Practical Machinery Safeguarding. Nigel Davy

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1 Practical Machinery Safeguarding Nigel Davy

2 Machinery Guarding Recognise machinery hazards Be aware of common machinery guarding issues Do this systematically Identify when improvements are required Select the appropriate safety devices Be aware of the standards Implement the correct management system for the equipment. Types of machine How the machines are used What to look for Machinery hazards PUWER & EHSR

3 Machinery Guarding Recognise machinery hazards Be aware of common machinery guarding issues Do this systematically Identify when improvements are required Select the appropriate safety devices Be aware of the standards Implement the correct management system for the equipment. What can go wrong Guarding arrangements Maintenance Effective interlock guards Effective fixed guards

4 Machinery Guarding Recognise machinery hazards Be aware of common machinery guarding issues Do this systematically Identify when improvements are required Select the appropriate safety devices Be aware of the standards Implement the correct management system for the equipment. Overview of legal requirements Supply Regs vs. PUWER Risk assessment BS EN Standards Taking into use

5 Machinery Guarding Recognise machinery hazards Be aware of common machinery guarding issues Do this systematically Identify when improvements are required Select the appropriate safety devices Be aware of the standards Implement the correct management system for the equipment. Machinery guarding What to look for Observation

6 Machinery Guarding Recognise machinery hazards Be aware of common machinery guarding issues Do this systematically Identify when improvements are required Select the appropriate safety devices Be aware of the standards Implement the correct management system for the equipment. Risk reduction Apply appropriate safeguards Make user aware of residual risks Design Safety distances Minimum gaps Guard types Guarding systems Potential guard failures Categories of safety control systems Controls & isolation

7 Machinery Guarding Recognise machinery hazards Be aware of common machinery guarding issues Do this systematically Identify when improvements are required Select the appropriate safety devices Be aware of the standards Implement the correct management system for the equipment. Machinery Directive EHSR PUWER requirements LOLER, PSR, EaW, Noise Standards A B C Specific standards Assessment Design Reach distances Control systems

8 Machinery Guarding Recognise machinery hazards Be aware of common machinery guarding issues Do this systematically Identify when improvements are required Select the appropriate safety devices Be aware of the standards Implement the correct management system for the equipment. Statutory inspection Electrical testing SSoW Normal production Other regular tasks Abnormal circumstances Isolation & lock off Training Pre start checks Inspections & audits Maintenance Tasks Safety devices

9 Tooling Conveyor Motor & drive

10 Tooling Conveyor Motor & drive

11 Tooling Conveyor Motor & drive

12 Tooling Conveyor Motor & drive

13 Outfeed reach in Infeed reach in Reach in & down End access Direct side access Outfeed conveyor nip Access from underneath Infeed conveyor nip

14 What type of interlock will be needed? How often will it be opened? Tooling Need for time delay? What is it protecting? What do we need from this guard? Conveyor Motor & drive What is it protecting? What do we need from this guard?

15 How do I start & stop it? Emergency stop & isolator! Where do the controls need to be? Who needs access to the controls? Outfeed reach in Infeed reach in Reach in & down End access Direct side access Outfeed conveyor nip Access from underneath Infeed conveyor nip

16 PUWER A few sneaky bits Specific Risks The way equipment is used, repaired, adjusted etc.

17 PUWER A few more sneaky bits Information and instructions Adequate health and safety information Written instructions if appropriate Same for supervisors & managers Information & instruction to include:- Conditions in which & methods by which it may be used Foreseeable abnormal situations and actions required Conclusions drawn from experience with the equipment

18 PUWER One more sneaky bit Regulation 22 Maintenance operations Maintenance operations involving a risk to health or safety to be carried out while equipment is shut down. If not:- Carried out without exposing the person to risk OR appropriate measures to be taken to protect the person THIS IS AN IMPORTANT REGULATION!

19 Machinery Guarding What can go wrong?

20 Machinery Guards A guard is not a guard when

21 A guard is not a guard when.. It is not fitted It has been removed It is too loose It is not fixed properly If fixed it can be removed by hand It is broken It has been defeated It has been modified incorrectly It is not properly maintained It is removed and the machine is running The interlock is defective The interlock is incorrectly adjusted Does not prevent contact Not the correct dimension It has been overridden

22 Maintenance Is it really guarded?

23 Flowrap Machine Is the guard effective? Could you touch the sealing jaws?

24 Machinery Guarding Issues

25 It s s all right Nigel! It s s Interlocked! Is the interlock effective?

26 Fixed Guards Is the guard effective?

27 A few general issues Blockages Reach In

28 Conveyors

29 Hazard/Danger Zone Any space within or around machinery in which a person can be exposed to a hazard. PUWER Reg.11 Danger Zone Any zone in or around machinery in which a person is exposed to risk from contact with a dangerous part of machinery or a rotating stock bar

30 Intended use of machine Use of a machine in accordance with the information provided by the manufacturer in the instructions for use

31 Routine production operation & All foreseeable abnormal situations

32 Reasonably foreseeable misuse Use of a machine in a way not intended by the designer, but which h may result from readily predictable human behaviour.? Standing on a machine to reach in?? Use of an interlocked door to stop a machine rather than walk to a switch panel?? Failure to isolate because isolation facilities are not readily y available?? Short cuts during cleaning and clearing blockages?

33 Hazard Identification Need to identify every hazard, this is a critical first step. If you have not identified the hazards you cannot control them. Must include all types of use, including:- Normal operation Cleaning Adjusting Maintaining Clearing blockages Setting up Dismantling & reassembly We often forget these!

34 Guarding

35 Machinery Guarding Practical Tips

36 Look underneath

37 Look at the sides

38 Look at the top

39 Look at the infeed and outfeed

40 Look at the motors & drives

41 Look at the controls Which buttons do I press to start and stop it?

42 Look at the Emergency Stop Switches

43 Look at the isolation facilities

44 Look at the conveyors

45 Look between the machines

46 Pop Out Rollers Do they pop out?

47 Look beside the machines

48 Look at the safety devices

49 Look at the access points

50 Look at the way we use the machine

51 Look at the abnormal uses of the machine

52 Abnormal Circumstances Cleaning Adjusting Clearing blockages Breakdowns Maintenance Observations Opening or removing guards

53 Loading and Adjusting

54 Cleaning or Clearing Blockages

55 Maintenance Activities

56 Observing

57 Practical Machinery Guarding A few tips!

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