Industrial Safety and Health for Goods and Materials Services - Chapter 18 doc

Check travel direction to ensure path is clear of pedestrians or other vehicles.. Stop vehicle, depress foot brake pedal 2.. Check travel direction to ensure path is clear.. Depress foot

18 Machine Safety

National Traumatic Occupational Fatality (NTOF) data from 1980 to 1998 occupa-tional injury from machinery was ranked third after motor vehicle and homicide as causes of death Fatalities from machine-related incidents accounted for approxi-mately 13% of the total The service industry did not rank among the highest sectors having machine-related incidents Some of the leading injuries experienced in these industries were as follows: struck by or against an object, caught in or compressed by equipment, and caught in or crushed in collapsing materials

According to the Bureau of Labor Statistics (BLS), 92,560 private-sector lost-time injuries during the year 2002 were caused by machinery The median number of lost workdays resulting from these injuries was 7 with 24% of the total incidents resulting in 31 or more lost workdays The type of machine (source) most often

injuries); material handling machinery (16,183 injuries); special process machinery (15,576 injuries); heating, cooling, and cleaning machineries (13,330 injuries);

fatal occupational injuries in 483 of 5915 total fatalities during 2002

The safe operation of all types of equipment takes a variety of approaches since the manufacturer cannot always be depended upon to provide inherently

Material handling equipment is usually guarded during manufacturing, and must be operated safely

safe machines It is often up to the owner (employer) to ensure that the machine= equipment is as safe as possible for their employees to operate This may require that

(SOPs) be developed

18.1 GUARDING

Although a more detailed approach to safeguard is found in Industrial Safety and Health for Administrative Services and Industrial Safety and Health for People-Oriented Services, a short review has been placed in this chapter Any mobile machine part presents a hazard Guarding eliminates or controls this danger The

in-running nip points; cutting actions; and punching, shearing, and bending The types

of machine guards and their uses are summarized as follows:

access to dangerous moving parts by enclosing them completely They are

machines, gear trains, drilling machines, etc

various kinds of work However, once they have been adjusted, they should

are not practicable They prevent operation of the control that sets the machine in motion until the guard or barrier is moved into position

starting when the guard is open

Electric contact or mechanical stop that activates a brake when any part of the

guillotine cutters, power presses, dough mixers, centrifugal extractors, tumblers, and some kinds of pressure vessels

the dangerous part of the machine while it is in motion, or must be able to stop the machine in case of danger Examples of these are pull-away or hand-restraint devices; and photoelectric relay switches that stop the power supply to the machine

maintained

operator from dangerous points of operation Examples are two-handed oper-ating devices; chutes, hoppers, conveyors, etc., to feed stock automatically;

and special jugs or feedi ng de vices made of met al or wood ; mecha nical or air-operat ed eject ing device s may be used to compleme nt anothe r type of guard or as a subst itute

18.2 SAFE PRACTICES REGARDING MACHINE GUARDS

No guard, barrier, or enclosu re should be adjus ted or remo ved for any reason by anyone other than a n author ized person Before remo val of safegu ards for repairs, adjustm ents, or servi cing, the power must be turne d off and the main switch locked out and tagged No machi ne shoul d be started unles s the guards are in place and in good condit ion Def ective or missin g guards shoul d be report ed to the superv isor immediatel y Emplo yees shoul d not work on or around mecha nical operat ing equ ip-ment while wear ing neck ties, loose clothing, watches, rings, or other jewelry

18.3 TRAINING

have not operat ed the equipm ent for a long time, they should recei ve renewed training

It is a superv isor s’ responsibi lity to make safe job observatio n to determin e if the employee is still pro fi cient on the safe operation of the machine or equipm ent If not, the superv isor must have the employ ee retrained or give hands- on training to ensure the safe operat ion of the machi ne or equipm ent One of the most importan t pieces of information that can be used to both check and retrain wor kers is an SOP for a piece of equipment or machine An SOP should exist for all pieces of equipment or machine

18.4 SAFE OPERATING PROCEDURES

Safe operat ing procedu res or stand ard operat ing procedu res shoul d incl ude safet y as

a part of the standard operat ing pract ices, which are delineated within it Worker s may not automati cally unders tand a task just because they have e xperience or training Thus, many jobs, tasks, and operations are best supported by an SOP The SOP walks the worker through the steps of how to do a task or procedure in a safe manner and calls attention to the potential hazards at each step

You might ask why an SOP is needed if the worker has already been trained to

usually keys in on those particular jobs which pose the greatest risk of injury or

development and use of an SOP There are times when an SOP, or step by step checklist, is useful This is the case when

recently

. Mistakes co uld cause damag e to equipment or proper ty.

. Job is done on an intermi ttent or infr equent basis

performanc e

. Procedur e o r acti on wi thin an o rganizati on is repetitive.

carried out exactl y according to detailed, step- wise instruct ions

control or syst em compa tibili ty

Since these are two very critical aspects of fl ying, a checkl ist for proceed ing in a safe manner is used to mit igate the potential for mis takes It is crit ical to provide help when a chance for error ca n resul t in grave consequ ences

Plastici zed SOPs should be placed on equipm ent, machi nes, and vehicl es for those individua ls who need a refres her before operation because they have not used the equipm ent or performed the task on an infr equent basis

Few people or wor kers want to admit that they do not kno w how to perfor m a job

or task They will not ask questions , let alone a sk for help in doing an assi gned task This is the time when a plast icized SOP or checklist could be placed at the wor ksite

or attached to a piece of e quipment This can prove to be a very effective accide nt-prevention technique It can safely walk a worker throu gh the correct sequenc e of necessa ry steps and thus avoid the exposur e to hazards whi ch can put the wor ker at risk of inju ry, ill ness, or death

These SOPs could be used when , for examp le, heli copters are used for lif ting, industri al forklifts are used, material s are moved manua lly, etc These types of SOPs should list the sequent ial steps requi red to perform the job or task safely, the potent ial hazards invol ved, and the person al prote ctiv e equipm ent needed Each step in the SOP shoul d provide all the informat ion needed to acc omplish the task safel y

If you do not have annu al training, the use of SOPs may instil l a sense of

effective appli cation A checkl ist is one form of an SOP A checkl ist is very effective and atte mpts to ensure that every step is foll owed

SOPs are only useful when they are up-to-date and readi ly access ible at the

format from this example, develop your own SOPs for procedures, jobs, tasks, or equipment

An SOP is only one accident-prevention technique or component of any safety

most and not as a cure-all for all your accidents and injuries Use it as one of the many tools for accident prevention

FIGURE 18.1 Forklift.

TABLE 18.1

An SOP for a Forklift

What To Do How To Do It Key Points

Perform a pre-start

up inspection

Walk around the vehicle checking overall conditions of:

1 Tires 1 Check tires to ensure adequate tread, no

cuts=missing chunks, all tire bolts are present and are tight.

2 Fluid leaks 2 Check hydraulic hose fittings for

evidence of fluid leak Look beneath vehicle for fluid on the floor.

3 Overhead guard 3 Check for missing bolts, bent frame.

4 Lifting forks and load backrest 4 Check the lifting forks and backrest for

damage Check that the lifting fork ’s width adjustment lock pins are in good condition and are working smoothly.

5 Preventive maintenance (P =M) sticker

5 If P =M expiration date is not valid, do not operate vehicle.

Perform operating

controls inspection

1 Sit in driver ’s seat and operate controls

1 Check to ensure emergency brake is engaged and gear shift is in park or neutral.

2 Adjust seat for effective operation and comfort

2 Seat should be adjusted to allow foot brake pedal to be depressed without reaching with foot.

(continued)

TABLE 18.1 (continued)

An SOP for a Forklift

What To Do How To Do It Key Points

Perform operating

controls inspection

(continued)

3 Fasten seat belt 3 Seat belt should be snugly across hips.

4 Turn on power to vehicle 4 Check 360 8 around vehicle to ensure no

one is standing near vehicle.

5 Turn on headlights 5 Headlights must be bright and in

position to ensure being seen by other vehicle operators or pedestrians.

6 Depress brake foot pedal 6 The pedal must be firm and brake lights

must function and be bright.

7 Depress horn button

8 Elevate lifting forks and tilt by pulling back on control levers

7 Horn should function easily and be loud.

8 Hydraulic controls shall operate smoothly.

9 Lower lifting forks to 2 –4 in.

above floor

10 Report any safety check failure

to supervisor immediately for repair

9 Keep lifting forks 2 –4 in above surface when in motion.

10 Do not operate if any safety check fails Ensure the vehicle is not operated until repaired.

Operating

procedure—

traveling to

designation

1 Depress foot brake pedal 1 Check 360 8 around vehicle to ensure no

one is standing near vehicle Keep lifting forks 2 –4 in above surface when

in motion.

2 Release parking brake 2 —

3 Select direction of travel 3 Engage gear drive Check travel

direction to ensure path is clear of pedestrians or other vehicles.

4 Remove foot from brake pedal 4 Remove foot slowly.

5 Depress accelerator pedal 5 Depress accelerator pedal slowly

to avoid quick, jerky start Keep lifting forks 2 –4 in above surface when in motion.

6 Obey safety rules and regulations

6 Travel at speeds which allow vehicle

to be under control at all times under any condition.

Travel single- file keeping to the right.

Pedestrians have right of way.

Emergency vehicles have right of way at all times.

Use lights and horn when necessary.

Allow at least 15 ft or three vehicle lengths between you and person in vehicle (PIV) in front.

TABLE 18.1 (continued)

An SOP for a Forklift

What To Do How To Do It Key Points

Operating

procedure —

traveling

to designation

(continued)

Do not pass other vehicles traveling

in the same direction at intersections

or blind spots, or narrow passages.

Ensure there is adequate overhead clearance.

Do not travel over objects.

Avoid sudden stops, except in emergencies.

Stop at all stop signs, blind corners,

or when entering intersecting aisle and look for pedestrians and vehicle traffic.

Operating

procedure—

material pick-up

1 Approach material slowly 1 Reduce speed to avoid sudden stop.

2 Stop vehicle, depress foot brake pedal

2 Apply slow, steady pressure until vehicle stops.

3 Shift to park or neutral 3 Never select direction while in motion.

4 Engage parking brake 4 If on an incline block wheels.

5 Unfasten seat belt and dismount, set forks for maximum load width

5 Know the vehicle ’s capacities and load weights.

6 Remount and fasten seat belt 6 Seat should be adjusted to allow foot

brake pedal to be depressed without over extending.

7 Depress foot brake pedal 7 Check 360 8 around vehicle to ensure

no one is standing near vehicle.

8 Release parking brake 8 —

9 Select direction of travel 9 Engage gear drive Check travel

direction to ensure path is clear.

10 Remove foot from brake pedal 10 Remove foot slowly.

11 Depress accelerator pedal 11 Depress accelerator pedal slowly to

avoid quick, jerky start.

12 Approach the load with lifting forks level

12 Lifting forks should be parallel with walking surface.

13 Penetrate forks to back of pallet

13 The pallet should be set against the backrest.

14 Depress foot brake pedal bringing vehicle to a stop

14 Apply slow steady pressure until vehicle stops.

15 Raise the lifting forks until pallet is 2–4 in above walking surface

15 Never raise forks while in motion.

(continued)

TABLE 18.1 (continued)

An SOP for a Forklift

What To Do How To Do It Key Points

Operating

procedure —

material pick-up

(continued)

16 Tilt the lifting forks back slightly

16 Tilt the forks backward slightly to prevent the load from falling forward.

17 Select direction of travel 17 Engage gear drive Check travel

direction to ensure path is clear of pedestrians or other vehicles.

18 Remove foot from brake pedal 18 Remove foot slowly.

19 Depress accelerator pedal 19 Depress accelerator pedal slowly to

avoid quick, jerky start.

20 Travel carefully to designation, obeying rules and regulations

20 Travel at speeds which allow vehicle

to be under control at all times under any condition.

Travel single-file keeping to the right.

Pedestrians have right of way.

Emergency vehicles have right of way at all times.

Use lights and horn when necessary.

Allow at least 15 ft or three vehicle lengths between you and PIV in front.

Do not pass other vehicles traveling

in the same direction at intersections

or blind spots, or narrow passages.

Ensure there is adequate overhead clearance.

Do not travel over objects.

Avoid sudden stops, except in emergencies.

Stop at all stops sign, blind corners,

or when entering intersecting aisle and look for pedestrians and vehicle traf fic.

Always drive with load facing up hill.

Drive backwards when view is obstructed by large loads Operating

procedure —

material drop-off

1 Depress foot brake pedal bringing vehicle to a stop

1 Apply slow steady pressure until vehicle stops.

2 Shift to park or neutral 2 Never select reverse while in motion.

3 Tilt forks forward until parallel with walking surface

3 Never lower forks while in motion.

TABLE 18.1 (continued)

An SOP for a Forklift

What To Do How To Do It Key Points

Operating

procedure —

material drop-off

(continued)

4 Lower lifting forks until pallet bottom is resting on surface and forks no longer support load

4 Lower load slowly to prevent sudden drop.

5 Engage reverse drive 5 Check 3608 around vehicle to ensure

no one is standing near vehicle.

6 Remove foot from brake pedal 6 Engage gear drive Check travel

direction to ensure path is clear of pedestrians or other vehicles.

7 Depress accelerator pedal 7 Depress accelerator pedal slowly to

avoid quick, jerky start.

8 Travel enough distance until lifting forks can clear pallet

8 Travel in reverse until there is enough distance between the end of lifting forks and pallet.

9 Depress foot brake pedal bringing vehicle to a stop

9 Apply slow steady pressure until vehicle stops.

10 Engage forward drive 10 Check 360 8 around vehicle to ensure

no one is standing near vehicle Never select directional change while in motion.

11 Remove foot from brake pedal 11 Check travel direction to ensure path is

clear of pedestrians or other vehicles.

12 Depress accelerator pedal 12 Depress accelerator pedal slowly to

avoid quick, jerky start.

13 Travel carefully to designation obeying rules and regulations

13 Travel at speeds which allow vehicle

to be under control at all times under any condition.

Travel single- file keeping to the right.

Pedestrians have right of way.

Emergency vehicles have right of way at all times.

Use lights and horn when necessary.

Allow at least 15 ft or three vehicle lengths between you and PIV in front.

Do not pass other vehicles traveling

in the same direction at intersections or blind spots, or narrow passages.

(continued)

18.4.1 COMPONENTS OF ANSOP

SOPs should provide clear instructions for safely conducting activities involved in

guidelines and instructions, other pertinent safety resources information, and

elements:

1 Steps for each operating phase

a Initial startup

b Normal operations

c Temporary operations

d Emergency shutdown including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to

TABLE 18.1 (continued)

An SOP for a Forklift

What To Do How To Do It Key Points

Operating

procedure —

material drop-off

(continued)

Ensure there is adequate overhead clearance.

Do not travel over objects.

Avoid sudden stops, except in emergencies.

Stop at all stop signs, blind corners, or when entering intersecting aisle and look for pedestrians and vehicle traf fic Operation

procedure —shut

down

1 Depress foot brake pedal bringing vehicle to a stop

1 Apply slow steady pressure until vehicle stops.

2 Shift to park or neutral 2 Never select directional changes while

in motion.

3 Engage parking park 3 If on an incline, block wheels.

4 Lower lifting forks slowly until resting on walking surface

4 Never lower forks while in motion.

5 Turn off power 5 Remove key.

6 Release seat belt 6 —

7 Dismount 7 Wheels must be blocked if parked on an

incline.

8 Perform walk-around inspection, noting damage or operational problems

8 Report all operation problems to supervisor for repair.

9 Remove all trash Source: From Reese, C.D Accident=Incident Prevention Techniques, Taylor & Francis, New York, 2001.