Madden Accident Analysis & Forensic Engineering
8803 Brecksville Road, Suite 7-216, Cleveland, Ohio 44141
phone: 440-838-1191 fax: 440-838-1192
email address: maddenforensic@yahoo.com
website: www.maddenforensic.com
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Madden
Accident
Analysis &
Forensic
Engineering
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afeguards, Safeguarding, including physical guards, light curtains, dual operating
buttons, safety instrumentation, etc.● other names for safeguards include machine
guards, guards, etc.
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Safeguarding and Safeguards in design are based on the knowledge from Human Factors and are an integral part of Safety Design. There is a long history of use of safeguards, and many safeguards that are routinely used have a proven effective history in use in various particular circumstances. Safeguards are enshrined in many generally accepted Codes, Standards and Recommended Practices.
- physical guards or barrier guards which literally prevent access to the hazard, at least during operations, often accompanied by safety instrumentation to sense the unauthorized disabling of the guard, and to stop or alter the operation to prevent access to the hazard, usually disruptively to the operation
- physical guards coupled with safety instrumentation for operations whose physical guards are intended to be circumvented at will, but preferably infrequently, during operation to alter or stop the equipment operation to eliminate the hazard when the physical guard is circumvented, such as a door to the hazard that can be opened at will while the equipment is operating - such an arrangement is often at least somewhat disruptive to operations when the safety instrumentation alters or stops the operation of the equipment, so its use is usually discouraged
- safety instrumentation which prevents access to the hazard when it is a hazard
- safeguarding devices that allow access to the normally hazardous area, and simultaneously prevent the hazard from being effective as a hazard to the operator and others with access at that time - such devices are usually closely integrated into the equipment operation and are not disruptive, or minimally disruptive, to the planned operations. although they may have a major impact on productions rates
Physical guards, barrier guards, are often effectively fencing or grating. They are commonly used to prevent access to hazards which require no access for operation of the equipment. They are often accompanied by safety instrumentation that will stop operations if the barrier guard is removed or altered enough to expose the hazard. This alteration or removal is not intended to be a part of normal operations, even occasionally.
- in running nip points associated with such items as meshing gears, belts and chains on sprockets
- rotating components such as flywheels, gears and shafts
- pinch points between moving and stationary components of machinery
Some Safeguarding Devices are very effective for the special problem of the point-of-operation. The point-of-operation is the location where items are being processed and worked. These safeguarding devices may allow access to a normally hazardous area, only when the area is not hazardous, or may prevent the hazard from being effective as a hazard to the operator and others when access is allowed, or may allow an operator to get close to a hazardous area without contacting the hazardous area, without using a barrier guard.
● Safeguards can be considered to consist of the following types:
Safety instrumentation which prevents access to the hazard when it is a hazard is most often used in conjunction with equipment that has varying times during its use when it would be hazardous to a user, and other times when its use would not be hazardous to a user. An example of that would be the doors to an elevator shaft. When the elevator occupant cage is properly located at the floor, opening the door and stepping through the doorway into the elevator shaft is safe. When the elevator occupant cage is located at a considerable distance from the floor, opening and stepping through the door would be very hazardous. When the elevator occupant cage is located several inches above or below the floor, opening and stepping through the door could lead to a serious fall. Such instrumentation to be true safety instrumentation must be fail-safe, which means that if there is a failure in the instrumentation, the equipment will be rendered safe, even at the cost of being non-operational, if that is the safe condition. In the case of the example elevator, the doors would not open for users until the failure in the safety instrumentation was repaired.
● Safeguards can be considered to cover at least the following issues:
- the point-of-operation for industrial equipment, commercial equipment and consumer products, such as the point of operation between the dies in a stamping press, where the metal part is stamped into a shape, under conditions where the metal part must be inserted in between the dies repetitively by an operator during the operation
- non-point-of-operation hazards for industrial equipment, commercial equipment and consumer products such as moving chains on sprockets (an example of an in-running nip point)
- intermittent hazards to users particularly for equipment passively used by the public, such as the doors on an elevator, where the location of the passenger cage (the elevator) determines whether it is safe for the doors to the elevator shaft to open
Safeguards and Safeguarding, characterized by issues
Physical Guards, Barrier Guards
Physical Guards, Barrier Guards, coupled with safety instrumentation for operations
Physical guards coupled with safety instrumentation for operations whose physical guards are intended to be circumvented at will, but preferably infrequently, can be used where operating problems may require that the operation be altered to resolve the operating problem, and part of that alteration involves accessing equipment locations which are hazardous in normal operation.
Safety instrumentation which prevents access to the hazard
Safeguarding Devices, especially for use at and near the point-of-operation
- presence sensing devices, such as light curtains associated with such equipment as automated presses, and presses operated by the operator with a foot pedal, a single hand button, or any other device that leaves his hand or hands free to go into the point-of-operation when they could be injured - these devices stop movement or take whatever action is necessary to protect from the hazard when they are interrupted by a body part
- dual operating buttons, such as dual palm buttons, useful wherever the operator alternates between accessing the point-of-operation, such as inserting a part between dies, and then must operate the next cycle of the equipment, usually creating a hazard to the operators hand(s) or other body parts during this cycle - the location of the dual operating buttons must be such that these body parts cannot be contacted by the hazard while the dual operating buttons are being actuated
- pullbacks which literally will pull an operators hands and/or arms from the area of danger at the time that the hazard exists - these devices must be put on by the operator and properly adjusted to be effective
- restraints which prevents a body part of the operator from entering the hazardous area, useful when the operator must get close to the point-of-operation during the operation, but does not have to get into the hazardous area of the point of operation, but cannot be isolated from the point of operation by a barrier guard - these devices must be put on by the operator and properly adjusted to be effective
- an automatically controlled moving barrier(s) which can be used when certain physical areas are hazardous at certain times, and not at other times. and which allows access to the normally hazardous area only when it is not hazardous to the operator
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Safeguarding and Safeguards are based on knowledge from Human Factors and are a
Safeguards and Safeguarding, characterized by types
Consultation is available before starting a case. We invite you to
consult with us. There is no charge for an initial phone consultation.
Call us, or if you prefer we can schedule the consultation in advance.
Consultation with James D. Madden, PE, a Professional Engineer, and Forensic
Engineering Consulting and Testifying Expert Witness, is available to the client at all
times during the work - before, during, and after the investigation,
engineering analysis, reconstruction, report, and any other work on the case.
The qualifications of James D. Madden, P.E., Senior Forensic Engineer, Consulting and Testifying
Forensic Engineer and Accident Reconstruction Engineer,
are listed in the Expertise and Work & Specialties sections.
Download a Summary or Detailed Curriculum Vitae (CV) / Resume' for James D. Madden, P.E.,
email us, and bookmark this website.
ualifications of James D. Madden, P.E., Senior Forensic Engineer
ownloads and Links - Curriculum Vitae, Email and Bookmark
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Over the last 28 years we have regularly worked on accidents which occurred in Ohio, Pennsylvania, Michigan, New York and nearby, including inspections of accident sites, equipment, and facilities, with reports and testimony. During these 28 years we have also worked on accidents which occurred in other states, and equipment and facilities located in other states, with inspections of accident sites, equipment, and facilities, from Utah to Vermont, to North Carolina, with reports and testimony for these accidents, when applicable.
eographic Area of Practice - North America
Contact us to discuss your case by phone at NO CHARGE.
This consultation can be scheduled in advance to meet your schedule.
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The choice of safeguards as the design solution to safety hazards is based on the principles of the Safety Design and particularly the Safety Design Hierarchy, which is the accepted system for design of safe equipment, systems, products and facilities. The Safety Design Hierarchy requires that safety hazards be designed out of the equipment, products and facilities wherever and whenever possible. Only if the hazards cannot be designed out, are safeguards used to protect against the hazards. The Safety Design Hierarchy also requires that Warnings not be used in place of Safeguards if Safeguards will protect against the hazard. If Safeguards will protect against the hazards, Warnings are used to complement safeguards when this adds to the safety of the installation where safeguards are being used to protect from hazards. Safeguards and Warnings are not interchangeable.
The information that follows is not intended to be exhaustive, Safeguarding is a large issue with many publications covering various aspects of the subject. The coverage below is intended to introduce the subject. The organization of the materials below is one way to look at the subject. The choice to use Safeguards, and the specifics of any particular Safeguard requires engineering analysis of many factors in the areas of Engineering Design, Human Factors and Safety Design.
For more information see >>
as a forensic engineer for over 28 years, routinely analyze Safeguards (physical guards, light curtains, dual operating buttons, safety instrumentation, etc.) and Warnings, and the requirements for Safeguards and Warnings, often analyzing to determine whether there is a need for Safeguards and/or Warnings, and to determine whether Safeguards and/or Warnings which are present met the needs for safety, and are the correct choice for safety.
Relationship of Safeguards and Safeguarding to Human Factors, Safety Design, Warnings, and Codes
and Standards
In our Forensic Engineering work, Safeguards, including physical guards, light curtains, dual operating buttons, safety instrumentation, etc., and Warnings are routinely analyzed. Safeguards and Warnings are closely related, but generally used for different conditions. The safety requirements for Safeguards and Warnings are used to determine whether there is a need for Safeguards and/or Warnings, and to determine whether Safeguards and/or Warnings which are present meet the needs for safety, and are the correct choice for safety.
Residential, commercial, industrial, manufacturing and construction equipment, components associated with this equipment, and associated facilities, are analyzed for the need and correct application of Safeguards and Warnings.
Consumer products and residential, commercial and industrial facilities, considered separately from equipment, are also analyzed for the need and correct application of Safeguards and Warnings.
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Contact us by phone, fax, mail or email for a copy of the Fee Schedule for charges for engineering
and consulting services and testimony. Click a button below for contact information.
ontact information
ee Schedule
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● verbal reports, by telephone or in face-to-face conferences
We present the results of our investigations, engineering analyses and reconstructions in
the client's choice of any, or all, of the following:
resentation of results of our work
For more on qualifications click on >>>
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Our work investigating, analyzing and reconstructing accidents, and presenting the results, may include any
or all of the following, depending on the needs of the case:
● inspection of the accident site, such as a roadway, outdoor facilities, building or industrial facilities
● inspection of the involved equipment, during operation (such as industrial equipment), or in damaged
condition (such as crashed vehicles)
● interviewing witnesses (often during the inspection of the accident site, product and/or equipment)
● coordinating or interfacing with others while they are preparing specialized exhibits such as video
animations and videos of demonstrations
● review and study of case documents, evidence and applicable codes, standards and recommended practices
● written reports and affidavits, and exhibits
● drawings, calculations, graphical analyses, computer analyses, etc.
as required to analyze and reconstruct the accident, and
to present the engineering analysis and reconstruction
● testing accident items and exemplar items (such as consumer products)
● photography and/or video of the accident site and involved equipment
● testimony in deposition, trial and arbitration
ur Typical Work Activities and Products, when warranted by the case
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● written reports and affidavits
● deposition testimony, including video deposition
● trial testimony and arbitration testimony
James D. Madden, P.E., while performing Forensic Engineering work full-time for over
the last 28 years, for both plaintiff and defendant, has to date:
orensic Engineering Work by Senior Forensic Engineer James D. Madden, P.E.
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● completed over 1000 cases
● written and issued over 600 reports
● testified in over 90 depositions
● written and issued over 60 affidavits
● testified in over 75 trials
as part of the Bachelors and Masters degrees in Engineering, took extensive coursework in Engineering
minored in Normal Psychology as part of the Bachelors degree work
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Combined, Engineering and Normal Psychology are the scientific bases of Human Factors and the related studies of the human-machine interface and human-facility interface, which comprise a significant part of the foundation for Safety Design and Safety Design Analysis. Human Factors and Safety Design are the bases for the requirements for Safeguards as well as Warnings. James D. Madden, P.E. has specific education in Engineering and Normal Psychology, as follows:
during 17 years in industrial operations and engineering design specified Safeguards and Warnings as part of the engineering design of equipment, systems and facilities, with analysis of Safeguards and Warnings as part of safety assurance
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during 17 years working in industrial operations and design engineering, made extensive use of Human Factors and Safety Design, the bases for Safeguards and Safeguarding, as an integral part of engineering design, including acquiring personal knowledge of the human-machine and human-facility interfaces while working in industrial operations
as a forensic engineer for over 28 years, routinely use Human Factors and Safety Design principles, the bases for Safeguards, in engineering analysis of accidents, and equipment and facilities involved in accidents
during 17 years as a design engineer and for over 28 years in forensic engineering, have made extensive use of Codes and Standards and Recommended Practices, including interpretation, inclusive of requirements for Safeguards and Warnings
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ur work with Safeguarding and Safeguards in Forensic Engineering Work
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<< click for a description of the typical activities and work performed
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click for discussion of many of the considerations for the engineering analysis of Safeguards and for their need and use with equipment, products and facilities
requirement in Safety Design. Safeguards are included in many generally accepted Codes, Standards and Recommended Practices. Warnings and Safeguards are used in prescribed manners related to the safety of the use of one or the other in particular circumstances. These subject areas are all closely related.
A door to such a hazardous location is an example of this type of safeguard. This door could be for access by a hand, such as on some lathes, or a whole person, such as with some plastics processing equipment. Safety instrumentation associated with physical guards coupled with safety instrumentation for operations is designed to be the least disruptive to the operations as is feasible, while still safe, as opposed to safety instrumentation associated with physical guards to prevent persons disabling the guards and continuing operation with the hazard exposed. Such instrumentation to prevent disabling the guards can be very disruptive to operations.
Often the operator or others must access the point-of-operation during operations. In some operations the operator may be required to access the point-of-operation repetitively many times an hour, perhaps every few seconds, even placing his hand repetitively between dies in a stamping press, for example. These safeguarding devices are intended to eliminate the hazard passively when the operator enters the point of operation (for example, with his hand), or to prevent the operator from accessing the point of operation when it is a hazard, without using a barrier guard.
Examples of safeguarding devices that allow access to a normally hazardous area only when it is not in a hazardous condition, or create the non-hazardous condition during access, which are especially useful at the point-of-operation, include:
Examples of hazards that may be effectively protected against by physical guards, barrier guards, usually without operational effects, include:
xperience and Qualifications of James D. Madden, P.E. in regard to Safeguards
and Safeguarding:
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Our work with Safeguarding includes engineering analysis to determine the adequacy of the Safeguarding used in industrial and commercial operations and construction activities, and the adequacy of Safeguards used as components of industrial and commercial equipment and consumer products. The purpose of this work is to determine whether these Safeguards were installed and used in a manner that would assure the safety of these activities and items. The purpose of this work is also to determine whether the Safeguards were chosen as required by the Safety Design Hierarchy, and whether the Safeguards, and their use, met the requirements of Codes, Standards and Recommended Practices. Safeguards include physical guards (barriers of various types), light curtains, dual operating buttons, interlocks and safety instrumentation, restraints, and similar items and devices that prevent persons from encountering a hazard.
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earned the Professional Engineers license (P.E.) by taking the National Council of Engineering Examiners' examination in Fundamentals of Engineering and the Mechanical Engineering and Chemical Engineering sections of the National Council of Engineering Examiners' (NCEE) examination in Principles and Practices of Engineering
earned 2 Engineering degrees, Bachelor of Science and Master of Engineering, and took additional credit coursework post-degree, taking coursework in physics, chemistry, mathematics, engineering mechanics, mechanical engineering, chemical engineering and normal psychology
at the start of forensic work, completed refresher and additional post-degree college credit coursework and continuing education coursework in mechanical engineering, metallurgy and materials
designated a Diplomate Forensic Engineer by the National Academy of Forensic Engineers in
accordance with the standards of the Council of Engineering and Scientific Specialty Boards (CESB)
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● attended engineering seminars presented by the National Academy of Forensic Engineers
regularly attend additional technical courses and seminars each year to meet the requirements for continuing engineering education for the Professional Engineer's license
● over 40 years of engineering experience, with:
● 17 years experience in industrial operations, engineering design and construction assistance
● 28 years experience in forensic engineering, including:
● working on over 1000 cases
● issuing over 600 reports and over 60 affidavits
● testifying in over 90 depositions and over 75 trials
See details of the pre-forensic work on the & .
See details of the forensic work throughout this website.
See a summary of the forensic work on the .
See more about qualifications of James D. Madden, P.E. on the .
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