Every supervisor on any shop floor can always benefit from reminders that the absence of accidents does not prove the absence of hazards. The best safeguarding systems become part of the manufacturing process, not obstacles workers feel compelled to bypass. With that in mind, the team at T.J. SNOW developed a practical safeguarding checklist for evaluating resistance welding operations.
Note: This checklist is intended as a practical reference and is not a substitute for a formal risk assessment or applicable OSHA, ANSI, AWS or company safety requirements.
Before assuming a resistance welding operation is adequately safeguarded, ask these questions:
1. Are all pinch points identified:
- Between welding electrodes?
- Between moving tooling?
- During power-up and power-down?
- From stored pneumatic or hydraulic energy?
2. Can the welding cycle be initiated while an operator’s hands are inside the hazard zone?
3. Are emergency stop devices:
- Easily accessible?
- Clearly identified?
- Tested regularly?
4. Are Lockout/Tagout (LOTO) procedures:
- Written?
- Current?
- Understood by operators and maintenance personnel?
5. Are all electrical enclosures:
- Properly grounded?
- Closed and secured?
- Free from damaged wiring?
6. Have all machine initiation devices been evaluated? Examples include:
- Foot switches
- Palm buttons
- Hand triggers
- Automatic cycle starts
7. Are weld sparks adequately controlled? Examples include:
- Eye protection
- Protective clothing
- Combustible materials removed
- Good housekeeping practices
8. Are workers exposed to hot metal or sharp edges?
9. Are stored-energy hazards identified? Examples include:
- Pneumatic systems
- Hydraulic systems
- Springs
- Gravity loads
10. Have all machine movements been evaluated during:
- Production?
- Setup?
- Maintenance?
- Troubleshooting?
- Recovery after a fault?
11. Is robot movement adequately safeguarded? Examples include:
- Safety fences
- Interlocked gates
- Light curtains
- Safe maintenance procedures
12. Are operators required to place their hands near moving electrodes? If yes, is point-of-operation safeguarding adequate?
13. Are presence-sensing devices functioning properly? Examples include:
- Light curtains
- Safety mats
- Area scanners
- Interlocks
14. Has every employee received documented safety training for this equipment?
15. Are safeguards inspected as part of preventive maintenance?
16. Have all equipment modifications been reviewed for their impact on safeguarding?
17. Are “near misses” investigated the same way as injuries?
18. Has a formal Risk Assessment or Job Safety Analysis been completed? If yes:
- Has it been reviewed recently?
- Have recommendations been implemented?
19. Ask one final question:
“If my newest employee were assigned to this welding station tomorrow, would I be completely confident they could operate it safely?” If the answer is anything less than yes, the safeguarding deserves another look.
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