safe operation of machines

8/9/2019 Safe Operation of Machines

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2008 All Rights Reserved

A TRAINING FOR THE

METALWORKING INDUSTRY

SAFE OPERATION OF MACHINESSAFE OPERATION OF MACHINES


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The following topics will be covered:

1. Introduction

2. Incidents related with machine operation3. Machine Hazards

4. Machine Safety

Risk Management

Control Measures

Safe Practices

Table of ContentsTable of Contents


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This slide is prepared for the workers in the metalworking

industry for a better understanding of the hazards associated

with the machines used in the industry. Hence, controlmeasures and risk levels can be assessed for effective control

of the hazards.

The hazards identified in the presentation may be applicable to

other industries.

1. Introduction1. Introduction


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Incidents occurred due to:

Lack of protection (e.g. equipment safeguards);

Not following procedures;

Lack of training;

Lack of maintenance;

Horseplay; and

Others

2. Incident History2. Incident History


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These incidents can cause:

Damage to the body, e.g. cuts, crushing of limb, etc

Injuries by energies released from the machine, e.g.

electrical shock, burn, etc

Fatalities



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Incidents associated with metalworking industry:


Sprains, Strains 860

Fractures 430

Cuts, Punctures 380

Bruises 230

Heat Burns --

Chemical Burns --

Amputations 50

Total Cases 3400

Source: Survey of Occupational Injuries and Illnesses in Cooperation with Participating State Agencies, Bureauof Labor Statistics, U.S. Department of Labor


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When identifying the hazards related with machines, weshall consider:

type of machines

layout of machines

driven method, e.g. electricity, air, etc

operating parameters, e.g. speed, pressure, temperature,

size of cut, mobility, etc.

materials to be processed or handled and method of feed

3. Machine Hazards3. Machine Hazards


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operator position and controls

access for setting adjustments and maintenance

environmental factors, e.g. dust, fumes, noise, temperature,

humidity etc

operating requirements including what the operator needs

to do



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Typical hazards related with operation of machines include:

mechanical:

e.g. crushing, shearing, cutting or severing,

stabbing or puncture high pressure fluid ejection

electrical shock

noise and vibration

contact with extremes of temperature

ergonomics

others



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Pictures or Graphs Within This Area

Unguarded Rotating Parts of Machine


LooseClothing


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Unguarded Rotating Parts of

Machine



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Pictures or Graphs Within This Area




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Picture Source: Concepts and Techniquesof Machine Safeguarding, U.S. DepartmentofLabor, OSHA 3067, 1992 (Revised)

Unguarded Rotating Parts of

Machine



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Picture Source: Concepts and Techniques of Machine Safeguarding, U.S. Department ofLabor, OSHA 3067, 1992 (Revised)




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Steps for risk assessment:

4.1 Risk assessment for machine operation

Step 1: Identify the hazards

Step 2: Identify the existing controls

Step 3: Assess the risk level based on the matrix

Step 4: Identify the need for additional control measures

Step 5: Assign the responsible persons

4. Machine Safety4. Machine Safety

Refer to Risk Management for Metalworking Industry and MOM Risk Management: Risk Assessment

Guidelines for detailed risk management description.


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Step 1: Identify the hazards

Breakdown the activities

Identify the hazards and Consequence of each activity (Section 3)



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any safeguards in place?

any written procedures to control or mitigate the risk? what are the PPE used?



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Severity Definition by MOM

Likelihood Definition by MOM



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MOM Risk Assessment Matrix:



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Step 4: Identify the need for additional control

What is the risk level with the consideration of existing

controls?

High risk must be reduced to at least medium risk before

startup of work

Whether the risk level can be further reduced to As Low As

Reasonably Practical (ALARP)?



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Step 5: Assign the responsible person

Responsible person shall be assigned for each identified

activity

Time frame for the activity can also be decided

Responsible person shall ensure the effective closure of the

activity



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HIERARCHY OF HAZARDS CONTROL



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Types of hazards control measures

4.2 Control Measures

Machine guarding

Using devices, e.g. sensor, gates, etc

Distance

Use of automatic or semi-automatic fed and ejection/robots

Use of feeding tools

Training, Procedures (LOTO), etc

PPE



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Types of machine guarding

Fixed guard

Interlocked guard Adjustable guard

Self-adjusting guard



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Machine Guard

Source: Machine Guarding, OSHA Office of Training and Education


Fixed Guard of Machine


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Machine Guard

Interlockedguard on

revolvingdrum



Interlocked Guard of Machine


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Machine Guard

Bandsaw bladeadjustable

guard

Source: MachineGuarding, OSHA Office ofTraining and Education


Adjustable Guard of

Machine


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Machine Guard

Circular tablesaw self-adjusting guard

Source: MachineGuarding, OSHAOffice of Training andEducation


Self-adjusting

Guard


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Devices

Source: MachineGuarding, OSHAOffice of Trainingand Education


Pullback Device


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Devices

Source: Machine Guarding, OSHAOffice of Training and Education


Restraint Device


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Devices

TripwireCable

Source: MachineGuarding, OSHA Office ofTraining and Education


Safety Tripwire Cable


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Devices



Two-hand Control


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Devices


Two-hand Control

Two-hand Control


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Devices


Two-hand Control

Two-hand Control


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Devices

Gate Open Gate Closed



Gates


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Devices

Picture Source: Conceptsand Techniques of MachineSafeguarding, U.S.Department ofLabor, OSHA3067, 1992 (Revised)


Sensor


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Devices

Picture Source: Concepts andTechniques of MachineSafeguarding, U.S. Department ofLabor, OSHA 3067, 1992(Revised)


Sensor


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Safeguard by Distance


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Automatic Feed RobotSource: Machine Guarding, OSHA Office of Training and Education


Automatic Feed and Robot


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Protective Shield


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Holding Tools


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Source: Concepts andTechniques ofMachine Safeguarding


Holding Tools


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Emergency switch is provided when emergency stoppingof machine is necessary, and hence, the switch shall:

Emergency Switch

Be easily accessible to the operator; and

Be designed for unexpected activation


When necessary, buddy system shall be considered.


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Emergency Switch


EmergencySwitches for Different Uses

Picture Source: www.globalspec.com

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Devices


Two-hand Control

Emergency Switch

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While using power trucks for material transportation, thefollowing could be applied:

Power Trucks

Do not block the vision

No passengers allowed

Wrap the load from falling

Limit the speed

Consider door access control to minimize the impact to

pedestrians

Refer to Safe Operation of Forklift for details.


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LOTO is used to control the

unexpected release of energy:

Electricity

Steam

Gas

Single Photo atthis/within

Size/Area

Physical Lockout/Tagout

Lockout/Tagout Procedure


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Lockout/Tagout Devices

Picture Source: http://en.wikipedia.org/wiki/Lock_and_tag

Physical Lockout/Tagout

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Picture Source: http://www.cirlock.com.au

Physical Lockout for Circuit Breaker

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Picture Source: http://www.cirlock.com.au

Physical Lockout/Tagout Devices

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What must be included in the LOTO Procedure?

Lockout/Tagout (LOTO) Procedure

A statement on how to use the procedures;

Steps to shut down, isolate, block, and securemachines;

Steps designating the safe placement, removal, andtransfer ofLOTO devices and identifying who hasresponsibility for the LOTO devices; and

Requirements to determine and verify theeffectiveness of lockout devices, tagout devices, andother energy-control measures.


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What must workers do before maintenance activities?


1. Prepare for shutdown;

2. Shut down the machine;

3. Disconnect or isolate the machine from the energysource(s);

4. Apply the lockout or tagout device(s) to the energy-isolating device(s);

5. Release, restrain, or render safe all potential hazardousstored or residual energy. Regularly inspect to avoid re-accumulation of energy if necessary.

6. Verify the isolation and de-energization of the machine.


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What must workers do before removing LOTO device andreenergize the machine?


Step 1: Inspect machines or their components to assurethat they are operationally intact and that nonessentialitems are removed from the area; and

Step 2: Check to assure that everyone is positionedsafely and away from machines.


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What are the limitations for tagout devices?


A tagout device is a prominent warning of the

hazards;

Tags do not provide the physical restraint of a lock;

Tags may evoke a false sense of security;

Therefore, lockout devices is considered more secure

and more effective than tagout devices in protectingemployees from hazardous energy.


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Before using any machine, you should:

Training

Be trained by qualified person/agent

Clarify any doubt on machine usage

Have the correct certificate, if required by law

Inspect the machine for good condition (or inspectedby qualified persons)

Do not operate machine unless authorized


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Before using any machine, you should ensure that:

PPE

Proper PPE is used to conduct the work

The PPE is in good condition

Proper training has been given on how to use PPE


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Some basic tips to improve ergonomics:

Ergonomics

Use equipment to aid material handling Use correct material handling position

Maintain comfortable position when working

Do the work with proper tools


Refer to Material Handling for Metalworking Industry for more details about ergonomic hazardcontrol.

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Ergonomics

Source: Ergonomics Guidelines for Manual MaterialHandling, CDC, NIOSH


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Ergonomics

Source: Ergonomics Guidelines for Manual MaterialHandling, CDC, NIOSH


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Ergonomics

Use Tools with Better Grip

Source: Easy Ergonomics: A Guide to Selecting Non-Powered Hand Tools, CDC, NIOSH


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Ergonomics

Select the Correct Tool for the Job



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Ergonomics

Adopt the Correct PostureSource: Easy Ergonomics: A Guide to Selecting Non-Powered Hand Tools, CDC, NIOSH


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Ergonomics

Select the Correct Tool



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The following practices shall be observed at all times:

Safe Practices

Always use the safety devices correctively;

Do not wear loose clothing/ties when operatingmachines with rotating parts;

Tie up or cover up long hair;

Use devices to remove trapped materials from

machine;

Switch off the machine before retrieving droppedmaterial(s) from inside the machine.


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ExerciseExercise

Identify the hazards associated with the machines usedby you, considering:

What control measures are in place to reduce the

hazard?

Whether the control measures are adequate, e.g.any incident occurred?

What improvements can be made to reduce therisk?

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1. Workplace Safety, Volume 4 of Safety at Work Series, John Ridley and John Channing,Butterworth Heinemann, 1999

2. Risk Management: Risk Assessment Guidelines, MOM

3. Machine Guarding, OSHA Office ofTraining and Education

4. Risk Management: Risk Assessment Guidelines, MOM

5. National OSH Programme-Based Engagement (ProBE), Technical Advisory For Metalworking

Industry Understanding the Hazards of Metalworking Industry.6. Handbook of OSHA Construction Safety and Health, 2nd Ed, Charles D. Reese, James Vernon

Eidson, CRC, 2006

7. Concepts and Techniques of Machine Safeguarding, U.S. Department of Labor, OSHA 3067,

1992 (Revised)

8. Control of Hazardous Energy (Lockout/Tagout), U.S. Department of Labor, OSHA 3120, 2002

(Revised)

9. Easy Ergonomics: A Guide to Selecting Non-Powered Hand Tools, CDC, NIOSH, 2004

10. Survey of Occupational Injuries and Illnesses in Cooperation with Participating State Agencies,

Bureau of Labor Statistics, U.S. Department of Labor

11. CP91:2001 Lockout Procedure

ReferenceReference

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safe operation of machines

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