Lifting _ Devices _ Conveyors _ ENg.pptx

lifting device

1. Dec. 2020 Raul Colin Enrique Hernandez, Lifting Devices on Conveyors

2. Lifting Tables on Conveyors Scope This training material on this document addresses the steps that the IE Engineers need to consider to design the right lifting devices on conveyors to meet safety and ergonomic standards. In addition, this document address the importance of the lifting devices to meet Takt Time requirements BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved.  2

3. Content BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved.  3

4. Importance of Lifting Devices on Conveyors Why are the Lifting Systems important? The main purpose of using a lift device is to bring the work to an operator’s ergonomic comfort zone so they won’t have to unnecessary bend, reach or overexert themselves, which places them at risk to safety issues or the worst case an work related injuries BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved.  4

5. How do lift tables improve safety? Forceful exertions . Lift tables bring the load inside the worker’s power zone Repetitive motions. Repeated exertion and forcing a worker outside the power zone places operators in a high risk of developing muscular-skeletal issues Awkward Postures . Using a lift device on conveyor prevents operators from being expose to awkward or unnatural postures Static Postures . Staying in one posture for extended periods can also cause MSD Pressure Points. Pressure or pinch points also place operators in danger of injury BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved.  5

6. How to design (Steps) a lifting device for conveyors Systems Selecting the proper lifting device requires a good grip on knowing what you need your lift for. The best step is making a list of all the reasons you need a lift table in your facility and what you want it to do. BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved.  6 Items to consider when designing lifting devices: Capacity:  You need to know how much your typical load weights are and size your lift to slightly exceed maximum expected weights. Stroke:  This is the industry term for the length of the lift’s reach. Like capacity, you want your lift table specified for a bit beyond maximum expected reach. Size:  This refers to your load platform or tabletop size. Lift tables elevating conventional pallets need a matching area whereas specialized lift sizes may be smaller. Drive:  Knowing what drive mechanism you need is critical in sourcing the right table. Common drives are manual, mechanical, electric, hydraulic, pneumatic or some combination of each. Safety:  If there’s one choice to get right, it’s selecting a lift table with suitable safety features that protect your workers and your products.

7. Considerations for Lifting Devices Capacity One of the main items to be considered for lifting devices during the design stage is the weight of the unit: Weight is going to drive the type of design for the lifting device: Is the unit too heavy to move it manually? Does the lifting device need to be operated manually or automatically due to the weight of the unit? Does the conveyor have enough capacity to allow the unit to move down the stream safely? Does the unit design allow the lifting device to raise it without causing any safety issues or cosmetic damage? 7 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved. 

8. Lifting Device Stroke The stroke of the lifting device depends on of the actual unit dimensions (size) and type of application: Does the operator will be working on sitting position or standing? Is the height of the conveyor according to ergonomic standards? Too low? Too high? Meet standards? Does the facility support hydraulic or pneumatic lifter for proper stroke? Air pressure supply available? Availability of standard hydraulic oils? 8 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved. 

9. Lifter Table Size (Plate) The size of the lifting table depends on the design of the unit that needs to be lifted. This lifting table should be design to protect the operator arms and hands as well as the integrity of the product. Considerations for lifting tables: The size of the lifting tables should be designed according to the size of the base of the unit It is not recommended to design lifter tables that exceed the size of the conveyor width The lifter table should be designed to support the weight of the unit (thickness of the plate) Proper guards should be designed to cover any gaps between the plate and the conveyor. Gaps should not allow to place any moving body parts in between the plate and the conveyor Lifting tables should be made of the proper materials including locator pins, clamping devices, sitting pads, etc. to prevent any damage of units. Excessive wear of softer materials used by lifter plates could cause unsafe condition 9 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved. 

10. Lifter Table Drive D rive mechanism is critical in sourcing the right table. The Drive will affect how the stroke of the lifting device is going to behave when lifting the load. Several types of Drive are available in the market: Manual operation Mechanical operation Electric Pneumatic Or a combination of all of them The IE Engineer will decide which Drive is the appropriate for the load to be lifted safely. If the IE Engineer does not have the expertise to understand this important factor, the lifting device should be designed by an expert 10 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved. 

11. Safety If there’s one choice to get right, it’s selecting a lift table with suitable safety features that protect your workers and your products. Jabil EHS has a variety of documents showing the main requirements when designing, installing, and operating equipment for manufacturing processes. These documents have information for: Machinery Risk Assessment Safe machinery operations Emergency stops Maintenance Interlocks Calibration Machine Guarding Presence sensing devices General safety Controls 11 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved.  The next slides will review commonly used  Machinery Safety elements. Refer to  Jabil Machinery Safety Standard  SE-ES20-00004

12. Section 3.2: Machinery Risk Assessment (MRA) - Columns A - I 12 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2019. All Rights Reserved.  A: Assessment number by machinery (can use equipment number) B: Document the type of risk Health & safety (H&S) or Environment (ENV) for the machinery. Examples of environment risk would be hydraulic spill potentials, or chemicals used in the machine C: Type of Machine: List the type of machine D: Machine Location: Location of the machine or machines E: Machine Manufacturer/ Description/ Model / Serial Number F: Hazard/ Aspect: all the hazards based on category G: Consequences/Impact: potential consequences of the hazards and/or impacts of the aspects based on the operational task of the machine H: Machine Usage: estimation of the machine usage (# shift per wk, hrs/mn) I: Condition in Which Risk is Being Assessed: Review the operation of the machine for Health and Safety concerns during under normal, abnormal, start-up, shut down and emergency shutdown scenario

13. Section 3.3 Safe machinery operations 13 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2019. All Rights Reserved.  Guard(s) shall be in place Presence Sensing Device (PSD) is active and functioning properly The machinery shall be designed so that it will not operate during normal operation if any safety related alarms are activated. Employees shall always be outside of hazard zone when machine is operating in automatic mode (i.e. not in manual control of the employee) Work Instruction shall: Document start-up, operation shutdown and steps to shut down in case of emergency Based on manufacturer’s operational instructions Operators trained on the safe startup, operation, shutdown, activating emergency system such us E-Stop and the safety controls associated with each machine before operating them.

14. Section 3.3.3 Emergency Stop (E-Stop) Requirements 14 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2019. All Rights Reserved.  Machinery Emergency Stop (E-Stop) Requirements (location, design) Purchase and install E-Stops that are designed in according with ISO 13850.  Install safety related parts of the control system or subsystems which perform E-Stop that comply with ISO 13849-1 Initiated by a single human action (i.e. only manual operation) Always operational Overrides all other functions and operations in all operating modes of the machine Shall remove energy sources to all hazards Shall be used for emergency shut down  Shall not be used to shutdown equipment during standard operation Shall stay engaged until manually reset Shall accessible from operator workplace and installed in manner as to avoid unintentional operation

15. 3.3.6 Servicing, maintenance, calibration, major adjustments of the machine and testing 15 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2019. All Rights Reserved.  Work instructions for preventative (PM) and routine maintenance  Post servicing/maintenance verification check Strongly recommended to add verification check to all maintenance work instructions and have this in a computerized preventative maintenance system. Followed of  SE-ES20-00010  Control of Hazardous Energy (LOTO) All equipment is required to have a LOTO procedure including all sources of energy (electrical, thermal, mechanical, pneumatic, hydraulic, etc.) Specify the requirements for only trained/ authorized employees to perform service and maintenance activities.  Remember: Everyone that performs tasks must be trained including Operators (if applicable) Inventory safety related devices (interlocks, light curtains, etc.) & PM schedule Inventory all fixed guards & PM or replacement schedule The safety devices shall be properly maintained and tested periodically to assure its effectiveness.

16. 16 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2019. All Rights Reserved.  Barriers height shall be high enough to prevent everyone for being able to access the machinery including reaching over, etc. Distance from the floor to the barrier shall be minimized to allow access from any part of the body. The distance from the floor to the barrier shall be low enough to prevent smallest foot to access the hazard zone. 3.4.2 Barrier / Perimeter / Hazard Zone Guarding X

17. 17 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2019. All Rights Reserved.  Interlocks shall meet minimum requirements: Installed to not be overridden (i.e. not able to defeat/non-defeatable) and tamper resistant Shall stop motion prior to allowing access to the hazard and prevent the equipment from starting Light curtains: Shall be mounted in a fixed position  Located so that access to the point of operation meets safe stop time distance calculations.  Guards shall be interlocked if the operator is required to open or remove the guard during normal operation of the equipment.  3.4.4 Interlock Devices

18. 18 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2019. All Rights Reserved.  Photoelectrical (optical) - light curtain, laser presence sensor Radiofrequency (capacitance) Pressure-sensitive (safety mat) Electromechanical 3.4.5 Presence Sensing Devices Hand Detection Safety Sensor

19. Training 19 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2019. All Rights Reserved.  Machinery Safety SME, employees authorized to work on machinery and employees who are required to modify, set-up, maintain, repair, inspect, install or are otherwise be exposed to machine hazards. Description and identification of hazards associated with machines/equipment or operation Description of the guards and their functions Instructions on how to use the guards Instructions on how and under what circumstances guards may be removed, and by whom Instructions on what to do if a guard is missing, damaged, or inadequate Machine energy isolation or lock-out/tag-out practices and safe electrical work practices Appropriate selection and use of personal protection equipment (PPE) and tools Hands-on practical review of a piece of equipment

20. Review/audit & Record Retention 20 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2019. All Rights Reserved.  Review, audit and validate effectiveness of local procedures in accordance with: Machinery Safety Local and corporate review Audit/validation procedures Note: When non-conformances and/or deficiencies are identified, sites shall develop a plan of action to address gaps and track actions to completion (EHSIP project) Record Retention Retain records according to the Jabil corporate record retention policy - 00-LL10-1000-001Jabil Records Management Policy Machinery Risk Assessments: until superseded

21. IE Safety and Ergonomic Training Materials Assembly Lifter General Guidelines  EM-IE20-00009.  IE-133 Ergonomics (Located in IE Portal) To learn more, refer to EHS Share Point Portal  : Machinery Safety Training 1 and 2 EHS Control of Hazardous Energy (LOTO) Training  Machinery Safety Standard SE-ES20-00004 Control of Hazardous Energy (LOTO) SE-ES20-00010 21 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved. 

22. 22 BUSINESS CONFIDENTIAL | ©Jabil Inc. 2020. All Rights Reserved.  Global EMS Automation