تطبيق معايير السلامة في مصنع انتاج انابيب غاز منزلية

transcript

Islamic University of Gaza

Industrial Engineering Department

Safety and Maintenance Improvements

for a Local Factory of Metallic Products

BYHAZEM SHEHADA

MOHAMMED SHAHEENMOHAMMED EL-LAQTTA

MOHAMMED ABU-SHABAN

Submitted to

M.S Waleed Hessen

Introduction:- Here, in our project, we submit some safety and

maintenance improvements for a factory of producing metallic products.

We visited this factory which is located in Salah-Al-Deen street.

We put here in our project, some details and ideas which we discussed to improve safety and maintenance affairs, and as a result improvement productivity and quality for the work.

We found that average rate of accidents isn’t small when comparing with the rate of production which is already so small.

Introduction The area of this factory is about 1500 m2

The main product is the Gas tube (by all of standard sizes) which is produced there, beside some other secondary metallic products.

The factory exports products to the west bank, beside supplying local markets in Gaza.

Actual workers in the factory are about 10, when the real work sequence needs more than 60 worker.

Actual production rate is about 100 gas tube / day.

This factory had been affected a lot by the current Palestinian Intefada which made products way to the west bank much difficult , reducing number of workers, and decreased production.

SAFETY OF WORKERSProblems

We saw that the workers didn’t apply safety constructions in their work.

They didn’t wear special uniform, gloves, eyes , head , earn, and respiratory protection, as in welding and deep drawing operations .

SAFETYWORKER

SAFETYOF WORKER

SAFETY OF WORKERS

PROTECTION FOR WORKERHead Protection

Safety helmets are used to protect the head from falling objects and from bangs against obstructions. They are made from a strong, lightweight, plastic material. On inside is a harness made from polythene which has adjustable straps to fit the head. Some are designed so that safety goggles can be easily fitted to the helmet.

Caps are used to keep the head and hair dry and clean and to prevent the hair from catching in the revolving parts of machine.

EYE AND FACE PROTECTION

Eye protectors are used to protect the eyes from injury. The accidents to the eyes are very painful and often result in permanent damage or blindness. So we will have to choose the correct type of eye protector for the kind of work being done.

Spectacles are used to prevent accidents from small chippings or particles of brittle materials such as when drilling or cutting process.

Goggles are used to protect the eyes in conditions where there is dust, chemicals.

Face screens are used to protect the eyes and face from small particles and flying objects.

HAND PROTCTION

Industrial gloves are used to protect the hands and wrists from injury. Cuts, abrasions and burns are the most common injuries. These are often caused when working with materials which have sharp edges. Burns are the result of handling hot metals.

Armored gloves have metal staples across the finger. These gloves are used when lifting metals and component which have very sharp edges on them.

Chrome leather gauntlets are longer in length than gloves. This gives protection to the wrist and bottom part of the arm. These used to handle hot items.

FOOT PROTECTION

Safety boots and shoes are used to protect the feet and toes from injury caused by heavy and sharp objects dropping on them.

The bottom or soles of them can resist heat, oil, others have steel plates or studs on the soles and heels to withstand heavy wear.

EAR AND MOUTH PROTECTION

Ear protectors, sometimes called ear muffs or ear shells, are used to protect the ears from damage caused by loud and prolonged noise. Another use is to reduce noise level so that the worker can concentrate.

Protective masks are used to protect the lungs from Toxic and non-toxic dusts.

Decibel levels for Various SoundsEnvironmental Noises Common Noise Sources Decibels

Jet takeoff (200 ft) 120Casting shakeout area Riveting machine 110

Electric furnace area

Printing press plant

Pneumatic peen hammer,textile weaving plantSubway train

Veryannoying

Inside sports car (50 mph)

Near freeway (auto traffic)

Pneumatic drillFreight trainVacuum cleaner (10 ft)Speech (1 ft)

Earprotectionrequired ifexposed 8hours ormore

Large storePrivate business officeLight traffic (100ft) Large transformer (200ft)

Intrusive

QuietMinimum levels, residentialareas in Chicago at night Soft whisper

30 Very quiet

Earprotection required

BODY PROTECTION AND TOTAL PROTECTION

Boiler suits are used to protect the body when working in dusty or dirty conditions. They fit close to the body and are safer to wear than loose jackets or shirts.

Total protection is essential when using portable tools such as disc grinders.

This is because the body has to be protected from dirt, the feet from falling objects, the eyes from sparks, the lungs from grinding dust, and the ears from noise.

ELECTRICAL SAFETYProblems

The workers are in direct contact with wires, and electrical shocks may occur as the body becomes a part of electric circuit.

Many fires may occur as a result of increased current flows through wires beside the absence of regulator devices.

Disarrangement of wires inhibits maintenance and good movements .

ELECTRICAL SYESTEM

ELECTRICAL SAFETY PROTECTION

Designing electrical equipment to reduce contact with humans.

Arrangement of wires and insulating them from contact with workers.

Wires for the same purposes should be collected together in order to keep easy for maintenance.

designing for ( wall electricity supplies and wires) to keep easy for good movements and fire protection.

Sealed Equipment : are used for electrical equipment to be sealed from heating environment.

Over current: devices: are used to regulate current flow through wires.

Individual circuit breakers : if a hazardous action is happened ,it breaks the current flow through any machine has an electrical problem .

Conduit and protective coverings: one of the reasons for placing electrical lines in metal condition is to prevent physical damage to them.

Another reason is to reduce the change of contact with energized conductors.

TOOLS,MACHINES AND EQUIPMENTSProblems and Protection

1. Deep Drawing Machines

The worker fixes the work piece manually.

Hazard: that fingers of the worker are in direct contact with the die.

Protection:

Fixing guards in a machine to keep worker hands so far away from the direct contact.

DEEP DRAWING DEPARTMENT

TOOLS,MACHINES AND EQUIPMENTS Machine Guarding

For machine guarding the most common ways are lexan, light curtains, mats, and palm buttons.

The lexan type windows have switches on them so you can tell when they are in place or removed.

The light curtains are nice but expensive. When you stick your hand (or anything else!) in the

light curtain, it closes a contact which tells the system to stop or pause.

Safety mats are placed around the machine and when someone steps on the mat a contact is closed telling the system to stop.

TOOLS,MACHINES AND EQUIPMENTS Machine Guarding

The palm buttons are a pair of buttons that require the operator to have their hands on the buttons for the machine to operate.

You assume that their hands are not in the machine. Operators try to place heavy objects on the palm buttons so their hands can be free.

Therefore you require (logic in your controller) that they remove their hands between sequences so that operators can not simply set something on the buttons.

There are now optical "palm buttons" where the operators rest their fingers in a cup -- instead of holding down push buttons.

TOOLS,MACHINES AND EQUIPMENTSProblem and Protection

2. Shot Bearing Machine

The process shots a small particles by high velocity, with generating resulted dust.

Protection :

Fixing guards in a machine to keep the workers from particles.

Vents should be used to eliminate this dust .

3. Welding Machine This operation ( welding ) was an unsafe act as

the worker body is in contact with equipments without a barrier from arcs.

It’s done through the general environment of the factory, without insulators from air gases.

Protection: welding equipment and operation should be

performed in a suitable environment which is insulated from gases.

Good training for workers is important for reaching safety.

Welding Department

Most of machines in the factory couldn’t be stopped directly from an existed stopping tool in emergency. (a separated tool)

Protection: Emergency stop controls should be

used. Such as , a button in the machine itself.

TOOLS,MACHINES AND EQUIPMENTS

GENERAL RECOMMENDATIONSFOR MACHINCES AND EQUPMENTS SAFETY

DO1. Keep machine clean and in good condition.2. Ensure that you know how to stop your machine

before starting it.3. Switch off machine immediately if anything goes

wrong.4. Keep machine and surrounding area tidy.5. Check oil levels before first starting machine.6. Check direction of cutter rotation before starting.7. Replace any worn or damaged nuts, bolts, clamps,

8. Switch off machine at the mains at the end of each shift.

9. Remove the chuck key before starting rotation of chuck.

10. Ensure that all guards are in position before starting machine.

11. Ensure that everything is properly clamped and secured before starting machine.

12. Ensure that the feed mechanism is not engaged before starting machine.

DO NOT1. Do not fool about on a machine.2. Do not attempt to operate the machine until

you are sure you understand it.3. Do not attempt to change the direction or

speed of the spindle whilst it is in motion.4. Do not mount or use a cracked or damaged

drill or cutter.5. Do not tamper with the machine.

6. Do not remove stops or trip dogs in an attempt to obtain more table travel, or the machine may be seriously damaged.

7. Do not remove guards unless the machine is stopped.

8. Do not touch revolving tools or cutters.

9. Do not lean on the machine.

MATERIAL HANDLINGProblems The common type of handling is manual in this

factory. The hazards result from this type is: Biomechanical analysis of lifting gives up in sight

into some of problems:1. When a person lifts and carries an object the

moment is greater when the load is held for far from body.

2. As in carrying the finished product the size of container makes the carrying be far from body.

3. This moment increases the effort on muscles and may causes injury.

MATERIAL HANDLING STORAGE OF MATERIAL

MATERIAL HANDLINGSTORAGE OF MATERIAL

The arrangement of materials in shelves is not sufficient as many some objects falls over the worker.

This result to a potential for injury from poorly storing of materials.

This also result to an interruption in handling of these materials.

Improper segregation of material may create hazards from fire and corrosion.

MATERIAL HANDLINGA Method to Improve Current Flow of Materials .

Using (From –To Chart) by taking distance as the entries of the followed

matrix.

MATERIAL HANDLINGFrom-to-Chart (current flow)

Stores Assembly drawing welding furnace shot painting

Stores

Assembly 12drawing 4welding 20furnace 25shot 4painting 15

MATERIAL HANDLINGFrom-to-Chart (Improved flow)

drawing welding Assembly shot furnace painting stores

drawing 4welding 20Assembly 12shot 4furnace 25painting 15stores

MATERIAL HANDLINGFrom-to-Matrix (Distance Units Entries)

Moment (current layout) =

15*6 + 2*20 + 4*1 + 4*1+ 12*4 + 25*2 = 211 m Moment (improved layout) =

4 + 20 + 12 + 4 + 25 + 15 = 80 m The current layout indicate that we need a

travel distance of 211 m. By rearrangement of layout, the flow distance

travel is reduced to 80 m.

MATERIAL HANDLINGReceiving/Shipping The space for shipping and receiving is small.

scraps, waste materials are accumulated close to this space. In the other hand, the gate does not permit good movements of vans and containers of raw materials.

Controls: Design a separated department for receiving

and inspection closed to the gate. Replace the location of the gate to be in front

of the main street which makes shipping and receiving easier where main street is wider.

MATERIAL HANDLINGSTORAGE CONTROL OF MATERIALS

“A place for every thing and every thing in its place”, is important for controlling hazards of materials storage, well planned, organized and maintained materials areas are essential.

Proper stacking is important as many kinds of materials are packaged.

Retaining walls can keep bulk materials from spreading out on collapsing on some one or equipment.

ENVIRONMENTAL SAFETYFireFloor IlluminationVentilation

ENVIRONMENTAL SAFETYFIRE

May result in this factory from:

Improper process of welding: As the worker is kept in touch with the flame of

welding equipments without any guards and personal safety equipments.

Some welding operations needs high temperature exceeds 1000c.

Improper electricity system:Explained previously

ENVIRONMENTAL SAFETYFIRE

Preventative controls: Fixing fire call equipments (Alarms). Designing of vents to allow hot gases to

escapes. The implementation of the safety is the

responsibility of the all workers inside the facility.

ENVIRONMENTAL SAFETYFLOOR As shown in photos, waste materials and

scarp are accumulated in many places on the floor which inhibits better flow of materials and movement of workers.

Oil and some lubricants spread is everywhere existed on the floor, that may cause slipping for workers.

As a result, morale of working are decreasing for employers and employees, beside a bad appearance for the whole factory.

GIGO: Garbage In, Garbage Out.

ENVIRONMENTAL SAFETYFLOOR

ENVIRONMENTAL SAFETYFLOOR Control

Applying periodic maintenance to the floor (Cleaning periodically), by decreasing wastes by all of its kinds, and preventing oils from leakage to floor.

Designing containers for garbage and wastes of materials in all over the factory.

As a result, movement will be easier for workers and materials. In addition, giving a better appearance for the whole factory.

ENVIRONMENTAL SAFETY Illumination

Approximately, it was suitable for the whole work.

Nobody complained from the degree of lighting inside the factory.

The lighting system depends on electrical sources, and holes around the building.

There’s no important improvements in this point.

Recommended Levels of Illumination

Good contrast,fairly large

objects

Task Condition Illumination Level(Ft-C)

Normal detail,prolonged

periods

Large objects 2-5

Type of Taskor Area

Type ofIllumination

Overhead ceilinglights and desk

Sewing,inspecting

dark materials

Small detail;Extremeaccuracy

Recreationalfacilities

Reading, partsassembly, general

office work

Restaurants,stairways,

warehouses

Overhead ceilinglights

ENVIRONMENTAL SAFETY Illumination

ENVIRONMENTAL SAFETYVentilation

Ventilation is an important method for allowing hot gases and dusts to be escaped .

Number of vents weren’t enough in many places, and other places were without.

ENVIRONMENTAL SAFETYVentilation

ENVIRONMENTAL SAFETYVentilation Control

Vents should be located within each area or section of work.

As a result, workers morale will be increased by existed cleaned air .

THE GATE SYSTEM PROBLEMS

It moves vertically without inefficient stops ,which may causing falling over workers.

It has a heavy weight to open. Waste materials are accumulated near the

gate which inhibits a good movements and transportation.

Designing of location of the gate is not suitable, that it makes difficulty in entrance and outrace of lorries ( receiving and shipping operations).

THE GATE SYSTEM

Conclusion After visiting this factory, and taking notes,

discussing the current situation, then putting our mentioned ideas and details to improve the safety and maintenance affairs, which directly will improve the productivity and quality of production, beside decreasing costs.

Following our theoretical work in this project have to be applied practically to show the benefits of applying all of our mentioned ideas.

REFFENCES

1. ROGER BRAUER ”SAFETY AND HEALTH FOR ENGINEERS”,1994.

2. G. TOMILNSON ”INDUSTRIAL WORKSHOP PRACTICE “ 1984.

3. KEMPSTER “ WORKSHP TECHNOLOGY FOR TECHNICIANS” 1970.

4. NUNNALLY “ MANAGING CONSTRUCTION EQUIPMENT “ 1987.