8/9/2019 Safe Operation of Machines
1/69
1
2008 All Rights Reserved
A TRAINING FOR THE
METALWORKING INDUSTRY
SAFE OPERATION OF MACHINESSAFE OPERATION OF MACHINES
8/9/2019 Safe Operation of Machines
2/69
2
2008 All Rights Reserved
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
8/9/2019 Safe Operation of Machines
3/69
3
2008 All Rights Reserved
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
8/9/2019 Safe Operation of Machines
4/69
4
2008 All Rights Reserved
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
8/9/2019 Safe Operation of Machines
5/69
5
2008 All Rights Reserved
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
2. Incident History2. Incident History
8/9/2019 Safe Operation of Machines
6/69
6
2008 All Rights Reserved
Incidents associated with metalworking industry:
2. Incident History2. Incident History
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
8/9/2019 Safe Operation of Machines
7/69
7
2008 All Rights Reserved
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
8/9/2019 Safe Operation of Machines
8/69
8
2008 All Rights Reserved
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
3. Machine Hazards3. Machine Hazards
8/9/2019 Safe Operation of Machines
9/69
9
2008 All Rights Reserved
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
3. Machine Hazards3. Machine Hazards
8/9/2019 Safe Operation of Machines
10/69
10
2008 All Rights Reserved
Pictures or Graphs Within This Area
Unguarded Rotating Parts of Machine
3. Machine Hazards3. Machine Hazards
LooseClothing
8/9/2019 Safe Operation of Machines
11/69
11
2008 All Rights Reserved
Unguarded Rotating Parts of
Machine
3. Machine Hazards3. Machine Hazards
8/9/2019 Safe Operation of Machines
12/69
12
2008 All Rights Reserved
Pictures or Graphs Within This Area
Unguarded Rotating Parts of Machine
3. Machine Hazards3. Machine Hazards
8/9/2019 Safe Operation of Machines
13/69
13
2008 All Rights Reserved
Picture Source: Concepts and Techniquesof Machine Safeguarding, U.S. DepartmentofLabor, OSHA 3067, 1992 (Revised)
Unguarded Rotating Parts of
Machine
3. Machine Hazards3. Machine Hazards
8/9/2019 Safe Operation of Machines
14/69
14
2008 All Rights Reserved
Picture Source: Concepts and Techniques of Machine Safeguarding, U.S. Department ofLabor, OSHA 3067, 1992 (Revised)
Unguarded Rotating Parts of Machine
3. Machine Hazards3. Machine Hazards
8/9/2019 Safe Operation of Machines
15/69
15
2008 All Rights Reserved
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.
8/9/2019 Safe Operation of Machines
16/69
16
2008 All Rights Reserved
Step 1: Identify the hazards
Breakdown the activities
Identify the hazards and Consequence of each activity (Section 3)
4. Machine Safety4. Machine Safety
8/9/2019 Safe Operation of Machines
17/69
17
2008 All Rights Reserved
Step 2: Identify the existing controls
4. Machine Safety4. Machine Safety
8/9/2019 Safe Operation of Machines
18/69
18
2008 All Rights Reserved
Step 2: Identify the existing controls
any safeguards in place?
any written procedures to control or mitigate the risk? what are the PPE used?
4. Machine Safety4. Machine Safety
8/9/2019 Safe Operation of Machines
19/69
8/9/2019 Safe Operation of Machines
20/69
20
2008 All Rights Reserved
Severity Definition by MOM
Likelihood Definition by MOM
4. Machine Safety4. Machine Safety
8/9/2019 Safe Operation of Machines
21/69
21
2008 All Rights Reserved
MOM Risk Assessment Matrix:
4. Machine Safety4. Machine Safety
8/9/2019 Safe Operation of Machines
22/69
22
2008 All Rights Reserved
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)?
4. Machine Safety4. Machine Safety
8/9/2019 Safe Operation of Machines
23/69
23
2008 All Rights Reserved
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
4. Machine Safety4. Machine Safety
8/9/2019 Safe Operation of Machines
24/69
24
2008 All Rights Reserved
HIERARCHY OF HAZARDS CONTROL
4. Machine Safety4. Machine Safety
8/9/2019 Safe Operation of Machines
25/69
25
2008 All Rights Reserved
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
4. Machine Safety4. Machine Safety
8/9/2019 Safe Operation of Machines
26/69
26
2008 All Rights Reserved
Types of machine guarding
Fixed guard
Interlocked guard Adjustable guard
Self-adjusting guard
4. Machine Safety4. Machine Safety
8/9/2019 Safe Operation of Machines
27/69
27
2008 All Rights Reserved
Machine Guard
Source: Machine Guarding, OSHA Office of Training and Education
4. Machine Safety4. Machine Safety
Fixed Guard of Machine
8/9/2019 Safe Operation of Machines
28/69
28
2008 All Rights Reserved
Machine Guard
Interlockedguard on
revolvingdrum
Source: Machine Guarding, OSHA Office of Training and Education
4. Machine Safety4. Machine Safety
Interlocked Guard of Machine
8/9/2019 Safe Operation of Machines
29/69
29
2008 All Rights Reserved
Machine Guard
Bandsaw bladeadjustable
guard
Source: MachineGuarding, OSHA Office ofTraining and Education
4. Machine Safety4. Machine Safety
Adjustable Guard of
Machine
8/9/2019 Safe Operation of Machines
30/69
30
2008 All Rights Reserved
Machine Guard
Circular tablesaw self-adjusting guard
Source: MachineGuarding, OSHAOffice of Training andEducation
4. Machine Safety4. Machine Safety
Self-adjusting
Guard
8/9/2019 Safe Operation of Machines
31/69
31
2008 All Rights Reserved
Devices
Source: MachineGuarding, OSHAOffice of Trainingand Education
4. Machine Safety4. Machine Safety
Pullback Device
8/9/2019 Safe Operation of Machines
32/69
32
2008 All Rights Reserved
Devices
Source: Machine Guarding, OSHAOffice of Training and Education
4. Machine Safety4. Machine Safety
Restraint Device
8/9/2019 Safe Operation of Machines
33/69
33
2008 All Rights Reserved
Devices
TripwireCable
Source: MachineGuarding, OSHA Office ofTraining and Education
4. Machine Safety4. Machine Safety
Safety Tripwire Cable
8/9/2019 Safe Operation of Machines
34/69
34
2008 All Rights Reserved
Devices
Source: Machine Guarding, OSHAOffice of Training and Education
4. Machine Safety4. Machine Safety
Two-hand Control
8/9/2019 Safe Operation of Machines
35/69
35
2008 All Rights Reserved
Devices
4. Machine Safety4. Machine Safety
Two-hand Control
Two-hand Control
8/9/2019 Safe Operation of Machines
36/69
36
2008 All Rights Reserved
Devices
4. Machine Safety4. Machine Safety
Two-hand Control
Two-hand Control
8/9/2019 Safe Operation of Machines
37/69
37
2008 All Rights Reserved
Devices
Gate Open Gate Closed
Source: Machine Guarding, OSHA Office of Training and Education
4. Machine Safety4. Machine Safety
Gates
8/9/2019 Safe Operation of Machines
38/69
38
2008 All Rights Reserved
Devices
Picture Source: Conceptsand Techniques of MachineSafeguarding, U.S.Department ofLabor, OSHA3067, 1992 (Revised)
4. Machine Safety4. Machine Safety
Sensor
8/9/2019 Safe Operation of Machines
39/69
39
2008 All Rights Reserved
Devices
Picture Source: Concepts andTechniques of MachineSafeguarding, U.S. Department ofLabor, OSHA 3067, 1992(Revised)
4. Machine Safety4. Machine Safety
Sensor
8/9/2019 Safe Operation of Machines
40/69
40
2008 All Rights Reserved
Source: Machine Guarding, OSHAOffice of Training and Education
4. Machine Safety4. Machine Safety
Safeguard by Distance
8/9/2019 Safe Operation of Machines
41/69
41
2008 All Rights Reserved
Automatic Feed RobotSource: Machine Guarding, OSHA Office of Training and Education
4. Machine Safety4. Machine Safety
Automatic Feed and Robot
8/9/2019 Safe Operation of Machines
42/69
42
2008 All Rights Reserved
Source: Machine Guarding, OSHA Office of Training and Education
4. Machine Safety4. Machine Safety
Protective Shield
8/9/2019 Safe Operation of Machines
43/69
43
2008 All Rights Reserved
Source: Machine Guarding, OSHAOffice of Training and Education
4. Machine Safety4. Machine Safety
Holding Tools
8/9/2019 Safe Operation of Machines
44/69
44
2008 All Rights Reserved
Source: Concepts andTechniques ofMachine Safeguarding
4. Machine Safety4. Machine Safety
Holding Tools
8/9/2019 Safe Operation of Machines
45/69
45
2008 All Rights Reserved
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
4. Machine Safety4. Machine Safety
When necessary, buddy system shall be considered.
8/9/2019 Safe Operation of Machines
46/69
46
2008 All Rights Reserved
Emergency Switch
4. Machine Safety4. Machine Safety
EmergencySwitches for Different Uses
Picture Source: www.globalspec.com
47
8/9/2019 Safe Operation of Machines
47/69
47
2008 All Rights Reserved
Devices
4. Machine Safety4. Machine Safety
Two-hand Control
Emergency Switch
48
8/9/2019 Safe Operation of Machines
48/69
48
2008 All Rights Reserved
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.
4. Machine Safety4. Machine Safety
49
8/9/2019 Safe Operation of Machines
49/69
49
2008 All Rights Reserved
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
4. Machine Safety4. Machine Safety
50
8/9/2019 Safe Operation of Machines
50/69
50
2008 All Rights Reserved
4. Machine Safety4. Machine Safety
Lockout/Tagout Devices
Picture Source: http://en.wikipedia.org/wiki/Lock_and_tag
Physical Lockout/Tagout
51
8/9/2019 Safe Operation of Machines
51/69
51
2008 All Rights Reserved
4. Machine Safety4. Machine Safety
Lockout/Tagout Devices
Picture Source: http://www.cirlock.com.au
Physical Lockout for Circuit Breaker
52
8/9/2019 Safe Operation of Machines
52/69
52
2008 All Rights Reserved
4. Machine Safety4. Machine Safety
Lockout/Tagout Devices
Picture Source: http://www.cirlock.com.au
Physical Lockout/Tagout Devices
53
8/9/2019 Safe Operation of Machines
53/69
53
2008 All Rights Reserved
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.
4. Machine Safety4. Machine Safety
54
8/9/2019 Safe Operation of Machines
54/69
54
2008 All Rights Reserved
What must workers do before maintenance activities?
Lockout/Tagout (LOTO) Procedure
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.
4. Machine Safety4. Machine Safety
55
8/9/2019 Safe Operation of Machines
55/69
55
2008 All Rights Reserved
What must workers do before removing LOTO device andreenergize the machine?
Lockout/Tagout (LOTO) Procedure
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.
4. Machine Safety4. Machine Safety
56
8/9/2019 Safe Operation of Machines
56/69
56
2008 All Rights Reserved
What are the limitations for tagout devices?
Lockout/Tagout (LOTO) Procedure
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.
4. Machine Safety4. Machine Safety
57
8/9/2019 Safe Operation of Machines
57/69
57
2008 All Rights Reserved
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
4. Machine Safety4. Machine Safety
58
8/9/2019 Safe Operation of Machines
58/69
58
2008 All Rights Reserved
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
4. Machine Safety4. Machine Safety
59
8/9/2019 Safe Operation of Machines
59/69
59
2008 All Rights Reserved
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
4. Machine Safety4. Machine Safety
Refer to Material Handling for Metalworking Industry for more details about ergonomic hazardcontrol.
60
8/9/2019 Safe Operation of Machines
60/69
60
2008 All Rights Reserved
Ergonomics
Source: Ergonomics Guidelines for Manual MaterialHandling, CDC, NIOSH
4. Machine Safety4. Machine Safety
61
8/9/2019 Safe Operation of Machines
61/69
2008 All Rights Reserved
Ergonomics
Source: Ergonomics Guidelines for Manual MaterialHandling, CDC, NIOSH
4. Machine Safety4. Machine Safety
62
8/9/2019 Safe Operation of Machines
62/69
2008 All Rights Reserved
Ergonomics
Use Tools with Better Grip
Source: Easy Ergonomics: A Guide to Selecting Non-Powered Hand Tools, CDC, NIOSH
4. Machine Safety4. Machine Safety
63
8/9/2019 Safe Operation of Machines
63/69
2008 All Rights Reserved
Ergonomics
Select the Correct Tool for the Job
Source: Easy Ergonomics: A Guide to Selecting Non-Powered Hand Tools, CDC, NIOSH
4. Machine Safety4. Machine Safety
64
8/9/2019 Safe Operation of Machines
64/69
2008 All Rights Reserved
Ergonomics
Adopt the Correct PostureSource: Easy Ergonomics: A Guide to Selecting Non-Powered Hand Tools, CDC, NIOSH
4. Machine Safety4. Machine Safety
65
8/9/2019 Safe Operation of Machines
65/69
2008 All Rights Reserved
Ergonomics
Select the Correct Tool
Source: Easy Ergonomics: A Guide to Selecting Non-Powered Hand Tools, CDC, NIOSH
4. Machine Safety4. Machine Safety
66
8/9/2019 Safe Operation of Machines
66/69
2008 All Rights Reserved
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.
4. Machine Safety4. Machine Safety
67
8/9/2019 Safe Operation of Machines
67/69
2008 All Rights Reserved
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?
68
8/9/2019 Safe Operation of Machines
68/69
2008 All Rights Reserved
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
69
8/9/2019 Safe Operation of Machines
69/69
2008 All Rights Reserved
Thank You
Top Related