01_DOLE Machine Guarding [Compatibility Mode]

7/30/2019 01_DOLE Machine Guarding [Compatibility Mode]

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International Wiring Systems (Phils.) Corp.International Wiring Systems (Phils.) Corp.

MACHINE GUARDING

BY: LESLIE T. BAUN


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Plant 41995

Admin. Bldg.2007

Central

WHSE2006

Plant 3/M1991

Plant 3/F1994

Address:

Luisita Industrial ParkSpecial Economic Processing Zone

San Miguel, Tarlac City

Shareholder

COMPANY PROFILECOMPANY PROFILE

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Exec. House2008

Plant 21991

Plant 11998

Gym1995

Sumitomo Wiring System, Ltd.SIIX CorporationJesus V. Del Rosario, Foundation Inc.

Establishment : July 1, 1991

Total Number of Employee(As of Sept. 30, 2012) : 5,841


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FINISHED GOODS DIST.

INSPECTION

ASSEMBLYTUBE CUTTING

AUTOMOTIVE WIRING HARNESS PROCESS FLOW 2 of 21

PACKAGING

CSS

LOADING

TUBE PRODUCTION

WPGCCS

WAREHOUSE


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DETAILS OF MACHINE RELATED ACCIDENTS

3

4

5

6

O

F

CASES

Tube

Production

Tube Cutting

Assy Machine

INDUSTRIAL ACCIDENTS

2006-2009

6

8

10

12

FC

ASES

Forklift

Bump aginst

hard object

Hit by sharp

object

Fall from same

level

Assy Machine7 CASES 7 CASES

10 CASES

INDUSTRIAL ACCIDENT STATISTICS

DETAILS OF MACHINE RELATED

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0

1

2

2006 2007 2008 2009

YEAR

N

O

.

Crimping &

Special

Process (CSS)

Cutting &

Crimping

(CCS)0

2

4

2006 2007 2008 2009

YEAR

NO

.O

Tube

Production

Tube Cutting

Crimping &

Special Process

(CSS)

Cutting &Crimping (CCS)

3 CASES

3 CASES 5 CASES 1 CASE 4 CASES

13 out of 27 reported workplace injuries involved machinery/ equipment(48% of total reported cases).


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Item Industrial Accidents 2006 2007 2008 2009

1 Cutting & Crimping (CCS) 0 3 1 1

2 Crimping & Special Process (CSS) 2 1 0 1

3 Tube Cutting 0 1 0 1

SUMMARY OF INDUSTRIAL ACCIDENT

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4 Tube Production 0 0 0 0

5 Assy Machine 1 0 0 1

6 Fall from same level 2 0 2 4

7 Hit by sharp object 1 1 0 1

8 Bump against hard object 1 1 0 1

9 Forklift 0 0 0 0

Total 7 7 3 10


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SUMMARY OF MACHINE RELATED ACCIDENT

ItemMachine 2006 2007 2008 2009

1 Cutting & Crimping (CCS) 0 3 1 1

2Crimping & Special Process

2 1 0 1

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3 Assy Machine 1 0 0 1

4 Tube Cutting 0 1 0 1

5 Tube Production 0 0 0 0

Total 3 5 1 4


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UNSAFE BEHAVIOR(Removed clogged terminal

With bare hand-instead of

picking tools )

Unsafe Condition

23%

Causes of Industrial Accidents

TOTAL MACHINE RELATEDACCIDENTS FOR

FY 2006-2009 (13 CASES)

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UNSAFE CONDITION

(Exposed to machine moving

parts)

ACCIDENT

10

1

2

Unsafe Behavior

92%


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Safety Feature: Enclosed Safety Cover

Picking Tools Limit Sensor Area Sensor

Magnetic Switch

SAFETY PRACTICESSAFETY PRACTICES

Machine Guarding: {Evolution}

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Safety Feature: Safety Cover

Picking tools

Hand Stopper

Safety Feature: Safety Cover (Partial Enclosure (Front)) Picking tools Limit Switch

Area Sensor

Machine Fails and Human Makes Error!!


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Basics of Machine Guarding

A Good Rule to Remember:

Any machine part, function

or process which may cause injury

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mus e sa eguar e . ere eoperator of a machine or accidental

contact with it can injure the operator

or others in the vicinity, the hazardsmust be either controlled or eliminated.


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A) Where mechanical hazard occur

The Point of Operation where work is performed

on the material, such as: Cutting, Shaping, Boring &Forming of stock

Power transmission apparatus all apparatus of

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mec an ca sys em w c ransm energy o e par othe machine performing work.

Other moving parts any parts of the machinewhich moves while the machine is working such as:

Rotating parts, Feed mechanism, Reciprocating parts,Transverse moving parts, & Auxiliary parts of themachine

Recognition of these hazards is the first step toward

protecting workers from the danger they present


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B) Requirements of Safeguards

Be securely attached Create no new hazards Withstand operational condition Allow for safe routine maintenance

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ow or sa e opera or a us men s Withstand environmental conditions Provide protection from falling objects Prevent contact with hazardous conditions Create no interference in the conduct of work


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C) Operator Training Considerations

Provide instruction and/ or hands on training Discuss the purpose of safeguards Cover associated hazards thoroughly Involve guard design in the training

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escr e ow o proper y use sa eguar s Describe how safeguards provide protection Describe circumstances for safeguard removal Explain what to do if safeguards are damaged Explain what to do if safeguards are missing


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Machine Guarding Benefits

Maintain a healthier workforce

Workers feel good about their work

Elevate SAFETY to a higher level ofawareness

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Machine Guarding Methods

1) Guards

Fixed (permanent part of the

machine, not dependent uponmoving parts to perform itsintended function)

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Interlocked(when opened orremoved, the trippingmechanism and/ or power

automatically shut off ordisengage


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2) Devices Photoelectric sensing

device(uses a system of

light sources and controlswhich can interrupt themachines operating

Area Sensors

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Two Hand Controls(requires constant,

concurrent pressure bythe operator to activatethe machine)


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Two-hand controllers Specific Requirement

a) When an operator activates two start switches to input two

signals simultaneously, the machine starts operation. If either orboth switches are released, the machine operation halts.

(Simultaneous Operation/ Output signal is OFF)

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b) The machine shall start operation only when the two startswitches are both operated within an interval of 0.5 seconds.(Simultaneous Start)

c) A circuit that prohibits repeat operation (anti-repeat circuit)

shall be installed in order to prevent the machine fromcontinuing operation in case of recovery after a failure, or if the

contacts of one switch are short-circuited, etc.


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d) Things to avoid in designing the two-hand controllers.

(4) Press switches withone hand and anotherpart of the body.

(3) Press both switcheswith both elbows.

(2) Press switches withthe elbow and hand(palm) of one arm.

(5) Press switchesusing a tool, jig, etc

(1) Press bothswitchessimultaneously usingone hand.x x x x x

Machine Guarding Methods16 of 21

Auto Crimp Press Mach with two hand controllers

Protective ring-type press button

was installed


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All machines fail and everyone make mistakes.

Therefore, basic design is to take every precaution to ensureworkers safety in the event of fault.

Safety Measures Concept

HumansMake

MachinesFail

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Ensuring Safety During Machine Setup ,Cleaning/ Maintenance.

Ensuring Safety Irrespective ofOperating Experience.

Making an adjustment

while

foot is on the switch

Check sensors/limitswitches function priorstart of work


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Principles of Machinery Hazard Prevention

[A] Isolation Principle: Safety

protection such as guards

(Separation between human andmachine workspaces)

HumanWorkspac

e

MachineWorkspace

HazardZone

Keep away frommachinery

duringoperations.

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[B] (Stoppage principle: Safetyprotection such as interlocking

devices)

An interlocking device refers to a mechanical or electrical device

that was designed to prevent machines from operating unlesscertain conditions are met. e.g. closing a guard.

Interlock DeviceSafety Cover


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Basic Principles for Prevention of Entanglement

The area in which an operator can become entangledshall be narrowed so that a human body part cannotenter or shall be widened so that an operator cannotbecome entangled. (If it is difficult to undertake suchmeasures, install Safety Protection Devices.)

300 mm Maximum 50mm

Body/Torso Head (Worst Position)Toes Foot

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Note) Clearance gap dimensions indicated in the box arespecified in the Safety Standard for Equipment Design

120 mm

100 mm

50 mm

ArmsHands-Wrists-Knuckles Fingers Leg


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4

5

6

FCASES

DETAILS OF MACHINE RELATEDACCIDENTS

TubeProduction

Tube Cutting

8

10

12

CASES

INDUSTRIAL ACCIDENTS2006-2011 Forklift

Bump aginst hardobject

Hit by sharp object

Fall from same level7 cases 7 cases

10 cases

DETAILS OF MACHINE RELATED

8 cases

INDUSTRIAL ACCIDENT STATISTICS20 of 21

0

1

2

3

2006 2007 2008 2009 2010 2011

N

O.

YEAR

Assy Machine

Crimping &SpecialProcess (CSS)

Cutting &Crimping

(CCS)0

2

4

6

2006 2007 2008 2009 2010 2011

NO

.O

YEAR

Assy Machine

Tube Production

Tube Cutting

Crimping & SpecialProcess (CSS)

Cutting & Crimping(CCS)

3 cases 5 cases 4 cases

3 cases

1case 1case 2 cases

2 cases

Machine related accident was reduced by 50% from 3.25 cases/ year (2006-2009) to1.5 case/ year (2010-2011)


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Management commitment and support from the

workforce is essential, without it, the program will fail.

That is why our Company Policy for FY2012 is developed.

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01_DOLE Machine Guarding [Compatibility Mode]

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