Maintenance Technology September 2017 - 30

PLANT SAFETY MATTERS
must be implemented several times a
day. Loss of time and profits creates
strong incentives to bypass LOTO
when performing repetitive machine
tasks. Disregarding these procedures,
however, violates OSHA requirements
and puts workers in danger.
Thankfully, OSHA 29 CFR 1910.147
also outlines Alternative Protection
Measure (APM) procedures that can
result in increased efficiency without
compromising the safety of the operation. This exception is also referred
to as the minor servicing exception.
Designed for machine tasks that
demand repetitive access, i.e., clearing
a jam on a conveyor or a minor
tool change, alternative measures
do not require that power sources
be completely cut off. Examples of
alternative-measure technologies
include key-controlled locks, control
switches, interlocked guards, and
remote devices and disconnects.
Locking out just a section of a piece
of equipment, rather than the entire
machine, is another approach.

ANSI requirements
The newest ANSI standard, ANSI/
ASSE Z244.1 (2016) The Control of
Hazardous Energy-Lockout, Tagout
and Alternative Methods, agrees with
OSHA in that workers should be
protected from injury due to unexpected equipment startup or release
of potentially hazardous energy. The
ANSI committee, though, did not try
to align fully with every historic OSHA
compliance requirement. Instead, the
new standard gives expanded guidance
beyond OSHA's regulatory limitation to
tasks that are "routine, repetitive, and
integral to production operations".
ANSI makes it very clear LOTO shall
be used unless a user can demonstrate
that a well-established alternative
method will provide effective protection. In situations where the task isn't
well understood or risk isn't assessed,
lockout shall be the default protective
measure applied to control machinery
or processes. Section 8.2.1 of ANSI/
ASSE Z244.1 (2016) specifies that
alternative methods shall only be used
after hazards have been assessed and

30 |

MAINTENANCE TECHNOLOGY

documented through the application of
a Practicability (or Justification) Study
to determine that the techniques used
will result in a negligible risk or no risk
for sudden startup.
Following the Hierarchy of Control

Year after year, lockout/
tagout is one of OSHA's
most frequently cited
violations.
model, ANSI/ASSE Z244.1 (2016)
provides detailed guidance on if, when,
and how a range of alternative control
methods can be applied to result in
equal or improved protection for people
performing specific tasks. In addition,
alternative risk-reduction methodology
is covered in detail specific to a number
of new technologies used in the
packaging, pharmaceutical, plastics,
printing, and steel industries, and
for dealing with certain challenges in
semiconductor and robotic applications.

LEARN
MORE

Navigating the requirements
Since the OSHA and ANSI standards
are somewhat conflicting, it's best
to review ANSI first to help identify
discrepancies that may not meet federal
minimum regulations.
At this point, it would be appropriate
to underscore that LOTO provides
the greatest level of protection and,
whenever possible, it should be utilized
to protect employees from hazardous
energy. In other words, inconvenience
alone is not an acceptable excuse to use
alternative measures. In addition, CFR
1910.147 clearly states that an allowable
alternative measure must provide the
same or greater level of protection as
LOTO. Otherwise, it is considered
noncompliant and therefore insufficient
to replace LOTO.
By using standard safety-rated
devices, such as interlock gates and
e-stop buttons, a plant manager
can achieve safe, reliable machine
access that replaces standard LOTO
procedures without violating OSHA
requirements. Implementing alternative procedures to ensure equivalent
protection for specific tasks can enhance
productivity without endangering
employees. But those procedures-and
their benefits-come with strings
attached, requiring a thorough understanding of the latest OSHA and ANSI
standards. MT
Information was provided by Matt
Brenner, a vice president at Rockford
Systems (rockfordsystems.com, Rockford,
IL), and Todd Grover, global senior
manager of Applied Safety Solutions for
The Master Lock Co. (masterlock.com,
Oak Creek, WI). An ANSI board member,
Grover helped write the Institute's LOTO
alternative-methods code.

For more information on applicable lockout/tagout
standards, see:

Occupational Safety & Health
Administration, Washington,
OSHA.gov

American National Standards
Institute, Washington,
ANSI.org

SEPTEMBER 2017


http://www.rockfordsystems.com http://www.masterlock.com http://www.OSHA.gov http://www.ANSI.org

Table of Contents for the Digital Edition of Maintenance Technology September 2017

Editorial
Uptime
On The Floor
Bionics Will Drive Future Factories
Filling The Skills Gap
Virtual Simulation and Plant Safety
Update Grounding Knowledge
Don't Overlook STF Hazards
Alternative LOTO Measures
SAP: Tips and Tricks
Compressed Air Filters
IR Inspections
Crack The Lube-Fault Code
DCIM Drives Efficiencies
Products
Ad Index
Showcase
Final Thought
Maintenance Technology September 2017 - Ad
Maintenance Technology September 2017 - Cover1
Maintenance Technology September 2017 - Cover2
Maintenance Technology September 2017 - 1
Maintenance Technology September 2017 - 2
Maintenance Technology September 2017 - 3
Maintenance Technology September 2017 - Editorial
Maintenance Technology September 2017 - 5
Maintenance Technology September 2017 - Uptime
Maintenance Technology September 2017 - 7
Maintenance Technology September 2017 - On The Floor
Maintenance Technology September 2017 - 9
Maintenance Technology September 2017 - Bionics Will Drive Future Factories
Maintenance Technology September 2017 - 11
Maintenance Technology September 2017 - 12
Maintenance Technology September 2017 - 13
Maintenance Technology September 2017 - 14
Maintenance Technology September 2017 - 15
Maintenance Technology September 2017 - Filling The Skills Gap
Maintenance Technology September 2017 - 17
Maintenance Technology September 2017 - 18
Maintenance Technology September 2017 - 19
Maintenance Technology September 2017 - Virtual Simulation and Plant Safety
Maintenance Technology September 2017 - 21
Maintenance Technology September 2017 - 22
Maintenance Technology September 2017 - Update Grounding Knowledge
Maintenance Technology September 2017 - 24
Maintenance Technology September 2017 - 25
Maintenance Technology September 2017 - Don't Overlook STF Hazards
Maintenance Technology September 2017 - 27
Maintenance Technology September 2017 - 28
Maintenance Technology September 2017 - Alternative LOTO Measures
Maintenance Technology September 2017 - 30
Maintenance Technology September 2017 - 31
Maintenance Technology September 2017 - 32
Maintenance Technology September 2017 - SAP: Tips and Tricks
Maintenance Technology September 2017 - Compressed Air Filters
Maintenance Technology September 2017 - 35
Maintenance Technology September 2017 - IR Inspections
Maintenance Technology September 2017 - 37
Maintenance Technology September 2017 - Crack The Lube-Fault Code
Maintenance Technology September 2017 - 39
Maintenance Technology September 2017 - 40
Maintenance Technology September 2017 - DCIM Drives Efficiencies
Maintenance Technology September 2017 - 42
Maintenance Technology September 2017 - Products
Maintenance Technology September 2017 - 44
Maintenance Technology September 2017 - 45
Maintenance Technology September 2017 - Ad Index
Maintenance Technology September 2017 - Showcase
Maintenance Technology September 2017 - Final Thought
Maintenance Technology September 2017 - Cover3
Maintenance Technology September 2017 - Cover4
https://www.nxtbook.com/atp/MaintenanceTechnology/epjulyaug2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epfeb2020
https://www.nxtbook.com/atp/MaintenanceTechnology/epjan2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovdec2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptoct2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epseptember2019
https://www.nxtbook.com/atp/MaintenanceTechnology/epaugust2018
https://www.nxtbook.com/atp/MaintenanceTechnology/0818schneider
https://www.nxtbook.com/atp/MaintenanceTechnology/epjuly2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjune2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmay2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epapril2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epmarch2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epfebruary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epjanuary2018
https://www.nxtbook.com/atp/MaintenanceTechnology/epdecember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epnovember2017
https://www.nxtbook.com/atp/MaintenanceTechnology/epoctober2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtsept2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2017
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtaugust2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjuly2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjune2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmay2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtapril2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtmarch2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtfebruary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtjanuary2016
https://www.nxtbook.com/atp/MaintenanceTechnology/mtdecember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtnovember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtoctober2015
https://www.nxtbook.com/atp/MaintenanceTechnology/mtseptember2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJune2015
https://www.nxtbook.com/atp/MaintenanceTechnology/M
https://www.nxtbook.com/atp/MaintenanceTechnology/0415endress
https://www.nxtbook.com/atp/MaintenanceTechnology/MTApril2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTMarch2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTFebruary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJanuary2015
https://www.nxtbook.com/atp/MaintenanceTechnology/MTDecember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTNovember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTOctober2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTSeptember2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTAugust2014
https://www.nxtbook.com/atp/MaintenanceTechnology/MTJuly2014
https://www.nxtbookmedia.com