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Tag: safety

Report uncovers hidden cost of workplace accidents

Posted on by David Priestman

A report published by health and safety solutions provider Seton suggests organisations may be unwittingly paying the price for poor health and safety practices in the workplace,.

While accidents that cause injuries, absences, compensation claims and fines are known to be costly, employers aren’t always aware that a poor safety culture can also impact staff morale, productivity and turnover – and ultimately their bottom line.

Seton has published a new report highlighting the benefits of prioritising employee safety, with insights from experts in personal injury law and HR.

Across the UK, almost 700,000 people suffered a non-fatal workplace injury in 2019/20, while 142 were killed in 2020/21, according to the HSE (Health and Safety Executive). This is clearly devastating for workers and their families but it also comes at a cost £5.6bn per year to individuals, employers and the government – or around £1.7m per fatal injury and £8,800 per non-fatal injury.

However, Alex Hinton, a product innovation manager at Seton, believes this is just the tip of the iceberg: “All employers have a legal obligation to protect their staff from harm but it’s more than a tick-box exercise. They need to create a safety culture, where everyone can perform their duties confident that they won’t be exposed to unnecessary risks.

“Choosing the right safety equipment is key. Barriers, for example, are a visible sign that organisations take their obligations seriously – but it’s important to choose ones that are easy to use and won’t leave staff feeling frustrated or worse still, reluctant to deploy them when needed.

“Employees who understand and consistently follow best practice are more likely to perform well and take fewer risks. Similarly, someone who is engaged with company life is more inclined to follow health and safety rules, which is why we’d urge health and safety teams to work closely with their HR teams to communicate relevant messages.”

His comments were echoed by HR consultant Jacqui Adams, of Tick HR, who also contributed to the report. She said: “Given employee expectations around health and safety, any organisation that falls short of the mark is likely to experience high turnover – which affects their bottom line. As well as the cost of replacing someone, they’ll also see skills, knowledge and experience walk out the door, which impacts productivity.

“HR and health and safety have many crossovers and best practice and engagement happens when the two teams work together to achieve the required outcomes.

“I’ve seen both health and safety teams and management view health and safety simply as a form-filling and box-checking exercise. It meant employees then saw health and safety as a ‘nuisance’ and paid little attention to the communications, which wasn’t in anyone’s best interests.”

CLICK HERE to read the full free report Worth the Risk? Counting the cost of health and safety breaches

Loading bay safety without high maintenance costs

Posted on by David Priestman

In  this article supplied by Castell Safety, we seek an answer to the question: Are your loading bay safety system maintenance costs cutting into profit?

The loading bay is an essential part of any manufacturing company, warehouse, or distribution centre. It is what allows the process of raw materials to enter and completed goods to be transported to consumers and end users. Unfortunately, the loading bay can be a hazardous environment where accidents can occur. It is estimated that 25% of all industrial accidents happen at the loading bay according to ISHN.

To mitigate the risk of accidents, organisations often invest in loading bay safety systems to mitigate the risk of accidents or injury at the loading bay. A variety of systems can be found on the market to prevent these incidents such as hook restraints, wheel chocks, blocking arms, and interlocking gladhand systems.

Organisations often invest in these systems to avoid accidental injuries at the bay and spend anywhere from thousands to millions for a corporate- or site-wide roll-out of one of these systems. Companies expect these systems to be a one-time investment that will prevent them from incurring the costs associated with a workplace injury or potential death.

What companies don’t expect is the high recurring maintenance costs associated with some types of loading bay safety systems.

Loading bay safety systems typically fall into the categories below and can vary in maintenance costs:

Automatic Wheel Restraints: Automatic wheel restraints such as powered chocks perform in a similar way to mechanical chocks; however, they are automatic and thus require no personnel in the yard to fit it. They are also integrated with other bay equipment which ensures that a safe process is enforced. Some systems are built in at sub ground level and therefore require significant installation effort, these can also be significantly affected by the elements. Systems that are installed above ground become an obstacle, especially in winter.

Like mechanical chocks, relatively high maintenance costs can be associated with these systems due to the number of moving parts, concrete work associated with damaged equipment, and the time associated with clearing snow/ice in harsh weather conditions.

Hook Restraints: Hook restraints can be manual or automatic systems that prevent drive-aways at the loading bay. The hook restraint is installed at the bay door and when a truck is present, the hook is engaged and clamps onto the ICC bar of the vehicle to prevent the trailer to pull away from the bay prematurely.

Hook restraint systems can require significant maintenance due to the number of moving parts, hydraulics, damage to equipment, and high forces involved in restraining the vehicle at the loading bay.

Mechanical Chocks/Wheel Restraint: Mechanical chocks build upon the principle of manual chocks however they typically have additional permanent structure that they are fitted to which provides increased restraining force. If the permanent structure is higher than ground level, these can become an obstacle, especially in winter when ploughing the site. Ground level plates can also be affected by winter conditions as they become covered in snow/ice, making it difficult to fit the chock.

There can be high maintenance costs associated with this these types of restraint systems due to the number of moving parts, damage to permanent structures, and the time associated with clearing snow/ice in harsh weather conditions.

Manual Chocks: Manual chocks are common, simple wedges of material that are placed closely against a vehicle’s wheel to prevent accidental drive-aways.

Chocks can be unreliable as they can easily be lost, stolen or break. Maintenance cost for manual chocks include complete product replacements and can vary due to the number of sets of chocks the facility owns.

Interlocking Gladhands: Gladhand devices are used to lock out the air brake of the trailer to prevent movement at the loading bay. When gladhand devices are interlocked with the bay door with fixed mounted trapped key interlock devices, they can create a sequential safety process that must be followed to load and unload the trailer that results in the prevention of drive-aways at the loading bay.

Maintenance costs associated with these systems are minimal as the only maintenance required is the greasing of the gladhand coupling device once per year depending on the temperature of your facility’s location.

In the below chart, common loading bay safety systems are ranked from the highest to lowest associated maintenance costs for a facility with 25 loading bays over the time period of one year:

As you can see, some safety solutions require more maintenance than others, resulting in high costs that cut into the facility’s profit. If you and your facility find yourself in the position of continually having to maintain components, replaced damaged equipment, order replacements, and spend entirely too much time and money on your loading bays safety system, it is time to reconsider your existing system.

Safety at the loading shouldn’t cause additional headaches, it should be simple, safe, and low maintenance. Lucky for you, there are other options than your existing solution that won’t cut into your facility’s profit.

Castell Safety believes everyone has the right to be safe at work. It protects people and assets within the energy, industry, and logistics sectors. Its logistics safety solution, Salvo Loading Bay Safety System, prevents accidental drive-aways at the loading bay by interlocking the trailers airbrakes with the bay door.

 

Safety first for warehouse automation

Posted on by David Priestman

Safe automation expert Pilz has recently been applying its wealth of experience to intralogistics applications taking a holistic approach with its portfolio of safety services, training and safe automation solutions.

With increased levels of automation, it is more important than ever to ensure that human and machine operate smoothly and safely within the warehouse environment. In key areas such as automated loading systems, Pilz consultants can work to achieve safety compliance without compromising productivity.

Getting on board as early as the design phase, when the system concept is developed, they provide support for new projects or retrofits right through to commissioning and sign-off.

State-of-the-art product solutions are also available incorporating control and sensor technology through to operating, monitoring and connectivity. These include:

  • Access management solutions – ensuring tasks such as maintenance can only be carried out by authorised and trained personnel
  • Industrial security – preventing manipulation of systems by external sources
  • Danger zone protection – bringing operations to a safe stop or safe speed if the zone is encroached by personnel
  • Safe operation of AGV or AMR systems – enabling safe stopping or navigation and interaction within shared work spaces

CILT Ghana supports Transaid programme

Posted on by Keith McKinley

International development organisation Transaid has signed a Memorandum of Understanding (MOU) with the Chartered Institute of Logistics and Transport (CILT) Ghana, aimed at promoting mutual cooperation in the area of road safety.

The agreement follows less than a year after Transaid began developing a professional driver training programme in the country’s capital, Accra; its first project of this kind to be launched in West Africa.

With funding secured from Puma Energy Foundation, Transaid has set out to raise training standards and expand training capacity for heavy goods vehicle (HGV) drivers.

The MOU was signed by Engr. Mark Amoamah, National President of CILT Ghana, and Caroline Barber, Transaid Chief Executive.

Barber says: “We have a long and rich history of collaborating with CILT Ghana and I am delighted to be partnering with them again to deliver this life saving work. They have already played a key role to support us in setting up this project, and it’s fantastic to see the relationship formalised.”

The signing of the MOU coincides with Transaid delivering the first ‘Training of Trainers’ module, designed to build training capability in Ghana, following a format used successfully by Transaid on similar projects in Zambia, Tanzania, Uganda and Malawi.

It follows a busy period gathering and analysing training material currently used in Ghana, establishing a national technical standards group and collaboratively assembling both a theory and practical training curricula, plus an instructor’s manual, to ensure the project got off to a successful start.

Barber says: “The provision of quality professional driver training will be expanded to increase access to training and ensure that drivers are trained to the highest standards. Our initial involvement is for three and a half years, and within this time we want to work with partners to ensure strong foundations are in place to facilitate sustainable and lasting change in Ghana.”

On signing the MOU, Engr. Amoamah announced that he planned to further support the initiative by offering free CILT Affiliate Membership to all those training as trainers.

Transaid is planning to put the first cohort of HGV driver trainers through both the theory and practical training within the next three to four months.

Complete solution for guarding pallet magazines

Posted on by David Priestman

Leuze has produced a complete safety solution for access guarding on pallet magazines.

Manufacturers and operators of machines and systems must comply with legal regulations. Applicable to manufacturers are, among other things, the Product Safety Act – for operating companies, the Ordinance on Industrial Safety and Health. Standards play another important role. They describe requirements and provide support in ensuring safety at machines and systems. These are, however, not legally binding in Europe.

For manufacturers or operators of machines or systems, type C standards are especially relevant. These are machine-specific safety standards. Among these are Normative framework: revised EN 415-4 “Safety of packaging machines – Part 4: Palletizers and depalletizers and associated equipment”.

The content of the standard from 1997 was significantly revised. In the forthcoming version of the standard, new requirements are placed on manufacturers and operating companies. This also affects the access guarding of pallet magazines with automatic restart.

Traditional concept with external induction loops

Up to now, many material transfer stations with automatic restart were safeguarded as follows: electrosensitive protective equipment (ESPE) secured the access point – if the ESPE is interrupted, the machine and conveyor are stopped. To avoid needing to restart the stopped machine after loading by a corridor supply vehicle, such as a forklift truck, two induction loops are used as muting signals. These are located in the floor in front of the ESPE.

When the forklift moves over the induction loops, the electro-sensitive protective equipment is temporarily bridged. This solution no longer corresponds to the current state of safety technology: The system often ends in a single-channel evaluation logic; as a result, the safety performance is no longer adequate for the given application under certain circumstances.

A new type of access guarding for a pallet magazine aims to prevent the entry of persons but simultaneously allow pallets to enter by means of a forklift truck.

Compliance with standards through sequence monitoring

Manufacturers and operating companies can now make use of a new solution that is described in the future version of standard EN 415-4. This thereby corresponds to the current state of the art. Two induction loops 1/4 are also used for this type of access guarding on pallet magazines. The difference to traditional concepts: Both of the induction loops are not located in front of the danger zone.

Instead, one is located outside of the danger zone and the second is located behind the electro-sensitive protective equipment, i.e, within the danger zone. The ESPE – the optoelectronic protective device – also remains at the previous position. As before, it separates the traffic zone and danger zone. In addition, there is also a safety system that monitors a defined sequence of signals and initiates the automatic restart.

Various possibilities for safeguarding areas of systems

For this solution, the following technical framework conditions must be implemented: the pallet magazine must be safeguarded at the adjacent areas. A person who passes through the ESPE must not be able to enter other areas of the system unnoticed. This can be ensured mechanically, e.g., by means of a height limitation. This allows an empty pallet to pass through, but not a person. Alternatively, a second piece of electro-sensitive protective equipment can be installed to detect the entry of a person into the danger zone. Another requirement: the outer induction loop over which the forklift truck travels requires sufficient space. This is somewhat larger than the inner loop.

In addition, the operating personnel must be instructed because this involves an automatic restart. The driver of the forklift truck is responsible for ensuring that no one gains access to the danger zone by moving alongside the forklift truck. If, there is still a person in the inner area at this time, the driver must not drive out, as the pallet magazine will otherwise be started. Alternatively, this risk can also be eliminated by means a safeguard that provides stepping behind protection.

Step-by-step to more safety

This type of access guarding functions along a defined process. Working in the background is a safety system that monitors precisely this process flow. Only once the sequence has been concluded does the system initiate the automatic restart of the machine. This process is also described in revised standard EN 415-4:

  1. The forklift truck arrives, the machine is in operation and the electro-sensitive protective equipment is active.
  2. The forklift travels over the outer induction loop and is thereby detected by the system. The pallet magazine continues to run.
  3. The ESPE is interrupted by the forklift truck. The pallet magazine is stopped. This also applies if a person passes by the ESPE.
  4. The forklift truck continues to move and is located within all sensors: over the outer and inner induction loops and in the protective field of the interrupted ESPE.
  5. The forklift deposits the pallet(s) and travels in reverse. This first frees the inner induction loop and then the ESPE.
  6. The forklift exits the outer induction loop. The sequence is concluded and automatic restart of the pallet magazine is initiated.

In summary, this means: If the presence of a forklift truck is detected by the induction loops and if the forklift then correctly executes the specified process sequence, the safety system initiates the automatic restart of the work process.

Perfect for performance level d

With this concept, operating companies benefit from a standards-compliant safety solution corresponds to the current state of the art. The requirements of EN 415-4 “Safety of packaging machines – Part 4: Palletizers and depalletizers and associated equipment” are thereby satisfied.

The system is designed for performance level d, the second-highest safety level. Thanks to the automatic restart of the machine without manual operator interventions, the packaging system can be optimally utilized. In addition to increased reliability, the advantages also include optimum protection against manipulation: the sequence- and time-monitored process contributes to high protection against bypassing. Furthermore, the system can easily be integrated in the safety circuit of the primary control and service costs remain minimal.

Another plus is the flexible usability: The solution is suitable for both palletizers as well as for depalletisers and offers freedom for transport materials to the left and right. Thanks to scalability, the safety system can be adapted to various applications through the use of appropriate components.

Ready-to-use system

Leuze offers the described safety solution for access guarding on pallet magazines with automatic restart as a complete package that has been tested and validated with respect to safety with the following components:

  • Induction-loop set with evaluation unit
  • MLC 500 safety light curtain, with device columns for floor mounting
  • MSI 400 safety control, programmable and with induction loop controller
  • Leuze safety program
  • 2-channel safety output
  • Acknowledgement box as electromechanical reset apparatus

The reset apparatus is used if a sequence is not correctly completed. Or a person interrupts the electrosensitive protective equipment. The button is used to confirm to the system that the process can be correctly restarted and that persons are no longer located in the danger zone.

As a ready-to-use system, the solution from the Sensor People at Leuze can be used immediately after installation. System owners are, thus, always on the safe side and already satisfy the requirements of the future EN 415-4 today.

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Equipment owners urged to review inspection programme

Posted on by David Priestman

Following a busy Christmas period, work equipment owners are being advised to examine their maintenance and inspection programme schedules to ensure everything is kept at a safe and legal standard throughout 2022.

CFTS – the industry’s accrediting body for Thorough Examinations in the UK – is aware that thousands of trucks and attachments may not currently have a suitable Thorough Examination plan to ensure they fulfil all requirements under LOLER and PUWER.

Geoff Martin, CFTS Chairman, explained: “A huge number of businesses have been working flat-out in recent months, so January is an ideal time to take stock and assess the condition of equipment.

“I’d suggest that your first step should be to check the truck’s paperwork for the last inspection date and see if there is a sticker on the equipment bearing the CFTS Quality Mark. If you don’t know what you are looking for, talk to the person at your company who oversees the equipment.”

Many companies also find themselves unclear over whose responsibility it is to book the inspections when trucks are leased or hired. It’s often assumed that any liability is with the company the trucks are hired from, but this is only sometimes the case. Speak to the hiring company if you are unsure of your obligations.

When trucks are owned outright, the responsibility is yours and if you let the inspection period lapse, you could potentially leave yourself open to fines or worse — letting the equipment become unsafe.

There is also a common misconception that the inspection is simply an annual undertaking, but in reality, it isn’t quite that simple.

“There’s no one-size-fits-all rule,” said Geoff Martin. “It’s important that each piece of equipment is on its own schedule appropriate to its type and use. Your nearest CFTS-accredited member will be able to advise on the frequency of inspections required on a case-by-case basis. And with the ever-changing situation we find ourselves in, it’s always best to be fully prepared as early as possible.”

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https://www.logisticsbusiness.com/uncategorised/increase-equipment-safety-compliance-with-visual-tagging-solutions/

 

Werma launches “new benchmark” for industrial signalling

Posted on by Keith McKinley

The new eSIGN signal tower is a breakthrough and a clear sign of Werma‘s continual technological progress: this signal tower sets new standards in terms of individuality and flexibility with full-surface signalling, robust industrial design and impressive features.

As early as 1994, Werma established a global industry standard with the launch of its KombiSIGN signal tower. And this standard has just been upgraded: the eSIGN is the next generation that will define the future of signal towers. Impressive features, supreme compatibility and an industrial design that combines functionality with style and durability.

The new eSIGN has generated a quantum leap in possibilities: full-surface signalling makes it considerably more conspicuous and optimises the signal tower’s potential. This enables all users to monitor processes even more extensively, more comprehensively, more accurately and more proactively. Werma claims the new eSIGN represents a new dimension of signalling.

The eSIGN is a shining example of a signal tower with visibly improved performance: more colours, more effects and more individuality. Thanks to the modularity of its electrical components combined with the latest LED technology, different signalling modes can be produced using multiple colours, brightness levels and light effects – from the classic traffic light display to fully customised settings. Variable fill-level displays or full-surface signals can also be generated with ease using this signal tower. This not only allows users to oversee processes, but also brings completely new possibilities.

Werma says the eSIGN is the best signal tower it has ever developed. The range of applications is as diverse as the eSIGN itself: from alarm signalling to access control, visual warnings, statuses, fill-level or fault displays right through to material stock levels and building security. It can even be used as an acoustic warning system.

Acoustic signalling is an indispensable component that supplements visual signalling in daily work processes across the globe, from production facilities to logistics, building technology or mechanical and plant engineering applications. Their aim is to ensure that processes run smoothly, to secure the safety of personnel and protect the equipment being used. With the comforting feeling that everything is running smoothly.

For this reason, the new eSIGN is equipped with a siren that can produce up to 10 different tones. These can also be configured to suit specific applications. Naturally, the siren can be combined with light effects, has variable volume options and is easy to set up.

The high technological standards and user-friendly operation of this new Werma signal tower are not at all contradictory: depending on the variant, eSIGN can be easily controlled using IO-Link or configured via USB. It can be mounted on the floor, on tubes or on walls.

The two different sizes of the eSIGN also offer maximum flexibility: 15 or 9 segments, with or without siren, standard 24V version with configuration transfer via USB or using IO-Link technology.

The robust industrial design also delivers what it promises: the high IP66/IP69k protection class ensures improved resistance to typical substances used in production, while the UL type 4X enclosure guarantees resistance to UV radiation and environmental influences.

Werma says the custom modes, acoustic signals, free selection of light effects and robust industrial design mean the new eSIGN is simply always the right choice.

Time to winterproof safety signage

Posted on by David Priestman

Winter is not the safest season. Slips and falls increase dramatically, especially when working outdoors, or simply walking to an office from the parking lot. When the cold and dark seem to conspire against health and safety and the need increases to highlight new safety communication to lower the risks, Brady is proposing signage solutions to help make the winter safe.

Reliable safety identification solutions to support Go for Zero programmes throughout winter include:

  • ISO-compliant ultra-visible reflective signs with excellent outdoor reliability to clearly identify on-site winter slip hazards and other risks, and easily guide employees, even in the dark
  • reliable pipe markers easy to apply to wet, rainy and cold outdoor pipe surfaces to make them compliant with any regulation or standard
  • PaintStripe stencils to quickly re-paint or create new, straight outdoor floor marking
  • outdoor safety cones and A-board floor stands to immediately highlight ice patches and other emerging winter hazards

While any solution can be pre-printed to a customer’s specifications, Brady also offers full flexibility to get through winter. With the BBP37 Multicolour & Cut Sign & Label Printer at their premises, a customer can quickly update safety and facility identification to reduce risks by:

  • creating reliable, industrial-grade outdoor signs, labels and pipe markers in any shape
  • using in stand-alone mode, or add Brady Workstation apps to design an even wider range of signs, pipe markers and safety labels
  • stocking a few blank label supplies – requiring minimal storage space – to sustain safety identification needs throughout winter

Briggs enhances safety at Port of Liverpool

Posted on by David Priestman

As part of the ongoing partnership between Briggs Equipment and Peel Ports Group (PPG), a new JCB machine equipped with innovative safety technology and telemetry has recently been delivered to the Port of Liverpool. The new truck is having an immediate impact with positive feedback from operators and management teams alike.

The machine has been fitted with a unique telemetry system, developed in conjunction with FTC, including an artificial intelligence-powered reversing camera that intuitively picks up whether a person is in the vicinity and alerts the driver in real-time.

Peel is also trialling a real-time, secure cloud portal that provides operational and safety data that can be viewed and interpreted much quicker and with greater accuracy. To highlight the effectiveness of the partnership between the two companies, and the joint focus on safety, Peel were benchmarked as the number one port in the UK for safety, as judged by Port Skills and Safety. They also recorded the lowest rate of significant injuries measured by lost time incidents (LTIs) in 2020/21.

Tony Worrall, Briggs Equipment’s National Account Manager, said: “The new JCB truck will help deliver real benefits to Peel’s efficiency, productivity and of course on-site safety. This investment in cutting edge technology and telemetry underlines Peel’s business wide safety focus and a clear ambition to remain at the forefront of the industry. It also demonstrates the strength of our Contract Management support.

“We’ve worked closely with our partners at FTC to deliver a telemetry solution that meets the demands of a modern work environment. The system is fully integrated with cloud-based technology and artificial intelligence to help provide real time data and instant safety alerts.

“We have an extremely strong partnership with Peel Ports and they remain committed to implementing a safety first culture across their business with our expert assistance and guidance.”

Phil Hall, Port Director – Mersey Division at Peel Ports, said: “We are delighted to be working with Briggs, a key strategic partner. This supports Peel Ports objective to stay at the forefront of innovation and our joined up approach contributes to delivering industry leading safety management systems.”

Platform improves worker safety at Lindab

Posted on by David Priestman

Factories and production lines have always faced challenges when it comes to protecting workers and maintaining operations. Accidents, however rare, must always be prevented as far as humanly and logistically possible. The margin for error is often little to none.

In work environments with heavy machinery and in Lindab Steel’s case, foil rolls sometimes weighing several hundred kilogrammes, accident prevention is of the utmost importance. With help from VPG, Lindab Steel’s cutting machine has been equipped with a platform that safely lifts the operator to the appropriate working height instead of the operator using ladders and stairs.

Erik Dahllöf, Sales Manager at VPG, was visiting Lindab’s factory on another matter and during his visit an additional opportunity to improve safety, ergonomics and operations presented itself. In cooperation with Lindab’s staff, including Production Engineer Patrik Hayes, a risk assessment of the cutting machine was conducted. Together they investigated ways to reduce the risk of accidents and improve ergonomics for operators.

The cutting machine is an important part of the production line. It straightens the sheet metal before it’s cut to the appropriate length, anywhere from 300mm to 4,000mm-long pieces. The machine is elevated and therefore can be cumbersome for operators to work with, increasing the risk of accidents. Before the new platform was installed, operators had to use stairs, ladders and even stand on their toes on top of the machine to properly adjust and set up for production,

“Ergonomically, the pros are substantial,” said Hayes. “Previously operators had to work with their hands above shoulder height. Now we can lift the operator to the correct working height no matter how tall or short they are.”

Work-related accidents are not only catastrophic for the person or people involved, whenever accidents happen it’s extremely costly for a company, on average €100,000.

“The cutting machine runs 24×7 and it’s incredibly costly if operations come to a halt,” added Hayes. “Our first priority is always the health and safety of our workers but maintaining production is of course key as well.”

Operators are very happy with the new platform, not only sparing their physical well-being but also helping them work more efficiently at the correct working height.

“No matter how much an operator values quality, if you spend too much time in an uncomfortable position quality will be affected over time,” said Hayes. “Investing in safer and more ergonomic solutions for workers will always give you returns on your investment, many times over.”

The end result of the project can only be said to be a huge success, appreciated by all involved parties. “Right now, it’s full steam ahead and everyone is very happy with the lifting platform solution,” Hayes concluded.

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