18 Jul Unsafe Equipment – Reporting Equipment Hazards
Unsafe Equipment – Reporting Equipment Hazards
Unsafe equipment must be identified, reported, and removed from service when defects could expose employees to injury. Employees who operate or work around tools, machinery, vehicles, and other equipment are often the first to notice developing problems and play an important role in preventing equipment-related incidents.
Why Equipment Defects Must Be Reported
Even with regular inspections and preventive maintenance, equipment can become damaged or defective between scheduled inspections.
Employees should remain alert for:
- Unusual noises, vibration, or movement.
- Loose, missing, cracked, or damaged components.
- Leaks or excessive heat.
- Defective controls or switches.
- Missing or damaged guards.
- Unexpected equipment operation.
- Electrical damage.
- Excessive wear or deterioration.
- Any condition that makes equipment unsafe to operate.
Never assume someone else has already reported a problem.
Machine and Tool Hazards
When using or working around machinery and tools, watch for:
- Missing, loose, damaged, or improperly positioned guards.
- Exposed gears, belts, pulleys, shafts, or other moving parts.
- Excessive movement or play in components.
- Loose or missing nuts, bolts, or fasteners.
- Cracked or damaged housings.
- Slipping or damaged belts.
- Defective emergency stops or safety devices.
- Broken handles, switches, triggers, or controls.
- Excessive vibration or unusual operating sounds.
- Equipment that requires lubrication, adjustment, or repair.
Never remove, bypass, defeat, or modify a machine guard or safety device to keep equipment operating.
Electrical Equipment Hazards
Electrical defects can result in shock, electrocution, burns, or fire.
Report conditions such as:
- Damaged or frayed cords.
- Broken or missing grounding prongs.
- Cracked plugs or receptacles.
- Broken switches.
- Missing electrical covers or faceplates.
- Loose conduit or fittings.
- Exposed or loose conductors.
- Burned or discolored electrical components.
- Motors or equipment that spark excessively.
- Equipment that repeatedly trips breakers or protective devices.
Do not attempt electrical repairs unless you are trained, qualified, and authorized to perform the work.
Conveyors and Material-Handling Equipment
When working around conveyors, inspect for:
- Missing guards around moving components.
- Damaged or improperly operating emergency-stop devices.
- Sharp or projecting components.
- Damaged walkways or crossovers.
- Missing required crossovers.
- Unsafe transfer points between conveyors.
- Loose, damaged, or misaligned rollers.
- Unusual movement, vibration, or noise.
Never reach into, climb onto, cross, or perform maintenance on operating conveyor equipment unless specifically permitted by an established safe work procedure.
Servicing or maintenance that exposes employees to hazardous energy requires appropriate lockout/tagout procedures.
Vehicles and Mobile Equipment
Operators should inspect vehicles and mobile equipment and report defects that could affect safe operation.
Potential problems include:
- Defective brakes or steering.
- Damaged tires or wheels.
- Hydraulic or fluid leaks.
- Defective lights, horns, alarms, or warning devices.
- Damaged forks, attachments, or lifting components.
- Missing or damaged seat belts.
- Defective controls or gauges.
- Damaged mirrors or visibility aids.
- Missing guards or protective structures.
Do not continue operating equipment when a defect makes it unsafe.
Hand Trucks and Carts
Simple material-handling equipment can also cause injuries when poorly maintained.
Watch for:
- Flat, damaged, or seized wheels.
- Loose wheels or axles.
- Broken crossmembers.
- Loose or damaged toe plates.
- Cracked, broken, or splintered handles.
- Sharp edges or projections.
- Damaged frames.
- Unstable or difficult steering.
Remove defective equipment from use until it has been repaired or replaced.
What to Do When You Find Unsafe Equipment
When an equipment defect is discovered:
- Stop using the equipment when the condition could affect safe operation.
- Warn others who may attempt to use it.
- Disconnect, isolate, tag, or otherwise remove the equipment from service according to company procedures.
- Report the defect promptly to your supervisor or other designated person.
- Provide enough information to clearly identify the equipment and the problem.
- Do not attempt repairs unless you are trained and authorized.
- Do not return equipment to service until the defect has been properly corrected and the equipment is safe to operate.
A handwritten warning or verbal message alone may not be sufficient if another employee could unknowingly use the equipment. Follow established procedures for controlling defective equipment.
Never Ignore Warning Signs
Do not continue using defective equipment because:
- The job will only take a few minutes.
- The equipment still operates.
- It has been defective for a long time.
- Someone else used it without getting hurt.
- Replacement equipment is inconvenient to obtain.
- Production is behind schedule.
Equipment does not have to completely fail before it becomes unsafe.
Remember
Reporting unsafe equipment gives the company an opportunity to correct a problem before it causes an injury. Inspect equipment before use, remain alert for changing conditions, and report defects promptly.
If equipment does not look, sound, feel, or operate correctly—stop, secure it from use, and report it.