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Posted By martin gray1
Hi All
Could anybody supply me with an alternative locking off procedure for single and 3 phase plastic cutting and welding machinery. I would just like to compare it against what we are currently using.
I am not after anybody doing my job but I have come up against problems of who unlocks machines when the shifts overlap on maintenance and repairs. Cannot seem to please everyone.
Many Thanks to anybody that can help.
MG
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Posted By Sally
Many years ago when in the paper industry we used a system where the machinery was locked off by eg the shift foreman and the keys placed in a box. This box then had a multi lock onto which numerous padlocks could be placed. At shift changeover workers just took their padlock off and incoming workers added theirs. This meant that the keys weren't accessable unless there were no padlocks on the lock. Only the shift foreman was 'allowed' to remove the keys but others were physically prevented from doing so if anyone still had their padlock on.
Not sure if this is the sort of thing you are looking for (or if I've explained it very clearly!)
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Posted By martin gray1
Thanks Sally for taking the time to respond.
This is the sort of thing I was after any other examples would be great.
Martin
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Posted By A Olsen
Martin,
We use a system similar to the one Sally describes but for single point isolations and to maintain control during shift changeovers the senior operator (who controls the machine) will apply a 'supplementary' or 'shop' lock. This could be in addition to his own personal lock if he is also working on that particular job. It means that he has ultimate control over when a piece of machinery starts up and that a piece of machinery on which work is not complete is not left without any locks in place. At shift changeover, the key is handed to his opposite number along with some form of handover on the status of the work.
Alison
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Posted By martin gray1
Hi Alison this sounds good could use this.
Many Thanks
Martin
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Posted By Alan Nicholls
Hi Martin We had a system on shift 4 rotating.
Each shift supervisor had a padlock colour coded and 1 key the shift engineers had a padlock with different colour code. Required number of padlocks to lock off 2 one supervisor one engineer.
To get the machine running you had to have one of each to unlock.
Unless the machine was unserviceable then the engineering manager put his padlock on(then 3) until it was fixed and signed off.
Alan N
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Posted By Merv Newman
First lock-off is by area supervisor. Then each person working on the machine places their own lock (unique key which they keep in their pocket)
At shift change everyone except supervisor takes off their lock. Incoming supervisor places his lock and outgoing supervisor removes his. (or hers)
The lock-out sequence is "Lock, Tag, Clear, Try" All involved should either do their own or at least witness the Try.
And we are talking ALL energy sources ; electrical, mechanical, hydraulic, pneumatic and potential (means heavy things falling on you)
I have seen situations where the operator is trained and authorised to do the first lock-off if his machine goes wonky. Operator then reports problem to supervisor who replaces operator lock with their own.
Anyone going home and forgetting to take off their lock is called back at their own expense. Or senior manager signs an authorisation to apply the bolt-cutters.
Lock-boxes are usually used where lots of people may be involved such as during a chemical plant maintenance shut.
I have seen combination locks used successfully. Owner sets their own comb. A quick phone call, followed by a spanking, could do away with the bolt-cutters
And I just loathe H&S people who accept a simple "danger, do not start" tag. There are some out there.
Merv
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Posted By martin gray1
Hi Allan
Did you just have the supervisor lock off for cleaning purposes, or was there still a second lock?
MG
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Posted By Alan Nicholls
Hi Martin
The machinery was locked off with both engineers and supervisors lock for cleaning and maintenance. The machines were fitted with interlocking guards and light curtains to prevent access during operation. Major adjustments were carried out with all motive power removed Air/electric, very minor adjustments could be carried out without the need for removing guards or locking off. This was achieved using the plc control.
Hope this is of use
Regards Alan N
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