Rank: Forum user 
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Hello,
Didn't get any replies last time so thought Id try again...........
I am relatively new to a manufacturing company who run 24/7.
The problem I have is ensuring compliance with interlock and emergency stop checks on lines. They are running on full capacity so lines are rarely down. The problem I have is I am being told they are unable to do these checks as lines would need to be shut down which would effect production.
the classic H&S verses production scenario!
I would be extremely grateful if anyone in similar circumstances could advise on what they do to ensure these checks take place?
Thanks in advance.
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Rank: Super forum user 
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Whilst the facility may be manned 24/7 there is no piece of plant or equipment which performs in this manner - there are always stoppages planned or breakdown maintenance, changeovers (raw materials or the product being produced) unexpected events (main electrical supply disruption, fire, flood).
So equipment will be reset / set-up and started - E-Stop and guarding device (interlock) operation validation can and should be written in to your safe system of work as part of the start up procedure so that no equipment in fault is brought in to operation.
If it is a large complex set of equipment with numerous E-Stop etc. the check can be devised on a rolling cycle validating one or two items per start-up.
Small regular planned time sacrifices are ultimately more beneficial compared to the risk of a major incident with protracted unplanned impact on scheduling.
Running equipment to/in fail is poor management practice - under the sentencing guidelines read a likely (very) high culpability.
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 2 users thanked Roundtuit for this useful post.
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Rank: Super forum user
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Whilst the facility may be manned 24/7 there is no piece of plant or equipment which performs in this manner - there are always stoppages planned or breakdown maintenance, changeovers (raw materials or the product being produced) unexpected events (main electrical supply disruption, fire, flood).
So equipment will be reset / set-up and started - E-Stop and guarding device (interlock) operation validation can and should be written in to your safe system of work as part of the start up procedure so that no equipment in fault is brought in to operation.
If it is a large complex set of equipment with numerous E-Stop etc. the check can be devised on a rolling cycle validating one or two items per start-up.
Small regular planned time sacrifices are ultimately more beneficial compared to the risk of a major incident with protracted unplanned impact on scheduling.
Running equipment to/in fail is poor management practice - under the sentencing guidelines read a likely (very) high culpability.
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2 users thanked Roundtuit for this useful post.
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Rank: Super forum user
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based on the risk assessment identify what inspections are required, and when, utilise the assistance of a competent person to assist you if you are not competent in identifying the hazards.
Read the PUWER regs and the ACOP l22 and INDG 291 for more info.
Try to schedule the inspections in at maintenance / breakdowns if possible
SBH
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Rank: Super forum user
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Or as part of a planned preventative maintenance system.
Or better still a combination of both approaches so different skill sets check the same device.
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Rank: Super forum user
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Or as part of a planned preventative maintenance system.
Or better still a combination of both approaches so different skill sets check the same device.
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We run 24 hours a day and we enforce these checks at the start of every 8 hour shift. We have made it mandatory for operators to check their lunn bars, e-stops, light guards etc. It takes roughly between 5-10 minutes but better to be safe than sorry! If this doesn't suit, then the introduction of a PPM system would be beneficial, so everyone is working off the same page and planned stoppages to conduct this work, wont come as a surprise to anyone.
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Rank: Super forum user
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Agree with the last few posts.
Essentially its poor production planning, not to factor in essential safety checks in the overall operation of a production line.
Symptomatic of possibly a poor safety culture.
Does the company MD run his Jaguar motor car until it breaks down or does he get it regularly serviced? I bet its the latter.
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Agree with JC
We do the same and the operators have to sign a Safety check form, to say they have completed the safety checks
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Rank: Forum user
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Also agree with the previous posts, however, why not 'sell' it as a business initiative rather than 'just' H&S... we introduced these checks with the line CILs too (CIL = Cleaning + ???? + Lubricants. Can't remember the "I". Sorry)
This way there was a defined stop for ppm and it wasn't seen as elf and safety getting in the way.
Pete
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Rank: Forum user
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Hi
We are a 24/7 food manufacturing site and what i've implemented is weekly guarding and interlock checks. Every Sunday nightshift a technician(engineer) checks all interlocks on 1 line on a week per week basis. We have 4 lines
Operators also do start up checks and Shift Managers do start up checks confirming all guarding and interlocks are okay.
I created a app on Access that they use when walking down the line signing off guards. I can happily give you it or help make one :)
Cheers Tom
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Rank: Super forum user 
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Planned maintenance, product changeovers, etc. 24/7 is rarely that.
Equally important to have a competent person (closely!) visually examining interlocks, stops, guards etc. to make sure they haven't been tampered with or by-passed. Beware the pitfalls of the MOT or tick-box approach.
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Rank: Super forum user 
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tomdignan wrote:Hi
We are a 24/7 food manufacturing site and what i've implemented is weekly guarding and interlock checks. Every Sunday nightshift a technician(engineer) checks all interlocks on 1 line on a week per week basis. We have 4 lines
Operators also do start up checks and Shift Managers do start up checks confirming all guarding and interlocks are okay.
I created a app on Access that they use when walking down the line signing off guards. I can happily give you it or help make one :)
Cheers Tom Hi Tom An app on Access, do you mean microsoft access ? if so on what device are they using it on when walking down the line ? Chris
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Rank: Forum user
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Hi Chris
I look after our IT system also
Yes on microsoft access then i check the DB on a Monday and see if all guarding has been signed off and is Okay.
I have it running on simple windows tablets or old laptops fixed a the lines.
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Rank: Super forum user
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The original question was related to compliance with checks. But you did not specify what the required frequency is.
I would certainly query any suggestion to do checks daily. Unless the machine is running flat out when the check is done, it will only be a partial check anyway; and I am sure you only want to do that infrequently.
It may be that checks are only required infrequently, in which case they have to be part of a production plan.
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Rank: Super forum user
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Thanks Tom
I wondered if you had it running on a phone. I have created a an access database for booking things in and out with a GUI created with VB, but the user is still able to get into the guts as all the access menu's are available.
Sorry for diverting from the original thread. Please carry on as I think the OP's question seems to be how often do other do these checks on continuous running production lines. I don't think they have the answer yet.
Sorry for the departure of thread.
Chris
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