How producers, manufacturers prioritize employee safety

The following transcripts were edited from two concurrent discussions at this year’s Pit & Quarry Roundtable & Conference.

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P&Q: MSHA stated in 2018 that it wants to hear from the mining industry about equipment and technology that can make operations safer. Producers: Are you exploring or implementing any new tech to make jobsites safer? Equipment suppliers: How are you designing new equipment while keeping safety in mind, and do you see any revolutionary tech coming that can keep people significantly safer on the job? Also, in 2018, MSHA launched safety efforts in a couple of key areas: powered-haulage equipment (large vehicles hitting small vehicles; seat belt use, conveyor safety) and fire suppression systems. Are these areas among the biggest safety concerns for your operation. Is the agency on point in adding emphasis to these areas?

Andy Blanchard (Syntron Material Handling): Listening to the voice of the customers, some of our underground mining customers have talked to us about dust concerns. As a result, we’ve taken that back to our engineers and designed equipment for them. We are building in a dust-suppression type of component. I think MSHA is starting to gear up on how you suppress dust within the operation.

P&Q: Would you like to see them emphasize that a little more going forward?

Blanchard: If it helps improve the work environment for miners, whether they are underground or aboveground, then I think it is good if it is good for the human being. Technology is easy enough to design [for] dust suppression. The industry will have to pay for that, obviously, but it can be done.

Craig Lamarque (John Deere): From a safety perspective in our mobile equipment, we look at three main constituents. Obviously, the operator will be one, and certainly the bystanders and support staff around the equipment are another. Thirdly, the service personnel that are going to work on the equipment.

As technology becomes available, we look at implementing it. But even today, we put some basic things in a machine that we think are effective. From the operator standpoint today – take a dump truck, for example – we’ve implemented something as simple as before the machine starts, the horn will go off automatically before he can put it into gear. If you think about some of the MSHA requirements, we are taking some of that responsibility away from the operator.

Similarly, if they back in and dump, we’ve got inclinometers in the machine so if the bed is at a certain angle it won’t dump over at a certain level. Simple things that you can consider not revolutionary, but simple enough and effective enough to take some of the functionality away from the operator to make sure they stay safe.

There are things we are doing today to keep all three of those constituents safer than they were before.

Blanchard: I was surprised to learn a [top] reason for fatalities in the mining industry has to do with people not wearing their seat belt. From a manufacturing standpoint, I think I’ve solved that in my factory, and I think most manufacturers would probably say that’s not an issue.

A question that was raised is could you build in technology with all your new equipment so the machine doesn’t start if it’s (seat belt) not properly clicked – and based on weights with somebody sitting in the seat and clicking it.

Lamarque: We are obviously reviewing that and, in fact, the first step in that is visibility. You will notice more machines coming out with orange seat belts as standard. Oftentimes with a black seat belt, when you’re standing outside the machine, the foreman can’t physically see if that person’s strapped in or not. So the simple change to an orange seat belt is the first step in that visibility.

Michael Johnson (NSSGA): The reason beyond basic safety and, obviously, pursuing zero [fatalities] is on [MSHA] Administrator [David] Zatezalo’s mind. It is his number one issue right now. He says he reviews way too many fatality reports and injury reports that simply could have been prevented had the operator been wearing the seat belt. There are too many times it’s not happening.

We (NSSGA) are going to launch an initiative to call awareness to it – probably something like breakroom posters that operators and employees have to sign, return to NSSGA and [we] deliver to MSHA to show our seriousness. But if we could work with the manufacturers to also start pushing the technology, whether you can’t put it in gear or can’t start it, if the seat belt is not engaged, I agree. It can’t be that expensive, and it saves a lot of lives.

Rick Madara (McLanahan Corp.): What was refreshing is seeing how the industry is accepting some of these things. To me, seeing the industry recognize that is refreshing. It’s been there forever, but now they are implementing to spend money to put in their own plants to make employees safer.

When you were developing any piece of equipment 20 years ago, safety wasn’t important. You looked at quality, efficiency and how you can make it less expensive. But now, safety is one of the number one things that we look at – even if it diminishes something else in the product and makes it more expensive, or doesn’t make it quite as efficient.

Matt Lepp (Van Der Graaf): We are seeing a trend the same way. We’ve always sold partly on the point of safety – less moving parts, less room for error.

Over the last couple of years, there’s been a surge of interest in that aspect of our product. Normally, the big selling points have been lack of maintenance, cost and energy savings. But there’s been a much larger emphasis lately on the safety aspect of it, which has helped us.

Even a new product line we came up with, the Grizzly Drive, we implemented some features in there: a design to prevent rock buildup inside the frame, keeping the frame clear, removing a necessity for somebody to go near the equipment to clear it out and maintain, and so forth. That’s been a huge advantage for us lately.

Brian Hollrah (Alleyton Resource Company): We use drones [for] mine planning and all sorts of different inventory, stockpiling and getting their readings. Something we implemented that is fairly simple but made a pretty big difference is digitizing our pre-trip [and] post-trip inspections. Doing it on iPads, it is going right to the shop. They are getting real-time information. They don’t have to wait for paper, so [you can] make your repairs and prioritize a lot sooner and faster and get that going. The turnaround time is a lot better with being electronic.

Sean Martell (Preco Electronics): We provide collision-warning active radar, a technology for mobile equipment, and we are seeing a big push in the industry. We are a global company and we provide on-road/off-road technology for mobile equipment. We are seeing more interest in our radar products to protect assets and people, whether it be an end user, or if you buy equipment and want to capitalize the radar into the equipment, you can have a dealer put it on. It’s a very effective product and it is a good investment if you are mitigating accidents.

John Garrison (Superior Industries): Part of our process when you launch a product is safety. We usually show it to the service technicians and our dealers and ask what are the pain points or biggest area of risk you see in the field.

There are even regions where dealers order conveyors with specific guarding [requirements] that are unique to them – just because they’ve had incidents where the inspector comes in and they have to change a guard or modify it.

Doing automation, interlocks and doors that shut down the plants are areas we are focusing on, as well. But I’d say, not just in new products that we develop, but in products that are already out in the marketplace, we are constantly evolving and adding to increase safety.

Blanchard: We talked a lot in [another Roundtable] discussion about labor retention and how difficult that is. Now, we are talking about safety.

All of us as leaders in our own businesses and in the industry at large have got to connect the two. You can’t have a high-morale workplace or workforce if you don’t have a safe work environment.

The number one thing that will destroy the culture you have, or prevent new employees from coming to work with you, is having a lousy safety record. Safety is critical to the beginning of having a good work culture.

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The following transcript was edited from a concurrent Pit & Quarry Roundtable & Conference discussion.

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Dana Boyd (NALC): On the operation side, if you’re starting to look at the different controls, one of the areas where we’re having a unique ‘paradigm shift’ within our organization is when you [inject] automation controls to plants, the old-school folks are used to the ‘pull box and lock it out.’ The automation controls nowadays have so many interlocks to the lockout/tagout program that the automation can convolute. So we have had to take a step back and actually install virtual disconnect boxes to every motor just to verify, clarify and eliminate the chance of someone making a mistake.

There are chances you can actually make things more efficient. The reality is, at the end of the day, operators will take shortcuts. So we kind of stepped back and reevaluated. Once we started seeing what was going on, listening to our employees, [we realized] the interlocks are tied to this and that.

The next thing you know, they just get confused and frustrated. With the younger generation, it’s easy for them to say, ‘I don’t understand it’ and move on. That’s when we had to kind of step back and relook at those parameters.

So whenever I order equipment now – just like when I had a section made with the motor, the drive, the gearbox and everything on it – it’s actually equipped with a quick disconnect. So not only does it make easier for me to rewire that system, but right there it’s a lockout location at that motor drive.

On rolling stock, I’m seeing all kinds of technology changes with our automobiles that we see now with proximity sensors and tests. With machines nowadays, there are so many different controls that it’s like driving your couch down the highway. But you still have to have that operator engaged in the activity.

The minute one of my operators over-brakes on a loader, I get a text immediately saying what’s going on. But at the end of the day, if my operator picks up three or four beers at lunchtime, downs them and he or she’s still in control of that machine, the liability concerns I have [can’t be] eliminated with all of that automation control.

Stewart Petrovits (Route 82 Sand & Gravel): There is some new technology out there. I haven’t seen a lot about it, where the employee who is on the ground will be able to wear a sensor or some type of technology that almost works like a geofence on GPS, something that can alert the machine operator that a pedestrian or laborer is nearby.

We’re seeing it on construction work zones, where you can put a geofence down the road with intrusion alert. It interests me because it all comes down to – not to be blunt, but – human stupidity a lot of the time and carelessness.

The sensor is on the vest. It goes on with you. Maybe it’s just another layer of protection that’s there every single day. I haven’t seen it in practice yet, but I was hoping someone might have tried it.

Kenneth Rogers (The Shelly Company/CRH): We’re currently doing that, but I don’t want to speak too much because I’m not as in tune with the construction side of it. But I do know we’re actively pursuing that with our employees.

I think we did some test runs with it last year with a handful of our traffic control people who set up the zones. From my understanding, it will indicate the fact that people are in that work zone.

Boyd: One of the big things in underground coal mines is people getting trapped and pinned.

When I go underground, they suit you up. They actually put a GPS coordinator on you. And if you get close to one of the continuous miners, the miner stops – just totally shuts off.

Some of the operations have haul trips that are just tunnels. They’re set up on a grid, they lock in and they go. And if there’s anyone intruding upon that, you can watch the computer screen and see where all the workers are actually located. You can set those parameters.

Lee Heffley (Brandeis Machinery & Supply Co.): What are some of you doing regarding cell phone use while operating machinery?

Boyd: With radios, what we actually do is put holders in the equipment. We talked to some of the manufacturers about integrating that into voice activation, just like you would your automobile. We’re finding, especially with the younger generation, it works better for them. We haven’t had any incidents with that.

If someone has an emergency or they see a text pop up that says, ‘hey, wife just called,’ that loader pulls off to the side – and they better pull off to the side.

We’re trying to force our workforce to communicate more. Let’s figure out a way to make that device work. Use the technology.

Rogers: From our perspective with us having union regulations, they (employees) do get breaks. So we [ask] them to leave [cell phones] in your lunch trailer. Within the timeframe of your 15-minute break, go ahead and check your cell phones.

Boyd: That’s one of the things that our guys went to. If you need to take a break, hop out of the machine and go do what you need to do. But we actually pay them all the way through. So if they want to eat on the fly, they eat on the fly. We’re making it as flexible as we can.

But the big thing is communicate. As long as the customers are being taken care of, I really don’t care. Just operate safely. Make it work.

Paul Ross (Douglas Manufacturing Co.): From a broader perspective, the Conveyor Equipment Manufacturers Association focuses on three major things: standardization, statistics and safety. Recently on the board, we moved safety to the front of that. I think it’s at the forefront of everybody’s mind, from the producers and manufacturers of the components and systems that you all use to the engineering companies.

The safety standards are co-developed by select committees within the organization. We work on that on a consistent basis to try to improve the safety of our products, their offerings and establish standards for their use and implementation.

There are training aids. There are labels. There are posters. Most safety information from the Conveyor Equipment Manufacturers Association is available free of charge, so you can download and post all over your plants and conveyors.

Rogers: We have very strict lockout/tagout policies. For us, we have zero tolerance for that. So if there are any lockout/tagout violations, they will be fired. We make it known in the beginning, but we do spend an extensive amount of time with the lockout/tagout procedure to make sure they do understand what it entails and what our expectations are.

Alex Kanaris (Van der Graaf): When you say you have zero tolerance, you actually fire the person?

Rogers: Yes. Anytime we have any lockout/tagout [violation], it doesn’t matter whether it’s the manager or an employee, yes. We’ve had things happen where we’ve had to let go of a whole crew. It was almost 100 years of experience. It hurt us.

Petrovits: You have to do that. It’s a policy. You’ve got to do it.

Rogers: Everybody got the message. Safety’s always got to be number one. That’s always been our policy.

Kanaris: You don’t give notice?

Rogers: As far as before we let them go? The notice is the policy. Everybody knows that’s what it is. You get two ways to get fired honestly: failed drug test and lockout/tagout [violation]. We let them know that. It’s really hard to get fired from us. But if you violate those two things, it’s no questions asked. You’re done.