Rockford Systems, LLC

CORPORATE OVERVIEW

Why Safeguard Machines?

It’s The Right Thing To Do

• According to OSHA statistics, workers who operate machinery suffer approximately 18,000 amputations, lacerations, crushing injuries, abrasions and more than 800 deaths per year.

• An alarming 50 percent or more of metal fabricating machinery in the United States does not comply with the critical safety requirement.

It’s Profitable

• Lack of machine guarding or improperly installed safeguarding equipment was one of the Top Ten Most Cited OSHA Violations (2000-2016) resulting in over $7 million in annual fines levied against businesses.

• Increased compliance reduces worker risk, thereby improving productivity and decreasing costs, resulting in increased profitability.

It’s The Law

• OSHA 1910.217• ANSI B-11.1-2009

Standards• NFPA 79

OSH Act of 1970• Under the OSH Act of 1970,

employers are responsible for providing a safe and healthful workplace. Employers must comply with all applicable OSHA standards. Employers must also comply with the General Duty Clause of the OSH Act, which requires employers to keep their workplace free of serious recognized hazards.

• By law, employers are legally required to follow OSHA regulations. That means an OSHA inspector will issue citations for noncompliance to their CFR (Code of Federal Regulations). 

OSHA’s CFR SubPart O—Machinery and Machine Guarding has six (6) machine specific safeguarding regulations which are:• 1910.213 Woodworking

Machinery• 1910.214 Coope rage

Machinery• 1910.215 Abrasive Wheel

Machinery• 1910.216 Mills and

Calendars• 1910.217 Mechanical Power

Presses• 1910.218 Forging Machines

OSH Act of 1970 (continued)• OSHA regulations for safeguarding most

other machines falls under 1910.212 General Requirements For All Machines which specifies that the operator and others in the machine area be protected from exposure to hazards.

• However, ANSI’s B11-Series Safety Standards (which has 24 machine categories) are often used to fill in the details for specific safeguarding and can be used as reference material by OSHA inspectors. Even though ANSI safety standards are voluntary, they could become legally mandatory if an OSHA citation mentions specific ANSI standard for you to comply to.

• The bottom line is that all employers should strive to exceed minimum OSHA requirements and abide by the best safety practices found in the ANSI B11 standards.

OSHA Inspection PrioritiesSince OSHA cannot inspect all 7 million workplaces it covers each year, the agency focuses its inspection resources on the most hazardous workplaces in the following order of priority (OSHA Fact Sheet DEP FS-3783):

Hazards that could cause death or serious physical harm receive top priority. Compliance officers will ask employers to correct these hazards immediately or remove endangered employees.

Imminent danger situations

Employers must report:•All work-related fatalities within 8 hours;•All work-related inpatient hospitalizations, amputations, or losses of an eye within 24 hours

Severe Injuries and Illnesses

Allegations of hazards or violations also receive a high priority. Employees may request anonymity when they file complaints.

Worker Complaints

Of hazards from other federal, state or local agencies, individuals, organizations or the media receive consideration for inspection.

Referrals

Inspections aimed at specific high-hazard industries or individual workplaces that have experienced high rates of injuries and illnesses also receive priority.

Targeted Inspection

Checks for abatement of violations cited during previous inspections are also conducted by the agency in certain circumstances.

Follow-Up Inspection

Normally, OSHA

conducts inspections

without advance notice.

Common Safeguarding Misperceptions

• Myth #1: New machines are safe because their manufacturers designed and built them to meet up-to-date safety standards and regulations

– REALITY: Not necessarily • Always conduct an Onsite Risk

Assessment and/or Onsite Machine Survey to identify OSHA 1910.212 “General Requirements for Machines” violations and identify how to bring machines into compliance.

• ANSI, Canadian and European standards often provide “Best Practices.”

Common Safeguarding Misperceptions

• Myth #2: Older machines are "grandfathered in” since they were designed and manufactured before safety standards and regulations existed

– REALITY: False, there are no grandfathering laws in effect. All machines must meet minimum OSHA regulations. For companies wanting to meet a higher safety benchmark, ANSI B11 Safety Standards offer the best available guidelines for metal processing machines.

Common Safeguarding Misperceptions

• Myth #3: Automation cells containing Industrial Robot are always properly safeguarded by the robot supplier

- REALITY: May not be true, some OEM’s provide this and some do not

CORPORATE OVERVIEW

Rockford Systems Overview

• Private company, founded in 1971

• Headquartered in Rockford, Illinois

• Acquired by Randolph Group (Chicago, Illinois) in 2014

• Deliver trusted machine safeguarding solutions for organizations working with industrial machinery

• Help organizations interpret and apply complex Occupational Safety and Health Administration (OSHA) regulations and American National Standards Institute (ANSI) machine safety standards for a broad array of industrial applications

• Provide complete Machine Safety Life-Cycle Management Solutions

• Improved the profitability of many of North America’s largest companies by increasing compliance, reducing worker risk, increasing productivity and decreasing costs

Rockford Systems, LLC4620 Hydraulic RoadRockford, IL 61109

1-800-922-75331-815-874-7891

Rockford Systems, LLC4617 American RoadRockford, IL 61109

Rockford Systems, LLC4585 American RoadRockford, IL 61109

Our Trusted Safeguarding Solutions

Exceed OSHA

Regulations and ANSI Standards

Geographic Coverage Area

Our Markets

Our Clients

Organization Structure

Randolph Group

Joe Nitiss, CEO

Matt Brenner, VP of Sales

Nick Zimmer, Central Region

Manager

Tom Hendryx, Western Region

Manager

Phil Reuter, Eastern Region

Manager

Ryan Kaltenbrun/Matt

Brenner, Southern Region Manager

Sheryl Broers, Inside Sales

Manager

Roger Harrison, Director of

Training

Carrie Halle, VP of Marketing

Brian Boes, VP of Engineering &

Operations

Ken Kranz, VP of Finance &

Administration

Industry Leadership

• Employee leadership:– ANSI B11.0 Committee– ANSI B11-19 Writing Committee

CAPABILITIES DISCUSSION

What is Machine Safety Life-Cycle Management?

• Delivering trusted machine safeguarding solutions that help keep your workers safe and increase your company’s profitability

• Rockford Systems provides complete Machine Safety Life-Cycle Management Solutions, including:• onsite risk assessments• onsite machine surveys• customized engineered design solutions• over 10,000 safeguarding products• installation and integration services• safety education and training• technical and in-field support• ongoing compliance validation

Safeguarding Standards are Complex & Changing

Industry Leading Safety Education

• Objective: Help safety personnel interpret and apply OSHA Regulations and ANSI Standards for a broad array of industrial applications. Attendees will learn to keep their companies in absolute compliance, reduce insurance costs, and help prevent employee accidents on metal working machinery, such as power presses and press brakes.

• Format: Monthly 2 ½ day seminars combine classroom discussion with live demonstrations on a number of machines to give attendees for a practical, hands-on learning experience.

• Target Audience: Safety personnel in Health & Safety, Human Resources, Operations, Manufacturing, Engineering and Insurance, Risk Management

• Information Covered: Occupational Safety and Health Administration (OSHA) 29 CFR regulations and American National Standards Institute (ANSI) B-11 series machine safety standards.

• Instructor: Roger Harrison, an industrial safeguarding expert with over 25,000 hours of training experience. Mr. Harrison is also a speaker at seminars sponsored by the Precision Metal Forming Association (PMA) and FABTECH.

Past Seminar Attendees:A.O. Smith, Alcoa, Arizona State University, Ball Corporation, Boeing, Borg Warner, Briggs & Stratton, CNA Insurance, Caterpillar, Coleman Outdoor Products, ConAgra Foods, Delco Remy, Eaton Corp, Ford Motor Company, General Dynamics, General Electric, General Motors, Georgia Tech, GKN Aerospace, Goodrich UTC Aerospace, Harley Davidson, Herman Miller, Hill-Rom, Honda, Honeywell, J.I. Case, John Deere, Lazy Boy, Liberty Mutual Insurance, Lippert Components, Lockheed Martin Aeronautics, Martin Marietta, Monroe Auto Equipment, Motorola, Navistar, Otis Elevator, Pratt Whitney, Purdue University, Rockwell Automation, Samsonite, Skorsky Aircraft, Square D, Stanley Bostitch, Steelcase, Stoughton Trailer, Sub Zero Freezer, Textron Gulf & Turf, Travelers Insurance, True Manufacturing, TRW, UT Automotive, Whirlpool, Zurich Insurance and many more.

Safeguarding Seminar AgendaDay One• Welcome, Introduction, and Objectives of Seminar• Brief History of ANSI, OSHA, and NFPA-79• Risk Assessment/Risk Reduction• OSHA 29 CFR 1910.211, Definitions• OSHA 29 CFR 1910.212, General Requirements for

All Machines and Auxiliary Equipment• OSHA 29 CFR 1910.217 Mechanical Power Presses• ANSI B11.1-2009 Mechanical Power Presses• Full-Revolution-Clutch Identification and Control

Requirements• Part-Revolution-Clutch Identification and Control

Requirements• Control Reliability and Brake Monitoring• Electrical Component Requirements (NFPA-79)• Hand-Feeding Tools• Point-Of-Operation Safeguarding—Guards,

Devices, Methods• Design, Construction, Setting, and Feeding of Dies• Inspection and Maintenance Records• Instruction to Operators• Reports of Injuries• Mechanical Power-Transmission Apparatus (OSHA

1910.219)

Day TwoANSI B11.2 Hydraulic Power PressesANSI B11.3 Power Press BrakesANSI B11.4 ShearsANSI B11.5 Iron WorkersANSI B11.6 Lathes (Manually Operated)ANSI B11.7 Cold Header and Cold FormersANSI B11.8 Drilling, Milling, and Boring MachinesANSI B11.9 Grinding MachinesANSI B11.10 Metal Sawing MachinesANSI B11.11 Gear Cutting MachinesANSI B11.12 Roll Forming and Roll Bending MachinesANSI B11.13 Automatic Screw/Bar and Chucking MachinesANSI B11.14 Coil Slitting Machines/Systems Withdrawn—See ANSI B11.18ANSI B11.15 Pipe, Tube, and Shape Bending MachinesANSI B11.16 Metal Powder Compacting PressesANSI B11.17 Horizontal Hydraulic Extrusion PressesANSI B11.18 Coil Processing SystemsANSI B11.19 Safeguarding Methods (Criteria)ANSI B11.20 Integrated Manufacturing (Cells)ANSI B11.21 Machine Tools Using Laser Processing (Cutting)ANSI B11.22 CNC Turning Centers and LathesANSI B11.23 Machining Centers—CNC Mills, Drills, BoringANSI B11.24 Transfer MachinesANSI/SPI B151.1 Horizontal (Plastic) Injection Molding MachinesBS ISO 14137 and JIS B6360 Electrical Discharge (EDM) MachinesANSI B152.1 Hydraulic Die Casting PressesANSI/RIA R15.06–1999 & 2012 Robots and Large Work EnvelopesOSHA 1910.147 Control of Hazardous Energy Lockout/Tagout

Onsite Risk Assessments

• Objective: Identification of machinery tasks and risk scoring of hazards using the ANSI B11.0-2015 safety standard methods.

• Format: A Risk Assessment Specialist will visit your plant(s) and go through the Risk Assessment Process (shown at right), which could take days, weeks or months.

• Target Audience: Safety personnel in Health & Safety, Human Resources, Operations, Manufacturing, Engineering and Insurance, Risk Management.

• Information Covered: All applicable OSHA, ANSI, and NFPA regulations and standards will be considered during the machine review. Based on the assessment findings, the risk rankings will be calculated. In addition, suggested guarding changes will be made and potential risk ranking improvements calculated. Detailed documentation will be provided.

Risk Assessment ProcessAn Onsite Risk Assessment will identify the task and associated hazards on your machinery and score the risk level using the ANSI B11.0-2015 safety standard methods. All applicable OSHA, ANSI, and NFPA regulations and standards will be considered during the machine review.

Pre-Assessment Meeting•Discuss the risk assessment process, set the scope of the project, and discuss the “acceptable or tolerable” risk perceptions.

•The presence of an electrician and experienced machine operator will be required.

Identify Hazards & Who Is At Risk•Detailed assessment forms and photo documentation will be used to identify the personnel tasks, identify the hazards, gather all applicable machine component and operational information necessary to determine the current machine risk ranking level.

Assess Hazard Level•Severity of Injury: An evaluation of the injury severity (or consequences) of each possible hazard and rank order them by severity of the outcome will be done.

•Exposure Frequency: The exposure frequency is the number of times personnel (while performing a task) are exposed to a hazard in a given time period. Evaluations of the current engineered controls will be made in order to establish the exposure rate.

• Avoidance Likelihood: The possibility of avoiding a hazard can be tied to the machinery or process design.

Post-Assessment Meeting•Discuss the findings, explain the preliminary risk rankings, discuss possible ways of reducing the risk rankings, and discuss the time frame for completion of the detailed assessments and summary file.

Implement Controls & Reassess•Recommended next step is the Onsite Machine Survey to identify specific solutions and costs to bring hazards into compliance.

Onsite Machine Surveys• Our professional personnel will visit your site(s)

to conduct full machine safety surveys and evaluate safety concerns.

• Detailed Machine Safety Surveys:– For updating machinery to meet or exceed

current safety regulations and standards (OSHA, ANSI B11 series, NFPA 79) or your corporate guidelines

– Thorough surveys conducted by qualified safeguarding specialists, using rapid Mobile Inspection tool

– Report-proposals generated after machine safety survey conducted

– Experience with all project sizes– Experience working with all company sizes– Experience working all machine types,

from the very old to the very new– Reputation as Industry Leader

Customized Engineered Design Solutions

• Many machine safeguarding projects identified in the Onsite Machine Survey require customized, engineered design solutions that integrate seamlessly into your company’s machines, plants and operations. Engineering reviews the customer-supplied electrical and hydraulic machine schematics, evaluates existing interfaces or controls for compliance, and identifies need for special interface or controls.

• From there, Rockford Systems delivers customized engineered and automated safety device interfaces or specialized machine controls manufactured to your exact size requirements and automated to reduce operator fatigue. In addition, detailed electrical and hydraulic schematics and Bills of Material (BOMs) are provided for compliance tracking and future parts ordering.

• All engineered design solutions meet or exceed all OSHA, ANSI and NFPA 79 standards for machine and operator safety. Experts in their field, Rockford Systems provides industry leadership on the ANSI B11.0 Committee and ANSI B11-19 Writing Committee and trusted, quality engineering solutions to many of North America’s largest companies.

Customized, Engineered Solutions Process

Identify NeedMachines that need a customized safeguarding interface or control

are identified in the Onsite Machine Survey and routed for

Engineering Design Customization

Evaluate Solution(s)Engineering reviews the customer-

supplied electrical and hydraulic machine schematics, evaluates existing control for compliance,

identifies need for special interface or controls

Delivering Solution(s)Designing customized engineered

and automated safety device interfaces or specialized machine

controls

Machine Safeguarding Products• Our line of over 10,000 machine safety products allows industry to meet or exceed

the OSHA and ANSI standards for machine guarding:• Catalog Items Including Safety Shields, Safety Signs, Safety Gauges, Motor

Controls• Custom Items Including Barrier Guards, Light Curtains, Laser Scanners, Laser

Devices, Safety Mats, Press and Press Brake Controls• EX-AL™ Proprietary Barrier and Perimeter Guarding Systems

• Auxiliary Safeguarding• Die-blocks and Accessories• Disconnects and Starters• Guard Opening Scales• LED Industrial Lighting• Lockout/Tagout Equipment• Machine Safeguarding Devices

• Perimeter Guarding• Safety Interlock Switches• Palm Button Assemblies• Safety Light Curtain Systems• Safety Shields• Training Aids

Quality Installation & Integration Services

• The Rockford Systems installation crews are highly skilled and trained, with a background in electrical engineering and many hours of on-the-job experience on all types of equipment.

• Rockford Systems installation crews provide complete integration and installation services in your plant or instruct your installation personnel on best practices. Installation crews integrate safety devices into sophisticated machine controls that meet or exceed all OSHA regulations and ANSI/NFPA standards.

• Installation crews also engineer and install minor modifications on the spot that might be required to improve operator usability and/or reduce operator fatigue.

• All installations conclude with operator safety training on the correct use of the new machine safeguarding equipment. In addition, safety training helps operators understand how to remain safe while also maximizing productivity.

Responsive Technical Support and In-Field Service

• Every purchase and installation is backed up with a professional, high-trained team of advisors:

– Technical Service Advisors available for emergency troubleshooting

– In-Field Service Technicians available for troubleshooting and repairs

– In-House Warranty and Non-Warranty Repairs

Our Commitment To

Machine and Operator Safety

Never Ends

Ongoing Compliance Validation

• An optional annual maintenance contract.

• Ensure that safeguarding products are working at optimal performance.

• Ensure that operators are using safeguarding solutions as designed and trained.

Compliant, Safeguarded Machines

Results

Increased OSHA and ANSI complianceReduced worker risk

Increased productivityDecreased costs

Improved profitability

Summary• As a trusted advisor since 1971,

Rockford Systems helps organizations interpret and apply complex OSHA regulations and ANSI machine safety standards for a broad array of industrial applications.

• In addition, Rockford provides complete Machine Safety Life-Cycle Management Solutions, ranging from Onsite Risk Assessments to Ongoing Compliance Validation.

• Rockford Systems has improved the profitability of many of North America’s largest companies by increasing compliance, reducing worker risk, increasing productivity and decreasing costs.

SAFEGUARDING ROI

What does a machine accident cost?

• Insurance studies indicate machine safeguarding provides an opportunity for businesses to reduce bottom-line operating costs by eliminating both the direct and indirect costs of an accident, while improving productivity and employee morale.

• Liberty Mutual reported in its annual Workplace Safety Index that U.S. employers spent $48.6 billion for wage and productivity losses, medical expenses and administrative expenses for workers hurt on the job. – This is roughly equivalent to the annual sales of Cisco, Pfizer or FedEx.

• A study by Colorado State University set the total direct and indirect cost of workplace injuries at a staggering $128 billion.

Direct Costs

• Direct costs of an accident refer to out-of-pocket expenses like hospital and medical bills.

• They also include the loss of a worker’s time because of the accident, the lost productivity by the machine involved in the accident being idled or requiring repairs, as well as the other machines further down the production line being shut down.

• Costs continue to cascade throughout the company with overtime required to make up the lost productivity and new workers who need to be hired and trained.

• The National Safety Council (NSC) estimates that lost time alone associated with the average injury costs nearly $30,000.

Indirect Costs• Analysis of most accidents reveal that the actual total cost can range from 4x to 10x

times the visible, direct cost stated by an insurance company. • For example, a single accident can result in OSHA fines up to $100,000 per machine

or more if the violation is found to be willful.– In 2010, 24 percent of OSHA’s Top 10 citations for manufacturing dealt with

machine guarding violations, resulting in more than $6 million in proposed penalties.

• In addition, insurance rates can rise dramatically or coverage can be dropped entirely.

• Investments targeted for company growth may need to be diverted to cover the costs of the accident, while employee morale and productivity can experience a significant drop

• The company’s brand and reputation will likely be damaged by negative publicity.• Legal fees, plus management time spent dealing with regulators and attorneys.• And while it is not calculated as an indirect cost, a poor safety record can make the

difference between a company winning and losing bids, especially with government contracts. A plant with a singularly bad reputation for safety may also find itself unable to attract workers at all or may have to pay wages well above market value to do so.

• Also, if the machine where a serious accident occurred is unique and is locked out for investigation or until the safeguarding deficiency is abated, the company may need to outsource the work at a much higher cost. It’s also possible that the work is so specialized that it’s impossible to outsource and therefore the company loses the business.

Do The Math• OSHA’s $afety Pays website (www.osha.gov/dcsp/smallbusiness/safetypays) makes it

easy for organizations to calculate direct and indirect costs of an accident. • As an example, let’s assume a fictional company with annual sales of $5 million and

an 8% pre-tax profit margin has an accident involving an employee whereby his hand was entangled in a drill press.

• By using insurance company claims data, $afety Pays can calculate that the crushing accident will cost that company, on average:– Direct Cost: $56,557– Indirect Cost: $62,212– Estimated Total Cost: $118,769

• By entering profit margin information, $afety Pays will also project the additional sales required to recover the costs of the injury. In this instance, additional sales revenue necessary to cover costs is $1,484,612 based on the 8% profit margin or approximately one third of annual sales. If pre-tax margins are less, the sales impact is even greater.

• On the other side of the ledger is the cost to safeguard the machine involved in the accident. For the purpose of this discussion, let’s assume that the same fictional company had an onsite risk assessment performed by a reputable firm that surveyed ten machines on the plant floor at a cost of $5,000, or $500 per machine. Next, assume that the drill press had been safeguarded per OSHA regulations and ANSI standards at a total cost of $1,000.

• Adding in its prorated share of the risk assessment, total cost to safeguard the drill press would be $1,500, a figure that compares very favorably to the estimated $118,769 cost of the accident.

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