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Mechanical hazard control Ahsanullah Soomro 02/06/22 Engr. Ahsanullah Soomro 1

Mechanical hazard control

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Health, Safety and Environment

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  • 1. Mechanical hazard control Ahsanullah Soomro 09/20/14 Engr. Ahsanullah Soomro 1
  • 2. General requirements for work equipment Any equipment used by an employee at work is generally covered by the term work equipment. The scope is extremely wide and includes hand tools, power tools, ladders, photocopiers, laboratory apparatus, lifting equipment, fork-lift trucks, and motor vehicles etc. 09/20/14 2
  • 3. General requirements for work equipment Employers must ensure that work equipment is suitable, maintained, inspected if necessary, provided with adequate information and instruction and only used by people who have received sufficient training 09/20/14 3
  • 4. Suitability of work equipment and CE (Conformit Europene) marking When work equipment is provided it has to conform to standards which cover its supply as a new or second-hand piece of equipment and its use in the workplace. This involves: its initial reliability the place where it will be used the purpose for which it will be used. 09/20/14 4
  • 5. Suitability of work equipment and CE marking There are two groups of law that deal with the provision of work equipment: One deals with what manufacturers and suppliers have to do. The CE marking ("Conformite Europeenne") certifies that a product has met EU health, safety, and environmental requirements, which ensure consumer safety. 09/20/14 5
  • 6. Suitability of work equipment and CE marking The other deals with what the users of machinery and other work equipment have to do Its primary purpose is to protect people at work. Under user law employers have to provide safe equipment of the correct type, ensure that it is correctly used and maintain it in a safe condition 09/20/14 6
  • 7. Suitability of work equipment and CE marking When buying new equipment, the user has to check that the equipment complies with all the supply law that is relevant. The user must check that the machine is safe before it is used. 09/20/14 7
  • 8. Prevention of access to dangerous parts of machinery Employers must to take effective measures to prevent access to dangerous parts of machinery or stop their movement before any part of a person enters a danger zone 09/20/14 8
  • 9. Prevention of access to dangerous parts of machinery The term dangerous part has been established in health and safety law. In practice, this means that if a piece of work equipment could cause injury and if it is being used in a predictable way, it can be considered a dangerous part. The risk assessment carried out to identify hazards presented by machinery. 09/20/14 9
  • 10. Prevention of access to dangerous parts of machinery The risk assessment should evaluate the nature of the injury, its severity and likelihood of occurrence for each hazard identified In most cases the objective of risk reduction measures is to prevent contact of part of the body or clothing with any dangerous part of the machine, for example by providing guards. 09/20/14 10
  • 11. Use and maintenance of equipment with specific risks Some pieces of work equipment involve specific risks to health and safety where it is not possible to control adequately the hazards by physical measures alone, for example the use of a bench-mounted circular saw or an abrasive wheel 09/20/14 11
  • 12. Use and maintenance of equipment with specific risks 09/20/14 12
  • 13. Use and maintenance of equipment with specific risks In all cases the hierarchy of controls should be adopted to reduce the risks by: eliminating the risks; or, if this is not possible taking physical measures to control the risks such as guards; but if the risks cannot be adequately controlled taking appropriate software measures, such as a safe system of work. Or use PPE The hierarchy of control is a sequence of options which offer you a number of ways to approach the control of hazards. 09/20/14 13
  • 14. Use and maintenance of equipment with specific risks Repairs, modifications, maintenance or servicing is also restricted to designated persons. A designated person may be the operator if he/she has the necessary skills and has received specific instruction and training. Another person specifically trained to carry out a particular maintenance task, for example dressing an abrasive wheel, may not be the operator but may be designated to do this type of servicing task on a range of machines. 09/20/14 14
  • 15. Use and maintenance of equipment with specific risks People using and maintaining work equipment, where there are residual risks that cannot be sufficiently reduced by physical means, require enough information, instruction and training to operate safely. 09/20/14 15
  • 16. Information, instruction and training The information and instructions are likely to come from the manufacturer in the form of operating and maintenance manuals. It is up to the employer to ensure that what is provided is easily understood, and set out logically with illustrations and standard symbols where appropriate 09/20/14 16
  • 17. Information, instruction and training The extent of the information and instructions will depend on the complexity of the equipment and the specific risks associated with its use. They should cover: all safety and health aspects; any limitations on the use of the equipment; any foreseeable problems that could occur; safe methods to deal with the problems; any relevant experience with the equipment that would reduce the risks or help others to work 09/20/14 17
  • 18. Information, instruction and training Everyone who uses and maintains work equipment needs to be adequately trained. The amount of training required will depend on: the complexity and level of risk involved in using or maintaining the equipment; the experience and skills of the person doing the work, whether it is normal use or maintenance. 09/20/14 18
  • 19. Information, instruction and training Training needs will be greatest when a person is first appointed but will also need to be considered: when working tasks are changed, particularly if the level of risk changes; if new technology or new equipment is introduced; where a system of work changes; when legal requirements change; periodically to update and refresh peoples knowledge and skills; following an accident. 09/20/14 19
  • 20. Information, instruction and training Supervisors and managers also require adequate training to carry out their function The training and supervision of young persons is particularly important because of their relative immaturity, unfamiliarity with a working environment and lack of awareness of existing or potential risks. 09/20/14 20
  • 21. Maintenance and inspection 09/20/14 21
  • 22. Maintenance Work equipment needs to be properly maintained so that it continues to operate safely The amount of maintenance will be required in the manufacturers instructions and will depend on the amount of use, the working environment and the type of equipment 09/20/14 22
  • 23. Maintenance Maintenance management should focus on those parts which deteriorate and need to be maintained to prevent health and safety risks. These techniques include the following: Preventative planned maintenance Condition based maintenance Breakdown based maintenance 09/20/14 23
  • 24. Preventative planned maintenance This involves replacing parts and making necessary adjustments normally set by the manufacturer, so that there are no hazards created by component deterioration or failure. Vehicles are normally maintained on this basis. 09/20/14 24
  • 25. Condition based maintenance this involves monitoring the condition of critical parts and carrying out maintenance whenever necessary to avoid hazards which could otherwise occur. 09/20/14 25
  • 26. Breakdown based maintenance here maintenance is only carried out when faults or failures have occurred. It is essential to ensure that maintenance work can be carried out safely. This will involve the following: competent well-trained maintenance people; the equipment being made safe for the maintenance work to be carried out. 09/20/14 26
  • 27. Breakdown based maintenance necessary procedures are required to make and keep the equipment safe and perform the maintenance tasks. This can often involve a formal permit-to-work scheme correct tools and safety equipment being available to perform the maintenance work without risks to people. For example special lighting or ventilation may be required. 09/20/14 27
  • 28. Inspection an inspection is, most generally, an organized examination or formal evaluation exercise to ensure continued safe operation an official process of checking that things are in the correct condition or not competent person for inspection would normally be an employee, 09/20/14 28
  • 29. Inspection but there might be circumstances where an outside competent person would be used. The inspection must be done: after installation for the first time; after assembly at a new site or in a new location and thereafter; at suitable intervals; each time special circumstances occur which could affect safety 09/20/14 29
  • 30. Safety Inspection
  • 31. Safety Inspection
  • 32. Safety Inspection
  • 33. Safety Inspection
  • 34. Safety Inspection
  • 35. Operation and working environment To operate work equipment safely it must be fitted with easily reached and operated controls, provided with adequate markings and warning signs. These are covered by PUWER 98, which applies to all types of work equipment. 09/20/14 35
  • 36. Controls Equipment should be provided with efficient means of: starting or making a significant change in operating conditions; stopping in normal circumstances; emergency stopping as necessary to prevent danger. 09/20/14 36
  • 37. Controls All controls should be well positioned, clearly visible and identifiable Markings should be clearly visible and remain so under the conditions met at the workplace. 09/20/14 37
  • 38. Controls (a) Start controls It should only be possible to start the work equipment by using the designed start control (b) Stop controls The action of normal stopping controls should bring the equipment to a safe condition in a safe manner. 09/20/14 38
  • 39. Controls (c) Emergency stop controls Emergency stop must be provided where the other safeguards in place are not sufficient to prevent danger (d) Markings Markings on equipment must be clearly visible and durable. 09/20/14 39
  • 40. Two-hand Control Emergency Switch
  • 41. MMaacchhiinnee HHaazzaarrddss Pictures or Graphs Within This Area Unguarded Rotating Parts of Machine Loose Clothing
  • 42. Unguarded Rotating Parts of Machine 33.. MMaacchhiinnee HHaazzaarrddss
  • 43. Controlling the Mechanical Hazards Following are the control measures: 1. Engineering controls. 2. Administrative controls. 3. Personal protective equipment.
  • 44. Controlling the Mechanical Hazards The most effective controls are engineering controls that physically change a machine or work environment to prevent employee exposure to the hazard. If this is not feasible, administrative controls may be appropriate. This may involve changing how employees do their jobs.
  • 45. Engineering Controls Engineering controls include the following: Elimination/minimization of the hazard Substitution of equipment or process to decrease hazard Isolation of the hazard with interlocks, machine guards, or other means; and Removal or redirection of the hazard such as with exhaust ventilation.
  • 46. Administrative Controls Administrative controls include the following: Written operating procedures, work permits, and safe work practices; Exposure time limitations (used most commonly to control heat stress and ergonomic hazards); Monitoring the use of highly hazardous materials; Alarms, signs, and warnings; and training
  • 47. PPE Personal Protective Equipment is acceptable as a control method in the following circumstances: When engineering controls are not feasible or do not totally eliminate the hazard; While engineering controls are being developed; When safe work practices do not provide sufficient additional protection; and During emergencies when engineering controls may not be feasible.
  • 48. Engineering Control Machine Safeguarding To determine the proper safeguarding method, determine: Type of operation Size & shape of stock Method of handling Physical layout of work area Type of Material Production requirements or limitations
  • 49. BASICS OF MACHINE GUARDING Requirements for Safeguards Be securely attached Create no new hazards Withstand operational conditions Allow for safe routine maintenance Allow for safe operator adjustments Withstand environmental conditions Provide protection from falling objects Prevent contact with hazardous conditions Create no interference in the conduct of work
  • 50. METHODS OF MACHINE GUARDING Safeguards Are Grouped Under 5 Classifications: 1. Guards 2. Devices 3. Locations/Distance 4. Feeding and ejection methods 5. Miscellaneous aids
  • 51. METHODS OF MACHINE GUARDING Guards: Guards are barriers which prevent access to danger areas, there are four general types: Fixed guards Interlocked guards Adjustable guards Self-Adjusting guards
  • 52. Fixed guards 1.Guards A fixed guard has no moving parts and should, by its design, prevent access to the dangerous parts of the machinery it may be constructed of sheet metal, screen, bars, plastic, or any other material This guard is usually preferable to all other types because of its relative simplicity. 09/20/14 52
  • 53. 1.Guards 09/20/14 53
  • 54. 1.Guards 09/20/14 54
  • 55. 1.Guards 09/20/14 55
  • 56. 44.. MMaacchhiinnee SSaaffeettyy Machine Guard Fixed Guard of Machine 1.Guards
  • 57. 1.Guards 09/20/14 57
  • 58. 1.Guards METHODS OF MACHINE GUARDING Fixed Guards: ADVANTAGES Can be constructed to suit many different applications In-plant construction is often possible Can provide maximum protection Usually requires minimum maintenance Can be suitable to high production operations
  • 59. 1.Guards METHODS OF MACHINE GUARDING Fixed Guards: LIMITATIONS May interfere with visibility Can be limited to specific operations Machine adjustments and repair often require guard removal, thereby necessitating other means of protection for maintenance personnel
  • 60. Interlocked Guards: Interlocked guards are designed to automatically shut off the machine if the guard is opened or removed AUTOMATIC AUDIBLE ALARM AUTOMATIC VISUAL ALARM 1.Guards
  • 61. Interlocked Guards: 1.Guards When this type of guard is opened or removed, the tripping mechanism and/or power automatically shuts off or disengages, the moving parts of the machine are stopped, and the machine cannot be started until the guard is back in place. 09/20/14 61
  • 62. 1.Guards 09/20/14 62
  • 63. 1.Guards METHODS OF MACHINE GUARDING Interlocked Guards: ADVANTAGES Can provide maximum protection Allows access to machine for removing jams without time consuming removal of fixed guards LIMITATIONS Requires careful adjustment and maintenance May be easy to disengage jams
  • 64. Adjustable Guards: 1.Guards Adjustable guards are useful because they allow flexibility in accommodating various sizes of stock. Provides a barrier that may be adjusted to facilitate a variety of production operations 09/20/14 64
  • 65. 1.Guards 09/20/14 65
  • 66. Adjustable Guards: 1.Guards ADVANTAGES Can be constructed to suit many specific applications Can be adjusted to admit varying sizes of stock LIMITATIONS Hands may enter danger area Protection may not be complete at all times May require frequent maintenance and or adjustment The guard can be defeated by the operator May interfere with visibility
  • 67. Self-Adjusting Guards: 1.Guards The openings of self-adjusted guards are determined by the movement of the stock. As the operator moves the stock into the danger area, the guard is pushed away, allowing an opening that is large enough to admit the stock. When the stock is removed, the guard returns to the rest position. Adjusts automatically to the work Accommodate various sizes of stock May require additional operator training Self-Adjusting guards are typically used on: Radial arm saws Table saws Circular saws Jointers Similar equipment
  • 68. Machine Guard 1.Guards Circular table saw self-adjusting guard 44.. MMaacchhiinnee SSaaffeettyy Self-adjusting Guard
  • 69. Self-Adjusting Guards: 1.Guards METHODS OF MACHINE GUARDING ADVANTAGES they make varying sizes of work accessible to the point of operation Have wide variety of applications LIMITATIONS Protection may not be complete at all times May require frequent maintenance and or adjustment May interfere with visibility
  • 70. METHODS OF MACHINE GUARDIN Devices: Devices fall into following general types: G Presence-Sensing devices Pullback devices Restraint devices
  • 71. METHODS Devices: OF MACHINE GUARDING Devices may perform one of several function: Stop a machine if a body part is in danger Restrain or withdraw a hand if it is in danger Require activation by the use of both hands Provide a barrier synchronized to the operation
  • 72. Presence-Sensing: 2. Devices Typically operate on Photoelectric, Radiofrequency, Electromechanical principle to disengage the machine when something is detected in the hazardous area. These are typically installed on press and other machinery. PRESS PRESS ACME PRESSES
  • 73. 2. Devices METHODS OF MACHINE GUARDING
  • 74. Pullback devices 2. Devices Pullback devices utilize a series of cables attached to the operator's hands, wrists, and/or arms. This type of device is primarily used on machines with stroking action. When the slide/ram is up between cycles, the operator is allowed access to the point of operation. When the slide/ram begins to cycle by starting its descent, a mechanical linkage automatically assures withdrawal of the hands from the point of operation. 09/20/14 74
  • 75. 2. Devices 09/20/14 75
  • 76. 2. Devices 09/20/14 76
  • 77. Pullback devices ADVANTAGES Eliminates the need for auxiliary barriers or other interferences at the danger area LIMITATIONS 2. Devices Limits movement of operator May obstruct work space around operator Adjustments must be made for specific operations and for each individual Requires close supervision of the operator's use of the equipment
  • 78. 2. Devices Restraint The restraint (hold-back) device utilizes cables or straps that are attached to the operator's hands and a fixed point. The cables or straps must be adjusted to let the operator's hands travel within a predetermined safe area. There is no extending or retracting action involved. Consequently, hand-feeding tools are often necessary if the operation involves placing material into the danger area. 09/20/14 78
  • 79. 2. Devices 09/20/14 79
  • 80. Restraint devices ADVANTAGES Simplicity of use LIMITATIONS 2. Devices Limits movement of operator May obstruct work space around operator Adjustments must be made for specific operations and for each individual Requires close supervision of the operator's use of the equipment
  • 81. 3. Location/Distance Safeguarding: METHODS OF MACHINE GUARDING Position Dangerous Areas of Machines So That They Are Not Assessable During Normal Operations. Examples Include: Position Hazard Areas Against a Wall Locate Hazards Out of Reach of Operators Design Stock Feeding Openings Away From Hazards Position the Operators Control Station Away From Hazards
  • 82. 4. Feeding and Ejection Methods: Automatic and Semiautomatic feeding and ejection of parts are other ways of safeguarding machine processes. These methods eliminate the need for the operator to work at the point of operation. In some situations, no operator involvement is necessary after machine is set up. In other cases, operators can manually feed the stock with assistance of a feeding mechanics. Properly designed ejection methods do not require any operator involvement after machine starts to function.
  • 83. 5.Miscellaneous Aids While these aids do not give complete protection from machine hazards, they may provide the operator with an extra margin of safety. Awareness Barriers Protective Shields (protection from flying debris) Hand-Feeding Tools Administrative Controls Personal Protective Equipment (PPE) 09/20/14 83