Safety in Manufacturing

8/12/2019 Safety in Manufacturing

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GITAM UNIVERSITY

In Association With

Indian Institute of Safety Management

Safety in Manufacturing

By

Lynel. SExecutive Director, IISM


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IGC 2ELEMENT 4

Work Equipment

Hazards and Risk controls


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Types of Work Equipment:

Hand Tools

Power tools

Machinery

Work Equipment

Hazards and Risk controls


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Work Equipment

Hand held Tools:


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Work Equipment

Hand held Non-powered ToolsHazards:

Broken/Split handles

Incorrect use of saws and chisels

Splayed spanners

Chipped or loose hammer heads

Incorrectly sharpened or blunt chisels

Dull tools

Damaged saw blades Use of pipes or similar equipments as extension handles

Mushroom headed chisels


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Work Equipment

Hand held Non-powered ToolsControl Measures:

Tools made of suitable quality materials

Use correct tools for the job

Prior inspection before every use

Do not use screw driver as chisel

Do not use flat screw driver to remove Phillips screw

Do not use the damaged tools

Discarding or prompt repair of defective tools Use of alloy or bronze hammers to prevent sparks

Proper maintenance and storage

PPE

Information, Instruction, Training and supervision


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Work Equipment

Hand held Powered Tools:


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Work Equipment

Safe use of Hand held Powered Tools:

Do not carry tool by cord

Never pull the cord to disconnect

Keep cord away from heat

Disconnect when not in use

Keep observers at safe distance

Secure work with clamps

Avoid accidental starting

Use RCDs on electrical tools

Maintain good footing and balance

Wear appropriate PPE

Inspect and maintain tools

Report defects and remove faulty tools


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Work Equipment

Mechanical Hazards: Entanglement - Machinery which grips loose clothing,

hair or working material such as emery paper.

Trapping/Drawing InTrap between running gear wheelsor rollers or between belts and pulley drives

ShearingShears part of the body typically hands or

fingers between moving and fixed parts of the machine or

between two moving parts

CrushingTrapped between moving part of a machine

and fixed structure such as wall or any material in a

machine


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Work Equipment

Mechanical Hazards:

ImpactA Moving object/part directly strikes a person

PunctureThrough ejection of particles from a machine orsharp operating component forced to the skin

Friction/AbrasionContact with grinding wheels or

sanding machines

CuttingContact with cutting edge such as saw or

rotating disc

EjectionHigh pressure fluid leakage from hydraulic

system


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Work Equipment

Trapping/Drawing In:


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Work Equipment

Shearing:


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Work Equipment

Crushing:


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Work Equipment

Impact:


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Work Equipment

Stabbing/Puncture:


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Work Equipment

Friction/Abrasion:


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Work Equipment

Cutting/Severing:


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Work Equipment

Ejection:


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Work Equipment

Non-Mechanical Hazards:

Noise

Vibration

Electricity

ThermalHigh & Low temperatures

Radiation

Pressure & vacuum

Dust and fumes Fire and Explosion

Biological

Chemical

Ergonomics, Manual Handling .etc


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Work Equipment

Methods of ProtectionGuards:

Fixed guards

Interlock guards

Automatic guards

Trip devices

Adjustable and self adjustable guards

TwoHand Control Devices


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Work Equipment

Fixed Guards:

A machine guard that is attached to the machine

with screws or other devices that require a tool for

removal.


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Work Equipment

Interlock Guards:

A guard that shuts off or disengages the power whenever it is

opened or pushed out of position.


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Work Equipment

Automatic Guards:

A guard which operates as the machine goes through its

cycle.


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Work Equipment

Trip Devices:

A type of sensing device that uses a trigger mechanism to

disengage the machine when the operator accidentally or

purposefully presses a bar, a wire, or another type of switch.


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Work Equipment

Adjustable and Selfadjustable guards:

A guard that may be moved or reconfigured to allow for

different types of production, such as different sizes of stock

or raw materials.


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Work Equipment

TwoHand Control Devices:

A machine start mechanism that requires simultaneous

pressure on two separate controls to activate the machine or

machine cycle


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Work Equipment

Other Methods - Safeguarding Devices

Protection Appliances

Emergency stop controls

PPE

Information, Instruction, Training and Supervision


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Work Equipment

Protection Appliances:

Jigs, Holders and push sticks are few of the protection

appliances help to keep the operators hands at a safe

distance from the danger area.


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Work Equipment

Emergency stop controls:

Rapid response to potentially dangerous situations


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Work Equipment

Machinery maintenance Hazards:

Working whilst motion

Unintentional starting of machinery

Dust, fumes, Vapour, gases and smoke Residues E.g. Toxic, flammables, corrosive

Poor lighting

Ergonomics

Extreme temperature

Chemical Hazards

Biological Hazards

Stored energy

Residual high or low pressure


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Work Equipment

Machinery maintenance Hazards:

Movement due to gravity

Hazardous atmosphere

Restricted access and egress Unauthorized entry

Incompetent person

Person unaware about danger

Lack of warning signs and barriers

Mechanical & Non Mechanical Hazards


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Work Equipment

Machinery maintenance Control Measures:

IsolationMechanical and Electrical

Allow hot machinery to cool

Ventilate work area Provide adequate lighting

Means of access and egress

Provide appropriate barriers

Release stored energy

Release residual pressure

Plan safe system of work

Ensure safe working environment

Competent person


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Biological & Chemical

Health Hazards and Risk control


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Biological

Forms of Biological Agents:

Bacteria

Viruses

Fungi


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Biological

Diseases caused by Biological Agents:

Rabiesby bite of a Wild infected Animal

Anthrax - disease caused by the bacteria found in animals

Legionnaires disease - a type of pneumonia or lunginfection

Weils disease - fatal infection transmitted through urine frominfected rats (due to Leptospira bacteria)

Hepatitis - Inflation of Liver caused by virus

AIDS
http://www.nhsdirect.nhs.uk/glossary/http://www.nhsdirect.nhs.uk/glossary/


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Biological Hazards

Biological Hazards Control Measure:

Cleaning and Disinfecting

Water treatment programmes

Vermin control - (pest control)

Personal hygiene

Immunisation

Health surveillance

Specific training Appropriate PPE/RPE


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Chemical Hazards

Forms of Chemical Agents and Routes of Entry:

Gases

Vapour

Mists

Aerosols

Smoke

Fumes

Dusts Liquids

Solids

Routes of Entry:

Inhalation

Ingestion

Absorption

Injection


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Chemical Hazards

Chemical Hazards:

Skin ContactIrritation, Dermatitis, Burns

Damage to Organs or SystemInhalation

Ingestion

Skin Contact

Acute or Chronic Effect

Fire and Explosion

Environmental Issues


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Chemical HazardsControl Measures

Labeling

MSDS

Safe Storage

Safe Use


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LEVLocal Exhaust Ventilation: (Workplace Control)

Discharge to atmosphere

Hood Ducting Filter Fan



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Provide IITS

(Information, Instruction, Training & supervision)

Provide PPE / RPE

Health surveillance and Vaccination

Responsible Disposal of waste



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Long term exposure limit (LTEL):

This is an amount timeweighted average, you can safely

breath, based on an eight-hourday over a period of 5 days.

Short term exposure limit (STEL):

This is an amount maximum average, you can safely be

exposed to 15 minute period.



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Electrical Safety


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Electrical Hazards:

Electrical Burns

Electrical Shock

Arcing

Fire of electrical origin

Explosion of electrical origin

Secondary Effects

Remember B SAFE with Electricity

Electrical Safety


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Electrical Safety

Factors affecting the severity of harm:

o Voltage and current

o Route taken through the body

o Length of contact timeo Health & age of the person

Size of current passing through the body depends on:

Dryness of the skin, Natural body resistance,

Ground conditions, & Type of footwear.

The frequency


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Effects of electricity on human body:

Muscular Contraction

Tissue burns at entry and exit

FibrillationIrregular heart beat

Cardiac arrest

Respiratory paralysisAsphyxiation

Physical trauma

Electrical Safety


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Electrical Fire: Causes

Overloading

Incorrect fuses

Poor insulation and wiring

Loose connections

Misuse of equipments

Unsuitable equipment

Inadequate maintenance

Use of defective equipments

Overheating of cables and electrical junctions

Overheating due to thermal insulation and lack of ventilation

Flammable material too close to electrical equipments

Flammable atmosphere

Electrical Safety


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Secondary Effects of Electricity:

Fall from height

Sudden movement of body- Throw off

Dislocation and amputation

Impact with surrounding objects

Unintentional movement of machinery

Failure of control measures and security systems

Loss of information and properties Loss of reputation

Electrical Safety


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Isolation:

Shutting off the electricity supply

Ensure that it cannot be reenergised by applying some

form of lock (Lock out or tag out) Effectiveness of isolationPTW system

Should be clearly labelled

Electrical Safety


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Earthing:

Electricity will always try to reach earth and earthing means

providing a low resistance path to earth

Specialist testing and maintenance Professional installation

Electrical Safety


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Fuse:

A specially designed weak link which is designed to melt at a

predetermined value of current

Protects equipment Will not protect individuals

Easy to override

Unsuitable or wrong fuse may be used

Electrical Safety


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Circuit Breakers:

Electromagnetic devices which perform the same function as

fuses but operate faster

Automatically switch or trip under fault conditions Does not protect the individual

Electrical Safety


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Residual Current Devices(RCD/ELCB):

Compares the electricity flow to the equipment with the return

flow and if a difference is detected the equipment is isolated

Very sensitive2 mA Very fast2 ms

Rapid and sensitive

Easy to use, test and reset

Cannot be reset with a fault on the circuit

Mechanical device which could fail

Only protects against earth leakage faults

Electrical Safety


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Reduced Voltage System:

Reducing voltage by step down transformer - 110volts or 55

volts - Centre tap to earth 55 volts shock

Reduce the effect of electric shock

Colour coded yellow for 110V and Blue for 240V

Special equipment required for 110 V

Electrical Safety


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Double Insulation:

Two separate layers of insulation are provided which allows

for fault detection where one layer has failed the other stillprovides protection

Not normally used with earth

Physical damage may failed to protect

Electrical Safety


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Portable Electrical EquipmentConditions and

practice leads to accidents:

Using unsuitable apparatus

Inadequate maintenance or misuse

Using defective apparatus

Modifications by unauthorised personnel

Modifications whilst the appliance is live

Using equipment in unsuitable environments No system of inspection

No removal of damaged equipment

Electrical Safety


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Copyright NIST Institute Private Limited - v.1.0 , May11

Fire Safety

FIRE: Is a chemical Chain reaction, in which Oxygencombines with heat in the presence of required heat.

Fire TriangleGraphical representation of elements(Oxygen,

Heat and Fuel) are combined together.

Smothering Cooling

Starving


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Sources of Ignition

Naked flames

Electricity (Overheating/Arcing)

Smoking materials

Hot work (Welding, burning)

Chemical reactions (Giving off heat)

Heating appliances (Hot surfaces)

Friction (Inadequate lubrication) Static electricity

Lightning

Unsafe use and handling of flammable liquids, gases and

materials

Fire Safety


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Classification of Fires

Class A: Combustible solidse.g. Paper, Wood and Plastics

Class B: Flammable liquids & liquefied solidse.g. Oil,Grease

Class C: Flammable gasese.g. Propane, H2S

Class D: Flammable metalse.g. sodium, magnesium

Class F or K: C cooking mediae.g. Cooking oils and fats

Fire involving energized electrical equipment

Fire Safety


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Method of Heat Transfer

Conduction

Convection

Radiation

Direct Burning

Fire Safety


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Common causes of fire

Smokers materials

Faulty or misused electrical equipments

DeliberateArson

Loss of control burning rubbish

Heating Equipments

Hot workWelding, Cutting etc.,

Mechanical HeatingFriction Unsafe use of flammable liquids and gases

Unsafe storage of flammable materials

Fire Safety


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Fire Safety


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Fire Safety


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Fire Prevention

Design and maintenance of electrical equipments

Lubrication of machinery to prevent friction

Control of portable heaters

Control of ignition sources

Control of smoking

Control of oxygen

Control of hot work

Eliminate or reduce the storage of flammable materials

Site security

Good Housekeeping


Fire Safety


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Fire Protection

Compartmentation - Splitting a building into separate sealed

areas made of fire-resisting materials

Restricts the spread of fire and smoke within a building

Structural fire protectionMain fabric of building and internal

partition

Thermal upgradesBricks, Concrete and structural steels

Fire stopping, cavity barriers and fire doors

Fire Safety


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Fire Precaution

Means of detection and warningFire/Flame/Smoke

detectors and fire alarms

Means of escape

Means of fighting the fire

Emergency evacuation procedures


Fire Safety


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Means of detecting fire

Smoke detection

Flame detection

Flammable gas detection Heat detection

Fire Safety


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Fire Safety


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Means of Fire Alarms

An audible means of sounding the alarmShouting, Gongs,

Bells, etc.,

Break glass manual call points on exit routes and adjacent tothe final exit

Automatic systems

Continuous detection alarm sounding

Fire Safety


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Types of extinguishers

Water

Foam

Dry powder Carbon dioxide

Wet Chemical foam

Fire Safety


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Types of extinguishers - Water

Colour code

Fire classA

MethodRemove Heat

ActionCool the fuel and surroundings

Fire Safety


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Types of extinguishers - Foam

Colour code

Fire classB & A

MethodBlanketting

ActionBarrier between the fuel and oxygen

Fire Safety


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Types of extinguishersDry powder

Colour code

Fire classA, B, C & E

MethodRemove oxygen

ActionFunctions by reacting chemically with constituents offire

Fire Safety


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Types of extinguishersCarbon dioxide

Colour code

Fire classB & E

MethodRemove oxygen

Action Cools and excludes oxygen

Black

Fire Safety


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Types of extinguishersWet chemical foam

Colour code

Fire classF or K

MethodRemove oxygen

ActionCools and excludes oxygen

Fire Safety


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Fixed Installations

Fire hose reels

Sprinkler systems

Flood systems

Fire Safety


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Fire Safety


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Fire Safety


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Siting of extinguishers

According to the specification of fire certificate / Fire Plan

30m max travel distance

Minimum of 1 extinguisher per 200 Sq. m.

Noticeable and accessibleHandle not over 1.1m above floor

In corridors, inside door ways or at a point of specific use

Suitable type

Protection against damage and weather

Fire Safety


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Fire Safety


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Maintenance of Fire Arrangements

Fire extinguishers

Escape routes

Emergency lighting Fire detection equipments and alarms

Daily checks

Weekly Inspection

Annually serviced by third party

Five yearly extended service/discharge

Twenty yearly replacement

Evacuation procedures and maintenance of records

Fire Safety


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Emergency Evacuation Procedure

Means of raising the alarm

Close all windows and doors

Leave the building by the nearest available exit and report tothe assembly point

Contacting the emergency services

Fire evacuation routes

Fire evacuation signs

Who are and the role of fire marshals

Assembly points/place of safety/roll call When not to tackle a fire

Do not attempt to fight a major fire

Do not take risks

D t t t ll t l b l i

Fire Safety

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