CORPORATE SAFETY TRAINING

Name: CORPORATE SAFETY TRAINING
Uploaded: 2017-12-24T14:12:11+00:00
Duration: PTM32S17
Channel: James Chelton
Description: CORPORATE SAFETY TRAINING

CORPORATE SAFETY TRAINING
MACHINE GUARDING CORPORATE SAFETY TRAINING 29 CFR WELCOME 1

BASIS FOR THIS COURSE Proper Machine Guarding Results in Accident Reduction Elimination of Workplace Injuries & Illnesses Where Possible Reduction of Workplace Injuries & Illnesses Where Possible Development of Efficient Machine Guarding Techniques OSHA Safety Standards Require: Machines Be Properly Guarded Training Be Conducted Hazards and Precautions Be Explained A “Safety” Program Be Established Job Hazards Be Assessed and Controlled 5

REGULATORY STANDARD THE GENERAL DUTY CLAUSE FEDERAL - 29 CFR 1903.1
EMPLOYERS MUST: Furnish a place of employment free of recognized hazards that are causing or are likely to cause death or serious physical harm to employees. Employers must comply with occupational safety and health standards promulgated under the Williams-Steiger Occupational Safety and Health Act of 1970. OSHA ACT OF 1970 7

INDUSTRY CONSENSUS STANDARDS
ANSI - B11.2 Hydraulic presses B11.3 Power Press Brakes B11.10 Metal Sawing Machines B11.11 Gear Cutting Machines B11.12 Roll-Forming and Bending Machines B11.14 Coil Slitting Machines B11.15 Pipe, Tube, and Shape Bending B11.16 Metal Powder Compacting Presses B11.17 Horizontal Hydraulic Extrusion B11.18 Coiled Steel Processing 9

INDUSTRY CONSENSUS STANDARDS
ANSI - B11.19 Machine Tools, Safeguarding B11.20 Manufacturing Systems/Cells 10

PROGRAM REQUIREMENTS Install Machine Safeguards
ALL EMPLOYERS MUST: MACHINE GUARDING PROGRAM Install Machine Safeguards Review Job Specific Hazards Implement Corrective Actions Conduct Hazard Assessments Conduct Accident Investigations Provide Training to All Required Employees Control Workplace Hazards Using PPE As a Last Resort 14

BASICS OF MACHINE GUARDING
Where Mechanical Hazards Occur The Point of Operation: Power Transmission Apparatus: Other Moving Parts: 22

Where Mechanical Hazards Occur The Point of Operation: Where work is performed on the material, such as: Cutting Shaping Boring Forming of stock LATHE 23

Where Mechanical Hazards Occur Power Transmission Apparatus: All components of the mechanical system which transmit energy to the part of the machine performing the work. 300 RPM 24

Where Mechanical Hazards Occur Other Moving Parts: Any part of the machine which moves while the machine is working. Rotating parts Feed mechanisms Reciprocating parts Transverse moving parts Auxiliary parts of the machine 25

Hazardous Mechanical Motions and Actions A wide variety of mechanical motions and actions may present hazards to the worker: Rotating members Reciprocating arms Moving belts Meshing gears Cutting teeth Any parts that impact or shear 26

Hazardous Mechanical Motions and Actions Recognition of these hazards is the first step toward protecting workers from the danger they present. 27

Hazardous Mechanical Motions Motions Rotating Reciprocating Transversing NIP POINT 28

Hazardous Mechanical Actions Actions Cutting Punching Shearing Bending SHEARITE CUTTING BLADES 29

Hazardous Mechanical Motions Rotating Motions - Collars - Couplings - Cams - Clutches - Flywheels - Shaft ends - Spindles - Meshing gears - Horizontal shafts - Vertical shafts 30

Hazardous Mechanical Motions Rotating Motions Rotating motions can grip clothing, and through mere skin contact force a limb into a dangerous position. The danger increases when projections such as set screws, bolts, nicks, abrasions, and projecting keys or set screws are exposed on rotating parts. 31

Hazardous Mechanical Motions Reciprocating Motions MOTION RECIPROCATING NIP POINT 32

Hazardous Mechanical Motions Reciprocating Motions MOTION RECIPROCATING CAUGHT “IN-BETWEEN” OR “STRUCK-BY” 33

TRAVEL IN-RUNNING NIP POINTS Hazardous Mechanical Motions Transversing Motions 34

Hazardous Mechanical Motions Rotating Motions NIP POINTS 35

Hazardous Mechanical Actions Cutting Actions - Rotating motions - Reciprocating motions - Transversing motions The danger of cutting action exists at the point of operation where finger, arm and bodily injuries can occur and where flying chips or scrap material can strike the head, particularly in the area of the eyes or face. 36

Hazardous Mechanical Actions Cutting Actions Bandsaws Circular saws Boring machines Drilling machines Turning machines (lathes) Milling machines 37

Hazardous Mechanical Actions Punching Actions 20 TON PRESS ACME PRESSES Power presses Iron workers The principle hazard occurs at the point of operation where stock is inserted, held or withdrawn. 38

Hazardous Mechanical Actions Shearing/Bending Actions DANGER CUTTING EDGE PRESS SHEARITE POWER SHEARS Mechanical shears Hydraulic shears Pneumatic shears The principle hazard occurs at the point of operation where stock is inserted, held or withdrawn. SHEAR TERROR 39

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 40

Nonmechanical Hazard Considerations: Power sources are potential sources of danger How will guarding affect equipment operation? Ensure proper grounding of systems Replace frayed, exposed , or old wiring Consider effects of - High pressure systems - Extreme temp. conditions - Pulsation, vibration, or leaks - Noise or unwanted sounds - Cutting fluids and coolants HOT SURFACE 41

Operator Training Considerations: Provide instruction and or hands-on training Discuss the purpose of safeguards Cover associated hazards thoroughly Involve guard designers in the training Describe how to properly use safeguards 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 42

Operator Training Considerations: Defeating, altering, or removing safeguards can cause injury to co-workers and can leave the person performing such actions liable under the OSHA Act of 1970. 43

Protective Clothing and Equipment Considerations: ENGINEERING CONTROLS  FIRST CHOICE  Work Station Design  Tool Selection and Design  Process Modification  Mechanical Assist  ADMINISTRATIVE CONTROLS  SECOND CHOICE  Training Programs  Job Rotation/Enlargement  Pacing  Policy and Procedures  PERSONNEL PROTECTIVE EQUIPMENT LAST CHOICE  Gloves  Wraps  Shields  Eye Protection  Non-Slip Shoes  Aprons 44

Protective Clothing and Equipment Considerations: Appropriate for the particular hazard(s) Maintained in good condition Properly stored when not in use Kept clean, fully functional, and sanitary 45

METHODS OF MACHINE GUARDING
Guarding Method Dependant on: Type of material Type of operation Method of handling Size or shape of stock Physical layout of the work area Production requirements or limitations 46

Manufacturers Recommendation: Before beginning the process of guard procurement, design, or installation, the equipment manufacturer should be consulted for advice. 47

Generally: Power transmission apparatus is best protected by fixed guards that enclose the danger areas Point of operation hazard guarding will vary 48

Safeguards Are Grouped Under 5 Classifications: Guards Devices Locations/Distance Feeding and ejection methods Miscellaneous aids 49

GUARDS 50

Guards: Guards are barriers which prevent access to danger areas, there are four general types: Fixed guards Interlocked guards Adjustable guards Self-Adjusting guards 51

Fixed Guards: Fixed guards are a permanent part of the machine and not dependent upon moving parts to perform its intended function. 52

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 Can be suitable to high repetition operations 53

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 54

Interlocked Guards: Interlocked guards are designed to automatically shut off or disengage the machine if the guard is opened or removed AUTOMATIC VISUAL ALARM AUTOMATIC AUDIBLE ALARM 55

Interlocked Guards: Interlocked guards may use: Electrical power Mechanical power Hydraulic power Pneumatic power OR ANY COMBINATION OF POWER SOURCES 56

Interlocked Guards: Interlocks should not prevent “inching” by remote control if required Replacing guards should not automatically restart the machine IMPORTANT 57

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 58

Adjustable Guards: Typically adjusted by the operator Accommodate various sizes of stock May require additional operator training Adjustable guards are typically used on: Bandsaws Tablesaws Power presses Routers Similar equipment 59

Adjustable 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 60

Self-Adjusting Guards: 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 Tablesaws Circular saws Routers Jointers Similar equipment 61

Self-Adjusting Guards: ADVANTAGES Off-the-shelf guards are often commercially available LIMITATIONS Protection may not be complete at all times May require frequent maintenance and or adjustment May interfere with visibility 62

DEVICES 63

Devices: Devices fall into four general types: Presence-Sensing devices Pullback devices Restraint devices Safety trip controls 64

Devices: 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 65

Presence-Sensing: Photoelectric Radiofrequency Electromechanical PRESS ACME PRESSES 66

Presence-Sensing: Before beginning the process of procurement, design, or installation, the equipment manufacturer should be consulted for advice. 67

Presence-Sensing: 20 TON PRESS ACME PRESSES Photoelectric Radiofrequency Electromechanical 68

Pullback Devices: NYLON PULLBACK STRAPS ATTACHED TO WRISTBANDS Attached to Wrists Positioning Critical Adjustment Critical Maintenance Critical Training Critical Must Stop Machine Immediately! 69

Restraint Devices: Uses Cables or Straps Affixes to Hands May Need Feeding Tools Adjustment Critical Positioning Critical Maintenance Critical Training Critical Must Restrain Body Part From Hazard! 70

Safety Trip Controls: Body Trip Bars Hand/Arm Trip Bars Tripwire Cables Positioning Critical Adjustment Critical Maintenance Critical Training Critical Manual Reset Needed Must Stop Machine Immediately! 71

Two-Hand Control: Needs Constant Pressure Needs Concurrent Pressure Positioning Critical Adjustment Critical Maintenance Critical Training Important Must Stop Machine Immediately! 20 TON PRESS ACME PRESSES 72

Location/Distance Safeguarding: 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 Add Enclosures or Fences to Restrict Access Design Stock Feeding Openings Away From Hazards Position the Operators Control Station Away From Hazards 73

Feeding and Ejection Methods: Automatic Feeds - Fed From Rolls, Indexed by Machine Semiautomatic Feeds - Fed by Chutes, Movable Dies, Dial Feed, Plungers, or Sliding Bolsters Automatic Ejection - Air or Mechanical Ejection Semiautomatic Ejection - Air or Mechanical Ejection Initiated by The Operator Robotics - Perform Work Usually Performed by Operator 74

Feeding and Ejection Methods: Manufacturers Should Be Consulted to Determine: Feeding and Ejection Add-on Options Latest Technology Available Best Available Technology Operator Training Requirements Maintenance Staff Training Requirements Cost Estimates for Upgrades Feasibility Assessment Information 75

Miscellaneous Aids: Examples of Possible Applications: Awareness Barriers - (Not adequate for continuous hazards) Color coding of hazard areas Signage Shields (i.e. splash, eye protective, thermal etc.) Holding and Positioning Tools 76

Guard Construction: Many Machines Come With Safeguards Many Older Machines Now Have Safeguards Available Manufacturers Are Increasingly More Concerned With Liability Companies Not Specialized in Guarding Issues 77

Builder Designed and Installed Guards: Usually Conform to Design and Function of Machine Better Can Be Designed to Strengthen the Machine in Some Way or to Serve Some Additional Functional Purposes 78

User Designed and Installed Guards: Often the Only Practical Solution for Older Equipment Can Be Designed and Built to Fit Unique & Changing Situations Can Be Installed on Individual Dies and Feeding Mechanisms Can Help Promote Safety Consciousness in the Workplace Sometimes Do Not Conform As Well As “Builder Designed” Depending on Talent and Resources May Be Poorly Designed 79

Point-of-Operations Guards : Defined as: “The area on a machine where work is actually performed upon the material being processed.” Complicated by the Number and Complexity of Machines in Use Must Fully Safeguard the Employee Must Allow Production to Continue Hazard Analysis Is Usually Required If Poorly Designed, Built, or Installed Guards May Create a Hazard Rather Than Eliminating One. 80

Mechanical Power Transmission Apparatus Guards: The only openings usually needed are for: Lubrication Adjustment Repair Inspection 300 RPM 81

Guard Material: Under Many Circumstances, Metal Is the Best Material for Guards. Guard Framework Is Usually Made From Structural Shapes, Pipe, Bar, or Rod Stock. Filler Material Generally Is Expanded or Perforated or Solid Sheet Metal or Wire Mesh. It May Be Feasible to Use Plastic or Safety Glass Where Visibility Is Required. Guards Made of Wood Generally Are Not Recommended Because of Their Flammability and Lack of Durability and Strength. However, in Areas Where Corrosive Materials Are Present, Wooden Guards May Be the Better Choice. 82

LOCKOUT TAGOUT OVERVIEW
29CFR 29CFR - SAFETY AND HEALTH STANDARDS GENERAL INDUSTRY 147 - LOCKOUT TAGOUT STANDARD 83

TITLE - CONTROL OF HAZARDOUS ENERGY SEPTEMBER 1, FINAL RULE ISSUED JANUARY 2, FINAL RULE TOOK EFFECT 84

Authorized Employee The Person Who Locks or Tags Out Machines To Perform Servicing or Maintenance. Affected Employee An Employee Whose Job Requires Him or Her To Operate or Use a Machine or Piece of Equipment On Which Servicing or Maintenance Is Being Performed. 85

LOCKED OUT This Lock/Tag may only be removed by NAME: _______________ DEPT : _______________ EXPECTED COMPLETION DATE: ________________ TIME: _________________ DO NOT OPERATE DANGER 86

Normal Operations 1. Covered If an Employee Must Remove or Bypass Guards or Devices 2. Covered Where Employees Are Required to Put A Body Part in a Machine Process Area 3. Covered Where Employees Are Required to Put A Body Part in a Machine Having a Danger Zone 87

TIPS FOR USING CONTRACTORS
REMEMBER, YOU CONTROL YOUR FACILITY OR AREA! REVIEW THEIR PROCEDURES WITH THEM BEFORE STARTING THE JOB! DETERMINE THEIR SAFETY PERFORMANCE RECORD! DETERMINE WHO IS IN CHARGE OF THEIR PEOPLE! DETERMINE HOW THEY WILL AFFECT YOUR EMPLOYEES! 88

MACHINE GAURDING

MACHINERY AND MACHINE GUARDING SAFETY
MECHANICAL POWER PRESSES AND BENCH GRINDERS

MECHANICAL POWER PRESSES
TWO TYPES: FULL REVOLUTION OR PART REVOLUTION (CLUTCH DRIVEN). NO GUARDS OR SWEEPS ALLOWED FOR HANDFEEDING. PRESENCE SENSING DEVICES ALLOWED ON PART REVOLUTION ONLY. PULLBACKS MAY BE USED, BUT REQUIRES INSPECTION FOR EACH SHIFT, OPERATOR OR DIE SETUP.

POWER PRESSES GATES ARE RECOMMENDED FOR HANDFEEDING:
TYPE A FOR BOTH PART OR FULL REV PRESSES. TYPE B NOT RECOMMENDED FOR FULL REV. ALL PRESSES REQUIRE POINT OF OPERATION SAFEGUARDING. FOR NON-HANDFEED OPERATIONS, GUARDS MAY BE USED. GUARD OPENINGS MUST CONFORM TO , TABLE O-10

BENCH GRINDERS WORK REST GAP MUST BE WITHIN 1/8 INCH OF WHEEL.
TONGUE GUARD GAP MUST BE WITHIN 1/4 INCH OF WHEEL. WHEEL GUARD MUST COVER SPINDLE, END NUT AND FLANGE. INSPECT BLOTTER, WHEEL MOUNTING HOLE, FLANGES, COLLET BEFORE USE. MAKE SURE SPINDLE SPEED DOES NOT EXCEED WHEEL RPM RATING.

CORPORATE SAFETY TRAINING

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