TOOL BOX TALK
Dry End Safety
11/30/2017
1
AGENDA
1. Reel crane safety
2. Reel Turn-ups
3. Focus on equipment operation
4. Core Cutter
5. Open Discussion – other Dry end issues
11/30/2017
2
REEL CRANE SAFETY
 This is an OSHA requirement.
 Do your inspection within the first hour of
starting your shift
 Anyone operating the crane must perform
the inspection. Perform the inspection
together.
 It is a visual inspection only. See what you
can see.
 Know where the crane disconnect is on the
south wall.
11/30/2017
3
REEL CRANE SAFETY
Occupational Safety and Health Administration
1926.1412(d)(1)
A competent person must begin a visual inspection prior to
each shift the equipment will be used, which must be
completed before or during that shift. The inspection must
consist of observation for apparent deficiencies. Taking
apart equipment components and booming down is not
required as part of this inspection unless the results of the
visual inspection or trial operation indicate that further
investigation necessitating taking apart equipment
components or booming down is needed. Determinations
made in conducting the inspection must be reassessed in
light of observations made during operation. At a minimum
the inspection must include all of the following:
11/30/2017
4
11/30/2017
5
1926.1412(d)(1)(i)Control mechanisms for
maladjustments interfering with proper
operation.
1926.1412(d)(1)(ii)
Control and drive mechanisms for apparent
excessive wear of components and
contamination by lubricants, water or other
foreign matter.
1926.1412(d)(1)(v)
Hooks and latches for deformation, cracks,
excessive wear, or damage such as from
chemicals or heat.
1926.1412(d)(1)(vi)
Wire rope reeving for compliance with the
manufacturer's specifications.
1926.1412(d)(1)(iii)
Air, hydraulic, and other
pressurized lines for deterioration
or leakage, particularly those
which flex in normal operation
1926.1412(d)(1)(viii)
Electrical apparatus for
malfunctioning, signs of
apparent excessive
deterioration, dirt or
moisture accumulation
Green Bay Packaging (GBMD Division)
Reel Crane Shift Inspection Sheet
These checks must be done at the start of the shift by ANYONE who will operate the reel crane during the shift. This is to
be done before the operator does anything with the crane during that shift. If when you come on shift and they are in
the middle of a crane task, the last shift's operator will finish the task before you begin your inspection.
Supervisor: Shift: Date:
20 Ton Dry End Crane Operator Names (Box Below):
Comments:
OK OK OK OK
1. Bring Hooks to the Floor
2. Power Off Crane Remote
A) Try All buttons and make sure they return to the
neutral position
B) Check to make sure All the button labels arelegible
3. Visually Inspect the Following
A) Check the Sheaves on the crane hoist for any indentions or
wear on thesheaves
B) Check the Wire Rope for damage such as breaksor
fraying.
D) Check the Blocks for damage to the body causing
impingment on the wire rope orsheaves.
E) Check the top of the Block for any metal flakes or
shavings.
F) Check the Crane Hooks for wear or damage. Make sure the
safety latch is secure.
G) Check the Spreader Bar Hooks for damage or excessive
wear.
4. Power on the Remote
5. Raise the Hooks Up
A) Inspect the Drum to ensure properwrapping.
B) Hold the Up Button and hit the Stop to ensure it is
active and responsive.
C) Check the Upper Limit
5. Run the Crane East and West
A) Check the Bridge Brakes.
6. Return Crane to Normal Operations or Placein
Designated Parking Position
REEL CRANE SAFETY
On 12/13/13, hit full reel while bringing empty
spool over the top causing it to fall out on
backside damaging the crane cables, safety
cage and spool starter switch resulting in 2
hours of downtime. Potential for serious injury.
11/30/2017
7
REEL CRANE SAFETY
Reel Turnover Accident on Saturday April 27th,
2013. While grabbing the reel that got stuck on the rails
with the hoist, Ryan came over and loaded the
Secondary arms. The problem was the Secondary
arms did not clear the reel that was kicked out (on the
back side) and the secondary arms pulled the reel back
and got caught under the primary arms with the newly
turned up reel. Sparks were flying, had a small fire to
put out and the hoist was stressed, reel was cocked on
an angle a put a gouge in front rail. We had to figure
out how to release the primary arm on the back side so
the secondary arm would free up.
11/30/2017
8
REEL CRANE SAFETY (CONT.)
 Strong Back Cradle?
 What is a Suspended load?
 When to enter or not enter inside the rail
system?
 Where to park the crane with the spool
waiting to go to the machine?
11/30/2017
9
11/30/2017
10
REEL TURN-UPS
 What to do when the reel does not make it to
the brake station.
 Bumping reel with crane and spool.
 Let spool stop spinning
 Pull the Pisser if necessary.
11/30/2017
11
11/30/2017
12
REEL TURN-UPS (CONT.)
 Parking crane with spool
 When to enter inside the rail system after
turn-up. (using the broom on reel)
 When to pull the pisser?
 Who makes the call?
 What are the criteria?
11/30/2017
13
FOCUS ON EQUIPMENT OPERATION
 Be aware in your area.
 Keep your eyes/mind on the task at hand.
 Do not distract someone that is operating a
piece of equipment or performing a task.
 Good house keeping practices.
 Safe handling of a stub rolls.
 Allow fifth hand room to handle stub and pulp
rolls.
 Cell phones are a distraction
11/30/2017
14
FOCUS ON EQUIPMENT OPERATION (CONT.)
 Extraction tool training and demonstrations
 Extraction tool maintenance inspections?
 Using the proper gloves and when?
 Handling stub rolls safely.
11/30/2017
15
CORE CUTTER
 Operation and Safety
 Pete Ross: update on new core cutter
11/30/2017
16
11/30/2017
17
UNWIND SECTION(s)
OPERATOR & DRIVE SIDE, UNWIND
BUC #D0599-00065A-P04 QTY=4
Locate at eye level in clear line of sight where operators enter the area
OPERATOR & DRIVE SIDE, UNWIND
BUC #D0599-00088A-P04 QTY = 4
Locate at eye level in clear line of sight where operators enter the area
OPERATOR & DRIVE SIDE, UNWIND STANDS - SADDLE AREA
BUC #D0599-00064A-P04 QTY = 4
Locate at eye level in clear line of sight where operators enter the area
DRIVE SIDE - CLUTCH AREA
BUC #D0599-00079A-P04) QTY = 2
Locate at eye level in clear line of sight where operators actuate the Clutch
6.0”
12.0”
SLITTER SECTION(s)
OPERATOR & DRIVE SIDE, SLITTER FRAMES
BUC #D0599-00065A-P04 QTY=4
Locate at eye level in clear line of sight where operators enter the area
OPERATOR & DRIVE SIDE, SLITTER FRAMES
BUC #D0599-00082A-P04 QTY = 8
Locate (2) at eye level in clear line of sight where operators enter the area
Locate (2) at eye level on Cross Machine beam that supports the Knife Holders
6.0”
12.0”
WIND-UP SECTION(s)
OPERATOR & DRIVE SIDE, WINDER FRAMES
BUC #D0599-00065A-P04 QTY = 4
Locate at eye level in clear line of sight where operators enter the area
Because we have these at the slitter section entrance, mount these closer to
discharge area. It can be combined with the placards below.
OPERATOR & DRIVE SIDE, WINDER FRAMES
BUC # D0599-00036A-P04 QTY = 4
Locate at eye level in clear line of sight where operators enter the Wind-Up area
CORE CHUCK AREA - OPERATOR & DRIVE SIDE, WINDER FRAMES
BUC # D0599-00086A-P04 QTY = 4
Locate at eye level in clear line of sight near where the core chuck stands outside the winder frame (TS)
If the Drive Side Chuck is adequately guarded, OR mill SOP’s DO NOT allow operators near the Drive
Side Chuck, this sign may not be needed.
6.0”
12.0”
WIND-UP SECTION(s) cont.
OPERATOR AND DRIVE SIDE BARRIER
BUC # D0599-00076A 003 QTY = 2
#1 Beloit/Hewett Winder Only
Locate at eye level in clear line of sight where operators enter the roll discharge area
ENTERY TO WIND-UP AREA / DRUM POCKET OPERATOR & DRIVE SIDE
BUC #D0599-00077A-P04 QTY = 4
Locate at eye level in clear line of sight where operators enter the Wind-Up area
6.0”
12.0”
ENTERY TO WIND-UP AREA / DRUM POCKET OPERATOR & DRIVE SIDE
BUC #D0599-00059A-P04 QTY = 4
Locate at eye level in clear line of sight where operators enter the Wind-Up area
ROLL DISCHARGE (CRADLE)
#2 Beloit
#1 Beloit / Hewitt
OPERATOR AND DRIVE SIDE CRADLE DISCHARGE AREA
D0599-00085A-P04 QTY = 2
Locate at eye level in clear line of sight where operators enter the
Roll Discharge Area
6.0”
12.0”
OPERATOR AND DRIVE SIDE RAMP DISCHARGE AREA
BUC #D0599-00092A-P04 QTY = 2
Locate at eye level in clear line of sight where operators enter between the
Gate/Ramp and Wind-Up area on the #1 Winder
HYDRAULIC POWER UNIT(s)
HYDRAULIC POWER UNIT / BULKHEADS / MANIFOLDS
BUC #D0599-00011A-P04 QTY = 4
Locate at Hydraulic Power Unit and Hydraulic Valve Manifold
CONTROLS ENCLOSURES
ALL CONTROLS ENCLOSURES
BUC #D0599-00058A-P02 QTY = 8
Locate at access panel opening for all Pneumatic Controls Enclosures
This is a peal and stick decal
6.0”
12.0”
3.0”
6.0”
OTHER DRY END ISSUES
Open Discussion
11/30/2017
24
TOOL BOX TALK: DRY END SAFETY
Thank you for your participation.
11/30/2017
25

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Tool box talk power point 3

  • 1. TOOL BOX TALK Dry End Safety 11/30/2017 1
  • 2. AGENDA 1. Reel crane safety 2. Reel Turn-ups 3. Focus on equipment operation 4. Core Cutter 5. Open Discussion – other Dry end issues 11/30/2017 2
  • 3. REEL CRANE SAFETY  This is an OSHA requirement.  Do your inspection within the first hour of starting your shift  Anyone operating the crane must perform the inspection. Perform the inspection together.  It is a visual inspection only. See what you can see.  Know where the crane disconnect is on the south wall. 11/30/2017 3
  • 4. REEL CRANE SAFETY Occupational Safety and Health Administration 1926.1412(d)(1) A competent person must begin a visual inspection prior to each shift the equipment will be used, which must be completed before or during that shift. The inspection must consist of observation for apparent deficiencies. Taking apart equipment components and booming down is not required as part of this inspection unless the results of the visual inspection or trial operation indicate that further investigation necessitating taking apart equipment components or booming down is needed. Determinations made in conducting the inspection must be reassessed in light of observations made during operation. At a minimum the inspection must include all of the following: 11/30/2017 4
  • 5. 11/30/2017 5 1926.1412(d)(1)(i)Control mechanisms for maladjustments interfering with proper operation. 1926.1412(d)(1)(ii) Control and drive mechanisms for apparent excessive wear of components and contamination by lubricants, water or other foreign matter. 1926.1412(d)(1)(v) Hooks and latches for deformation, cracks, excessive wear, or damage such as from chemicals or heat. 1926.1412(d)(1)(vi) Wire rope reeving for compliance with the manufacturer's specifications. 1926.1412(d)(1)(iii) Air, hydraulic, and other pressurized lines for deterioration or leakage, particularly those which flex in normal operation 1926.1412(d)(1)(viii) Electrical apparatus for malfunctioning, signs of apparent excessive deterioration, dirt or moisture accumulation
  • 6. Green Bay Packaging (GBMD Division) Reel Crane Shift Inspection Sheet These checks must be done at the start of the shift by ANYONE who will operate the reel crane during the shift. This is to be done before the operator does anything with the crane during that shift. If when you come on shift and they are in the middle of a crane task, the last shift's operator will finish the task before you begin your inspection. Supervisor: Shift: Date: 20 Ton Dry End Crane Operator Names (Box Below): Comments: OK OK OK OK 1. Bring Hooks to the Floor 2. Power Off Crane Remote A) Try All buttons and make sure they return to the neutral position B) Check to make sure All the button labels arelegible 3. Visually Inspect the Following A) Check the Sheaves on the crane hoist for any indentions or wear on thesheaves B) Check the Wire Rope for damage such as breaksor fraying. D) Check the Blocks for damage to the body causing impingment on the wire rope orsheaves. E) Check the top of the Block for any metal flakes or shavings. F) Check the Crane Hooks for wear or damage. Make sure the safety latch is secure. G) Check the Spreader Bar Hooks for damage or excessive wear. 4. Power on the Remote 5. Raise the Hooks Up A) Inspect the Drum to ensure properwrapping. B) Hold the Up Button and hit the Stop to ensure it is active and responsive. C) Check the Upper Limit 5. Run the Crane East and West A) Check the Bridge Brakes. 6. Return Crane to Normal Operations or Placein Designated Parking Position
  • 7. REEL CRANE SAFETY On 12/13/13, hit full reel while bringing empty spool over the top causing it to fall out on backside damaging the crane cables, safety cage and spool starter switch resulting in 2 hours of downtime. Potential for serious injury. 11/30/2017 7
  • 8. REEL CRANE SAFETY Reel Turnover Accident on Saturday April 27th, 2013. While grabbing the reel that got stuck on the rails with the hoist, Ryan came over and loaded the Secondary arms. The problem was the Secondary arms did not clear the reel that was kicked out (on the back side) and the secondary arms pulled the reel back and got caught under the primary arms with the newly turned up reel. Sparks were flying, had a small fire to put out and the hoist was stressed, reel was cocked on an angle a put a gouge in front rail. We had to figure out how to release the primary arm on the back side so the secondary arm would free up. 11/30/2017 8
  • 9. REEL CRANE SAFETY (CONT.)  Strong Back Cradle?  What is a Suspended load?  When to enter or not enter inside the rail system?  Where to park the crane with the spool waiting to go to the machine? 11/30/2017 9
  • 11. REEL TURN-UPS  What to do when the reel does not make it to the brake station.  Bumping reel with crane and spool.  Let spool stop spinning  Pull the Pisser if necessary. 11/30/2017 11
  • 13. REEL TURN-UPS (CONT.)  Parking crane with spool  When to enter inside the rail system after turn-up. (using the broom on reel)  When to pull the pisser?  Who makes the call?  What are the criteria? 11/30/2017 13
  • 14. FOCUS ON EQUIPMENT OPERATION  Be aware in your area.  Keep your eyes/mind on the task at hand.  Do not distract someone that is operating a piece of equipment or performing a task.  Good house keeping practices.  Safe handling of a stub rolls.  Allow fifth hand room to handle stub and pulp rolls.  Cell phones are a distraction 11/30/2017 14
  • 15. FOCUS ON EQUIPMENT OPERATION (CONT.)  Extraction tool training and demonstrations  Extraction tool maintenance inspections?  Using the proper gloves and when?  Handling stub rolls safely. 11/30/2017 15
  • 16. CORE CUTTER  Operation and Safety  Pete Ross: update on new core cutter 11/30/2017 16
  • 18. UNWIND SECTION(s) OPERATOR & DRIVE SIDE, UNWIND BUC #D0599-00065A-P04 QTY=4 Locate at eye level in clear line of sight where operators enter the area OPERATOR & DRIVE SIDE, UNWIND BUC #D0599-00088A-P04 QTY = 4 Locate at eye level in clear line of sight where operators enter the area OPERATOR & DRIVE SIDE, UNWIND STANDS - SADDLE AREA BUC #D0599-00064A-P04 QTY = 4 Locate at eye level in clear line of sight where operators enter the area DRIVE SIDE - CLUTCH AREA BUC #D0599-00079A-P04) QTY = 2 Locate at eye level in clear line of sight where operators actuate the Clutch 6.0” 12.0”
  • 19. SLITTER SECTION(s) OPERATOR & DRIVE SIDE, SLITTER FRAMES BUC #D0599-00065A-P04 QTY=4 Locate at eye level in clear line of sight where operators enter the area OPERATOR & DRIVE SIDE, SLITTER FRAMES BUC #D0599-00082A-P04 QTY = 8 Locate (2) at eye level in clear line of sight where operators enter the area Locate (2) at eye level on Cross Machine beam that supports the Knife Holders 6.0” 12.0”
  • 20. WIND-UP SECTION(s) OPERATOR & DRIVE SIDE, WINDER FRAMES BUC #D0599-00065A-P04 QTY = 4 Locate at eye level in clear line of sight where operators enter the area Because we have these at the slitter section entrance, mount these closer to discharge area. It can be combined with the placards below. OPERATOR & DRIVE SIDE, WINDER FRAMES BUC # D0599-00036A-P04 QTY = 4 Locate at eye level in clear line of sight where operators enter the Wind-Up area CORE CHUCK AREA - OPERATOR & DRIVE SIDE, WINDER FRAMES BUC # D0599-00086A-P04 QTY = 4 Locate at eye level in clear line of sight near where the core chuck stands outside the winder frame (TS) If the Drive Side Chuck is adequately guarded, OR mill SOP’s DO NOT allow operators near the Drive Side Chuck, this sign may not be needed. 6.0” 12.0”
  • 21. WIND-UP SECTION(s) cont. OPERATOR AND DRIVE SIDE BARRIER BUC # D0599-00076A 003 QTY = 2 #1 Beloit/Hewett Winder Only Locate at eye level in clear line of sight where operators enter the roll discharge area ENTERY TO WIND-UP AREA / DRUM POCKET OPERATOR & DRIVE SIDE BUC #D0599-00077A-P04 QTY = 4 Locate at eye level in clear line of sight where operators enter the Wind-Up area 6.0” 12.0” ENTERY TO WIND-UP AREA / DRUM POCKET OPERATOR & DRIVE SIDE BUC #D0599-00059A-P04 QTY = 4 Locate at eye level in clear line of sight where operators enter the Wind-Up area
  • 22. ROLL DISCHARGE (CRADLE) #2 Beloit #1 Beloit / Hewitt OPERATOR AND DRIVE SIDE CRADLE DISCHARGE AREA D0599-00085A-P04 QTY = 2 Locate at eye level in clear line of sight where operators enter the Roll Discharge Area 6.0” 12.0” OPERATOR AND DRIVE SIDE RAMP DISCHARGE AREA BUC #D0599-00092A-P04 QTY = 2 Locate at eye level in clear line of sight where operators enter between the Gate/Ramp and Wind-Up area on the #1 Winder
  • 23. HYDRAULIC POWER UNIT(s) HYDRAULIC POWER UNIT / BULKHEADS / MANIFOLDS BUC #D0599-00011A-P04 QTY = 4 Locate at Hydraulic Power Unit and Hydraulic Valve Manifold CONTROLS ENCLOSURES ALL CONTROLS ENCLOSURES BUC #D0599-00058A-P02 QTY = 8 Locate at access panel opening for all Pneumatic Controls Enclosures This is a peal and stick decal 6.0” 12.0” 3.0” 6.0”
  • 24. OTHER DRY END ISSUES Open Discussion 11/30/2017 24
  • 25. TOOL BOX TALK: DRY END SAFETY Thank you for your participation. 11/30/2017 25

Editor's Notes

  • #16: What are the proper gloves on the winder? What is the glove policy on the winder?