MAC000-HBK-ENG

Transcription

1 Machine Guarding MAC000-HBK-ENG

2 Machine Guarding This employee handbook is one of a series of fully-illustrated employee handbooks, informative posters, broadcast-quality video training programs, interactive CD-ROM and Web-based courses produced by Coastal Training Technologies Corporation. Each product is the result of painstaking analysis, design, development and production by the instructional designers and technical specialists on our staff. Our catalog is constantly being revised and expanded, so we would appreciate any comments on current titles or suggestions for future ones. For further information on any Coastal product, or to receive a free catalog, call Coastal Training Technologies Corp. (Virginia Beach, VA) at or send a FAX to Visit us on the Web at This handbook is for educational purposes only, and is designed to be used in conjunction with a qualified trainer. Nothing herein is to be regarded as indicating approval or disapproval of any specific practice or product. Copyright 1998, 1994 Coastal Training Technologies Corp. All Rights Reserved. No part of this handbook may be copied by any means or for any reason without the written permission of Coastal Training Technologies Corporation. Printed in U.S.A. CD-ROM AND WEB-BASED COURSES FROM COASTAL Asbestos Awareness Back Safety Bloodborne Pathogens Confined Space Entry Defensive Driving Electrical Power Generation Electrical Safety Employment Terminations Environmental Awareness Ergonomics Fall Protection Fire Safety First Aid Forklift Safety Hazard Communication Hearing Protection HAZMAT Preparation HAZMAT Transportation HAZWOPER Awareness Hydraulics Indoor Cranes Industrial Electricity Interviewing Lab Safety Lockout/Tagout Office Safety Performance Appraisals Personal Protective Equipment Pneumatics Respiratory Protection Safety Orientation Sexual Harassment Stairways and Ladders Teamwork Time Management Trenching and Shoring Walking and Working Surfaces Vibration Analysis VIDEO-BASED PROGRAMS FROM COASTAL Accident Investigation Anhydrous Ammonia Asbestos Series Back Safety Series Behavior-Based Safety Series Bloodborne Pathogens Series Chemical Handling Series Chlorine Safety Series Commercial Driver Series Confined Space Series Contractor Safety Construction Safety Series Crane Safety Series Disaster Planning Series DOT Drug & Alcohol Testing Driving Safety Series Electrical Safety Series Electrical Power Generation Series Emergency Planning Series Employment Terminations Environmental Series Ergonomics Series Fall Protection Series Fire Safety Series First Aid First Aid for Schools Foot Protection Forklift Safety Series Asbestos Series Back Safety Bloodborne Pathogens for Schools Bloodborne Pathogens Series Chemical Handling Series Chlorine Safety Confined Space Series Contractor Safety Driving Safety Series DOT Drug & Alcohol Testing Electrical Safety Series Environmental Series Ergonomics Series Eye Protection Fall Protection Series Fire Safety First Aid for Schools First Aid on the Job Foot Protection Forklift Safety Series Groundskeeping Safety Hand Safety Hand Tool Safety Series Handwashing Hard Hat Safety Hazard Communication for Schools Hazard Communication Series HazWaste Transportation Series HAZMAT Transportation Series HAZWOPER Training Series Hearing Protection Heat Stress Highway Work Zone Series Hotel Safety Orientation Hydrogen Sulfide Indoor Cranes Interviewing ISO 9000 Series Lab Safety Series Laser Safety Lead Safety Line Breaking Lockout/Tagout Series Low-Lift Trucks Machine Guarding Mechanical Power Press Safety Media Relations Motor Vehicle Awareness Hand Safety Hazard Communication Series HAZMAT Transportation Series HAZWOPER Training Series Hearing Protection Heat Stress Holiday Safety Series Hotel Safety Hydrogen Sulfide Indoor Cranes Interviewing Lab Safety Lead Safety Lockout/Tagout Series Low-Lift Trucks Machine Guarding Mechanical Power Press Safety Office Safety Performance Appraisals Personal Protective Equipment Off-the-Job Safety Series Office Safety OSHA Inspection Series Performance Appraisals Phosphoric Acid Pollution Prevention Series PPE Series Pro-Active Safety Series Process Safety Series RCRA Respiratory Protection Series Rope Rescue Series Safety Orientation Sexual Harassment Slips, Trips & Falls Stairways and Ladders Static Electricity Substance Abuse Prevention Series Teamwork Time Management Train the Trainer Series Trenching & Shoring Series Tuberculosis Awareness Walking & Working Surfaces Welding Safety Series Winter Safety Series Workplace Violence ILLUSTRATED HANDBOOKS FROM COASTAL Pollution Prevention Series Pro-Active Safety Series Process Safety Respiratory Protection Safety Orientation Scaffold Safety Series Sexual Harassment Slips, Trips & Falls Stairways and Ladders Static Electricity Teamwork Time Management Trenching & Shoring Series Tuberculosis Awareness Vacation/Summer Safety Video Display Terminals Walking & Working Surfaces Warehouse Safety Winter Safety Series Workplace Violence

3 Contents Introduction 2 Becoming Too Comfortable 3 Mechanical Hazards 4 Safeguard Qualities 5 Altering Safeguards 5 Guards 6 Fixed 6 Interlocked 6 Adjustable 7 Self-Adjusting 7 Devices 8 Safety Trip Controls 8 Two-Hand Control 9 Two-Hand Trip 9 Presence-Sensing Devices 10 Gates 10 Troubleshooting Your Machines 11 Nature of the Work 11 Location of Operator 12 Location of the Machine 12 Feeding and Ejection System 12 Review 13 Summary 14 Quiz 15 Introduction The dangerous aspects of machine work are apparent as soon as the power is activated. Using machinery is a big part of your job, but it also puts you at risk. That s why it is so important to understand your first and best form of protection, machine safeguards. Any machine part, function or process which may cause injury must be safeguarded. Hazards from operations or accidental contact must be controlled or eliminated. Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. 2

4 Becoming Too Comfortable Often, working with your machine becomes routine, sometimes to the point that the machine begins to feel like an extension of yourself like another hand or arm. You find yourself no longer concentrating on operation, because operation is second nature, just like breathing. This feeling of security can lead to disaster. Therefore, always be alert to the dangers of the machines with which you work. Mechanical Hazards There are three places where most mechanical hazards occur and where safeguarding is the most important: The point of operation The power-transmission apparatus Transverse motion. Point of Operation Power-Transmission Apparatus Transverse Motion It may seem like a large task to provide protection against all these possible hazard spots, but it s not impossible. 3 Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. 4

5 Safeguard Qualities Regardless of the specific type, a guard should: Be designed and constructed so that it may not be removed or tampered with easily Not create interference with the operation of any machinery Keep all human parts out of danger Prevent hand tools from falling into moving machinery. Altering Safeguards Guards Guards are physical barriers that prevent access to danger areas. Guards can be divided into four general types: Fixed A permanent part of the machine. Not dependent on any moving or supplemental parts to perform their intended function. Made of sheet metal, screen, wire cloth, bars, plastic or any material strong enough to withstand whatever impact and prolonged use they may receive Usually the preferred type of guard because of its simplicity and durability. Safeguards can be safely changed or improved upon, but only if authorized. Your supervisor will know what safety requirements must be met and will help in creating a better system that protects you without slowing your work. Interlocked Connected to a tripping mechanism which cuts off the power automatically Use electrical, mechanical, hydraulic, or any combination of these systems. Should rely on manual resetting. 5 Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. 6

6 Devices Adjustable Flexible in accommodating various sizes of stock. Devices are general systems that involve several parts, including moving parts, that work together to protect the operator. There are several different types of devices. Safety Trip Controls Safety trip controls provide a quick means for de-activating machinery in emergency situations. Body bars, trip rods and safety trip wires require bodily contact to deactivate machinery. Self-Adjusting Openings are determined by the movement of the stock. Do not always provide maximum protection Can decrease visibility of the point of operation. Any machine safeguard that stops a machine s cycle must have manual resetting. Manual resets are important and should not be overlooked. Pressure-Sensitive Body Bar Pressure-sensitive body bars are activated by bodily contact which could ultimately lead to entrance into the point of operation or other hazard point. Their placement is critical. A bar should be at waist, chest or eye level. A bar placed too close to the floor or above the operator s head reduces the chance of accidental contact and defeats the purpose of the guard. Safety Trip-Wire Cables Safety trip-wire cables must be readily available and should always be within easy reach of your usual working area. For full protection, you should be able to reach the cable with either hand. 7 Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. 8

7 Two-Hand Control Requires constant, simultaneous pressure by both hands in order to start the machine. Requires a part revolution clutch, brake and brake monitor if used on a power press. Keeps both hands out of the danger zone and on the control buttons while the machine operates. Presence-Sensing Devices Presence-sensing devices combine with safety guards to protect you. The machine s cycle is stopped when you cross the light beam created by this device. It is recommended that a barrier guard be used should the light system fail. Maintenance must be thorough and regular. Two-Hand Trip Requires simultaneous pressure from both hands to initially activate the machine. After activation, your hands can be removed from the controls. Trips must be placed far enough away to make it impossible for hands to slip into the point of operation Usually used with machines equipped with full-revolution clutches. Gates Function as a barrier to guard or prevent entry to the dangerous point of operation. Also function as a device that halts the machine cycle when not properly in place. 9 Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. 10

8 Troubleshooting Your Machines Nature of the Work Machine safeguarding is not an exact formula but an answer to specific needs. Machine work is risky business. Take a minute and think about the machine you work with. What are the materials with which your machine works? What does the machine do to the material? What is the by-product? Location of the Operator Where are you standing when the machine is activated? What is the danger from potential nip points? Where are you in relation to the point of operation? Is there danger from other moving parts? What is the motion of the machinery does it rotate, move back and forth, or move up and down? If you think ahead to what your machine will do when activated, you can better avoid potential danger. Location of the Machine Where are co-workers in relation to machinery? What is the probability of accidental contact? Is there a good chance of foreign materials being accidentally drawn into the machinery? Feeding and Ejection Systems Are feeding and ejection systems automatic or semi-automatic? Can they be made automatic? Where are the potential nip points? 11 Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. 12

9 Review Remember, machine accidents don t always happen to operators. As you walk past machinery in your shop or warehouse, be alert. Summary Evaluating each machine with these things in mind will tell you whether the machines you work with are adequately guarded. Machine safeguarding is the number-one priority of any machine shop. Machine safeguarding works so make sure it works for you. A loose shirttail could be grabbed by a machine. Stumbling over something on the floor could be disastrous if you happen to trip near a machine in operation. If you are operating a machine, be sure the mechanisms are clear of people and objects Be sure you are not wearing any jewelry or loose clothing that could get snagged during the machine s operating cycle. 13 Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. 14

10 Quiz 1. True False Safeguarding is your first and best form of protection against the dangers of machinery. 2. True False Deciding what machine parts should be safeguarded is completely arbitrary. 3. True False You do not need to pay attention to safeguards when your machine starts to feel like an extension of yourself. 4. True False The point of operation is the only place where mechanical hazards exist. 5. True False A safeguard should be designed and constructed so that it may not be removed or tampered with easily. 6. True False As the operator, you can decide when to change the safeguards on your machine. 7. True False Guards and devices are different types of safeguards intended to protect you. 8. True False A fixed guard is dependent on moving or supplemental parts to perform its function. 15. True False To understand the safeguards you use, it is important to think about the machine you work with, the materials it uses, the by-product and the motion of the machinery. 16. True False You must determine whether or not your machines are adequately safeguarded by asking yourself questions like who is the manufacturer of the machine and how long your shifts will be. 17. True False Tuck away any loose clothing such as shirttails because they can be grabbed by a machine. 18. True False Operators are the only people who are involved in machine accidents. 19. True False Typically, safeguards should not create interference with the operation of any machinery and, if they do, should be reported to your supervisor. 20. True False The number-one priority in a machine shop is machine safeguarding. 9. True False An interlocked guard is connected to a tripping mechanism which cuts off the power automatically. 10. True False Any machine safeguard that stops a machine s cycle must have manual resetting. 11. True False A pressure-sensitive body bar should be at waist, chest or eye level because anywhere else the chance of accidental contact is reduced. 12. True False Gates serve as a physical barrier and they halt the machine cycle when not properly in place. 13. True False A presence-sensing device is ineffective as a safeguard because if the light beam malfunctions, there is no other protection. 14. True False The two-hand control and two-hand trip systems require you to alternate pressure on the controls between hands. ACKNOWLEDGEMENT OF TRAINING I have read and understand the training handbook, Machine Guarding. I have also completed and passed the comprehensive quiz at the conclusion of this handbook. Employee s Signature Trainer s Name Date Date NOTE: This record may be included in the employee s personnel or training file. 15 Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. Copyright 1998 Coastal Training Technologies Corp. May not be reproduced in any form without written permission. 16