sf11 - machinery safety: processes for achieving and maintaining regulatory compliance
TRANSCRIPT
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
PUBLIC INFORMATION
Sustainability Solution for Enterprise Lockout-Tagout ProgramsProtecting program investment and capturing performance data
Name – John Jauquet
Title – ScanESC – Sustainability Solution
RA TechED 2015
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 2
Agenda
Summary
Benefits to safety and efficiency
ScanESC solution overview
Common pitfalls
Review of basic requirements
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 3
Agenda
Summary
Benefits to safety and efficiency
ScanESC solution overview
Common pitfalls
Review of basic requirements
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Review of OSHA requirements
4
OSHA requires that each procedure be audited every year (+ employees)
1910.147(c)(6)
Periodic inspection.
www.osha.gov
1910.147(c)(6)(ii)
The employer shall certify that the periodic inspections have been
performed. The certification shall identify the machine or equipment on
which the energy control procedure was being utilized, the date of the
inspection, the employees included in the inspection, and the person
performing the inspection.
1910.147(c)(6)(i)
The employer shall conduct a periodic inspection of the energy control
procedure at least annually to ensure that the procedure and the
requirements of this standard are being followed.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 5
Agenda
Summary
Benefits to safety and efficiency
ScanESC solution overview
Common pitfalls
Review of basic requirements
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Common Pitfalls
6
Failing to audit each procedure.
Failing to properly document audits.
Failing to audit authorized employees.
Failing to properly document employee audits.
Enterprise level program often fail due to unanticipated manpower required to properly maintain.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 7
Agenda
Summary
Benefits to safety and efficiency
ScanESC solution overview
Common pitfalls
Review of basic requirements
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
ScanESC – Solution overview
8
Audits can be performed much quicker (up to 85% quicker in some cases)
by allowing users to identify and document who did the audit, what checks
were conducted, when it was done and if there were any findings from that
audit for each procedure….All from simply scanning a QR code.
ScanESC addresses common compliance gaps by systemizing the process to keep it simple, consistent, and quick.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
What it is…
Cloud enhanced, not cloud based.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
iPad App Overview
Internally manage and maintain your
LOTO programs
Easily demonstrate real-time
compliancy status
Access to procedural updates
Automatically pushed down through server
RevolutionaryPatented and only one of its kind
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Complete Audit Control
Utilize ScanESC to:
Audit procedures
Audit authorized employees
View lockout-tagout procedures
Track lockouts
Quickly view corporate policy
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Simply Sign Into ScanEsc
Access your database with your
personal username and password.
This tracks who is conducting the audit.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Lockout Tracking
Lock symbol indicates what
equipment is locked out.
Usage log is generated
automatically and accessible
online.
Track LOTO usage
Track group lockouts
View lockout timeline (how
long LOTO takes, service
time, etc.)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Procedure QR Codes
Scan QR codes
Installed on equipment
Procedures never lost
Quickly finds procedure
Simple to assign.
QR codes easily replaced as needed.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
See it in action – Locking out EQ
Select Procedure or Scan Barcode
Initiate lockout
Select employees
Once steps are completed select
Finish LOTO
Lock logo will appear over
procedure and in list to visually
show it’s locked out.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
See it in action – Auditing Procedures
Real-time audit data accessible on server and other iPads.
Audit time reduced up to 85%.
Higher quality audit data (who, what, when, etc.)
Pushed to server instantly, or held offline until connection reestablished.
Audit data helps improve proactive program maintenance (identifies “pencil whipping”)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Tutorial Included and Updatable
Easy reference tutorial
Procedure Auditing
Employee Auditing
Task List
Easily updatable as program usage
matures.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Web Portal (company.escapps.com)
Log in to view client specific procedures and
audit status
Dashboard
Manage Procedures
Equipment Status
Accessible on any computer from
anywhere in the world.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Dashboard
Easily view procedure and employee
audit status
Multiple facility statuses available
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Manage Procedures / View Status
Easily manage and upload procedures
to server
Automatically pushes updates down to
all iPads
View critical data
LOTO status (locked or unlocked)
Audit status (who audited, when,
which equipment)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 22
Agenda
Summary
Benefits to safety and efficiency
ScanESC solution overview
Common pitfalls
Review of basic requirements
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Tablet Solution Benefits
Cut overall audit time by up to 85% or
more.
Watch audit status unfold real time.
Interact with your employees to
proactively manage your program and
ensure compliance.
Improve overall productivity by targeting
improvements for equipment with high
frequency/extended lockout times.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Benefits – Using modern tools to streamline
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How ROI is captured:
ScanESC™
Reduces annual admin burden
Gives better and consistent audit data
Allows group collaboration
Alternative Procedures to LOTO (SOP, APM)
Allows safe servicing of equipment for select tasks (without LOTO)
Improves productivity by shortening lockout or in some cases even eliminating
shutting the machine down.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Benefits - Capturing / Harvesting Data
Manage your procedures with the safety and security of the cloud.
Use ScanESC offline (doesn’t require internet access to work).
Streamline your safety program and manage your leading indicators.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Benefits – Capturing / Harvesting Data
26
Access on website portal
from any browser anywhere
in the world.
Procedure, employee, and
equipment status are
synchronized with the QR
code and updated data from
the tablets.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Benefits – Future Proof – No Fees
27
ScanESC uses MS Excel® files as the backbone for all procedures.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 28
Agenda
Summary
Benefits to safety and efficiency
ScanESC solution overview
Common pitfalls
Review of basic requirements
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 29
ScanESC - Summary
• Lockout-Tagout compliance is
nearly impossible for large
companies with multiple
locations due to high burden
of audit requirements.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 30
ScanESC - Summary
• ScanESC helps relieve the
burden while also providing key
data to help schedule
improvements to overall program
as data matures.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 31
ScanESC - Summary
• ScanESC’s future will allow
for more collaboration
between Rockwell and
clients by integrating other
procedure types (SOP, APM,
and more).