1.

MAINTENANCE PROCEDURE
FOR SAFETY
OVERVIEW
maintenance is a high-risk activity because it often requires working alongside a running process and
in close contact with machinery. During normal production operations, automation typically diminishes
the likelihood of human error that can lead to accidents. However, in maintenance activities, contrary to
normal operation, direct contact between the maintenance crew or personnel and machine cannot be
reduced substantially, as maintenance is an activity where close contact with processes and machinery
is unavoidable.
Maintenance often involves unusual work, non-routine tasks, and it is often performed in exceptional
conditions, such as in confined spaces, as example. Maintenance operations typically include both
disassembly and reassembly, often involving complicated machinery. This can be associated with a
greater risk of human error, increasing the accident risk. Working under time pressure is also typical for
maintenance operations, especially when shutdowns or high-priority repairs are involved.

As a result, there is a high risk of accidents related to maintenance activities. Here are some of the most
common:
• Crushing by moving machinery or unexpected machine start-up
• Falls from heights or accidents involving falling objects
• Electrocution, electrical shocks or burns
• Confined spaces resulting in asphyxiation (suffocation)
• Explosions and fire.
In order to mitigate the risk to maintenance personnel, there are five basic rules
for safe maintenance.
1. Planning. Maintenance must start with proper planning. A risk assessment must be
carried out and workers should be involved in this process. Issues to be covered at the
planning stage are:
a) The scope of the task – what needs to be done, and how it will affect other workers and
activities in the workplace.
b) Risk assessment – potential hazards have to be identified (e.g., dangerous substances,
confined spaces, moving parts of machinery, chemical substances or dust in the air), and
measures need to be developed to eliminate or minimize the risks.
c) Permits to work and lock-out systems.
d) The time and resources that the activity will require.
e) Communication between maintenance and production staff, and all other parties
concerned.
f) Competence of the employees and adequate training.
Management must ensure that personnel or workers have the skills that they need to carry
out the necessary tasks, informed about safe work procedures, and know what to do when
a situation exceeds their competence.
2. Making the workplace safe.
The work area needs to be secured by preventing unauthorized access, by using barriers and signs,
for example. The area also needs to be kept clean and safe, with electrical and (or) presure power
locked-out, moving parts of machinery secured, temporary ventilation installed, and safe routes
established for workers to enter and exit the work area.
Warning cards should be attached to machinery, with the date and time of lock-out-tag-out, as well as
the name of the person authorized to remove the lock.
This way, the safety of the maintenance personnel performing the maintenance on the machine will not
be jeopardized by another personnel or worker inadvertently starting it up.
summarily:
• using barriers and/or tapes,
• placing warning signs in appropriate positions.
• informing any persons who may be affected.
• isolating power or pressure sources.
• obtaining official clearance (permit to work).
• cleaning work areas after spillage, leakage or contamination.
(absorbent substances, detergents and solvents, approved waste disposal
methods)
• All sources of hazardous energy locked & tagged

• Any stored hazardous energy released or blocked

• 1-Person, 1-Lock, 1-Key: Every person applies a lock & tag and
retains key

• Only LOTO Authorised Workers isolate & reinstate

• Equipment-specific LOTO instructions if:

• >1 source of hazardous energy OR
• Potential to store/accumulate hazardous energy
3. Use of appropriate equipment.
Personnel involved in maintenance tasks should have the appropriate tools and equipment.
They must also have appropriate personal protective equipment (PPE).

With respect to the equipment and tools to be used, it should be ensured that:
 The right tools and equipment for the job are available (together with instructions in using them, if required) and
they are in an appropriate good condition.

 Appropriate for the work environment (e.g., no sparking tools in flammable atmospheres), and they have an
ergonomic design. (All personal protective equipment must).

 Be appropriate for the risks involved, without the equipment itself leading to any increased risk i.e. correspond to
existing conditions at the workplace.

 Also take account of ergonomic (appropriately comfortable) requirements and the worker’s state of health.
4. Working as planned.
 Safe work procedures have to be communicated and understood by workers and
supervisors, and applied correctly. The work should be monitored so that the
agreed safe systems of work and jobsite rules are observed.

 Maintenance is often carried out under pressure – for example, when a fault has
brought the production process to a standstill. Safe procedures need to be followed
and not compromised, even when there is time pressure. Shortcuts could be very
costly if they lead to accidents, injuries damage to property or fatality.

Procedures need to be in place for unexpected events. Part of the safe system of
work should be to stop work when faced with an unforeseen problem or a problem
exceeding one’s own competence. It is very important to remember that exceeding
the scope of one’s own skills and competence may result in accidents.
5. Final check.
The maintenance process needs to end with checks to make sure that the task has been
completed, that the machine under maintenance is in a safe condition, and that all waste material
that has been generated during the maintenance process has been cleaned away. When all is
checked and declared safe, then the task can be signed off, and supervisors and other workers
can be notified.

This final step also involves completing a report, describing the work that has been performed and
including comments on any difficulties that have been encountered, together with
recommendations for improvement. Ideally, this should also be discussed at a staff meeting
where the workers involved in the process – as well as those working around them – can
comment on the maintenance activity and come up with suitable suggestions to improve the
process.

Safety first: Statistics shows that around 15% to 20%

(depending on the province) of all accidents and 10% to
15% of all fatal accidents are related to maintenance
operations. Maintenance workers, please be safe !
SAFETY TIPS-GENERAL PRECAUTIONS
 Your safety is your personal responsibility.
 Always follow the correct procedures.
 Never take shortcuts.
 Take responsibility and clean up if you made a mess.
 Clean and organize your workspace.
 Ensure a clear and easy route to emergency exits and equipment.
 Be alert and awake on the job.
 Be attentive at all times to your work surroundings.
 When in doubt, contact your supervisor or manager for instruction, guidance, or training.
 Never take risks when it comes to safety.
 Obey safety signs, stickers, and tags.
 Take short breaks when you keep up a repetitive motion for a long period of time, and sit,
stand, or walk with good posture.
 Report serious injuries immediately to a supervisor and get emergency assistance.
 Keep things in perspective. Hazards may be limitless, so focus on the most likely risks first.
SAFETY IS A TEAM EFFORT
 Educate everyone in the workplace about the safety requirements and consider posting a
list of workplace safety tips. A workplace safety training will help them reduce or eliminate
injuries and illnesses from occurring in the workplace.
 Always keep the communication lines open with your co-workers, employers, or
employees in order to promote and maintain a safe environment.
 Immediately notify others of any (new or old) hazards that you perceive.
 Be alert to hazards that could affect anyone— not just yourself; in this respect, maintain
a team mentality at all times.
 Report a hazardous condition immediately to your manager or supervisor.
 Be conscious as to what others are doing around you, and do your best to ensure you
don’t pose a hazard to them (and vice versa).
 If you’re an employer, invite and involve your employees in safety planning; obtain their
insight, give and take suggestions, and ensure that everyone is on the same page.
 GENERAL
AN UPLIFTING THOUGHT: LIFTING AND CLIMBING SAFELY
 Always use both hands when lifting a heavy or cumbersome object.
 Adopt a proper stance for lifting: put the strain on your legs, not your back (crouch at your feet, keep your back straight, and don’t bend at the waist).
 Test the weight before you lift something up completely; it might be too late if you realize a few seconds later that it’s too heavy or cumbersome for you. An easy way to do
this is to nudge it with your foot first.
 Consider a back brace if the work is heavy or you have a sensitive back.
 Move your feet, not your back, when you want to travel or turn while carrying a heavy load.
 Lift slowly and smoothly.
 Keep your burden close to your body; this means less strain on you.
 If your load is too heavy for you to handle alone, don’t be shy—ask for help!
 Ensure ladders are secure and steady before climbing aboard.
 Never climb on improvised ladders. Shelves and storage units are poor substitutes. Don’t be lazy, and find a proper solid ladder.
 Don’t let appearances fool you. Railings might appear solid and fixed, but they might be improperly secures; at least, test them first.
 Use safety harnesses if your job includes heights.
 Eliminate distractions when working on a roof, scaffold, or other elevated platform. More than ever, stay focused and alert!
 Keep an eye out on the floor to ensure it’s free of obstacles and spills. If it isn’t, get cleaning!

AN UPLIFTING THOUGHT: LIFTING AND CLIMBING SAFELY

 Always use both hands when lifting a heavy or cumbersome object.
 Adopt a proper stance for lifting: put the strain on your legs, not your back (crouch at your feet, keep your back straight, and don’t bend at the waist).
 Test the weight before you lift something up completely; it might be too late if you realize a few seconds later that it’s too heavy or cumbersome for you. An easy way to do
this is to nudge it with your foot first.
 Consider a back brace if the work is heavy or you have a sensitive back.
 Move your feet, not your back, when you want to travel or turn while carrying a heavy load.
 Lift slowly and smoothly.
 Keep your burden close to your body; this means less strain on you.
 If your load is too heavy for you to handle alone, don’t be shy—ask for help!
 Ensure ladders are secure and steady before climbing aboard.
 Never climb on improvised ladders. Shelves and storage units are poor substitutes. Don’t be lazy, and find a proper solid ladder.
 Don’t let appearances fool you. Railings might appear solid and fixed, but they might be improperly secures; at least, test them first.
 Use safety harnesses if your job includes heights.
 Eliminate distractions when working on a roof, scaffold, or other elevated platform. More than ever, stay focused and alert!
 Keep an eye out on the floor to ensure it’s free of obstacles and spills. If it isn’t, get cleaning!
GEARING UP FOR SAFETY
 Always wear appropriate clothing and shoes respective to your job.
 Fire extinguishers must be available and readily attainable.
 First aid kits must be available and readily attainable.
 Never remove or tamper with safety devices.
 Use a back brace if you’re lifting heavy objects or you’ve got a sensitive back.
 A hard hat will protect you if there’s a risk of falling objects
 Wear gloves if you’re handling sharp objects or toxic substances.
 Wear goggles if your work poses a hazard to your eyes.
 Wear safety harnesses if you’re working from an elevated location and there’s the risk of falling.
 Wear non-skid footgear:
• If your workspace involves slippery surfaces (kitchens, spas, pools, etc.)
• If you’re lifting heavy items.
 Wear a breathing mask at all times, especially if:
• You deal with dangerous or toxic chemicals or fumes
• Your workspace has poor ventilation
• Your workspace has debris, dust, and other flying particles.
 Wear the protective equipment that is intended and recommended for your particular task.
• Seat belts.
• Safety glasses or goggles.
• Protective clothing, headgear, and/or footgear.
• Safety harnesses, etc.
T H A N K S