Safety FIRST

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Safety FIRST
During FIRST Robotics Manufacture, Assembly, Test Operation Greg Kirksey, OSHA General Industry Outreach Trainer Scot Marshall, Lockheed Martin Space Systems, Team 1913
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Overview Signage Prevention Training Personal
Protective Equipment (PPE) Anatomy of Accidents
Hazard Analysis Safeguards Team
Safety Transportation Abuse
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Examples of Safety Signs
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General Safety

• Comply with final inspection requirements as soon
  as possible to prevent accidents
• Arena Safety/Operation
• Essential personnel only
• Stay behind barriers
• Enter when authorized
• Energize when approved
• Pit Safety Not just at competition
• Eye and foot protection at a minimum
• Assume you are at risk
• Scan for hazards
• Chemical Safety
• Material Safety Data Sheets (MSDS)

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Prevention Overview
System components must be designed, installed,
and secured so that the hazards associated with
stored energy are minimized. Adequate room must
be provided for a robot's movement as well as for
workers. There must be a means for controlling
the release of stored energy in all the robotic
systems and for shutting off power from outside
the restricted envelope. A detailed risk
assessment should be performed to ensure the
safety of workers who operate, service and
maintain the robotics system.
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Control Prevention

• Eliminate EXPOSURE to the hazard if at all
  possible
• If there is NO EXPOSURE there is NO RISK of
  injury
• Minimize the hazard if it cant be eliminated
• Restrict Access to necessary personnel
• Train/Educate those at risk
• Personnel who program, operate, maintain, or
  repair robots or robot systems should receive
  adequate safety training and be able to
  demonstrate competency in performing their jobs
  safely.
• Protect against the damage or injury
• Personnel Protective Equipment (PPE)
• Barriers and Safeguards

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Hazards when Powered OFF

• When the tool is OFF is it Safe?
• Not necessarily
• Stored Energy
• Potential Energy
• Sharp points and edges
• How do you know if it is Safe?
• Only if you know all the tools systems and
  hazards
• Learn what components can store energy
• Learn how energy can be released
• Learn the hazards associated with each tool
• LEARN HOW TO OPERATE EACH TOOL BEFORE YOU USE IT

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Training

• Safety training is necessary for new operators,
  new or altered safeguards, or new machines or
  operation
• Provide instruction or hands-on training in the
  following
• Describe and identify the hazards associated with
  each machine
• The safeguards themselves, how they provide
  protection, and the hazards for which they are
  intended
• How to use the safeguards and why
• How and under what circumstances safeguards can
  be removed, and by whom (Remove an repair by
  qualified technician when safeguards are damaged,
  return to svc.)
• What to do and what action to take if a safety
  incident occurs

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Typical Personal Protective Equipment (PPE)

• Hand
• Gloves
• Face
• Face Shield
• Eye
• Glasses, Goggles
• Ear
• Ear Plugs, Ear Muffs
• Lung
• Mask, Respirator
• Head
• Hard Hat

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Not Just PPE

• No Loose Clothing
• Unnecessary risk around moving or rotating
  machinery
• Tripping Hazard
• Can catch on nearby equipment
• Lift properly to avoid injury
• Head Up, Straight Back, Bend at Hips
• Load close to body and directly in front
• Lift with Legs, shift feet to turn, elbows in

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Before PPE Selection Survey the Site

• Conduct a walk-through to identify sources of
  hazards to workers and co-workers from the basic
  hazard categories
• Impact
• Penetration
• Compression (roll-over)
• Chemical
• Heat
• Harmful dust
• Light (optical) radiation

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PPE Selection Hazard Sources

• Motion
• Machinery or processes where movement of tools,
  machine elements or particles could exist, or
  collision with stationary objects
• High Temperatures / Chemical Exposures
• Harmful Dust
• Light Radiation
• Welding, brazing, cutting, furnaces, heat
  treating, high intensity lights, etc.
• Falling objects or potential for dropping objects
• Sharp objects
• Rolling or pinching objects which could crush the
  feet
• Layout of workplace and location of co-workers
• Electrical hazards
• Review injury/accident data to help identify
  problem areas

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Anatomy of Robotic Accidents

• Lower Incidence During
• Demonstrated Autonomous Mode
• Operator Control with an Experienced Operator
• Higher Incidence During
• Operator Orientation, Training, and
  Experimentation
• Programming Program Touchup
• New Operations
• Maintenance
• Adjustment
• Testing
• Repair
• Setup
• Thats What Youll Be Doing Most!

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Sources of Hazards

• Human Errors
• New/One-time operations (e.g. crating/uncrating)
• Prior to programming
• Interfacing activated peripheral equipment
• Connecting live devices or sensors to the
  microprocessor or a peripheral
• The greatest problem, however, is overfamiliarity
  with the robot or tool so that an individual
  places himself in a hazardous position.
• Control Errors
• Faults within the control system of the robot
• Errors in software
• interference - Electromagnetic or Radio frequency
• Unauthorized Access
• Entry into a robot's safeguarded area is
  hazardous because the person involved may not be
  familiar with the safeguards in place or their
  activation status.

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Sources of Hazards

• Transportation
• Rough/uneven floor
• Wheels that are too small for surface
• Visibility over and around the robot
• Robot that doesnt fit dolly
• In a hurry to cue
• Grade
• Cueing/Staging
• Unaware of blocking the way for another team
• Field behind schedule
• Roboteers at rest
• Out-of-Pit Repairs
• Improper tool or support
• Inadequate time for attempted repair

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Sources of Hazards

• Mechanical Failures
• Operating programs may not account for cumulative
  mechanical part failure, and faulty or unexpected
  operation may occur.
• Environmental Sources
• Electromagnetic or radio-frequency interference
  (transient signals)
• Power Systems
• Pneumatic or electrical power sources
• Electrical shock and release of stored energy
  from accumulating devices
• Improper Installation
• The design and layout of equipment, and
  facilities, if inadequately done, can lead to
  inherent hazards.

Transportation
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Types of Accidents

• Contact
• Movement, component malfunction, or program
  changes
• Crushing, Trapping, Piercing
• Failure
• Components
• Drive System
• End Effectors
• Peripheral Equipment
• Trips, Slips, Falls
• Restricted Space

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Risk of Injury or Damage

• The WORKING ENVELOPE of the machine
• More than just the robot Any machine or tool
• Maximum, Restricted, Working
• Exists when there is energy to be released
• Changes DIMENSION when the robot MOVES
• The risk exists to the edge the ENVELOPE

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Energy Storage and Release

• Mechanical Energy Storage
• Compressed Spring
• Gear
• Stalled Motor
• Chain Tension
• Momentum
• Electrical Energy Storage
• Battery, Capacitor
• Pneumatic Energy Storage
• Charged Air Cylinders
• Compressed Air in Lines
• Potential Energy Storage
• Extended Appendages
• Bound Joints
• Lifted Weights

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Eliminate the Hazard

• Release stored energy before power-down
• Return it to its home position
• Power the equipment OFF

Safety FIRST
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Safeguard Requirements

• Prevent Contact
• The safeguard must prevent hands, arms, and any
  other part of a worker's body from making contact
  with moving parts.
• Secure
• Workers should not be able to easily remove or
  tamper with the safeguard
• Protect from falling objects
• The safeguard should ensure that no objects can
  fall into moving parts.
• Create no new hazards
• A safeguard defeats its own purpose if it creates
  a hazard of its own.
• Create no interference
• Any safeguard which impedes a worker from
  performing the job quickly and comfortably might
  soon be overridden or disregarded.
• Allow safe maintenance if possible.

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Safeguards

• RISK ASSESSMENT. At each stage of development of
  the robot and robot system a risk assessment
  should be performed.
• SAFEGUARDING DEVICES. Personnel should be
  safeguarded from hazards associated with the
  restricted envelope (space) through the use of
  one or more safeguarding devices
• Mechanical limiting devices
• Nonmechanical limiting devices
• Presence-sensing safeguarding devices
• Fixed barriers (which prevent contact with moving
  parts)
• Interlocked barrier guards
• AWARENESS DEVICES
• Chain or rope barriers
• Supporting stanchions or flashing lights
• Signs, whistles, and horns

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Moving Part Safeguarding

• Point of operation
• That point where work is performed on the
  material, such as cutting, shaping, boring, or
  forming of stock.
• Power transmission apparatus
• All components of the mechanical system which
  transmit energy to the part of the machine
  performing the work. These components include
  flywheels, pulleys, belts, connecting rods,
  couplings, cams, spindles, chains, cranks, and
  gears.
• Other moving parts
• All parts of the machine which move while the
  machine is working. These can include
  reciprocating, rotating, and transverse moving
  parts, as well as feed mechanisms and auxiliary
  parts of the machine.

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Team Safety

• Safety Captain
• Independent monitor of operations during concept,
  manufacturing process, shipping / receiving,
  field trip, and competition
• Uninvolved in the proceedings while observing
• Answers only to Coach Mentors
• Identifies safety hazards and prevents safety
  incidents
• Spotters
• Used during every movement of a tool or equipment
• Eliminate hazards for the transportation team
• Ensures clearances, accessibility, coordination
• Disciplinarian Consequences of Safety
  Infractions
• Verbal
• Documentation
• Cumulative documentation
• Disciplinary action up to and including
• Being relieved of you job on the team
• Exclusion from travel to the regional
• Dismissal from the team

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Team Safety Operations Checklist

• Personnel in working area without Safety Briefing
• Visitors
• Nonessential Personnel
• Authorized and qualified personnel on break
• Equipment Location
• Equipment Configuration
• Improper fixturing of parts
• Misplaced Tools
• Damaged Tools
• Hazardous Situations
• Eye, Ear, Face, Hand, Body, Foot, Trip,

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Abuse

• Abuse and harassment may be emotional, physical,
  or sexual.
• FIRST now has eligibility procedures for
  volunteer selection, training and supervision for
  FIRST Robotics Competition (FRC) regional events
  and all components of the FIRST Championship
  similar to those being used by many other
  youth-serving organizations.
• Staff and volunteers at FIRST events are easily
  distinguishable.
• Participants are expected to be in pairs or
  larger groups at all times going to, coming from,
  and during FIRST events.
• Volunteers and participants should avoid isolated
  situations where incidents or allegations are
  more likely to occur.
• Report any suspicions of harassment or abuse
  immediately.
• FIRST will follow up on all reports, and will
  take appropriate action.

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Safety During Transportation

• Transportation-related risks for drivers,
  vehicles, and passengers
• Drivers of vehicles should be properly licensed,
  insured, be adequately trained to drive the kind
  of vehicle used.
• Drive prudently and not be under the influence of
  alcohol or drugs.
• Vehicles should be in good condition, and have
  required safety equipment, insurance, and
  inspections, and not be overloaded.
• Passengers should act safely, refrain from
  distracting the driver, and take proper safety
  precautions (i.e., use seat belts in vehicles so
  equipped).

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Remember Safety FIRST
FIRST asks everyone involved in FIRSTs programs
to place the highest priority on safety, looking
out not only for ones own safety but also the
safety of others. Do not hesitate to speak up or
act in the interest of safety. FIRST particularly
wants to highlight safety measures in the areas
of transportation, equipment and work safety, and
guarding against abuse.
http//www.osha.gov/SLTC/robotics/solutions.html
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Safety Captains Job

• My job is to make sure every teammate goes home
  from the FIRST Robotics work in the same
  condition as when they came to it!

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Back-up Charts
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Team Safety Discipline Consequences

• All students wishing to be a part of FIRST
  ROBOTICS competition must avoid receiving 10 or
  more checks on the following check list
• Students that collect 10 checks or more will not
  be able to go to the Regional and will lose all
  possible recognition for participation.
• Checks 1 thru 9 can result in lost of
  participation at the Regional and or
  Championship. In some cases, careless action
  while on school grounds and field trip activities
  may invoke school administrative discipline.
• First offense - Verbal warning with check box on
  check list circled
• Two (2) or more circled check points will be
  considered a check for each.
• Second offense - Check made in check box
• Third offense Additional checks, invoke appeal
  process, consequences
• Students are either returned to team assignment,
  reassigned, placed on suspension, or dismissed
  from the team.
• Academic Probation, failing a class, school
  suspension or expulsion are considered severe and
  may result in immediate expulsion from FIRST
  ROBOTICS
• Court of Appeals Teacher / Mentors. Students
  will have a right to explain their complaints or
  differences.

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Team Safety Discipline Checklist

• Horseplay during construction, manufacturing,
  shipping, field trip, competition
• Disregard for posted signs and set safety rules
  in place
• Lack of Gracious Professionalism or respect
  among fellow students and mentors
• Operating tools or equipment unsafely
• Careless handling or a hazard to self or others
• Abuse or playing with equipment or tools
• Irresponsible to team duties or no participation
  in work activity
• Disrespect of rules set forth by Team Captain,
  Safety Captain, Mentors, or Coaches
• Theft of school, robot, or team members property
• Absent, late, or unexcused early departure from
  Robotics program activity
• Failing a class, academic probation, suspension
  or expulsion

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Training Project

1. Have Students create their own version of Robotic
   Safety
2. Use the following slide to get students involved
   with making safety signage
3. Discuss what causes accidents between man and
   machines
4. With Coaches, Mentors and Team members.

You can make your own Safety Sign