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Student Workbook

LV01 Health, Safety and Housekeeping in a Vehicle Workshop

LV01/SWB

Student Workbook for Technical Certificates

In Light Vehicle Maintenance and Repair

Health and Safety Commission and Unsafe acts 24

Regulation and Codes of Practice 3 Indirect causes 25

Health and Safety Policy Statement 5 Accident prevention 27 Working environment 6 Reporting accidents 28 Legislation that affects maintenance Exercise 3 29 and repair 7 Reporting faulty equipment 30

Types of dangerous substances 13 Priorities 31

Progress check 18 The Fire Precautions Act (1974) 33

Causes of fire 33

Personal Protective Equipment Extinguishing fire 34

Means of escape 36

Employee Duties under the Health

and Safety at Work Act (1974) 22

(Contd)

Page Page

Fire hazards within a motor Electric arc 55

Practice good engineering hygiene 41 What does asbestos do? 59 What has to be cleaned 41 What kind of work creates asbestos

Cleaning agents and equipment 41 dust? 59 Environment Protection Act (1990) 42

Other cleaning duties 42

Risk Assessment and Record

Safe removal of petrol from vehicles 48

Equipment fro removing petrol 49

The Law

Health and Safety Commission and Executive

The motor vehicle industry is highly regulated The health and safety of the people that work within it is of primary importance, and therefore subject to a number of regulations

The Health and Safety Commission has responsibility for:

 general policy, research and dissemination of information

 development of law through proposals for regulation and codes of practice and to consult with employer and employee organisations where

 research, information and advice

Regulation and Codes of Practice

The Health and Safety at Work Act (HASAWA) was introduced by the

Government in 1974 and facilitates regulation to:

 modify or replace existing legislation

 provide for new situations as they arise

The Act enables approved codes of practice to be introduced and to provide practical guidance

Regulations are enforceable by law; codes of practice are not but are

admissible in evidence as failure to comply

Powers of inspectors

HSE inspectors carry out periodic inspection of premises to ensure

compliance with the law They have a number of powers and they are able to:

 enter premises at any reasonable time (accompanied by a police

constable if necessary)

 examine and investigate, and to this end can order premises to be left undisturbed

 take samples

 issue improvement and prohibition notices and initiate prosecutions

 take possession of any dangerous substance or article for examination or use in legal proceedings

Upon completion of an inspection, there are a number of options open to the inspector

Improvement notice: This is issued by the inspector and used to improve or remedy a situation A time limit for completion is specified

Prohibition notice: A prohibition notice is used when an inspector decides that there is a risk of serious injury and directs that certain activities cease until the situation is remedied

Fines: In the event of a prosecution-taking place, which could be against a company or any individual from chief executive to vehicle technician, a

magistrate can impose heavy fines (unlimited) The offender can also be sent

to prison for a maximum of two years

Health and Safety Policy Statement

An employer must: “Ensure, so far as is reasonably practicable, the health,

safety and welfare at work of the people for whom they are responsible and the people who may be affected by the work they do”

In order to comply with this requirement, an employer must:

 prepare a written statement of general health and safety policy

 set down the organisation and arrangements for carrying out the policy, i.e who is responsible and for what

 revise and update this policy as necessary

 bring the policy and arrangements to the notice of all employees

The company health and safety policy is in short a statement answering the following questions:

1) What are they going to do?

2) Who is going to do it?

3) How is it going to be done?

The working environment

Your employer must provide:

 a safe place of work

 safe systems of work

 safe equipment to work with

 a healthy and safe environment to work in

Without active support, any attempt at organised accident prevention will be useless Avoidance of accidents requires a sustained, integrated effort from all departments, managers, supervisors and workers in any organisation Only management can provide the authority to ensure everything is co- ordinated, directed and funded but every employee has a responsibility to ensure that they do their bit - this includes you! Management’s influence will

be seen in the policy made, the amount of scrutiny given to it and the ways in which violations are handled

The company policy should contain references to other arrangements not contained in the safety policy itself, which should include:

 training - identification of training needs

 the environment - heating, ventilation, lighting, good housekeeping,

cleaning schedules

 emergencies – fire, accident and violent behaviour

 reporting procedures - accidents, near misses and hazards

 first aid

 rules and procedures for using and maintaining equipment

 COSHH – mostly chemicals and dust (see next section)

Legislation that affects vehicle maintenance and repair

The Control of Substances Hazardous to Health Regulations (1988) (COSHH)

This regulation requires that any risk arising from the use of substances within the workplace is studied and the information made available to all affected persons i.e those employees who may come into contact with such

substances COSHH data sheets must be made available so that any

employee, who has doubts about the safety of any substance and its use, can study the relevant information The availability of such data sheets should not

be considered as an acceptable substitute for training

To be suitable and sufficient, the assessment must consider any risks arising from the use (or generation of) hazardous substances A collection of

supplier’s data sheets will not suffice as a COSHH assessment Only the employer can establish the risk of exposure, as this arises from the way that the substance is actually used COSHH assessments must be formally

reviewed at least every five years Other than in the most simple of cases, a COSHH assessment should be recorded in writing

The Health and Safety (Display Screen Equipment) Regulations (1992)

Employers must assess the risk to health and safety arising through the use of display screen equipment, in particular, the risks of muscular-skeletal injury, eye problems and mental stress A record should be kept in retrievable form except where the workstation is temporary, no significant risk was found, or the assessment is easily repeatable

The Manual Handling Operations Regulations (1992)

Where a hazardous manual handling operation cannot be avoided, a thorough assessment of risk must be undertaken and measures must be introduced to reduce risks of injury to an acceptable level

The assessment must take into account the tasks, the loads, the working environment, individual capability and other factors Records of the

assessment must be kept unless:

 the handling operation is short lived

 there are no significant risks

 the assessment is easily repeatable

The Control of Asbestos at Work Regulations (1987)

A thorough assessment must be taken before commencing work in an

environment where exposure to asbestos may occur The type of asbestos should be established, as should appropriate control measures The

effectiveness of control measures should be monitored, with records kept for

at least five years Where the regulations require health records to be

maintained, these must be kept for a minimum of 40 years

The Personal Protective Equipment at Work Regulations (1992)

Prior to selecting personal protective equipment (PPE), the employer or self- employed person must ensure that an assessment has been made to

ascertain whether the proposed equipment is suitable The assessment must take account of risks to health or safety that have not been avoided by other methods, the sort of performance and characteristics necessary for the

equipment to be effective and comparison of the proposed equipment with the required performance and characteristics When a person dons PPE, it is only this equipment that provides a barrier to the risk Could this risk have been eliminated by other means?

Other record keeping requirements

There are many other situations in which records must be kept in addition to those mentioned thus far Accident books must be kept for a minimum of three years and under COSHH, local exhaust ventilation inspection records must be kept for a minimum of five years Other records which should be kept but without specific time scale include records of electrical equipment

inspection, details of examinations of hoists and lifts, lists of authorised lift truck drivers and details of those qualified in first aid

The European Directive

Known as the ‘Framework Directive’ it deals generally with the introduction of measures to encourage improvements in the health and safety of people at work It is based on article 118A of the Treaty of Rome and is activated

largely by the management regulations in the UK

The Offices, Shops and Railway Premises Act (1963)

With the implementation of the Health and Safety at Work Act (1973) the general health and safety of all persons at work was protected However, much of the specific legislation contained in The Offices, Shops and Railway Premises Act (1963) is still in force for those specific premises covered by it and follows closely the provisions identified in the Factories Act such as

machine guarding, ventilation, cleanliness and provision of sanitary

conveniences Section 27 makes it an offence for an employee to misuse or interfere with the facilities provided to meet with the requirements of the Act

The Electricity at Work Regulations (1989)

This regulation introduces a control framework incorporating principles of electrical safety applying to a wide range of plant, systems and work activities They apply to all places of work and electrical systems at all voltages All electrical systems must be constructed and maintained at all times to prevent danger

The Abrasive Wheels Regulations (1970)

These regulations do not apply to new equipment taken into use after the 1 January 1993, which is subject to the Provision and Use of Work Equipment Regulations 1992 This regulation was introduced for a number of reasons mainly due to the number of injuries arising from the use of abrasive wheels in industry, a high proportion of which were due to faulty mounting of the wheel Under these regulations every person who changes an abrasive wheel must

be trained, competent and appointed in writing to do so

The Reporting of Injuries, Diseases and Dangerous Occurrences

Regulations (1985) (RIDDOR)

The main purpose of RIDDOR is to provide enforcing authorities with

information on specific injuries, diseases and dangerous occurrences arising from work activities covered by the Health and Safety at Work Act The

authorities are not able to investigate all of these, so the regulations aim to bring the most serious to their attention quickly

These include:

 the death of a person as a result of an accident arising out of or in the connection of work

 a dangerous occurrence, which could have resulted in deaths or injuries

Records must be kept at the place of work or business for at least three years from the date they were made

The Workplace (Health, Safety and Welfare) Regulations (1992)

This implements most of the requirements of the Workplace Directive

concerning minimum standards for workplace health and safety The

objective of the regulations is to place obligations on employers and others in control of workplaces to reduce risks associated with work in or near

buildings

Significant areas that affect vehicle maintenance and repair are:

 traffic route - for pedestrians, vehicles (or both) and includes stairs, fixed ladders, doors, ramps and loading bays and walk ways

Workplace means any non-domestic premises made available to any person

as a place of work; premises include any outdoor place, but not domestic premises

There are fourteen major topics in the Workplace (Health, Safety, and Welfare) Regulations:

 maintenance of workplace and equipment servicing

 ventilation, temperature and lighting

 cleanliness

 workspace allocation

 workstation design and arrangement

 traffic routes and floors

 fall protection

 glazing

 doors and gates

 escalators

 sanitary and washing facilities

 drinking water supply

 accommodation for dressing

 facilities for changing, rest and meals

The Noise at Work Regulations (1989)

These regulations are made under the provision of the Health and Safety at Work Act (1974) and therefore apply to all places of work

Employers must carry out an assessment of employees exposure to noise where such exposure is at or likely to exceed the first action level (FAL) or the peak action level (PAL) The FAL is 85dB(A) the second action level (SAL) is

90 dB(A), PAL is 200 Pascal’s sound pressure Noise is measured by a noise meter which is an instrument designed to respond to sound in the same way

as the human ear

Noise control

The following are ways of providing protection to reduce risk to hearing:

 noise reduction techniques

With machinery, small changes at the design stage can result in large noise reductions at very little cost

Other methods of reducing noise are:

 damping - adding a layer of a damping material to the vibrating structure

 silencing - mufflers are devices which reduce the transmission of sound

Dangerous Substances (COSHH)

Classification

Dangerous substances can be categorised in many ways When describing them in health and safety terms they are categorised according to the type of harm they can cause Some can cause harm after a single exposure or incident, others may have long term effects on the body following repeated exposure

Speed of action

Chronic - the effects become apparent over a long period

Acute - the effects are immediate or become apparent over a short period

These substances are hazardous through their ability to release large

amounts of energy very rapidly The products of explosion or combustion could also be harmful in other ways

Organic solvents are often explosive It should be noted that powders that at face value would appear harmless, could become highly explosive when mixed with oxygen in airborne form; even custard powder!

Harmful

Substances thus labelled are harmful if inhaled, ingested or absorbed through the skin They often present only a limited risk to health but must be treated with respect

Irritant

Substances labelled as an irritant adversely affect the skin or respiratory tract Acrylate is such a substance Some people react more severely to irritants than others

Poison

Substances that interfere with body functions Organs can be overloaded, i.e the liver and kidneys Lead is a poison, as is mercury Arsenic prevents the body from absorbing oxygen; you effectively suffocate

Progress check

1) What does the acronym COSHH stand for?

2) A vehicle falls off a two poster ramp, narrowly missing a technician working nearby Under which regulation must this incident be reported?

3) Can you be prosecuted under current health and safety law?

4) If a substance has been identified as an ‘Irritant’ which of the labels should the product display?

Personal Protective Equipment (PPE)

The use of Personal Protective Equipment (PPE) is a method of reducing injury from risks that are recognised as present, but measures should be taken to attempt to eliminate the risk rather than protect workers from it This

is not always possible and therefore PPE is sometimes required and if so it must be worn You must protect yourself and ensure others do the same

Employee Duties under the Health and Safety at Work Act

(1974)

You have a duty of care to yourself and your colleagues In order to fulfil your responsibilities you must make yourself aware of the following:

 what hazards may exist in your workplace

 the nature of risk within your workplace and the precautions you must take

 the importance of remaining alert to the presence of hazards in the

workplace

 the importance of dealing with or promptly reporting hazards

 the precautions to be taken

 agreed workplace policies relating to controlling risks to health and safety

 responsibilities for health and safety in your job description

 the responsible persons to whom you report health and safety matters

 the specific workplace policies covering your job role

 suppliers and manufacturers instructions for the safe use of equipment, materials and products

 safe working practices for your own job role

 the importance of personal presentation in maintaining health and safety in the workplace

 the importance of personal conduct in maintaining the health and safety of yourself and others

 your scope and responsibility for rectifying risks

 workplace procedures for handling risks which you are unable to deal with Read your company health and safety policy Anything you are unsure of bring to the attention of your supervisor Ensure you have had correct training for the tools you use and do everything you can to minimise risks or hazards that arise with your job

Be aware of your safety and others who work with you

The way you react to situations can either contribute to danger or reduce it

pressures on a customer’s car are subsequently over-inflated

The customer goes on holiday in the car with his extended family, towing a caravan The customer fails to adjust the tyre pressures in accordance with the vehicles load It’s a very hot day and the customer is travelling above the legal speed limit for a vehicle towing a caravan The stresses on the tyre prove too much and the tyre fails A fatal accident results

Any one of these failures in isolation would be unlikely to cause the accident However, all factors combined made an accident inevitable

Unsafe acts

This is a dangerous situation arising from something that is either done or should have been done but was not (an omission)

The following are examples of these:

 fooling around (horseplay)

 not ensuring equipment is safe to work on

 having PPE but not using it

 removing guards

 leaving spilt liquids on the floor

 incorrect manual handling

Indirect causes

These are factors arising from the way in which an employee is made to feel

at work, and/or their actions outside work hours

Exercise 2

Study the following scenario The parts in italics fall into the previously

discussed categories They will be one of the following:

1) Direct cause/unsafe act

2) Direct cause/unsafe condition

3) Indirect cause/social pressure

4) Indirect cause/work pressure

Write next to each italic part in the brackets provided which of the above contributing factors (1, 2, 3 or 4) is applicable (the first 2 are done for you as

an example):

John the technician was late for work (4); the previous night he was out with

the lads and didn’t get in until the early hours (3) It was Jack’s idea to go out;

he wanted to celebrate his recent promotion to workshop supervisor John

didn’t really want to go - his wife had given him nothing but grief since hearing

of Jack’s promotion (and the new house in a better area of town that was bound to follow) ( ?) John decided to really go for it at work on that day - if

he could just improve his productivity by 10% or so ( ?), he may be picked

up for promotion as well

His first job was a bit of a nightmare, a brake reline all round on an old

scrapper To add to his frustration, his ramp was being used for a clutch change (because he was late for work), so he had to do the brakes on the floor He hated doing brake relines at the best of times as the dust always

irritating his hands and arms ( ?) He had asked the supervisor on a

number of occasions for plastic gloves but they refused due to the cost ( ?)

He jacked up the car at the rear and removed the wheels Someone had

moved the axle stands ( ?) from where they were usually kept so he

carried on without them He knew he was taking a bit of a chance but he didn’t want to go back into the workshop office to ask about the stands in case

they noticed he wasn ’t wearing any safety boots ( ?) (forgot them in his

hurry to get to work)

He was making good progress with the brakes at the rear when his good friend Bill came over to give him a hard time about being late for work

Bill had took the clock off the workshop wall and shouted:

“Time flies when you’re having fun, eh John?”

And with that, threw the clock at him ( ?) As John lunged to the left to

catch the clock, he knocked the car, and the jack (which had never been

much good) gave way ( ?) The resulting accident cost John his left foot,

amputation had been the only option

Research has shown that for every event leading to a major injury there can

be as many as 10 causing minor injury, 30 causing property damage and hundreds that result in neither injury nor damage The latter are known as critical incidents Recognition and control of these incidents by the supervisor and all other employees is the true basis of any accident prevention and control system

The situation is often likened to a tip of an iceberg, with only the tip of the problem visible

Reporting accidents

All accidents, no matter how small, must be reported to a supervisor A minor cut may not appear to be much, but if that cut becomes infected then it may become a major issue

The supervisor must enter all relevant details into the accident book These details will include the date and time of the accident, the nature of the

accident, any injury that resulted and the action taken by any first-aider or other medical authorities

It is possible that further reporting may be necessary under RIDDOR (see page 8); it really depends on the nature of the incident

Exercise 3

Label all the areas of the body that could become damaged, and how, in your area of work:

Reporting faulty equipment

In the event of any failure of equipment you must isolate the source of energy (electricity, engine, water, compressed air) from the equipment Then, either place the equipment in the control of your supervisor or label it clearly as unserviceable Inform your supervisor of the fault so that procedures can be put in place to bring about a repair

Do not attempt to repair the equipment yourself unless trained and authorised

to do so If faulty equipment is not reported, the next person to use it may be injured!

First Aid

Note: First aid practices change regularly You should make efforts to keep

up with latest best practice and should consider anything in this publication as out of date until proven otherwise

First aid is help administered to an injured party until the medical authorities arrive on the scene There are two main principles:

1 To not become a casualty yourself

2 To reduce the risk of further injury to the patient

A typical sequence of events following the discovery of an accident resulting

in casualties would be to:

 make the area safe

 administer first aid

 take appropriate action to reassure the injured party

 raise the alarm