During FIRST RoboticsDuring FIRST RoboticsManufacture, Assembly, Test & OperationManufacture, Assembly, Test & Operation

Greg Kirksey, OSHA General Industry Outreach TrainerGreg Kirksey, OSHA General Industry Outreach TrainerScot Marshall, Lockheed Martin Space Systems, Team 1913Scot Marshall, Lockheed Martin Space Systems, Team 1913

SafetySafety FIRSTFIRST

Overview

SignagePrevention

TrainingPersonal Protective Equipment (PPE)

Anatomy of Accidents Hazard Analysis

SafeguardsTeam Safety

TransportationAbuse

Examples of Safety SignsExamples of Safety Signs

Comply with final inspection requirements as Comply with final inspection requirements as soon as possible to prevent accidentssoon as possible to prevent accidentsArena Safety/OperationArena Safety/Operation

Essential personnel onlyEssential personnel onlyStay behind barriersStay behind barriersEnter when authorizedEnter when authorizedEnergize when approvedEnergize when approved

Pit Safety – Not just at competitionPit Safety – Not just at competitionEye and foot protection at a minimumEye and foot protection at a minimumAssume you are at riskAssume you are at riskScan for hazardsScan for hazards

Chemical SafetyChemical SafetyMaterial Safety Data Sheets (MSDS)Material Safety Data Sheets (MSDS)

General Safety

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.

Prevention Overview

Control & Prevention

Eliminate EXPOSURE to the hazard if at all possibleIf there is NO EXPOSURE there is NO RISK of injury

Minimize the hazard if it can’t be eliminated

Restrict Access to necessary personnel

Train/Educate those at riskPersonnel 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 injuryPersonnel Protective Equipment (PPE)

Barriers and Safeguards

When the tool is OFF is it Safe?When the tool is OFF is it Safe?– Not necessarilyNot necessarily

Stored EnergyStored Energy

Potential EnergyPotential Energy

Sharp points and edgesSharp points and edges

– How do you know if it is Safe?How do you know if it is Safe?Only if you know all the tools’ systems and hazardsOnly if you know all the tools’ systems and hazards

Learn what components can store energyLearn what components can store energy

Learn how energy can be releasedLearn how energy can be released

Learn the hazards associated with each toolLearn the hazards associated with each tool

LEARN HOW TO OPERATE EACH TOOL LEARN HOW TO OPERATE EACH TOOL BEFORE YOU USE ITBEFORE YOU USE IT

Hazards when Powered OFF

Safety training is necessary for new operators, Safety training is necessary for new operators, new or altered safeguards, or new machines or new or altered safeguards, or new machines or operationoperationProvide instruction or hands-on training in the Provide instruction or hands-on training in the following: following:

Describe and identify the hazards associated with each Describe and identify the hazards associated with each machinemachineThe safeguards themselves, how they provide protection, The safeguards themselves, how they provide protection, and the hazards for which they are intendedand the hazards for which they are intendedHow to use the safeguards and whyHow to use the safeguards and whyHow and under what circumstances safeguards can be How and under what circumstances safeguards can be removed, and by whom (Remove an repair by qualified removed, and by whom (Remove an repair by qualified technician when safeguards are damaged, return to svc.)technician when safeguards are damaged, return to svc.)What to do and what action to take if a safety incident occursWhat to do and what action to take if a safety incident occurs

Training

HandHandGlovesGloves

FaceFaceFace ShieldFace Shield

EyeEyeGlasses, GogglesGlasses, Goggles

EarEarEar Plugs, Ear MuffsEar Plugs, Ear Muffs

LungLungMask, RespiratorMask, Respirator

HeadHeadHard HatHard Hat

Typical Personal Protective Equipment (PPE)

No Loose ClothingNo Loose ClothingUnnecessary risk around moving or rotating Unnecessary risk around moving or rotating machinerymachinery

Tripping HazardTripping Hazard

Can catch on nearby equipmentCan catch on nearby equipment

Lift properly to avoid injuryLift properly to avoid injuryHead Up, Straight Back, Bend at HipsHead Up, Straight Back, Bend at Hips

Load close to body and directly in frontLoad close to body and directly in front

Lift with Legs, shift feet to turn, elbows inLift with Legs, shift feet to turn, elbows in

Not Just PPE

Conduct a walk-through to identify sources Conduct a walk-through to identify sources of hazards to workers and co-workers from of hazards to workers and co-workers from the basic hazard categories:the basic hazard categories:

ImpactImpactPenetrationPenetrationCompression (roll-over)Compression (roll-over)ChemicalChemicalHeatHeatHarmful dustHarmful dustLight (optical) radiationLight (optical) radiation

Before PPE Selection – Survey the Site

MotionMotionMachinery or processes where movement of tools, machine Machinery or processes where movement of tools, machine elements or particles could exist, or collision with stationary objectselements or particles could exist, or collision with stationary objects

High Temperatures / Chemical ExposuresHigh Temperatures / Chemical ExposuresHarmful DustHarmful DustLight RadiationLight Radiation

Welding, brazing, cutting, furnaces, heat treating, high intensity Welding, brazing, cutting, furnaces, heat treating, high intensity lights, etc.lights, etc.

Falling objects or potential for dropping objectsFalling objects or potential for dropping objectsSharp objectsSharp objectsRolling or pinching objects which could crush the feetRolling or pinching objects which could crush the feetLayout of workplace and location of co-workersLayout of workplace and location of co-workersElectrical hazardsElectrical hazardsReview injury/accident data to help identify problem Review injury/accident data to help identify problem areasareas

PPE Selection – Hazard Sources

Anatomy of Robotic AccidentsLower 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

That’s What You’ll Be Doing Most!

Human ErrorsHuman ErrorsNew/One-time operations (e.g. crating/uncrating)New/One-time operations (e.g. crating/uncrating)Prior to programmingPrior to programmingInterfacing activated peripheral equipmentInterfacing activated peripheral equipmentConnecting live devices or sensors to the microprocessor or Connecting live devices or sensors to the microprocessor or a peripherala peripheralThe greatest problem, however, is overfamiliarity with the The greatest problem, however, is overfamiliarity with the robot or toolrobot or tool so that an individual places himself in a so that an individual places himself in a hazardous position.hazardous position.

Control ErrorsControl ErrorsFaults within the control system of the robotFaults within the control system of the robotErrors in softwareErrors in softwareinterference - Electromagnetic or Radio frequencyinterference - Electromagnetic or Radio frequency

Unauthorized AccessUnauthorized AccessEntry into a robot's safeguarded area is hazardous because Entry into a robot's safeguarded area is hazardous because the person involved may not be familiar with the safeguards the person involved may not be familiar with the safeguards in place or their activation status. in place or their activation status.

Sources of Hazards

TransportationTransportationRough/uneven floorRough/uneven floorWheels that are too small for surfaceWheels that are too small for surfaceVisibility over and around the robotVisibility over and around the robotRobot that doesn’t fit dollyRobot that doesn’t fit dollyIn a hurry to cueIn a hurry to cueGradeGrade

Cueing/StagingCueing/StagingUnaware of blocking the way for another teamUnaware of blocking the way for another teamField behind scheduleField behind scheduleRoboteers at rest Roboteers at rest

Out-of-Pit RepairsOut-of-Pit RepairsImproper tool or supportImproper tool or supportInadequate time for attempted repairInadequate time for attempted repair

Sources of Hazards

Mechanical FailuresMechanical FailuresOperating programs may not account for cumulative Operating programs may not account for cumulative mechanical part failure, and faulty or unexpected mechanical part failure, and faulty or unexpected operation may occur.operation may occur.

Environmental SourcesEnvironmental SourcesElectromagnetic or radio-frequency interference Electromagnetic or radio-frequency interference (transient signals)(transient signals)

Power SystemsPower SystemsPneumatic or electrical power sourcesPneumatic or electrical power sourcesElectrical shock and release of stored energy from Electrical shock and release of stored energy from accumulating devices accumulating devices

Improper InstallationImproper InstallationThe design and layout of equipment, and facilities, if The design and layout of equipment, and facilities, if inadequately done, can lead to inherent hazards. inadequately done, can lead to inherent hazards.

Sources of Hazards

Transportation

ContactMovement, component malfunction, or program changes

Crushing, Trapping, Piercing

FailureComponents

Drive System

End Effectors

Peripheral Equipment

Trips, Slips, Falls

Restricted Space

Types of Accidents

Risk of Injury or DamageThe 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

Mechanical Energy StorageCompressed SpringGearStalled MotorChain TensionMomentum

Electrical Energy StorageBattery, Capacitor

Pneumatic Energy StorageCharged Air CylindersCompressed Air in Lines

Potential Energy StorageExtended AppendagesBound JointsLifted Weights

Energy Storage and Release

Release stored energy before power-downRelease stored energy before power-down

Return it to its “home” positionReturn it to its “home” position

Power the equipment OFFPower the equipment OFF

Eliminate the Hazard

Prevent ContactPrevent ContactThe safeguard must prevent hands, arms, and any other part of a The safeguard must prevent hands, arms, and any other part of a worker's body from making contact with moving parts. worker's body from making contact with moving parts.

SecureSecureWorkers should not be able to easily remove or tamper with the Workers should not be able to easily remove or tamper with the safeguardsafeguard

Protect from falling objectsProtect from falling objectsThe safeguard should ensure that no objects can fall into moving The safeguard should ensure that no objects can fall into moving parts. parts.

Create no new hazardsCreate no new hazardsA safeguard defeats its own purpose if it creates a hazard of its own.A safeguard defeats its own purpose if it creates a hazard of its own.

Create no interferenceCreate no interferenceAny safeguard which impedes a worker from performing the job Any safeguard which impedes a worker from performing the job quickly and comfortably might soon be overridden or disregarded.quickly and comfortably might soon be overridden or disregarded.

Allow safe maintenance if possible.Allow safe maintenance if possible.

Safeguard Requirements

RISK ASSESSMENT. RISK ASSESSMENT. At each stage of development of the robot and robot system a risk assessment should be performed.

SAFEGUARDING DEVICESSAFEGUARDING DEVICES. . Personnel should be safeguarded from hazards associated with the restricted envelope (space) through the use of one or more safeguarding devices:

Mechanical limiting devicesMechanical limiting devicesNonmechanical limiting devicesNonmechanical limiting devicesPresence-sensing safeguarding devicesPresence-sensing safeguarding devicesFixed barriers (which prevent contact with moving parts) Fixed barriers (which prevent contact with moving parts) Interlocked barrier guardsInterlocked barrier guards

AWARENESS DEVICESAWARENESS DEVICESChain or rope barriersChain or rope barriersSupporting stanchions or flashing lightsSupporting stanchions or flashing lightsSigns, whistles, and hornsSigns, whistles, and horns

Safeguards

Point of operation: Point of operation: That point where work is performed on the material, such as That point where work is performed on the material, such as cutting, shaping, boring, or forming of stock.cutting, shaping, boring, or forming of stock.

Power transmission apparatus: Power transmission apparatus: All components of the mechanical system which transmit All components of the mechanical system which transmit energy to the part of the machine performing the work. These energy to the part of the machine performing the work. These components include flywheels, pulleys, belts, connecting components include flywheels, pulleys, belts, connecting rods, couplings, cams, spindles, chains, cranks, and gears.rods, couplings, cams, spindles, chains, cranks, and gears.

Other moving parts: Other moving parts: All parts of the machine which move while the machine is All parts of the machine which move while the machine is working. These can include reciprocating, rotating, and working. These can include reciprocating, rotating, and transverse moving parts, as well as feed mechanisms and transverse moving parts, as well as feed mechanisms and auxiliary parts of the machine.auxiliary parts of the machine.

Moving Part Safeguarding

Safety CaptainSafety CaptainIndependent monitor of operations during concept, manufacturing Independent monitor of operations during concept, manufacturing process, shipping / receiving, field trip, and competitionprocess, shipping / receiving, field trip, and competitionUninvolved in the proceedings while observingUninvolved in the proceedings while observingAnswers only to Coach & MentorsAnswers only to Coach & MentorsIdentifies safety hazards and prevents safety incidents Identifies safety hazards and prevents safety incidents

Spotters Spotters Used during every movement of a tool or equipmentUsed during every movement of a tool or equipmentEliminate hazards for the transportation teamEliminate hazards for the transportation teamEnsures clearances, accessibility, coordination Ensures clearances, accessibility, coordination

Disciplinarian – Consequences of Safety InfractionsDisciplinarian – Consequences of Safety InfractionsVerbalVerbalDocumentationDocumentationCumulative documentationCumulative documentationDisciplinary action up to and including:Disciplinary action up to and including:

– Being relieved of you job on the teamBeing relieved of you job on the team– Exclusion from travel to the regionalExclusion from travel to the regional– Dismissal from the teamDismissal from the team

Team Safety

Personnel in working area without Safety BriefingPersonnel in working area without Safety Briefing VisitorsVisitors Nonessential PersonnelNonessential Personnel Authorized and qualified personnel on breakAuthorized and qualified personnel on break

Equipment LocationEquipment Location Equipment ConfigurationEquipment Configuration Improper fixturing of partsImproper fixturing of parts Misplaced ToolsMisplaced Tools Damaged ToolsDamaged Tools Hazardous SituationsHazardous Situations

– Eye, Ear, Face, Hand, Body, Foot, Trip, Eye, Ear, Face, Hand, Body, Foot, Trip,

Team Safety – Operations Checklist

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.

Abuse

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).

Safety During Transportation

FIRST asks everyone involved in FIRST’s programs to place the highest priority on safety, looking out not only for one’s 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

Safety Captain’s JobSafety Captain’s Job

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

Back-up ChartsBack-up Charts

All students wishing to be a part of FIRST ROBOTICS competition must All students wishing to be a part of FIRST ROBOTICS competition must avoid receiving 10 or more checks on the following check listavoid receiving 10 or more checks on the following check listStudents that collect 10 checks or more will Students that collect 10 checks or more will notnot be able to go to the be able to go to the Regional and will lose all possible recognition for participation. Regional and will lose all possible recognition for participation. Checks 1 thru 9 can result in lost of participation at the Regional and or 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 Championship. In some cases, careless action while on school grounds and field trip activities may invoke school administrative discipline. field trip activities may invoke school administrative discipline. First offenseFirst offense - Verbal warning with check box on check list circled - Verbal warning with check box on check list circled– Two (2) or more circled check points will be considered a check for each.Two (2) or more circled check points will be considered a check for each.

Second offenseSecond offense - Check made in check box - Check made in check boxThird offenseThird offense – Additional checks, invoke appeal process, consequences – Additional checks, invoke appeal process, consequences

Students are either returned to team assignment, reassigned, placed on Students are either returned to team assignment, reassigned, placed on suspension, or dismissed from the team.suspension, or dismissed from the team.Academic Probation, failing a class, school suspension or expulsion are Academic Probation, failing a class, school suspension or expulsion are considered severe and may result in immediate expulsion from FIRST considered severe and may result in immediate expulsion from FIRST ROBOTICS ROBOTICS Court of Appeals: Teacher / Mentors. Students will have a right to explain Court of Appeals: Teacher / Mentors. Students will have a right to explain their complaints or differences.their complaints or differences.

Team Safety – Discipline Consequences

Horseplay during construction, manufacturing, shipping, field Horseplay during construction, manufacturing, shipping, field trip, competitiontrip, competition

Disregard for posted signs and set safety rules in placeDisregard for posted signs and set safety rules in place Lack of “Gracious Professionalism” or respect among fellow Lack of “Gracious Professionalism” or respect among fellow

students and mentorsstudents and mentors Operating tools or equipment unsafelyOperating tools or equipment unsafely Careless handling or a hazard to self or othersCareless handling or a hazard to self or others Abuse or playing with equipment or toolsAbuse or playing with equipment or tools Irresponsible to team duties or no participation in work activityIrresponsible to team duties or no participation in work activity Disrespect of rules set forth by Team Captain, Safety Captain, Disrespect of rules set forth by Team Captain, Safety Captain,

Mentors, or CoachesMentors, or Coaches Theft of school, robot, or team member’s propertyTheft of school, robot, or team member’s property Absent, late, or unexcused early departure from Robotics Absent, late, or unexcused early departure from Robotics

program activityprogram activity Failing a class, academic probation, suspension or expulsionFailing a class, academic probation, suspension or expulsion

Team Safety – Discipline Checklist

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.

Training Project