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Risk Identification & Assessment Study, Safety Upgrade Proposals and LOTOTO (Lock Out - Tag Out - Try Out) Implementation Study for Roll Mill Line 1

Risk Identification & Assessment Study, Safety Upgrade Proposals and LOTOTO (Lock Out - Tag Out - Try Out) Implementation Study for Roll Mill Line 1
SUBMITTED FROM:

Μ.Ι.ΜΑΙΛΛΗΣ ΜΟΝΟΠΡΟΣΩΠΗ Α.Ε.Β.Ε

With over 40 years of operation, “Maillis Metals Solutions” is a major player in the European steel strapping business with the largest Vertical Integrated manufacturing facility in Europe. Offering a comprehensive product portfolio along with engineering support, we cover a wide spectrum of application requirements in more than 1200 customers worldwide.   

https://www.maillis.com/en/brands/maillis-metals-solutions



Objective Action

Preparation of a Hazard Identification and Risk Assessment Study, as well as proposals for measures to satisfy the “Zero-Access” condition, based on Greek law 57/2010 (Directive 2006/42/EC) and the ELOT EN ISO 12100 standard, for a Roll Mill machinery complex of the MAILLIS factory located in Oinofyta. The purpose of the proposed measures is to minimize or eliminate the risk while taking into account the needs and specificities of the production process of the line.

Preparation of a Study and Method of Implementation of Lock Out – Tag Out – Try Out (LOTOTO) for the Roll Mill 1 line, which concerns the procedures that must be followed for the safe stopping and immobilization of all or part of the equipment included in the installation, together with the prevention of its voluntary or involuntary starting during an intervention in order to avoid the risk of accidents for workers.

 

Target Audience

 

The program is addressed to the company's employees as well as to external stakeholders (customers, partners, local community, regulatory authorities) and confirms the company's commitment to implementing actions aimed at the protection of workers in the facility from occupational accidents.

 

 

Duration

6 months


Description

The Risk Identification & Assessment study will include the following points:

  • The determination of the Health and Safety requirements that the machines and/or machine assemblies must meet based on European directives as well as proposed measures, for which harmonized standards of the European Union will be taken into account. The purpose of the proposed measures is to minimize or eliminate the risk while taking into account the needs and specificities of the production process of the line.
  • The proposed measures will reflect all the requirements and specifications of the barriers and electrosensitive safety equipment and will result from interviews with the machine operators, monitoring of the production processes by specialized engineers who will go to the factory and conduct on-site visits. The measures will be finalized after consultation and consensus with the competent production engineers, the technical management and the company's Health and Safety management.
  • For each identified risk, a special risk sheet will be produced with appropriate name coding, which will depict the finding, the dangerous zone, the risk assessment, the proposed measures and finally the assessment of the remaining risk after the measures (technical and/or organizational) have been taken.
  • All identified points will be recorded on a Matrix table from which the findings can be managed and the actions monitored.

The LOTOTO process will include the following stages:

  • Positioning the equipment to be intervened in a “zero energy state”.
  • Safe and discrete isolation of the equipment from all power supply networks that serve it.
  • Placing isolation signs on the equipment.
  • Checking the isolation of the equipment and test starting the equipment from all possible starting points to confirm the impossibility of voluntary starting.
  • “Test starting” of the device (perhaps the most dangerous) where the isolation points are partially removed in order for the intervention personnel to perform the necessary equipment functions for the intervention.
  • Restarting the device and returning it to the production process by a specific and authorized employee. During this stage, the removal and collection of the locks, the restoration of the interruptions and the assurance that all LOTO equipment has been removed from the machines are carried out in a completely controlled manner.
  • The Instructions that will be drawn up will be accompanied by visual material (photographs, diagrams, illustrations of the zones and equipment on the layouts of the machines, etc.) so that the points involved and the corresponding application equipment are immediately understandable.
  •  After the completion of the study, the corresponding training texts will be prepared and be presented to the operators - maintainers of these lines in a "live" presentation. Upon completion of each course, an individual "Training Certificate" will be issued separately for each trainee.

 


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Impact on Society

This specific initiative will result in the protection of maintenance workers and machine operators from occupational accidents that could be caused by the intentional or unintentional starting of the machine during a maintenance or repair operation.



Initiative Location

Steel strap production factory at Inofyta Viotias, Greece.


Working with Organization

The project will be carried out by the company "Ergonomia", whose main activity is the provision of integrated services in the areas of Ergonomics, Occupational Health & Safety and Environment.


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Workers Participation

It is noted that the availability of the following departments will be required from our company

  • Electrical and mechanical maintenance / Technical management
  • Safety and Health
  • Production executives
  • Machine operators

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Benefits for Οrganization

Preventing and avoiding work-related accidents in the workplace will have multiple significant benefits for our company.

1. Cost reduction from:

• Avoiding compensation for work-related accidents

• Reduced insurance costs due to lower risk.

• Lower productivity losses due to employee absence.

• Avoiding fines from labor or other regulatory authorities.

2. Increased productivity

• Employees feel safe and can perform better.

• Production interruptions caused by accidents or inspections are reduced.

3. Improved reputation and credibility of the company

• The company acquires a positive image as a responsible employer.

• The trust of customers, partners and investors increases.

4. Boosting employee morale and engagement

• Employees feel that management cares about their safety.

• This leads to improved relationships, fewer turnovers, and lower absenteeism.

5. Compliance with legislation

• Accident prevention helps the company comply with labor laws and European directives, avoiding legal problems.




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