HUM Safety and Environment. Equipment Safety Management

Transcription

1 HUM Safety and Environment Equipment Safety Management

2 HUM Equipment Safety Management Legislation Safety policy and action guidelines High level risk assessments Equipment safety procedure Isolation and lockoff Risk assessments Equipment Layout PUWER Equipment assessment Permit to work & Authority to run Documents and checklists Lifting equipment Gas welding Operation standards Abrasive wheels Noise Vibration Audits and tours Risk assessment Fire Design / CAPEX assessment Manual Handling

3 HUM Equipment Safety Management - Legislation Health and safety At Work etc Act 1974

4 HUM Equipment Safety Management Legislation Safety policy and action guidelines High level risk assessments Equipment safety procedure Isolation and lockoff Risk assessments Equipment Layout PUWER Equipment assessment Permit to work & Authority to run Procedures Lifting equipment Gas welding Operation standards Abrasive wheels Noise Vibration Audits and tours Risk assessment Fire Design / CAPEX assessment Manual Handling

5 HUM Equipment Safety Management - Policy SAFETY POLICY - STATEMENT HUM will ensure a healthy and safe working environment by incorporating safety into the daily work processes and equipment, and by achieving relevant legal compliance. All associates have a responsibility for their own health and safety and that of others, and must follow HUM s safe systems of work. THERE CAN BE NO PRODUCTION WITHOUT SAFETY Action Guidelines Equipment - HUM will ensure that all equipment is designed and installed for safe operation, achieves European and national safety standards, is assessed prior to use and is maintained to ensure continued safe operation.

6 HUM Equipment Safety Management Legislation Safety policy and action guidelines High level risk assessments Equipment safety procedure Isolation and lockoff Risk assessments Equipment Layout PUWER Equipment assessment Permit to work & Authority to run Procedures Lifting equipment Gas welding Operation standards Abrasive wheels Noise Vibration Audits and tours Risk assessment Fire Design / CAPEX assessment Manual Handling

7 HUM Equipment Safety Management High Level Risk assessment

8 HUM Equipment Safety Management Legislation Safety policy and action guidelines High level risk assessments Equipment safety procedure Isolation and lockoff Risk assessments Equipment Layout PUWER Equipment assessment Permit to work & Authority to run Procedures Lifting equipment Gas welding Operation standards Abrasive wheels Noise Vibration Audits and tours Risk assessment Fire Design / CAPEX assessment Manual Handling

9 HUM Equipment Safety Management Procedures

10 HUM Equipment Safety Management Legislation Safety policy and action guidelines High level risk assessments Equipment safety procedure Isolation and lockoff Risk assessments Equipment Layout PUWER Equipment assessment Permit to work & Authority to run Procedures Lifting equipment Gas welding Operation standards Abrasive wheels Noise Vibration Audits and tours Risk assessment Fire Design / CAPEX assessment Manual Handling

11 HUM Equipment Safety Management - Audits

12 HUM Equipment Safety Management Risk assessments

13 HUM Equipment Safety Management PUWER assessments Regulation 4 Regulation 5 Has a risk assessment been completed to select the most suitable equipment for the task? This must assess the risks to operators, maintenance personnel and others who work with the equipment. Has Honda know how and industry best practice guidance been used in the equipment design and specification? Are assessments for critical machine parts contained in the Technical File, are they fit for purpose? Is the durability of parts and materials suitable for the work situation foreseen? Have ergonomic considerations such as light operating controls and working height, reach and posture been included in the equipment design? Anything moved or clamped by hand should have suitable hand grips. Does the location and installation of the equipment minimise risks to the user and maintenance personnel? Is there sufficient access space? Have trap points around the equipment been eliminated? Can all chemicals or substances used or produced by the equipment be supplied or removed safely? Is there protection against oxygen deficiency in pits and confined spaces? If flammable atmospheres or wet and slippery conditions are present, does the design take this into account? Is there adequate ventilation in place to remove any fumes that maybe emitted. Is the work equipment maintained in efficient working order and in good repair. This is a visual health check of the process. Guards missing, items damaged / loose? Is there a register of the machine highlighting which areas require and who should maintain what part of the machine? (ie PS, Tooling, Die Maintenance, Production) Is there a maintenance log of the work carried out, who carried out the work, the date of the check and a list of problems found and countermeasures introduced with dates? Regulation 6 Regulation 7 Regulation 8 Regulation 9 Regulation 10 Are the maintenance schedules up to date. Does this demonstrate compliance to the agreed maintenance schedules? Is there a daily start-up check sheet for each of the processes and does it include checks on safety devices, (Electronic Guards, Extraction and Maintenance of PPE etc, where required) Has an electrical installation test certificate been issued including earth bonding and adequate guarding of live accessible contacts Have lightguard conformance certificates been issued including separation distances to BS EN 999? Is there a process map / register of the equipment in place highlighting area's of Specific Risk? Is access / use of these area's / processes limited to those maintenance, setting and users who have had suitable and sufficient training? Are operation standards available, include safety and environment care points and signed by the operators on each shift? Are there op standards for foreseeable abnormal situations? Are maintenance manuals, instructions and information readily available in English? Has operator and maintenance personnel training on equipment been completed and records kept? If the work equipment was first put into service after 31 st December 1992, is it CE marked and is the mark displayed? If the work equipment was first put into service after 31 st December 1992, is there a declaration of conformity or declaration of incorporation? (does it include LVD & EMC) Regulation 11 Regulation 12 Regulation 13 Regulation 14 Regulation 15 Have adequate measures been taken to prevent access to all dangerous parts and potential trap points of the work equipment / process? If guarding or doors to hazardous areas are opened for regular intervention are interlocks in place to prevent exposure to hazard? Are guards robust, durable and see through? It must be difficult to bypass or misuse the guards. Can guards only be removed by means of an interlock system or with the use of a tool. If the guards are unfastened, will they swing open or fall off? Are all guards situated at sufficient distances from the danger zone preventing such hazards as leaning / reaching over the top, hand entry through the guards etc. The guards should be positioned to prevent crushing risks inside the machine. Are all maintenance entry points protected by trapped key exchange interlock system which allows a key to be taken by the operator inside the machine to prevent persons being trapped inside? Have jigs, holders or push sticks been provided for use with machinery where it is not practicable to put fixed guarding. Is it constructed to allow work necessary for replacement parts and maintenance. Are guards capable of containing ejected parts from the process? Are there mechanical stops on linear motions to prevent overruns? Does the guarding system contain weld splatter? Is dust, gas or liquid created by the machine safely vented or contained? Are extreme hot or cold areas guarded and are suitable materials used in the construction? Is fireproof construction used in a flammable area? Is it possible to start work equipment only by deliberate action? Does this also apply to restart it after a stoppage? (ie following a failure the machine / line will not start automatically) Does this also apply for the control of a significant change in the operating conditions (speed, pressure, etc.), when it entails a hazard? Are the controls / control panel located in such away as to minimise the risk of accidental start ups or actions? Are control button labels and control screen instructions consistent with their resulting function? Is the work equipment fitted with a control to stop it in a safe condition and in a safe manner? (Further information on the categories of the stop function may be found in BS EN ) Is each workstation fitted with a control to stop some or all of the work equipment? Does the stop control take priority over any operating or start control? When the work equipment or the dangerous parts of it have stopped, is the energy supply of the actuators concerned depressurised, (EG Hydraulics, pneumatics or stored energy) Ensure this doesn't compromise safety ie suspended loads, grippers or breaking systems. Is an appropriate emergency stop fitted, is it in good condition? Does it latch? Does it stop the machine as expected in a controlled manner, affecting a rapid response including upstream and downstream machinery if appropriate? Description item Is there an E/Stop at each control point and at other appropriate locations to enable quick action (Number and location of mutiple E/Stops to be determined by risk assessment) After an emergency stop, has all motive power such as air pressure been removed? If the E/Stop circuit does not operate with redundancy, is there a system of work in place to control this risk? (Ie. Periodic operational check) If the E/Stop circuit is not completely hard wired, does it employ a Safety PLC? (Ie. Not standard PLC / Software) Are all controls clearly visible, identifiable and appropriately marked (ie. E/Stop - Red Button on yellow background Use details from BS EN as guidance)? Description item Suitability of work equipment Maintenance Description item Installation inspections Specific Risks and Restriction in Use Information and Instructions Training Conformity with Community Requirements Description item Dangerous parts of machinery High or low temperature Stop Controls Regulation 16 Emergency stop Regulation 17 Protection against specific hazards Can the controls be operated by an associate wearing gloves or other PPE? Are controls located outside danger zones? Are controls located in such a way that they do not expose the operator to any risk when used? If not reasonably practical for the operator at the control position to ensure there is no-one at risk, has a system of work been devised and used, if so is it working? (Ie. Audible / visual warnings) If regular entry is required which involves entry into or removal of, or opening of safe guards for maintenance are interlocks or similar devices in place. Is there an explanation or indication of how the control system works? Is there a drawing of the control system and list of components that form the control system? (Ie. E/Stop matrix, Control Matrix + Drawings etc) Does the component list reflect the actual components fitted? Does the control system work as described above? Is there a history of failure or reported faults? Does a failure of any part of the control system lead to a fail safe condition Does the control system respond to the input controls and operate in the particular manner expected from the input controls? If the control system has been modified, have the modifications been recorded and agreed? Have abuse tests been conducted and the results documented? When assessing new equipment, does the control system follow BS EN & BS EN ? Have the SIL levels been determined from BS EN (Most equipment at HUM will be SIL level 3) If in some modes the machine works with its protection devices neutralised, is auto operation disabled and slow speeds only permitted using hold to run controls? Following an interruption or re-establishment of power supply, will the machine remain at rest until deliberately restarted and will protection devices and control interlocks remain effective? Regulation 19 Isolation from sources of energy Is it possible to isolate the work equipment from all its energy sources? (eg. Pneumatics, Electricity, Steam) Are these means to isolate, clearly identifiable and readily accessible? Are these means to isolate, lockable? Description item Can energy sources be reconnected without causing risk to health or safety? Is the effectiveness of the isolation device checked / maintained? Can stored energy be safely dissipated or made safe by other means? Requirement Requirement met? applicable? Yes No Yes No Requirement Requirement met? applicable? Yes No Yes No Requirement Requirement met? applicable? Yes No Yes No Requirement Requirement met? applicable? Yes No Yes No Controls for starting or making a significant change in operating conditions Controls Description item Description item PUWER is an approximation of the WORK EQUIPMENT DIRECTIVE 89/655/EEC Amended by 95/63/EC and 2001/45/EC Requirement Requirement met? applicable? Yes No Yes No Regulation 18 Control Systems (Hydraulic, Pneumatic, Electrical etc.) If so answer the following: Is failure of the control system likely to put the operator or any other people, to any Health & Safety risk? Requirement Requirement met? applicable? Yes No Yes No Requirement Requirement met? applicable? Yes No Yes No Check method Comment Check method Comment Check method Comment Comment Check method Comment Check method Comment Check method Comment Check method ASSESSMENT of THE MINIMUM HEALTH AND SAFETY REQUIREMENTS as required by the Provision and Use of Work Equipment Regulations Lifting Operations and Lifting Equipment Regulations Pressure Systems Safety Regulations The Regulatory Reform (Fire Safety) Order Dangerous Substances and Explosive Atmospheres Regulations PUWER Group Assessment (Ref. - HS/D/P22/17FEB06) Work equipment : Description : Date assessment : Assessed by :

14 HUM Equipment Safety Management Design & CAPEX

15 HUM Equipment Safety Management Legislation Safety policy and action guidelines High level risk assessments Equipment safety procedure Isolation and lockoff Risk assessments Equipment Layout PUWER Equipment assessment Permit to work & Authority to run Procedures Lifting equipment Gas welding Low Accident Rate Minimal EL Abrasive claims wheels Legal Compliance Noise Vibration Operation standards Audits and tours Risk assessment Fire Design / CAPEX assessment Manual Handling

16 HUM Safety and Environment Equipment Safety Management Any Questions