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Federal Register / Vol. 86, No. 39 / Tuesday, March 2, 2021 / Notices
the Trumpf laser cell and the safety and health instructions provided by the manufacturer for the operation of laser cutting equipment; and 6. Gestamp must implement a procedure to ensure that no other servicing and/or maintenance activities aside from cleaning will be performed on the laser cutter, unless full lockout is used.

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E. Steps Required To De-Energize the System Gestamp must implement a detailed procedure for de-energizing the laser cutting machine that will consist of the following steps to ensure that the laser cell door is prevented from closing and the machine starting during cleaning activities within the laser cell:
1. The authorized employee entering the laser cell will communicate to the Operator and co-workers in that area that cleaning will take place;
2. At the HMI screen, the Operator shall change the Series Production from Continuous Job to Single Job;
3. Once the turntable has come to a complete stop, the Operator shall open one of the doors on the side of the laser cell by using the handle;
4. After the door is open, the Operator shall communicate the lockout to his coworkers and move the red slide bar to prevent the door to the laser cell from being shut while personnel are inside;
5. All personnel entering the laser cell must individually lockout, by placing a lock on the slide bar or hasp. If more than one person is to enter on either side, a lockout hasp must be used;
6. Each employee entering the cell must remove his own personal key from the lock or hasp, take the key into the cell, and keep the key in his possession the entire time he is in the cell;
7. If more than one employee enters the laser cell, one of the employees shall be designated the Leader of the cleaning operation;
8. After locking out the laser cell, the Operator shall verify that the Feed Hold Through Safety Device Error is displayed on the HMI screen; and 9. To verify that the turntable will not move while working inside of the laser cell, the Operator shall hit the green activation button. Entry is not to be made into the cell until the previous 8
steps have been completed.
F. Steps Required To Re-Energize the Laser Cell Gestamp must implement a detailed procedure for re-energizing and intentionally starting motion in the laser cutter in order to resume normal operations at the conclusion of the cleaning operation. The procedure for
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re-energizing the laser cell will consist of the following steps:
1. When work is completed inside the laser cell, all employees who entered the cell, except the Leader when more than one employee entered, shall exit and remove their locks;
2. The Leader/Solo Employee shall open the mechanical latch;
3. The Leader/Solo Employee shall visually inspect the area for the presence of persons or tools within the laser cell;
4. Once all other employees are outside of the laser cell, the Leader/Solo Employee must verify his location and hit the Danger Zone Acknowledge Button on the inside of the cell door;
5. The Leader/Solo Employee must exit immediately, remove his lock, move the slide bar back to allow the door to shut, and shut the door. The door must shut within 34 seconds of hitting the Danger Zone Acknowledge Button. The 34 second limitation ensures that no one can enter or re-enter into the machine enclosure between the visual inspection and restart.
6. Once the cleaning operation is complete and employees are clear of the restricted area, the Leader/Solo Employee shall place the laser HMI back into production by placing the Series Production from Single Job to Continuous Job by pressing the Continuous Job button;
7. After the HMI has been released to production, the Leader/Solo Employee shall press the green button which resets the light curtains and causes the robot to place the next part on the turntable; and 8. Both entry doors to the laser cell must be closed before operations can resume. An engineering control within the Trumpf laser cell prevents engagement of the laser until both doors are closed.
G. Communication Gestamp must:
1. Implement a system that informs workers using energy isolation devices of any hazardous occurrences or conditions that might affect their safety;
and 2. Provide a means of communication among affected workers where unassisted voice communication is inadequate.
H. Worker Qualifications and Training Gestamp must develop and implement a detailed worker qualification and training program. All training must be provided in a language that the employees can understand.
Gestamp must:
1. Develop an energy control training program and train each authorized
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employee on the latch system and the procedures required under it;
2. Develop and document a training program and train each affected employee in the purpose and use of the alternative energy control procedures using the latch system;
3. Develop a training program and train other employees whose work operations are or may be in an area where energy control procedures may be utilized. These employees will receive training about the procedure and about the prohibition relating to attempts to restart or reenergize machines or equipment that are locked out;
4. Ensure that each authorized employee, affected employee, and other employees have effective and documented training in the contents and conditions covered by this permanent variance and interim order;
and 5. Ensure that only trained and authorized employees perform energy control procedures for the task of performing cleaning of the laser cell at Gestamps facility.
I. Inspections, Tests, and Accident Prevention Gestamp must develop and implement a detailed program for completing inspections, tests, program evaluations, and incident prevention.
Gestamp must:
1. Ensure that a competent person authorized employee conducts daily visual checks and monthly inspections and functionality tests of the laser cell components and configuration or operation and energy control procedures that ensure that the procedure and conditions of this permanent variance and interim order are being followed;
2. Ensure that a competent person conducts weekly inspections of the work areas associated with the cleaning of the laser cell;
3. Develop a set of checklists to be used by a competent person in conducting weekly inspections of the energy control procedures used while performing cleaning activities at the laser cell;
4. Remove from service any equipment that constitutes a safety hazard until Gestamp corrects the hazardous condition and has the correction approved by a qualified person; and 5. Maintain records of all tests and inspections of the laser cell, as well as associated corrective actions and repairs, at the job site for the duration of the variance. The maintenance, servicing, and installation of replacement parts must strictly follow the manufacturers specifications,
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