Safety equipment is essential for protecting workers from hazards and injuries in the workplace. However, if not maintained properly, safety equipment can become ineffective, damaged, or even dangerous. Here are some of the most common safety equipment maintenance mistakes and how to avoid them.
One of the biggest mistakes is to skip regular inspections of safety equipment. Inspections are necessary to check for wear and tear, defects, malfunctions, and compliance with standards. Without inspections, you may not notice problems until it is too late and the equipment fails or causes harm. You should follow the manufacturer's guidelines and industry best practices for inspecting your safety equipment and documenting the results.
Uno de los errores más comunes suele ser él no comprobar el correcto funcionamiento de lo equipos de seguridad. Confiamos en que están ahí y siempre funcionan de manera correcta y cuando los necesitamos nos damos cuenta de que no paran nuestra cinta transportadora, no cortan la corriente principal o no paran nuestra maquinaria, para que podamos intervenir de manera segura.
Le Manque de préparation des chantiers est également une erreur qui conduit à une mauvaise maintenance des équipements. Elle se traduit par : -Equipe mal outillé -Pièce de rechange non disponible ou inadéquate -Délais de réalisation trop long -Travail réaliser sans aucunes procédure ou gamme d'exécution Les conséquences que cela peut entrainer sont : -Des intervenants qui travaillent sous pression, et omettent de réaliser les travails efficacement, -Des intervenants qui sans procédure d'exécution conforme aux recommandation du fabriquant, -Des équipes opérationnelles qui utilise des pièces inadéquat pour remplacer les pièces usées ou ne remplace pas certaines pièces à cause de leurs indisponibilité,
1. Not referring to OEM Manuals and inspection or parts replacement frequencies (as a baseline) 2. Adjust OEM inspection/preventative maintenance cycles to your operations/equipment running time (very overlooked) 3. Specifically for safety equipment using OEM parts (not 3rd party off brand parts). 4. When failures happen, not understanding root cause and adjusting strategy accordingly. 5. Not identifying the way a piece of equipment is being used or kept (usage out of operating parameters, human error in operation, lack of cleaning or basic lubrication)
Common equipments maintenance mistakes: 1. using the wrong tool for the right job. 2. Not taking component maintenance mannual into consideration when carrying ot maintenance. 3. Overlooking near-miss. 4. Lack of proper training.
Missing safety devices and machine guarding after maintenance. Apart from this matter, recording and replacing parts not according to the specification but according to the cost.
Another common mistake is to ignore or delay repairs of safety equipment. Repairs are essential to fix any issues that are found during inspections or reported by users. Ignoring repairs can compromise the performance and reliability of the equipment and increase the risk of accidents and injuries. You should prioritize repairs and use qualified technicians and quality parts to restore your safety equipment to optimal condition.
To backup your point here with direct observation and experience I’ve had in the past, the lack of Standard Operating Procedure (SOP) is another major factor, when SOP and not in place or not duly follow it can leads to safety risk.
Well, actually this as been some of the attitude that many companies adopt, for example in my company we have some equipment out of use, equipment with 15 years old, they never been replaced, why ? the answer is obvious, just because it gives much profit. On the other side, we may be thinking that finally we are saving once not...
In the aspect of repairs, operations personnel must insist that a repair is done properly before returning to use faulty equipment. Management also has a huge role to play in the aspect of repairs. Most time, running costs and the cost of repair can make the management compromise on repairs. Repairs are essential.
From what I have seen over my career, the times repairs have been ignored is due to the need to produce or be productive. This to me is a culture is with some employers to be productive or safe. It is a red flag for me and I will not work for such companies.
Employers who ignore repairs to safety equipment are violating the basic and fundamental obligation of ensuring that the workplace must be free from harm to employees. Such employers (managers) are directly responsible for placing their employees in harm's way and must be held directly liable for any harm to their employees.
Improper cleaning of safety equipment can also lead to problems. Cleaning is important to remove dirt, dust, grease, and contaminants that can affect the functionality and durability of the equipment. However, cleaning should be done carefully and according to the manufacturer's instructions. Using the wrong products, methods, or tools can damage the equipment or leave residues that can interfere with its operation. You should use the appropriate cleaning agents and equipment and follow the recommended frequency and procedure for cleaning your safety equipment.
Improper cleaning can lead to equipment overheating resulting in premature component failure. Lose bolts, nuts , cracks and oil leaks can only be visible if the machine is washed thoroughly before carrying out tasks and repair. Avoid using diesel as a cleaning agent because it will components become dirty easily especially on radiator and coolers.
Housekeeping is an integral part of safety. It helps to expose hidden faults in a machine. Equipment cleaning is a preventive maintenance practice.
This may be redirected to asset management. All equipment must be assigned to particular individuals who will ensure that they are used, stored and maintained as per manufacturer's recommendations. These individuals must first be trained.
In my role as an electrical engineer, I emphasize the significance of proper cleaning in safety equipment maintenance. Cleaning is pivotal to remove dirt, dust, grease, and contaminants that can impact equipment functionality and durability. Yet, it's crucial to approach cleaning with care, adhering strictly to the manufacturer's instructions. Using incorrect products, methods, or tools may damage the equipment or leave residues that hinder its operation. Employing suitable cleaning agents, tools, and following recommended frequencies ensures the effective maintenance of safety equipment in line with industry standards and best practices.
Uma limpeza mal executada pode fazer um equipamento parar e causar estragos no mesmo, causando paradas as vezes longas para corrigir o defeito pela falta de limpeza e ainda refazer a limpeza n?o realizada. Os transtornos s?o gigantescos para a produ??o de uma empresa bem como os custos para arcar com a parada n?o planejado.
Inadequate storage of safety equipment can also cause damage and deterioration. Storage is crucial to protect the equipment from exposure to moisture, heat, sunlight, chemicals, and other harmful factors that can affect its quality and lifespan. Improper storage can also lead to loss, theft, or misuse of the equipment. You should store your safety equipment in a secure, dry, and ventilated place that is away from sources of heat, light, and corrosion. You should also label, organize, and inventory your safety equipment to keep track of its location and condition.
All of the abovementioned are the most common mistakes in equipment maintenance or lack of it, but in my experience in my line of work, industry and location, the oil drilling industry is in crisis as the NOC is in serious debt, expending most of its allocated budget in paying loans and interests, unwillingly creating problems to its suppliers and service providers by delaying their payments for weeks or even months, therefore causing strains in their finances as they now have to ask for loans in order to keep operating, so whenever they are in deep trouble as they cannot default their contracts, they start cutting back on expenses, by reducing maintenance and training, loosing support from OEM, etc. Its bad situation.
This is another obligation for asset management requirements. Use, storage and maintenance of equipment is necessary in any organisation.
store equipmentsfully covered to prevent switches which are sensible to water. As well set a designated area for machines after work to avoid spillage to all areas
Contractors need to make people accountable for what they use to work with !! When I started out people cared , had pride with what they used to do their jobs !!! Now it seems as if they tear something up it has no consequence . Make them accountable including all of their safety protocols as well
The importance of adequate storage for safety equipment cannot be overstated. Improper storage exposes the equipment to damaging elements like moisture, heat, sunlight, and chemicals, compromising its quality and lifespan. Additionally, inadequate storage heightens the risk of loss, theft, or misuse. To mitigate these risks, safety equipment should be stored in secure, dry, and well-ventilated spaces, away from heat, light, and corrosion sources. Employing labeling, organization, and inventory practices is vital for tracking equipment location and ensuring its condition remains optimal.
Insufficient training of workers on how to use and maintain safety equipment can also lead to mistakes. Training is vital to ensure that workers know how to operate, adjust, and care for the equipment correctly and safely. Without training, workers may not use the equipment properly or notice signs of problems. They may also neglect, abuse, or tamper with the equipment, which can compromise its effectiveness and safety. You should provide regular and comprehensive training to your workers on how to use and maintain your safety equipment and update them on any changes or updates.
Inadequate site inductions and instructions for job specific roles where individuals are left to figure things out for themselves are leaving workers in a highly dangerous situation. You don't know what you don't know. Are you brave enough to step up, put pride aside and ask for a proper induction/orientation?
La falta de formación, se puede complementar mediante conferencias, como también mediante el incentivo de la investigación por medio de la socialización de documentos avalados por organismos reguladores.
Training of personnel on equipment handling is very important. From my experience, a piece of well-maintained equipment can fail during operation. A well-trained and experienced operator will know the first line of action to take in the event of such failures to prevent a catastrophic or fatal accident.
As an electrical engineer, I stress the critical role of sufficient training for workers in the proper use and maintenance of safety equipment. Training is indispensable to ensure that workers operate, adjust, and care for the equipment correctly and safely. Without adequate training, there's a risk of improper usage and oversight of potential issues. Neglect, abuse, or tampering may occur, jeopardizing equipment effectiveness and safety. Regular, comprehensive training sessions are essential, keeping workers informed about the correct utilization and maintenance practices, and updating them on any changes or advancements in safety protocols.
Training is key for the team, if you want people to learn and understand how the equipment runs then you need to train them, if something new comes up then you need to share the knowledge not keep it to yourself and be a hero later
Lacking policies on safety equipment maintenance can also result in errors and oversights. Policies are important to establish clear rules, responsibilities, and procedures for maintaining your safety equipment. Without policies, you may not have a consistent and systematic approach to ensuring the quality and safety of your equipment. You may also face legal or regulatory issues if you do not comply with the relevant standards and requirements. You should develop and implement policies on safety equipment maintenance that cover aspects such as inspection, repair, cleaning, storage, training, and documentation.
Al no tener políticas se puede formar un comité el cuál puede definir ciertas reglas y parámetros a ser ejecutados, con el objetivo de evitar accidentes.
Los cursos de reciclaje en Prevención de Riesgos Laborales (PRL) son esenciales para mantener actualizados a los trabajadores en las últimas normativas y prácticas de seguridad. Proporcionan conocimientos actualizados sobre prevención de accidentes, garantizan el cumplimiento normativo, adaptan a los trabajadores a cambios tecnológicos y fomentan una cultura de seguridad. La formación continua mejora la capacidad para identificar y mitigar riesgos, contribuye a la eficiencia operativa y asegura un entorno laboral seguro y saludable.
Other common mistakes include inadequate training for personnel responsible for maintenance, not keeping records of maintenance activities, using the wrong type of maintenance for the equipment, and ignoring expiration dates on safety equipment like fire extinguishers or first aid supplies.
I have worked as an operation engineer in fertilizer complex a decade ago. We were using pneumatic control systems. One of the key challenges is about not Utilizing Equipment Data. While conducting regular inspections is necessary, it’s important to remember that some issues might not be visible at first, and technicians might not be able to detect some hidden problems with a quick visual inspection. That’s where equipment telematics becomes very beneficial. Telematics is a technology that captures various data about assets, including the GPS location, while monitoring usage, performance anomalies, and maintenance alerts.
Disabling or bypassing a safety device other than troubleshooting or repair by an authorized person. Seat belts are considered safety devices and their use should be mandatory. Working on electrical equipment without isolation or lock out tag out. Being under a suspended load unless it has been properly supported or blocked to prevent movement. Work at heights greater than 6 feet without effective safeguards in place, like guard rails, or harness and lanyard tied off to a stationary point
Provision should always be made for a standby or auxiliary equipment to act in the event of a planned or scheduled maintenance on any equipment. This will make for a thorough inspection, repair, and or maintenance without the fear of downtime.
Not allowing enough time for proper machine maintenence! Most employers want it done now which causes inspections to be done less thoroughly.