12 Aug Maintenance and Repair – JSA

Maintenance and Repair Job Safety Analysis (JSA)

Job / Task

Routine and non-routine maintenance, inspection, adjustment, troubleshooting, servicing, and repair of tools, machinery, vehicles, equipment, building systems, and related components using hand tools, power tools, replacement parts, lifting devices, and other authorized equipment.

Purpose

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with maintenance and repair activities and establishes safe work practices and controls to prevent unexpected startup, release of hazardous energy, electrical shock, caught-between and struck-by injuries, burns, cuts, falls, chemical exposure, and other incidents.

Personnel Qualifications

Employees shall be trained, qualified, and authorized as required for the maintenance or repair work they perform and for the equipment, tools, and hazardous-energy control procedures involved.

Employees shall:

• Understand the equipment, system, task, and hazards before beginning work.
• Perform only maintenance and repair activities for which they are trained, qualified, and authorized.
• Follow manufacturer instructions, applicable procedures, permits, and site requirements.
• Apply lockout/tagout or other required hazardous-energy control procedures before servicing or maintenance when unexpected energization, startup, or release of stored energy could cause injury.
• Inspect tools, test instruments, lifting devices, and other equipment before use.
• Use required PPE and maintain guards, barricades, and other protective measures.
• Stop work when an unexpected condition or uncontrolled hazard is identified.
• Report damaged equipment, unsafe conditions, incidents, and near misses to supervision.

Required PPE

PPE shall be selected based on the equipment, energy sources, materials, and work environment and may include:

• Safety glasses with side protection.
• Safety footwear with appropriate toe protection and slip-resistant soles.
• Work gloves appropriate for the task and materials.
• Hard hat where overhead or falling-object hazards exist.
• High-visibility apparel where vehicles or mobile equipment are present.
• Face shield for grinding, cutting, chemical splash, or other applicable hazards.
• Hearing protection where noise exposure requires it.
• Electrical protective equipment when required for qualified electrical work.
• Fall protection where required by the work condition.
• Respiratory protection when required by the hazard assessment and Respiratory Protection Program.
• Chemical-resistant or heat-resistant PPE when required by the task.
• Additional PPE required by the equipment, material, or worksite.

PPE does not replace hazardous-energy control, machine guarding, engineering controls, safe work practices, or other required protective measures.

JSA – Job Steps, Hazards, and Controls

Step 1 – Plan the Maintenance or Repair Work

Potential Hazards

• Unrecognized hazards.
• Incorrect repair procedure.
• Unexpected equipment operation.
• Inadequate tools or replacement parts.
• Conflicting operations.

Required Controls

• Review the work order, equipment condition, manufacturer information, and scope of work before beginning.
• Identify electrical, mechanical, hydraulic, pneumatic, thermal, chemical, gravitational, pressure, and other energy sources.
• Determine required permits, lockout/tagout procedures, specialized qualifications, and PPE.
• Coordinate the work with affected employees and other contractors.
• Conduct a pre-task briefing for complex, non-routine, or higher-hazard work.

Step 2 – Inspect and Secure the Work Area

Potential Hazards

• Slips, trips, and falls.
• Vehicle or equipment traffic.
• Poor lighting.
• Unauthorized entry.
• Overhead or adjacent hazards.

Required Controls

• Inspect the work area before beginning.
• Provide adequate lighting and safe access.
• Remove or control housekeeping hazards.
• Establish barricades, signs, or an exclusion zone when the work could expose others to hazards.
• Control vehicle and pedestrian traffic as necessary.
• Keep emergency equipment and exits accessible.

Step 3 – Shut Down and Isolate Equipment

Potential Hazards

• Unexpected startup.
• Electrical shock.
• Mechanical movement.
• Pressure release.
• Stored or residual energy.

Required Controls

• Use normal shutdown procedures before servicing.
• Identify all hazardous-energy sources and energy-isolating devices.
• Apply lockout/tagout in accordance with the hazardous-energy control program when required.
• Disconnect, block, bleed, restrain, discharge, or otherwise control stored energy.
• Do not rely solely on control switches, push buttons, interlocks, or emergency stops as energy-isolating devices.

Step 4 – Verify a Zero-Energy or Safe Condition

Potential Hazards

• Incorrect isolation.
• Residual electrical energy.
• Stored hydraulic or pneumatic pressure.
• Gravity or spring energy.
• Unexpected movement.

Required Controls

• Verify isolation before work begins using the method required by the energy-control procedure.
• Attempt normal operating controls where appropriate after ensuring personnel are clear, then return controls to the off or neutral position.
• Use properly rated test equipment for electrical verification when required and only by qualified personnel.
• Check for residual pressure, elevated components, springs, capacitors, heat, or other stored energy.
• Install blocking or restraints where gravity or mechanical movement could occur.

Step 5 – Inspect Tools, Parts, and Repair Equipment

Potential Hazards

• Defective tools.
• Wrong tool or replacement part.
• Damaged electrical equipment.
• Tool failure.
• Flying particles.

Required Controls

• Use tools and replacement parts suitable for the task and equipment.
• Inspect hand tools, power tools, cords, test instruments, jacks, stands, hoists, and other equipment before use.
• Remove defective equipment from service.
• Use guards and safety devices as designed.
• Verify test instruments and electrical tools have appropriate ratings for the intended use.

Step 6 – Disassemble or Remove Components

Potential Hazards

• Pinch and crush points.
• Unexpected movement.
• Sharp edges.
• Hot surfaces.
• Falling components.
• Strains and sprains.

Required Controls

• Support components before removing fasteners or restraints.
• Use appropriate lifting devices for heavy or awkward parts.
• Keep hands and body parts clear of pinch and crush points.
• Allow hot components to cool or use appropriate protection.
• Release tension, pressure, or stored mechanical energy in a controlled manner.
• Use proper lifting and material-handling practices.

Step 7 – Perform Maintenance or Repair

Potential Hazards

• Cuts and abrasions.
• Flying particles.
• Electrical hazards.
• Burns.
• Chemical exposure.
• Noise.
• Entanglement.

Required Controls

• Follow the approved repair procedure and manufacturer instructions.
• Maintain required machine guards whenever feasible; do not bypass safety devices without an authorized procedure and equivalent protection.
• Secure workpieces before cutting, drilling, grinding, or similar work.
• Use ventilation, dust control, hot-work controls, or chemical precautions as required.
• Keep loose clothing, jewelry, hair, and body parts away from moving components.
• Maintain good housekeeping throughout the repair.

Step 8 – Lift or Support Equipment and Components

Potential Hazards

• Crushing injuries.
• Dropped loads.
• Jack or support failure.
• Rigging failure.
• Unstable equipment.

Required Controls

• Use lifting equipment with adequate rated capacity.
• Inspect jacks, stands, hoists, slings, and rigging before use.
• Use designated lifting points when provided.
• Support raised equipment with approved stands, blocking, cribbing, or other suitable means before working beneath or between components.
• Never rely solely on a hydraulic or mechanical jack to support equipment while employees are exposed beneath it.
• Keep personnel clear of suspended loads.

Step 9 – Replace Guards and Reassemble Equipment

Potential Hazards

• Missing guards.
• Loose components.
• Tools or parts left inside equipment.
• Incorrect assembly.
• Unexpected movement.

Required Controls

• Inspect the work before reassembly.
• Install components, fasteners, covers, guards, and safety devices in accordance with manufacturer requirements.
• Remove tools, rags, temporary blocking, and loose materials from the equipment.
• Verify guards and protective devices are correctly installed before returning equipment to service.
• Do not leave bypasses or temporary modifications in place unless specifically authorized and controlled.

Step 10 – Restore Energy and Test Equipment

Potential Hazards

• Unexpected startup.
• Electrical or mechanical hazards.
• Personnel in danger zone.
• Equipment malfunction.
• Flying or moving parts.

Required Controls

• Follow the established lockout/tagout release procedure when hazardous-energy control was used.
• Inspect the area and verify nonessential items have been removed and components are operationally intact.
• Ensure employees are safely positioned before energy is restored.
• Notify affected employees as required.
• Restore energy in a controlled manner and test equipment from a safe position.
• Stop immediately if abnormal noise, vibration, leakage, movement, or other unsafe condition occurs.

Step 11 – Troubleshoot Energized Equipment When Necessary

Potential Hazards

• Electrical shock or arc hazards.
• Unexpected movement.
• Caught-between injuries.
• Exposure to live systems.

Required Controls

• Energized troubleshooting shall be limited to situations where energization is necessary for the diagnostic task.
• Only qualified or authorized employees shall perform work requiring specialized electrical or equipment qualifications.
• Use the minimum exposure necessary to perform testing or diagnosis.
• Maintain required guards, barriers, approach boundaries, PPE, and safe positioning.
• De-energize and apply required energy control before performing repairs after troubleshooting is complete.

Step 12 – Complete Work and Return Equipment to Service

Potential Hazards

• Residual defects.
• Leaks.
• Tools or debris left in area.
• Unreported modifications.
• Unsafe equipment returned to service.

Required Controls

• Perform a final inspection and functional check.
• Verify leaks, guards, fasteners, controls, alarms, and safety devices are acceptable.
• Clean the work area and remove waste, used parts, and maintenance materials.
• Document completed work and outstanding deficiencies as required.
• Do not return equipment to service when a condition remains that could affect safe operation.
• Communicate equipment status to supervision and affected personnel.

General Safe Work Requirements

• Follow applicable manufacturer instructions, maintenance procedures, permits, and site requirements.
• Use lockout/tagout whenever servicing or maintenance exposes employees to hazardous energy and the applicable energy-control standard requires it.
• Do not remove guards or place body parts into danger zones until hazardous motion and energy have been controlled.
• Use approved blocking or support before working beneath raised equipment or components.
• Use only properly rated tools, test equipment, lifting devices, and replacement parts.
• Maintain good housekeeping and control oil, grease, fluids, parts, cords, and tools that could create hazards.
• Do not perform specialized electrical, welding, rigging, or other qualified work unless properly trained and authorized.
• Replace guards and safety devices before equipment is returned to normal operation.
• Stop work when equipment condition, energy sources, or work scope differs from the original plan or cannot be safely controlled.

Training

Employees shall receive training appropriate to the maintenance and repair activities they perform. Training shall include hazard recognition, hazardous-energy control, tool and equipment safety, material handling, machine guarding, chemical hazards, required PPE, emergency procedures, and stop-work expectations. Employees performing electrical, powered industrial truck, crane, rigging, welding, or other specialized work shall meet applicable training, qualification, certification, or authorization requirements.

References

• OSHA 29 CFR 1910.147 – The Control of Hazardous Energy (Lockout/Tagout).
• OSHA 29 CFR 1910 Subpart O – Machinery and Machine Guarding.
• OSHA 29 CFR 1910 Subpart P – Hand and Portable Powered Tools and Other Hand-Held Equipment.
• OSHA 29 CFR 1910 Subpart S – Electrical.
• OSHA 29 CFR 1926 Subpart I – Tools – Hand and Power.
• OSHA 29 CFR 1926 Subpart K – Electrical.