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					Checklist: Incentive to bypass protective devices on
machinery
Version 1.1
The incentive to bypass protective devices on machinery is dependent upon the associated benefits. This checklist serves as an aid to assessment of the incentive to
bypass protective devices. The potential benefit of bypassing is classified for each relevant task. Classification must be undertaken by individuals who are very familiar
with operation of the machine, for example by machine users, service technicians, cleaning personnel, etc.

Company:

Machine:

Protective device:                                         …

In what way can the protective device be                   …
tampered with:
Date:

Checklist processed by:
                    Benefits without protective device:
                    0 None + Minor ++ Substantial
            Ta
              sk
                   pe
                     rm                       Gr                                                                      Brief instructions:
                     iss                         ea                                                                          1. Add operating modes if
                        ib Ta                       te
                                                       ru
                          le       sk                                                  Gr                         In              appropriate
                               in                         s                                                          ce
         Modes of                 th pos             Fa e, e                              e a Im
                                                                                             te pro      Av             nt
                                                                                                                           ive
                                                                                                                                   2. Determine
                                     es sib       Ea ste .g.                                   rf           oi                          relevant tasks
         operation                     e m le        sie r, g for                                 re ved dan                   to
                                          od wit             r                        Le            ed                            by        3. Complete blue
                                             es ho r/mo eate larg Gre               Be ss p            om flow ce o                  pa             cells line
                                               of ut        re   r p er    at Bet                 R                  f                  ss
                 Au                                op tam co ro wo           er  te tter hys edu of m of m inte                            fo             by line
                                                                                    r                   c
                    to                                er    pe nve duc rkp prec vis aud ical ed ove ove rrup                                  rt
                                                                                                                                                 he
                       m Se Man                          at    r    n    t    i   i     ib     ib     e      tr   m      m       t
                         at
                            ic    tu     ua etc etc ion? ing? ien ivit eces sion ility ility ffor ave en en ion etc                                 ta
                                                                                                                                                       sk
Tasks:                               p     l     .      .              t    y                              t    l      t       t      s      .
           Help                             Help              Help Help                                  Help                                            Help
Initial Operation
Program test/
test run
Setup/adjustment
conversion/tooling/
Machining
Manual intervention
for swarf removal
Manual change of
workpiece
Manual intervention
for trouble shooting
Checking/random
sampling
                                                                                                                                    2. Determine
                                                                                                                                        relevant tasks
                                                                                                                                            3. Complete blue
                                                                                                                                                  cells line
                                                                                                                                                      by line




                    Benefits without protective device:
                    0 None + Minor ++ Substantial
            Ta
              sk
                   pe
                     rm                       Gr                                                                      Brief instructions:
                     iss                         ea                                                                          1. Add operating modes if
                        ib Ta                       te
                                                       ru
                          le       sk                                                  Gr                         In              appropriate
                               in                         s                                                          ce
        Modes of                  th pos             Fa e, e                              e a Im
                                                                                             te pro      Av             nt
                                                                                                                           ive
                                                                                                                                   2. Determine
                                     es sib       Ea ste .g.                                   rf           oi                          relevant tasks
        operation                      e m le        sie r, g for                                 re ved dan                   to
                                          od wit             r                        Le            ed                            by        3. Complete blue
                                             es ho r/mo eate larg Gre               Be ss p            om flow ce o                  pa             cells line
                                               of ut        re   r p er    at Bet                 R                  f                  ss
                 Au                                op tam co ro wo           er  te tter hys edu of m of m inte                            fo             by line
                                                                                    r                   c
                    to                                er    pe nve duc rkp prec vis aud ical ed ove ove rrup                                  rt
                                                                                                                                                 he
                       m Se Man                          at    r    n    t    i   i     ib     ib     e      tr   m      m       t
                         at
                            ic    tu     ua etc etc ion? ing? ien ivit eces sion ility ility ffor ave en en ion etc                                 ta
                                                                                                                                                       sk
Tasks:                               p     l     .      .              t    y                              t    l      t       t      s      .
          Help                              Help              Help Help                                  Help                                            Help
Manual intervention
for measuring/
finetuning
Manual change of
tools
Maintenance/
servicing
Rectification of faults
Machine
Cleaning, e.g. removal
of swarf
etc.
etc.
Protective device:                                                      …
                    Benefits without protective device:
                    0 None + Minor ++ Substantial
            Ta
              sk
                   pe
                     rm                      Gr                                                                      Brief instructions:
                    iss                         ea                                                                          1. Add operating modes if
                       ib Ta                       te
                                                      ru
                         le       sk                                                  Gr                         In              appropriate
                              in                         s                                                          ce
       Modes of                  th pos             Fa e, e                              e a Im
                                                                                            te pro      Av             nt
                                                                                                                          ive
                                                                                                                                  2. Determine
                                    es sib       Ea ste .g.                                   rf           oi                          relevant tasks
       operation                      e m le        sie r, g for                                 re ved dan                   to
                                         od wit             r                        Le            ed                            by        3. Complete blue
                                            es ho r/mo eate larg Gre               Be ss p            om flow ce o                  pa             cells line
                                              of ut        re   r p er    at Bet                 R                  f                  ss
                Au                                op tam co ro wo           er  te tter hys edu of m of m inte                            fo             by line
                                                                                   r                   c
                   to                                er    pe nve duc rkp prec vis aud ical ed ove ove rrup                                  rt
                                                                                                                                                he
                      m Se Man                          at    r    n    t    i   i     ib     ib     e      tr   m      m       t
                        at
                           ic    tu     ua etc etc ion? ing? ien ivit eces sion ility ility ffor ave en en ion etc                                 ta
                                                                                                                                                      sk
Tasks:                              p     l     .      .              t    y                              t    l      t       t      s      .
         Help                              Help              Help Help                                  Help                                            Help
In what way can the protective device be tampered with:                …
Incentive to bypass the protective device:                                      low
Use of this checklist:


Step 1            Complete the relevant entries on the "Machine data" worksheet. Should the machine have several protective devices, complete
                  a separate checklist for each protective device.

Step 2            Define modes of operation

                  Enter the modes of operation which are possible on the machine. The existing cell entries can be overwritten.

Step 3            Define relevant tasks

                  The left-hand column lists the tasks usually performed on machines. Not all need necessarily apply. Dedicated entries can be
                  added in the last two lines. Now complete the entries line by line for the tasks relevant to the machine concerned:


Step 4            Proceed line by line, marking the modes of operation in which the task is performed with a cell entry, e.g. "X". The cells which
                  must now be completed are marked in colour.

Step 5            Task permissible in this mode of operation?

                  Certain modes of operation may be used only with restrictions. At this point, you are asked whether performance of the task is
                  permissible in this mode of operation. Restrictions apply for example to the "process observation" mode of operation, also
                  termed the 4th mode of operation on machine tools. Observe the organizational arrangements applicable in such cases. Select
                  from the options offered, yes/no, for the entry. If the task is not permissible in this mode of operation, enter "no". In this case, no
                  further entries are required in this line.
Step 6            Task possible without tampering?

                  On some machines, the necessary modes of operation are not available for all tasks. If the task cannot be performed without
                  bypassing of the protective device, enter "no". In this case, no further entries are required in this line. Select from the options
                  offered, yes/no, for the entry.
Step 7    Benefits without protective device:

          If the task is permissible in this mode of operation and is possible without bypassing of the protective device, consider for each
          task whether the benefit stated for the work would apply without the protective device. Indicate as follows:

          0 No benefit
          + Minor benefits
          ++ ++ Significant benefits

          Select from the options offered for the entry. The benefit "etc." can be replaced. Comments can be added to the assessments
          for subsequent administrative handling (click with the right mouse button on the cell concerned).

Result:   Incentive to bypass the protective device

          Depending upon the task, the incentive to bypass the protective device is assessed as follows:

                  Low Bypassing protective device would not result in any benefit (no "+" or "++" entry).

                         Bypassing the protective device would produce benefits (at least one "+"- or "++" entry): the protective device
              Present
                         hinders operation of the machine. Further studies and possibly measures are required.

                         The machine cannot be operated unless the protective device is bypassed. The machine is unsafe: an immediate
                  High
                         need for action exists.

				
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posted:7/11/2011
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