Winter is a popular time to perform maintenance on farm equipment so you are ready to roll once the spring weather arrives. Maintenance work on equipment can come with some serious risks.
Even if these are tasks you have done many times in the past, it is important to consider what can go wrong during the maintenance process and what steps you can take to ensure your own safety and the safety of those around you.
General maintenance safety
All equipment must be inspected on a regular basis and maintained in good working condition. Regular maintenance should be performed to reduce the risk of emergency maintenance. A more in-depth inspection and maintenance process must take place on an annual basis. This may include replacing parts, lubrication, deep cleaning and general repair of operations and field equipment.
Anyone performing maintenance must be trained, competent for the task they will be completing and must understand the specific lockout procedure for each piece of equipment. Any major repairs must be made by a qualified mechanic or other competent person. Contractors performing maintenance must provide proof of licensing, certification and/or training depending on the tasks they will be completing.
When performing maintenance, you must always wear appropriate personal protective equipment (PPE) such as eye protection, hearing protection and any other required PPE. Ensure the area around the equipment is clear of slip, trip and fall hazards. Clean up spills, debris or other hazards before you begin maintenance. Use proper lifting techniques when handling large or awkward items.
Machine guards
Guards must be in place on all moving parts of tools and equipment, and in areas where material can fall or be thrown causing injury to a person. Guards must be in place where an employee or other person may contact a dangerous moving part of a machine; a pinch point; cutting edge; point of a machine at which material is cut, shaped, bored or formed; an open flame and any surface with a temperature that may exceed 80ºC or may be less than minus 80ºC.
The guards must be effective and must not be modified unless the modification has been approved by a qualified engineer and the guard continues to offer adequate protection following the modification.
Never remove a guard from a machine that is operating if the guard is not designed to be removed when the machine is operating. When completing maintenance or repair, you must follow the lockout/tagout procedure for the equipment or machine before removing any guards. You must replace guards before starting up equipment after completing maintenance or repairs.
Lockout/tagout
Do not begin maintenance, repair, cleaning or any other work to equipment until the equipment has been locked out following these steps:
1. Prepare for shutdown. Ensure there is a documented lockout procedure for each piece of equipment. This must include how to lock out all forms of energy.
2. Notify all other affected employees.
3. Shut down the equipment following the lockout procedure for the specific piece of equipment. The equipment or machinery must be turned off and/or disconnected from all energy control points, such as electrical plugs, switches, valves and circuit breakers.
Lock out energy from all sources. Locking out energy is not just about unplugging equipment. Though equipment must be powered down and not have any residual electrical energy, you must also consider other sources of energy, such as:
- Compressed springs: Block springs from releasing.
- Parts of a machine held up by hydraulic or pneumatic power: Parts must be blocked to prevent falling. Hoses must be inspected for damage or deterioration.
- Freewheeling parts: Ensure all parts of the equipment have stopped moving before going near the equipment. Use blocks or chocks on wheels or moving parts.
- Pressurized lines: Bleed the pressure from the lines.
- Components that are hot: Allow sufficient time for cooling before work begins.
- Capacitors that may store electrical energy: Discharge the energy from the capacitor.
- Apply the energy-isolating devices such as locks, chocks and removal of keys. Each energy source must be locked out, completely isolating the equipment.
- Apply the tagout devices.
Verify that all potential energy sources are released prior to performing maintenance activities. Test equipment by using the normal start-up function and confirming that it will not start.
Maintenance in the field
When possible, maintenance on farm equipment should be performed in the shop. If emergency maintenance is needed in the field, you must assess the area before beginning to ensure it is safe to do so. Follow the lockout procedures above and in that equipment’s lockout procedure policy. Ensure all parts of the machine are off and have stopped moving before going near the machine or attachments. Remove the key, chock wheels and block all raised parts using cylinder blocks or other blocking devices. Ensure all freewheeling parts have stopped, and allow time for hot parts to cool. If guards are removed for maintenance, they must be replaced prior to operating the machine. Ensure used oil and other chemicals are disposed of properly.
Training and safe operating procedures
Training is critical when it comes to the safety of all employees on the dairy, especially when performing equipment maintenance. All employees must follow the safe operating procedures and have completed proper training, including hands-on training, before they can be considered qualified to perform maintenance.
