Tom Andel, Editor over at Penton’s  Material Handling and Logistics blog, raised an interesting paradox the other day.

“Not only is it hard  to recruit people into warehousing,” he says, ” but those who do get hired often exhibit an attitude problem about using personal protective equipment (PPE) like ear plugs or safety glasses. ”

In the U.S. employers provide PPE...

Tom goes on to say “Al Will, who now trains young people in the ways of warehousing…followed up with me afterwards, adding: “It seems as though we’re in a Catch-22. If a company fires workers for PPE non compliance, they can’t readily find replacements.”

Hey Tom, we have the same situation going in Precision Machining and Manufacturing!

Back to Tom’s Post :”That’s why supervisors are sometimes lax in enforcing safety rules. Good material handlers are hard to find. One industry magazine article I read recently advocated a “take no prisoners” approach to safety enforcement:

“The rules are that a careless workman must be discharged and a foreman who keeps a careless operator, even though he be a good workman, lacks the discipline necessary to safely handle materials in a plant.”

“This article spread the blame for safety negligence in a plant across all functions: “the employer, for not having proper and sufficient equipment, the foreman for not properly instructing the workman, and the workman who does not complete his part of a task, as when he removes a barrel head and carelessly leaves nails protruding in the barrel.”

You can read the rest of Tom’s Blog post here.

What do you think? Are you a member of the “take no prisoners” camp? Or are you a member of the “we can even rehabilitate the folks we have to hire- they’re all we can get”  School of Hard Knocks?

There is no doubt that OSHA holds the employer responsible for the safety of  all employees

So how do you solve this paradox?

OSHA cited Advantage Powder Coating in Defiance, Ohio, for 15 safety violations and fined the company $159,600 after a pedestal grinder operator was killed when the abrasive wheel on the grinder exploded and struck the operator on the head.

Pay attention! This one can bite.

 Two willful violations were cited for pedestal grinder violations:

  • Lack of properly adjusted safety guards;
  • Lack of properly adjusted work rests;

OSHA placed Advantage Powder Coating in its Severe Violator Enforcement Program (SVEP), which mandates targeted follow-up inspections to ensure compliance with the law. Advantage Powder Coating was placed in the program for receiving two willful violations covered under the agency’s National Emphasis Program on Amputations.

Pedestal grinders are a foundational piece of equipment in precision machining shops. It is up to us to assure that the potential hazards that they can present are controlled. Here are four tips from my experience to keep your shop grinders in compliance:

  • Don’t allow wheels to get out of dress.
  • Assure that the proper clearance and no more exists between properly dressed wheel and front tool rests
  • Assure that all grinders have all guards in place. If guards are missing- LOCK IT OUT!
  • Assure that the grinder is mounted to the floor if the pedestal was designed to be bolted to the floor. If no bolt holes are present, then bolting down is not necessary.

The safe use of grinders is a key part of our craft. It is up to us to keep the potential hazards that grinders can present safely controlled by insisting on safe grinder practices and inspections to assure guards are in place and properly adjusted.

Here is the news release

Grinder photo

Here are 5 factors to keep in mind when analyzing work.

  1. Focus on the process. In my experience, it is seldom the people. If you start with the work instructions and compare to the process, you will find the answer.
  2.  Most waste comes from working on the wrong things. Are the activities being done actually adding value?
  3.  Classify the activities as definitely adding value, necessary, unnecessary, idle. Do everything in your power to eliminate all that do not add value.
  4.  Question “why?” for every activity that is being performed. Legacy is seldom worth paying for. How would a new startup today do this?
  5. Communicate with everyone. Continuous improvement requires buy- in from the team, and their contributions may well out-value what an outside observer will develop.

Whether you use  work sampling, just observation, time study, spaghetti diagram, flow charts, or notes scribbled on work instructions doesn’t really matter. The five points given above are the key to getting a savvy analysis of the job at hand.

Great sidebar in an article in Automation World.  If you are doing or working with Machine Automation, this list is for you.

File this info under "Safety Standards, Knowledge Retention"
  • ISO 12100-1 and ISO 14121: Safety of machinery – principles for design and risk assessment
  • IEC 60204-1: Safety of electrical equipment
  • NFPA79 (2006): Electrical Standard for Industrial Machinery
  • ISO 13849-1, -2: Safety related parts of machinery (SRPCS)
  • IEC 61326-3-1: EMC and functional machinery
  • IEC 61508: Functional Safety (basic standard)
  • IEC61496: Safety
  • IEC61131-6: Safety for PLCs
  • IEC61800-5-2: Safety function for drives
  • IEC 61511: Standards for fire & gas systems
  • ANSI B11.19: Performance criteria for the design, construction, care and operation of safeguarding
  • ANSI B11.TR6: Safety control systems for machine tools
  • ANSI / RIA 15.06, CAN / CSA Z434: Safety requirements for robots and robot systems
  • IEC 62061: Functional safety of safety-related electrical, electric and programmable electronic control systems.

Standards for risk assessment

  • ANSI / RIA15.06, CAN / CSA Z434: Safety requirements for robots and robot systems
  • ANSI B11.TR3: Risk Assessment and risk reduction – A guide to estimate, evaluate and reduce risks associated with machine tools.
  • ANSI B11.2008: General safety requirements common to ANSI B11 machines.
  • ISO 14121: Safety of machinery – principles of risk assessment.

To read the feature article relating to this story, go to Feature Article 

The latest Institute for Supply Management Index for Manufacturing  activity fell to 50.9 in July from 55.3 percent in June. The July reading was the lowest since the end of the recession in June 2009.

Not so fast...

The important fact to know about the ISM numbers is that they indicate growth or contraction in manufacturing. For the past 23 months the index has shown that manufacturing has been expanding.

23 straight months of manufacturing expansion!

 So the July 2011 data  of 50.9 indicate that – guess what- manufacturing is still expanding, but just barely so. Why would we expect this to go on forever and ever?

After 23 straight months of expansion, a slow down in that expansion is hardly a sky is falling moment.

The PMPA’s Business Trends Sales Index is at its highest level at 131- with year 2008 as base year of 100.

Our latest data is strongly ‘remains the same’  or ‘positive’  so far.

So if you are one of the people wringing your hands over the <gasp> fact that after 23 straight months of expansion, the rate of growth and expansion in manufacturing might be slowing- well, here’s a nice cup of camomile tea.

Relax...

There will be a blue sky up above you next month folks. One data point out of 23 is not reason to go to Defcon 1.

See you next month...

ISM Graph

The Scream

Defcon 1

Tea

On hot rolled bars to be cold drawn, the dark oxide surface is called scale.

What we see on the surface is "scale"- a combination of oxides of iron.

Scale is the name given to the oxides of iron that are formed on as wrought products as a result of mill operations (high temperature rolling or furnace treatment)

Rust is the commonly used term for iron oxide from weathering or corrosion.

Scale is

  • Hard
  • Brittle
  • High Coefficient of Friction

So we need to get it off the steel if you are to have any chance of keeping the tool edge sharp.

There are 3  oxides of iron:

Hematite   ( Fe2 O3)  has a microhardness of  ~ 1030 D.P.H., is red  in color, and is not soluble in acid.

Magnetite  (Fe3O4)  has a microhardness of  ~ 420-500 D.P.H., is black in color, and is not soluble in acid. 

Wustite  (FeO) has a microhardness of  ~ 270 -350 D.P.H., is blueish in color, and is soluble in acid. Wustite is the phase that makes up the innermost scale on the bars or rods.

Hematite and Magnetite make up the outer layers of the scale, and due to their composition, make up the larger mass of scale present. Due to their hardness and quantity they are the real dealbreakers for machining as they create tool edge wear.

One of the ways that Cold Finished Steel bars aid machinability is  by removing these hard abrasive oxides from the workpiece, so that they don’t destroy your tools and contaminate your cutting fluids.

Bar Coils

The much awaited Budget deal is sure to disappoint anyone expecting real help for the budget, deficit, or the country.

Nice job , boys...

The spending cuts don’t even arrive immediately, instead they are implemented over a period of years- just $2.4 trillion over a decade.

So much for urgency, seriousness, or responsibility.

The bulk of those cuts have not been identified- kicked down the road to a future Congressional Commission.

All this deal does is kick  the real work of building a responsible budget down the road past the 2012 elections.

When are savings not savings?

When they are promised but never achieved.

Some Deal!

Kick The Can

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