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Machine Safety for Injection Molding Machines
OccupationalSafety and HealthAdministration
The Societyof the PlasticsIndustry, Inc.
A Presentation of the OSHA-SPI Alliance
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Course Objectives• Identify the types of injuries that can
occur while operating injection molding machines
• Describe the possible causes of these injuries
• Identify ways to safely operate injection molding machines
• Recognize the importance of a total safety and health approach
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Reasons to Focus on Injuries in the Injection Molding
Process
• High injury/illness rates
• OSHA citations
• National Emphasis Program
• Site-Specific Targeting
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Types of Injuries
• Fatalities
• Amputations
• Avulsions
• Fractures
• Cuts and bruises
• Sprains and strains
• Burns
• Electric shock
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Some Causes of Injuries
• Reaching around, under, over or through guards into hazardous areas
• Removing or bypassing guards
• Reaching into equipment to remove stuck parts
• Not using LOTO procedures
• Machine/equipment malfunctions
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Causes of Injuries (cont’d)
• Lack of recognition of hazards of the job
• Lack of familiarity with the equipment
• Inadequate training, comprehension, or both
• Operating machines with missing or inoperable guards and improper or inadequate machine maintenance
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Injection Molding Machinery
• Horizontal injection molding machine (HIMM)
• Vertical injection molding machine (VIMM)
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Vertical Injection Molding Machines - VIMMs
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
VIMMs
• Combinations of vertical and horizontal clamp and injection configurations of machines
• Regardless of the configuration of the machine, basic machine guarding and good safe work practices must be applied– Point of operation– Other moving machine parts
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
VIMMs: Unique Hazards and Issues
• Gravity
• Plastic splatter/missing insert
• Flying inserts
• Unexpected bystander interventions
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Horizontal Injection Molding Machines - HIMMs
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
HIMMs: Mechanical Hazards
• Point of operation
• Pinch points
• Nip points
• Rotating parts
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Potential Injuries from Mechanical Hazards
• Fatalities• Amputations• Avulsions• Crushing injuries• Fractures
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Safety Guards and Devices
• Types of guards and devices • Movable guards with interlocks• Fixed barrier guards• Presence-sensing devices
• Mechanical safety bars • Locations of guards
– Over moving equipment – Around electrical hazards– Around thermal hazards
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Operator’s Gate
• Equipped with redundant interlocks– Electrical– Hydraulic– Mechanical safety bar
• Allows the machine to operate only when the gate is closed
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Electrical Interlock
• Allows the electrical system to operate and close the clamp
• Actuated when the operator’s gate is opened or closed
• Prevents clamp from closing when the operator’s gate is open
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Hydraulic Interlock
• Actuated by opening or closing the operator’s gate
• Each hydraulic IMM requires at least one
• Prevents clamp from closing when the operator’s gate is open
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
• Prevents clamp from closing when the operator’s gate is open
• Must have at least one mechanical device on all IMM’s
Mechanical Safety Device
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Other Guarding
• Rear guard• Top guard• Parts discharge
guard• Feed opening guard
• Electrical system guards
• Purge guard• Injection barrel
cover
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Rear Guard
• Prevents clamp from closing when interlocked rear guard is opened
• Should have at least two interlocks
• Prevents access to mold areas
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Top Guard
• Required if operator can reach over the top of the machine and into hazardous areas
• Should be interlocked if movable
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Top Guards (cont’d)
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Parts Discharge Guard
• Keeps employees from reaching under operator’s gate and into the danger zone
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Purge Protection
• Covers the nozzle and purging area
• In combination with PPE, minimizes exposure to molten plastic during purging
• Window allows observation through purge guard, if equipped
• Should be equipped with an interlock
Purge guard
Safety window
Barrel cover
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Injection Barrel Cover
• Protects from exposure to high voltage and high temperatures
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
How to Protect Yourself
• Recognize the hazards in the job you are doing
• Understand the requirements for guarding machines
• Implement guarding solutions
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Virtual Safety Tour
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Emergency Stop
Know:
• Where it is located
• What it controls
• When to use it
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Signs and Warnings
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Colors used with Safety Signs have meaning!
DANGER
White Lettering/Red Background
WARNING
Black Lettering/Orange Background
CAUTIONBlack Lettering/Yellow
Background
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
High Voltage
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Rotating Screw
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
High Temperature
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
High Pressure
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Robots
• Used to automate repetitive or hazardous tasks
• Must be guarded to prevent workers from entering or reaching into hazardous areas
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
The Robot
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Our sincere thanks to:
• United Southern Industries, Inc.
• OSHA Region V
• The OSHA Training Institute
• OSHA’s Salt Lake Technical Center
• Paulson Training Programs, Inc.
• The Society of the Plastics Industry, Inc.
OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Questions?