First Safety Systems Training Services

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Basic Occupational Safety and Health Seminar

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 First Safety Systems Training Services
‘ Your total safety solutions’

Ground Rules
–Bags against the wall
–Cell phones off or on “vibrate mode”
–One conversation at a time
–Respect for each other
–Active participation
–Maximum interaction
–Any other ground rules?
Safety Contact
 Safety Contact

A worker was severely injured when an accident

happened
He was working as a contract worker in a
manufacturing plant
Unfortunately, he was dead before arrival in the
hospital
 Safety Contact

Nabagsakan lang…
 Safety Contact

The Plat Manager, Department Manager and

the Safety Officer visited on his wake
To show the company’s sympathy and affirm
their support to the family and
To the pregnant, young widowed wife who is
crying non-stop to the untimely death of her
husband
 Safety Contact

“Madam”, said the PM, “we are very sad of what

happened .”
The SO butted in, “ Misis, your husband was often
times caught violating safety rules, but he always
reasoned himself out of the penalties “.
 Safety Contact

“Sirs, if that was the case”, said the young wife,

“far better if you had suspended; or even
terminated my husband before, so that my children
would grow up still with a father on their sides.”
Mag-ingat lagi. May naghihintay sa bahay…
Sila ay ang ating
mga mahal sa
buhay…

Ang ating
Pamilya!...
O… si Misis!

Kaya lagi
akong mag-
Safety First!
 WORLD CLASS SAFETY-BENCHMARKING

14
13.3

12

10 10
9.4

8
Frequency Rate

4 3.8
3
2.5
2.1
2
1.1
0.45 0.5 0.5
0.29
0
nt on oa n e ll ia r e ot ti m e
uP o ohns Alc Ex
xo Sh hod i l e ve
a far g euge men olci a non
D J R Un L P lce H D
J& Ita

TO BE AMONG THE SAFEST INDUSTRIAL PLANT BY 2012

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MACHINE SAFEGUARDING

Objective: To give detailed description on mechanical hazards,

and safe use of machines through guarding and safeguarding

BASICS OF MACHINE GUARDING

SAFEGUARDS are essential for protecting workers from

needless and preventable injuries.

RULE OF THUMB
Any machine part, function, or process which may cause injury
must be safeguarded

Crushed hands and arms, severed fingers, blindness - the list of possible
machinery-related accidents …is horrifying!!!
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While machines allow more sufficient,

productive work, you must use them with
great caution.

Safety should be foremost in your mind.

When working with moving machine parts.

If it’s possible to wear PPE on maintenance

work, the better, and use safety features and
tools correctly.

You are in charge of your own personnel

safety on the job.

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Where are the Regulations?

The Occupational Safety and Health Administration

(OSHA) has put forth several regulations that applies to the
use of electrically powered machinery.

In general, remember that any machine part, function,

or process that may cause injury must be guarded. Where the
operation of a machine or accidental contact with it, can
injure you or others, these hazards must be either controlled
or eliminated.

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Basic Safety
Basic Safety
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Serious Injuries are Possible

Crushed hands and arms, severed fingers,

blindness the list of possible machinery-
related injuries is as long as it is horrifying.
There seems to be as many hazards created
by moving machine parts as there are types
of machines.

Guards are essential for protecting workers

from needless and preventable injuries.

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In addition, most machines and power

tools are powered by electricity.
Electrical hazards are equally
debilitating.

Electricity will give you a shock if you

accidentally become a ground.

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You can see that it’s absolutely

necessary to pay attention as you
use equipment. A machine can be
pretty unforgiving if you slip up-be
sure you’re in charge.

ิ
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WHERE MECHANICAL HAZARDS OCCUR

Point of operation
Power transmission apparatus
Other moving parts

POINT OF OPERATION

The point in the machine where work is performed on the material.

Examples: Cutting, shaping, boring or forming stock.

POWER TRANSMISSION APPARATUS

All components of the mechanical system which transmit energy to the part of the
machine performing the work.
Examples: Flywheels, pulleys, belts, couplings, gears.

OTHER MOVING PARTS

All parts of the machine which moves while the machine is working.
Examples: Reciprocating, rotating, and transverse moving parts.
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Hazardous Mechanical Motions and Actions

Different types of hazardous mechanical motions and actions

are basic to nearly all machines.

Recognizing them is the first step you can take toward protecting
yourself from the dangers they present. We will briefly examine
the following types of hazards in turn:

Rotating motion can be dangerous, even smooth, shaft ends,

spindles, and horizontal or vertical shafting are some examples of
common rotating mechanisms which may be hazardous. There is
added danger when bolts, nick, abrasions, and projecting keys or
set screw are exposed on
rotating parts of machinery.

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HAZARDOUS MECHANICAL MOTIONS

Rotating (including in-running nip points)

Reciprocating
Traversing

ROTATING MOTION

Rotating motion can be dangerous:

smooth, slowly rotating shafts can grip clothing
mere skin contact can force an arm or hand into the dangerous position

Examples: Collars, couplings, shaft ends.

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3 TYPES OF IN-RUNNING NIP POINT

Type 1 - Parts rotate in opposite direction while axes are parallel to each other.
Type 2 - Between rotating and tangentially moving parts.
Type 3 - Between rotating and fixed parts which create a shearing, crushing or
abrading action.

RECIPROCATING MOTION

Back-and-forth motion or Up-and-down motion.

Danger: Struck by or caught between a moving and a stationary part.

TRANSVERSE MOTION

Movement in a straight continuous line.

Danger: Struck by or caught in a pinch or shear points.
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 Transmission Conveyors
Guarding bridging points

* Use lightweight rollers

* Ensure pop-out is not blocked
* Ensure gaps are less than 5mm
* If necessary to use more than one
roller to bridge, only the first roller
need be made as a pop out
* Fix bridging strips to conveyor framework
© JLBHAssociates, 1999
 POLYCORD INFILL GUARDS

* Gaps less than 5mm

* Link guards to shaft giving automatic relocation
* Fabricate in Perplas.
* Also OK for wire ropes.
* Guard will also keep pulley groove clean Fix to conveyor framework
with bolts

©JLBHAssociates, 1999
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HAZARDOUS MECHANICAL MOTION

CUTTING ACTION

Involve rotating, reciprocating, or transverse motion.

Dangers: Direct contact, flying chips or scrap materials.
Examples: Band saws, circular saws, boring or drilling machines

PUNCHING ACTION

Result when power is applied to a slide (ram) for the purpose of blanking,
drawing, stamping metal or other materials.

Dangers: Point of operation, where stock is inserted, held and withdrawn

by hands. (Example: Power presses)

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SHEARING ACTION

Involves applying power to a slide or knife in order to trim or shear metal or

other materials.
Dangers: Point of operation, where stock is inserted, held and withdrawn by
hands.

Examples: Mechanically, hydraulically, or pneumatically powered shears.

BENDING ACTION

Power is applied to a slide in order to draw or stamp metal or other materials.

Dangers: Point of operation, where stock is inserted, held and withdrawn by

hands.

Examples: Power presses, press brakes, and tubing benders.

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5 CLASSIFICATIONS OF SAFEGUARDS

Guards
Devices
Location/Distance
Feeding & Ejecting Method
Miscellaneous Aids

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Guard Requirements

What must a guard do to protect you from mechanical hazards? Guards

must meet these minimum general requirements:

Prevent contact: The guard must prevent hands, arms, or any part of your body
or clothing form making contact with dangerous moving parts.

Secure: Guards should not be easy to remove or alter; a guard that can easily be
made ineffective is no guard at all. Guards and safety devices must be made of
durable materials that will withstand the conditions of normal use. They must be
firmly secured to the machine.

Protect from falling objects: The guard should ensure that no objects can fall into
moving parts. A small tool which is dropped into a cycling machine could easily
become projectile and could strike and injure someone.

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Guard Requirements

Create no new hazards: A guard defeats its own purpose if it creates a

hazard of its own such as shear points, a jagged edge, or an unfinished
surface which can cause a laceration. The edge of guards, for instance,
should be rolled or bolted in such a way that they eliminate sharp edges.

Create no interference: You might soon override or disregard any guard

which keep you from doing your job quickly and comfortably. Proper
guarding can actually enhance efficiency since it can relieve your worries
about injury.

If possible, one should be able to lubricate the machine without removing the
guards.

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Even the most elaborate guarding system cannot offer effective protection unless
you know how and why you use it.

You should be aware of the following:

A description and identification of the hazards associated with particular machines.

The guards themselves; how they provide protection, and the hazards for which they are
intended.

How to use the guards and why

How and under what circumstances guards can be removed, and by whom ( in most
cases, repair or maintenance personnel only.)

What to do (e.g. contact your supervisor) if a guard is damaged, missing, or unable to

provide adequate protection.

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Guards are barriers which may prevent access to danger areas.

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DEVICES

A safety device may perform one of several functions, namely;

Stop the machine if a hand or any part of the body is inadvertently

placed in the danger area.

Restrain or withdraw the operator’s hands from the danger area

during operation.

Require the operator to use both hands on machine controls. Thus

keeping hands and body out of danger

Provide a barrier that synchronized with the operating cycle of the

machine in order to prevent entry to the danger area during
the hazardous part of the cycle.

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 CONVEYORINFILLGUARD

* Ensure gaps are less than 5mm.

* Fabricate fromPerplas.
* Link guard to pulley shaft to keep relationship on adjustable pulleys
* Ensure guard has a full back face to prevent internal access
 Conveyor Box Guard

1MMin.
fromnip

Notes:
1. Keep adjusters and lubrication points OUTSIDEguard
2. Use mesh small enough to stop access
3. Make it strong enough to stand up to abuse
4. Bolt it in place
5. Paint frame red or orange. Mesh matt black
6. Fix Emergency Stop "taut and slack wire" switches to
sides of guard so that conveyor is disabled if guard
is removed
7. Talk to users about equipment usage before designing and making guard
© JLBH Associates, 1999
Head Pulley Box Guard

• Make from expanded

metal or weldmesh
• Use sheet material +
angle iron to strengthen
• Ensure mesh is small
enough to prevent
access
• Paint mesh matt black
to ensure visibility
• Ensure at least 1M
reach access
• Securely fix using bolts
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Snub Roll + Head Pulley Guard

• Make from expanded
metal or weldmesh
• Use sheet material +
angle iron to strengthen
• Ensure mesh is small
enough to prevent
access
• Guard underside with
feed chute
• Paint mesh matt black
to ensure visibility
• Ensure at least 1M
reach access
• Securely fix using bolts
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Conveyor Idler guarding

Bolt guards to side of hopper

and carry across front and rear,
to enclose all inrunning nips

Option 1

Fix to conveyor framework.

Use mesh with gaps small enough to prevent
finger access. Strengthen with 15 x 3 mm
flat bar at each end.

Option 2

Fix to conveyor framework.

Fabricate from angle, heat shaped to fit
between conveyor and roller surface
Drive Shaft and Coupling Guards

• Make from sheet metal

• Fix with flanges using bolts
Hazards ….. Guarding
Safe Equipment Design – Guarding
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DEVICES

Presence Sensing

Uses systems of light.

Principle of operation: When the light beam is broken, machine will not start to cycle or
stopping mechanism will be activated.

Fixed Guards

Permanent part of the machine and not dependent upon moving parts to perform its
intended function.

Interlocked

When the guard is opened or removed, the tripping mechanisms and/or power shut off
or disengage and the machine cannot cycle or be started until the guard is back in
place.

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Two Hand Control

Requires constant, concurrent pressure by the operator to activate the machine.

LOCATION/DISTANCE

Dangerous parts located high enough to be out of the normal reach of any worker.

Operator location at safe distance from the hazardous parts of machine.

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FEEDING AND EJECTING METHOD

Automatic Feed

Stock fed by chutes, hoppers or conveyors, movable dies.

Enclosure will not admit any part of the body.

Automatic Ejection

Work pieces are ejected by air or other mechanical means.

Enclosure will not admit any part of the body.

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MISCELLANEOUS AIDS

Supplement to the protection that other safeguards provide.

Use of push stick or block when feeding stock.

MINIMUM GENERAL REQUIREMENTS

Prevent contact Prevent contact with

Secure moving parts
Protect from falling objects
Create no new hazards
Create no interference
Allow safe lubrication

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Safe Work Practices – Warning Sign
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NON-MECHANICAL HAZARDS

Not grounded properly (electrical)

Failure of high pressure system (pneumatic)
Noise (unwanted sound)
Potentially harmful substances (cutting fluids, coolants)

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OPERATOR TRAINING

A description of hazards associated with particular machine.

The safeguards themselves, how they provide protection, and the
hazards for which they are intended.
How to use the safeguards and why.
How and under what circumstances safeguards may be removed and by
whom.
What to do if safeguard is damaged, missing, or unable to provide
adequate protection.

Proper operator training – use of

the 2-hand push button to keep
fingers out of the machine
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Hazardous Mechanical Motions and Actions

Different types of hazardous mechanical motions and actions are basic

to nearly all machines.

Recognizing them is the first step you can take toward protecting
yourself from the dangers they present. We will briefly examine the
following types of hazards in turn:

Rotating motion can be dangerous, even smooth, shaft ends, spindles,

and horizontal or vertical shafting are some examples of common rotating
mechanisms which may be hazardous. There is added danger when
bolts, nick, abrasions, and projecting keys or set screw are exposed on
rotating parts of machinery.

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Miscellaneous aids do not provide complete protection from machine
hazards, but provide an extra margin of safety.

One example is an awareness barrier. An awareness barrier serves to

remind you that you are approaching a danger area.

Remember
!
One Hazard you
know and
removed today

Means that you

reduce one
accident
tomorrow
Safe Equipment Design – Restricted Access
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Personnel Protective Equipment

Engineering control that eliminates the hazard at the source and do not rely on behavior for their
effectiveness offer the best and most reliable means of safeguarding. Therefore, engineering
control must be the employer’s first choice for eliminating machine hazards. But where
engineering control is not available or is not fully capable of protecting you, you must wear
protective clothing or personal protective equipment (PPE).

PPE is, of course, available for different parts of the body. Hard hats can protect the head from
the impact of bumps and falling objects when you work with stock. Caps and hair nets can help
keep your hair from being caught in machinery.

If machine coolants could splash or particles could fly into the operator’s eyes or face, then face
shields, safety goggles, glasses, or similar kinds of protection might be necessary.

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Personnel Protective Equipment

Hearing protection may be needed when operating noisy machine.

To guard the trunk of the body from cuts or impact from heavy or rough-edged stock, there are
certain protective coveralls, jackets, vest, aprons, and full-body suits.

Workers can protect their hands and arms from the same kinds of injuries with special sleeves
and gloves.

Safety shoes and boots, or other acceptable foot guards, can shield the feet against injury when
handling heavy loads which might drop. It is important to note that protective clothing and
equipment can create hazards.

A protective gloves which can be caught between rotating parts, or a respirator face piece which
hinders the wearer’s vision, for example, require alertness and continues attentiveness
wherever they used.

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 The Control Hierarchy
Elimination
1
Substitution

2
Engineering
Control 3
Administrative 4
PPE
5
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Some General Safety Rules

General safety rules apply to both stationary and portable equipment.

Never let over confidence lead you into taking unnecessary risks.
The following rules apply to every machine or power tools you use:

Keep your work area well lit and dry .

Maintain your tools. For best and safety performance, keep them sharp, oiled and
stored in a safe, dry place. Regularly inspect tools, cords and accessories, repair or
replace problem equipment immediately.

Keep your work area clean. Sawdust, paper, and oily rags are a fire hazard
and can damage your tools.

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Some General Safety Rules

Use safety features like three-plugs, double- insulated tools, and safety switches.
make sure machine guards are in place on large and small equipment.

Use protective equipment when necessary. This might include safety glasses,
hearing protection and respiratory protection.

Dress right. Never wear clothing or jewelry that could become entangled in power
Tools.

Install or repair equipment only if you’re qualified. A faulty job may cause fires
or seriously injure you or other workers.

Use the right tools for the job. Don’t force a small tool to do a heavy-duty work.
Keep electric cables and cords clean, free from kinks.
Never carry a tool by its cords.

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Evaluation of the Controls

Are the changes made working

successfully?
 Have the changes been correctly
implemented?
 Are the changes causing further problems?
 Do they help reduce injuries?

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Coffee Break