagout device to the
group lockout device

135
Outside Personnel
 Whenever outside servicing personnel are
engaged in activities covered by
lockout/tagout, the on-site employer and
the outside employer shall inform each
other of their respective lockout or tagout
procedures

136
Tagout Tags

137
Lockout Device

138
Group Lockout

139
Tagout Tag

140
Lockout Signage

141
Review
 1. What is the best way to avoid hurting yourself when moving material?
 2. What is most dangerous when wearing gloves around rotating equipment?
 3. Describe the best method for lifting.
 4. What is the best way to carry a small box or carton?
 5. What equipment can you use to move a barrel alone?
 6. Describe how to handle moving a loaded hand truck down a ramp.
 7. When is it permissible to ride on the platform of a moving truck?
 8. What must be checked before entering a trailer on a shipping dock?
 9. What is the best way to prevent accidents while working on conveyors?
 10. What does the angle of a lifting sling have to do with the stress placed on it?
 11. What is a pinch point?
 12. What is meant by the term “point of operation”?
 13. What word is used to mean a back and forth motion?
 14. What is the correct spacing for a grinder wheel from the work rest?
 15. What type of machine guard limits the operator’s access to the danger zone?
 16. Which type of machine guard prevents access to the danger zone altogether?
 17. What type of guard cannot be moved while the machine is running?
 18. What type of guard, when removed, prevents the machine from running?
 19. What type of guard physically pulls the operator out of the danger zone?
 20. How fast should a machine stop when it is equipped with a presence sensing
guard?

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Industrial Safety Lecture Four 11/07/21