wt4603 unit1 week2-12-09-2011
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Week 2 - Risk AssessmentTRANSCRIPT
WT4603 Wood Processing Safety & PracticeAUTUMN 2011Lecture Unit 1
Machine Provision, Hazard Identification, Risk Assessment & Week 2 Labs Lecturer: Mr. Joseph Lyster [email protected] Notes prepared by: Mr. Joseph Lyster Notes available on www.slideshare.net/WT4603
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• Section 8(2)e of the 2005 (Now 2007) Act states that it is the duty of every employer“to provide systems of work that are planned, organised, performed and maintained so as to be, so far as is reasonably practicable, safe and without risk to health.”
• Health and safety management is a practical and systematic approach to identifying hazards and evaluating the extent of associated risk
Health & Safety Management
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Can be identified by:▫High accident/injury rates.▫Poor machinery guarding.▫Poor cleaning and housekeeping arrangements.▫Limited interest of OHS by employers/management.▫Lack of care/respect for safety rules.▫Poor safety culture.
Unsafe Workplaces
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Can be identified by:
•Regular inspection of workplace•Consultation between employer and employees.•Clearly defined structure of responsibilities….•Employees are trained…•Exceeds the specific requirements of the law –
manages safety not for fear of being reprimanded but for the employees.
Safe Workplaces
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The Key steps of any Health & Safety Management scheme are:
1. Policy2. Hazard identification3. Risk Assessment4. Control Measures.5. Recording Findings (Safety Statement)6. Monitoring, Review and Auditing
Safety Management
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Importance of being able to Assess Risk
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Required Reading
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The Safety Management Process
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Health & Safety Policy
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Health & Safety Policy
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More information can be found byconsulting manufacturer’s manual
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Health & Safety at Work Act 2005
Pg. 30 of Health & Safety at Work Act
2005
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Identify Hazards (Hazard Identification)
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Hazards in the Workplace
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Department of Manufacturing & Operations Engineering
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Department of Manufacturing & Operations Engineering
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Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
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Department of Manufacturing & Operations Engineering
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Department of Manufacturing & Operations Engineering
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Department of Manufacturing & Operations Engineering
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Definition: Hazard
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Hazards in the Workplace
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Some Possible Hazards
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Common Machinery/Mechanical Hazards
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Wrap Point: (Entanglement)
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Shear Point and Cutting Hazards
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Crush Points
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Ejection Hazards
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Other Hazards
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Hazards
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• You will need to develop a template for your lesson risk assessment.• Strategies will need to be developed to:
Reduce or eliminate risk Demonstrate safe use of machine(s) Teach key learning points relating to machine or process Assess and record pupil learning and competence Ensure adequate supervision of activities
Classroom Risk Assessment:
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Room Layout
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Room Layout
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Room Layout
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Room Layout
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Assess Risk (Risk Assessment)
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A. Eliminate the Hazard Completely.B. Substitute Hazard with a safer alternative.C. Isolate the Hazard.D. Use engineering controls to reduce risk at the source
(Guarding).E. Provide training on how to avoid risks.& if all that fails…F. Use PPE.
Hierarchy of Risk Control
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Risk Assessment
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• Hazard • means anything that can cause harm (eg
chemicals, electricity, working from ladders, etc)
• Risk • is the chance, high or low, that
somebody will be harmed by the hazard.
Difference Between A Hazard & Risk
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Importance of being able to Assess Risk
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• Consequences
▫Minor Injury/Ill Health ( minor cuts, abrasions etc.)▫ Injury/Ill Health (burns, sprains, minor fractures etc.)▫Serious Injury/Ill Health (breaks, deafness etc.)▫Major Injury/Ill Health (amputations, cancer, multiple breaks
etc.)▫Fatality (one or more fatalities)
Risk Assessment Considerations
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▫Knowledge▫Skills▫Training▫Experience▫Attitude
▫Motivation▫Risk perception▫Mental condition▫Physical condition▫Accident proneness
Factors Effecting Likelihood & OccurrenceIndividual Factors
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Risk Magnitude
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Factors Effecting Likelihood of Occurrence
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Risk Magnitude Matrix
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Risk Magnitude Matrix: Severe Cut/Amputation from Bandsaw
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Which Poses the Greatest Risk?
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Department of Design & Manufacturing Technology
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Department of Design & Manufacturing Technology
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Department of Design & Manufacturing Technology
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Department of Design & Manufacturing Technology
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Department of Design & Manufacturing Technology
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RISK ASSESSMENTLocation: SR2-047 Date: 24-09-2010 Assessment Carried out by: Mr. Joe LysterAssessment of: PILLAR DRILL CE Marking (Machines): Yes □ No □Page 1 of 1 Assessment Review Date: 24-09-2010
HAZARD RISK MAGNITUDE PERSONS AT RISK EXISTING CONTROLS REQUIRED CONTROLS PERSONS RESPONSIBLE TARGET DATE
Weekly etc…
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Risk Assessment Template
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RISK ASSESSMENTLocation: SR2-047 Date: 24-09-2010 Assessment Carried out by: Mr. Joe LysterAssessment of: PILLAR DRILL CE Marking (Machines): Yes □ No □Page 1 of 1 Assessment Review Date: 24-09-2010
HAZARD RISK MAGNITUDE PERSONS AT RISK EXISTING CONTROLS REQUIRED CONTROLS PERSONS RESPONSIBLE TARGET DATE
1. Entanglement
2. Violent Ejection
3. Piece Spinning4. Electric Shock Hazards5. Cuts
6. Inadvertent Starting7. Space around Machine8. Tripping/Slipping9. Pinch Point
10. Falling Table
11. Noise Levels
12. Crushing
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1. ENTANGLEMENTSEVERITY
Slightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
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2. VIOLENT EJECTIONSEVERITY
Slightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
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3. PIECE SPINNINGSEVERITY
Slightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
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4. ELECTRIC SHOCKSEVERITY
Slightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
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5. CUTSSEVERITY
Slightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
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6. INADVERTENT STARTING
SEVERITYSlightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
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7. SPACE AROUND MACHINE
SEVERITYSlightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
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8. TRIPPING/SLIPPINGSEVERITY
Slightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
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9. PINCH POINTSEVERITY
Slightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
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10. FALLING TABLESEVERITY
Slightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
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11. NOISE LEVELSSEVERITY
Slightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
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12. CrushingSEVERITY
Slightly Harmful
Moderately Harmful
Quite Harmful
Very Harmful
Extremely Harmful
LIKELIHOO
D
Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate
Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial
Likely Tolerable Moderate Moderate Substantial Substantial
Quite Likely Moderate Moderate Substantial Substantial Intolerable
Highly Likely Moderate Substantial Substantial Intolerable Intolerable
Department of Design & Manufacturing Technology
WT4603
Department of Design & Manufacturing Technology
WT4603
Department of Design & Manufacturing Technology
WT4603
Department of Design & Manufacturing Technology
WT4603
Department of Design & Manufacturing Technology
WT4603
RISK ASSESSMENTLocation: SR2-047 Date: 24-09-2010 Assessment Carried out by: Mr. Joe Lyster
Assessment of: PILLAR DRILL CE Marking (Machines): Yes No □□̷Page 1 of 1 Assessment Review Date: 24-09-2010
HAZARD RISK MAGNITUDE PERSONS AT RISK EXISTING CONTROLS REQUIRED CONTROLS PERSONS RESPONSIBLE TARGET DATE
1. Entanglement Intolerable User of Machine Securing Clothes/Hair Chuck Guard Teacher/Students 24-09-2010
2. Violent Ejection Moderate All in Class Spring Loaded Chuck Chuck Guard Teacher/Students 24-09-2010
3. Piece Spinning Moderate All in Vicinity Clamp Correct Clamping Teacher/Students 24-09-2010
4. Electric Shock Hazards Moderate User of Machine Inspection of
EquipmentRegular Inspection of electrical components
Teacher/Students 24-09-2010
5. CutsModerate User of Machine Training
Exclusion zones marked clearly in
relation to work areaTeacher/Students 24-09-2010
6. Inadvertent Starting Moderate All in Vicinity Lockable Isolator
SwitchLock isolator in the off position when not in
useTeacher/Students 24-09-2010
7. Space around Machine Substantial User of Machine Nothing
Safe work area exclusion zone marked
around machineTeacher/Students 24-09-2010
8. Tripping/Slipping Moderate User of Machine Nothing Sign posts Teacher/Students 24-09-2010
9. Pinch Point Substantial User of Machine Nothing Chuck Guard Teacher/Students 24-09-2010
10. Falling Table Moderate User of Machine Pillar Post Lock Handle Correct Locking/Clamp Teacher/Students 24-09-2010
11. Noise Levels Trivial All in Class Nothing PPE & Sign posts Teacher/Students 24-09-2010
12. Crushing Intolerable All in Vicinity Nothing Secure Fixing Teacher/Students 24-09-2010
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CLASSROOM MANAGEMENT:
Health & Safety…
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Department of Manufacturing & Operations Engineering
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• Students should only work in a high risk area when it is fully under the control of a person competent to work in and supervise that area.
• Close monitoring of students using machinery.• Students must not be permitted to use equipment while
unsupervised.• It is the responsibility of the schools to ensure that the
machines are not accessible to unauthorised persons▫Cleaners▫Visitors▫Unsupervised students.
Supervision & Access
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Department of Manufacturing & Operations Engineering
Supervision & Access
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Department of Manufacturing & Operations Engineering
Power operated equipment and tools should be locked in the “OFF” position in the following situations:▫When left unattended for any period of time.▫When the competent person (supervisor) is not in the work
area.▫Before cleaning out any blockage.▫Before the machine is cleaned.▫Before any maintenance work is carried out on the machine.▫Before guards are adjusted.▫Before tools or accessories are adjusted or changed.▫Before removing waste or swarf.▫When a machine is awaiting repair or maintenance.
Supervision & Access
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Department of Manufacturing & Operations Engineering
Supervision & Access
WT4603
Department of Manufacturing & Operations Engineering
Machines not to be used while pupils are in the classroom:
• Spindle Moulder• It is recommended that the use of the circular saw and planer
thicknesser machines while the students are in the classroom should be strictly prohibited.
• All preparatory work involving these machines should take place before class.
• May not be achievable immediately but plans should be made to try…in the interim control measures should be put in place to reduce exposure to as low levels as possible.
Supervision & Access
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The CE Marking is not a mark indicating conformity to a standard but rather a mark indicating conformity to the legal requirements of EU Directives.
CE Mark
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• CE Marking is the symbol as shown on the top of this page. • The letters "CE" are the abbreviation of French phrase
"Conformité Européene" which literally means "European Conformity". • The term initially used was "EC Mark" and it was
officially replaced by "CE Marking" in the Directive 93/68/EEC in 1993.
CE Mark
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• Machinery must bear the “CE” mark in order to be deemed in compliance with these regulations.
• Must not add to machinery – must be there… criminal offence to try to add it.
• Also an offence to reduce the visibility of the “CE” Marking on a machine.
CE Mark
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The existance of the “CE” marking on a piece of machinery should indicate that its manufacturer has met all relevant standards and requirements.
CE Mark
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Never assume that machinery is safe just because it has a “CE” marking
CE Mark
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Machine guards must:▫ Be of robust construction.▫ Not give rise to any additional hazard.▫ Not be easily removed or rendered inoperative.
(Removed with the use of a tool)▫ Be situated a sufficient distance from the danger zone.▫ Not restrict more than necessary the view of the operating cycle of the
equipment
Guarding
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• An assessment of each workshop should be carried out in order to determine the safe operational area around each machine.
• Hard wearing and clearly visible markings should be set down on the floor to indicate these safe operation areas.
• If necessary, machines should be moved to accommodate this safe operational area.
Exclusion Zones
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Lighting
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Emergency Isolators and Emergency Stops
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Start/Stop• Are there appropriate start / stop controls ?• Location• Colour• Flush mounted• Mushroom head
▫ Turn release▫ Key release
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Stop control must have priority over the Start control.
Start Control Flush Recessed
Stop Control Mushroom Head Push Bar
Start/Stop
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Some machines may have two stopping devices.
Hand Operated
Foot/Knee Operated
Emergency Stop
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Push Sticks
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Material Preparation
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Maintenance of Machinery
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Preventative Maintenance
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Maintenance Records
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Inspection of Machinery
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Inadvertent Starting
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Machinery Rundown Time
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A brief look at Safety Signage
Mandatory/Action
Regulatory/Prohibited
Emergency/Permission
Warning/Caution-
Danger
Week2: Lab 1 & 2•Table
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Week 2: Lab 1 & 2• Machine Exposure:▫ Surface Planer▫ Planer Thicknesser▫ Bandsaw
• Material Process – Component A:▫ Each student will receive an unprocessed plank of red deal measuring 750 x 245 x
50 (mm)
▫ Aim of week 2 labs is to square the material to a clean workable condition of required dimension.
WT4603
740
242
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Surface Planer
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Surface Planer 1 Guide Fence
2 Infeed Table
3 Isolator
4 Infeed Dept Adjustment Wheel
5 Start/Stop Control
6 Infeed Adjustment Lock Handle
7 Blade Guard
8Blade Guard Clamp/Release Mechanism
9 Outfeed Table
10 Guide Fence Adjustment Wheel
11 Guard Guide
12 Guide Fence Lock Handle
2
1
3
4
57
9
8
6
11
12
10
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Step 1:Isolate machine
Step 2: Squaring guide fence• Set up surface planer guide fence @ 90⁰ to
table surface• Note infeed and outfeed table. • Square to infeed using right angle square.• Use red lock handles to open and adjust fence.• Lock gently when fence is perpendicular to
infeed table.
Infeed Table
Out feed Table
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Step 3: Setting infeed dept• This machine is calibrated in metric.• Maximum recommended material removal is 1-
2mm/pass• Dept stop to be set at 2mm• Open infeed lock handle• Turn wheel to left to drop table to 2mm• Lower you drop, the more the planer cutting
block is exposed• Close infeed lock handle when required dept is
achieved.• * Do not adjust outfeed table level, this is for
maintenance purposes only*
Infeed Infeed
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Step 4: Setting the guide fence width• Minimum blade exposure• Width of material + 10mm is recommended• This results in 10mm blade exposure - Safety• Adjust lock handle to wind in or out guide fence• Lock in appropriate position
242 + 10
242 + 10
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Step 5: Guard adjustment• Guard set for face side = handle up – 10mm
blade exposure• Guard set for face edge = handle flat – no blade
exposure
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Step 6: Material Inspection• Inspect material for the following defects
• Cupping• Bowing• Twist• Knots• Loose grain
• Example - if material is bowed, set the bowed face to the surface planer table surface and process. Material should never be run through hump side down.
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Step 7: Determining face side and face edge• Use machine surface to check square• Select appropriate face side and face edge
based on inspection• Preliminary surface marking using an ‘X’ with
no less than a HB pencil• Ensure extraction gate valve is open and
extraction is on• Proceed to plane material – face side and face
edge only!Gate Valve locate on extractor pipe just above surface planer
X X
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Step 8: Planing face side• Material position • Hand positions
Ensure Guard Guide is in a vertical position to plane face side
Dept of Hand Dept of Hand
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Department of Design & Manufacturing Technology
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Note Hand Positions in relation to material
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Step 9: Planing face edge• Material position• Hand position
Ensure Guard Guide is in a horizontal position to plane face edge
Dept of Hand Dept of Hand
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Note Hand Positions in relation to material
Split second blade ExposureBlade guard flat onto table
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Thicknesser
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Thicknesser
1
2
4
3
1 Extractor Pipe
2 Control Panel
3 Adjustment Lever
4 Thicknesser Bed
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• Lab sequence – Thicknesser• Step 1:
1. Unlock twist release stop mechanism2. Press green button to start3. Allow machine to build up, this can be determined by
noise consistency4. When noise is consistent flip delta switch to on position5. Feed rate, i.e. Speed at which material is passed, is set.6. Adjust table height as required7. Feed material as directed
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Delta Switch
Twist Release Stop
Display Panel
Feed Rate Control
Stop/Start
Thicknesser Bed Adjustment
Control
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Bandsaw
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The bandsaw
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See you all next week!•Next week:▫Machine Provision▫Risk assessment▫Week 3 ripsaw labs
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Department of Design & Manufacturing Technology