Case Studies

Case Study: Manufacturing Company

Background: A safety products company was contracted to perform a risk assessment.Risk Assessment Case Study

Result: The most expensive products and solutions were recommended by the product safety company. The client purchased and installed the materials, resulting in an improper application of a safety device. The hazard was not effectively abated. The Employer’s liability existed until MSS identified the problem, the light curtain was replaced, and the system was validated. Machine Safety Specialists specified the correct light curtain and a compliant, cost-effective solution was finally installed.

This really happened  – Don’t let it happen to you !

Another question….

Q:  Which safety product company do we trust to perform a risk assessment with your best interest in mind?

A:  None of them. Companies selling safety products have a hidden agenda – sell the most products and charge insane dollars for installation! Machine Safety Specialists are safety engineers and consultants who have your best interest in mind. We will conduct a risk assessment and recommend the most sensible, lowest cost, compliant safeguards on the market – with no hidden sales agenda!




Case Study: Machine Safeguarding Example

One Photo, Two Points of View….Machine Safeguarding Case Studies

Safety Product Company Recommendation:

“Wow – This Customer needs $50K of functional safety equipment on each machine. Add light curtains, safety system, etc….”.  Problem solved for $50,000.


MSS Recommendation:

“Bolt down the existing guard, add end cap, remove sharp edges and secure the air line. Add a warning sign with documented training….”.  Problem solved for $50.


Once again, this really happened  – don’t let it happen to you !




Case Study: Risk Reduction

“Machine Safety Specialists’ comprehensive approach to risk reduction ensured the most complete, sensible, and least expensive solution for compliance” – Safety Manager

Green Circle (right): We use all methods of Risk Reduction (elimination, signs, training) – not just guards and protective devices. This is the least expensive and most comprehensive approach.

Red Circle (right): Guarding company methods of risk reduction (guards and protective devices) are very expensive, time consuming, and do not mitigate all of the risk.

Risk Reduction Case Study Columbus Ohio

Case Study - Why Perform a Risk Assessment?

Another frequently asked question is: “Why do I need a Risk Assessment?”

To answer this, please see Case Study: “Applicable U.S. Machine Safety Codes and Standards”, then please see below…

Why Perform a Risk Assessment?

A written workplace hazard assessment is required by law.  In section 1910.132(d)(2), OSHA requires a workplace hazard analysis to be performed.  The proposed Risk Assessment fulfils this requirement with respect to the machine(s).

1910.132(d)(2): “The employer shall verify that the required workplace hazard assessment has been performed through a written certification that identifies the workplace evaluated; the person certifying that the evaluation has been performed; the date(s) of the hazard assessment; and, which identifies the document as a certification of hazard assessment.”

A Risk Assessment (RA) is required by the following US standards:

  • ANSI B11.0
  • ANSI Z244.1
  • ANSI B11.19
  • ANSI B155.1
  • ANSI / RIA R15.06
  • NFPA 79

Please note the following excerpt from an actual OSHA citation:

“The machines which are not covered by specific OSHA standards are required under the Occupational Safety and Health Act (OSHA Act) and Section 29 CFR 1910.303(b)(1) to be free of recognized hazards which may cause death or serious injuries.”

In addition, the risk assessment forms the basis of design for the machine safeguarding system.  The risk assessment is a process by which the team assess risk, risk reduction methods, and team acceptance of the solution.  This risk reduction is key in determining the residual risks to which personnel are exposed.  Without a risk assessment in place, you are in violation of US Safety Standards, and you may be liable for injuries from the unassessed machines.

 To learn about our Risk Assessment Software and Apps, click here.


Case Study:  Applicable U.S. Machine Safety Codes and Standards

We are often asked: “What must I do for minimum OSHA compliance at our plant?  Do I have to follow ANSI standards?  Why?”

The following information explains our answer…

Please note the following excerpt from an actual OSHA citation:

 “These machines must be designed and maintained to meet or exceed the requirements of the applicable industry consensus standards.  In such situations, OSHA, may apply standards published by the American National Standards Institute (ANSI), such as standards contained in ANSI/NFPA 79, Electrical Standard for Industrial Machinery, to cover hazards that are not covered by specific OSHA standards.”

 U.S. regulations and standards used in our assessments include:

  • OSHA 29 CFR 1910, Subpart O
  • ANSI B11.0
  • ANSI B11.19
  • ANSI B155.1
  • ANSI/RIA 15.06
  • ANSI/ASSE Z244.1
  • NFPA 79
  • Plus, others as applicable….

Please note the following key concepts in the U.S. Safety Standards:

  • Control Reliability as defined in ANSI B11.19 and RIA 15.06
  • Risk Assessment methods in ANSI B11.0, RIA 15.06, and ANSI/ASSE Z244.1
  • E-Stop function and circuits as defined in NFPA 79 and ANSI B11.19
  • OSHA general safety regulations as defined in OSHA 29 CFR 1910 Subpart O – Section 212
  • Power transmission, pinch and nip points as defined in OSHA 29 CFR 1910 Subpart O -Section 219
  • Electrical Safety as defined in NFPA 79 and ANSI B11.19.

Note:  OSHA is now citing for failure to meet ANSI B11.19 and NFPA 79.