机械安全操作金属加工行业培训

SAFEOPERATIONOFMACHINES

机械安全操作ATRAININGFORTHEMETALWORKINGINDUSTRY金属加工行业培训TableofContents目录Thefollowingtopicswillbecovered:以下话题包括：Introduction介绍Incidentsrelatedwithmachineoperation机械加工相关事故

MachineHazards机械隐患MachineSafety机械安全RiskManagement风险管理ControlMeasures控制措施SafePractices安全实践1.IntroductionThisslideispreparedfortheworkersinthemetalworkingindustryforabetterunderstandingofthehazardsassociatedwiththemachinesusedintheindustry.Hence,controlmeasuresandrisklevelscanbeassessedforeffectivecontrolofthehazards.Thehazardsidentifiedinthepresentationmaybeapplicabletootherindustries.2.IncidentHistoryIncidentsoccurreddueto:Lackofprotection(e.g.equipmentsafeguards);Notfollowingprocedures;Lackoftraining;Lackofmaintenance;Horseplay;andOthers2.IncidentHistoryTheseincidentscancause:Damagetothebody,e.g.cuts,crushingoflimb,etcInjuriesbyenergiesreleasedfromthemachine,e.g.electricalshock,burn,etcFatalities2.IncidentHistoryIncidentsassociatedwithmetalworkingindustry:Sprains,Strains860Fractures430Cuts,Punctures380Bruises230HeatBurns--ChemicalBurns--Amputations50TotalCases3400Source:SurveyofOccupationalInjuriesandIllnessesinCooperationwithParticipatingStateAgencies,BureauofLaborStatistics,U.S.DepartmentofLabor3.MachineHazards机械隐患Whenidentifyingthehazardsrelatedwithmachines,weshallconsider:当识别与机械相关的隐患时，我们考虑：typeofmachines机械类型layoutofmachines机械布局drivenmethod,e.g.electricity,air,etc驱动方法，例如电，空气等operatingparameters,e.g.speed,pressure,temperature,sizeofcut,mobility,etc.操作参数，例如，速度，压力，温度，切割尺寸，运动等materialstobeprocessedorhandledandmethodoffeed待加工或者处理的材料及进料方法3.MachineHazards机械隐患operatorpositionandcontrols操作者位置和控制accessforsettingadjustmentsandmaintenance设置调整和维护的入口environmentalfactors,e.g.dust,fumes,noise,temperature,humidityetc环境因素，例如灰尘，烟雾，噪音，温度和湿度等operatingrequirementsincludingwhattheoperatorneedstodo需要操作者做的操作要求3.MachineHazardsTypicalhazardsrelatedwithoperationofmachinesinclude:mechanical: e.g.crushing,shearing,cuttingorsevering, stabbingorpuncturehighpressurefluidejectionelectricalshocknoiseandvibrationcontactwithextremesoftemperatureergonomicsothers3.MachineHazardsLooseClothingUnguardedRotatingPartsofMachine3.MachineHazardsUnguardedRotatingPartsofMachine3.MachineHazardsUnguardedRotatingPartsofMachine3.MachineHazardsUnguardedRotatingPartsofMachinePictureSource:ConceptsandTechniquesofMachineSafeguarding,U.S.DepartmentofLabor,OSHA3067,1992(Revised)3.MachineHazardsUnguardedRotatingPartsofMachinePictureSource:ConceptsandTechniquesofMachineSafeguarding,U.S.DepartmentofLabor,OSHA3067,1992(Revised)4.MachineSafety4.1RiskassessmentformachineoperationStepsforriskassessment:Step1:IdentifythehazardsStep2:IdentifytheexistingcontrolsStep3:AssesstherisklevelbasedonthematrixStep4:IdentifytheneedforadditionalcontrolmeasuresStep5:AssigntheresponsiblepersonsReferto“RiskManagementforMetalworkingIndustry”andMOMRiskManagement:RiskAssessmentGuidelines”fordetailedriskmanagementdescription.Step1:IdentifythehazardsBreakdowntheactivitiesIdentifythehazardsandConsequenceofeachactivity(Section3)4.MachineSafety4.MachineSafetyStep2:Identifytheexistingcontrols4.MachineSafetyStep2:Identifytheexistingcontrolsanysafeguardsinplace?anywrittenprocedurestocontrolormitigatetherisk?whatarethePPEused?4.MachineSafetyStep3:AssesstheriskbasedonthematrixRiskLevel=Likelihood×Severity4.MachineSafetyLikelihoodDefinitionbyMOMLevelLikelihoodDescription1RareNotexpectedtooccurbutstillpossible.2RemoteNotlikelytooccurundernormalcircumstances.3OccasionalPossibleorknowntooccur.4FrequentCommonoccurrence.5AlmostCertainContinualorrepeatingexperience.4.MachineSafetySeverityDefinitionbyMOMLevelSeverityDescription5CatastrophicDeath,fataldiseasesormultiplemajorinjuries.4MajorSeriousinjuriesorlife-threateningoccupationaldiseases(includesamputations,majorfractures,multipleinjuries,occupationalcancers,acutepoisoning,disabilitiesanddeafness.3ModerateInjuryorill-healthrequiringmedicaltreatment(includeslacerations,burns,sprains,minorfractures,dermatitisandwork-relatedupperlimbdisorders)2MinorInjuryorill-healthrequiringfirst-aidonly(includesminorcutsandbruises,irritation,ill-healthwithtemporarydiscomfort)1NegligibleNegligibleinjury.4.MachineSafetyMOMRiskAssessmentMatrix:Rare(1)Remote(2)Occasional(3)Frequent(4)AlmostCertain(5)Catastrophic(A)MediumMediumHighHighHighMajor(B)MediumMediumMediumHighHighModerate(C)LowMediumMediumMediumHighMinor(D)LowMediumMediumMediumMediumNegligible(E)LowLowLowMediumMedium4.MachineSafetyRiskLevelRiskAcceptabilityRecommendedActionsLowAcceptableNoadditionalriskcontrolmeasuresmaybeneeded.Frequentreviewandmonitoringofhazardsarerequiredtoensurethattherisklevelassignedisaccurateanddoesnotincreaseovertime.MediumTolerableAcarefulevaluationofthehazardsshouldbecarriedouttoensurethattherisklevelisreducedtoaslowasreasonablypracticable(ALARP)withinadefinedtimeperiod.Interimriskcontrolmeasures,suchasadministrativecontrolsorPPE,maybeimplementedwhilelongertermmeasuresarebeingestablished.Managementattentionisrequired.HighNotAcceptableHighRisklevelmustbereducedtoatleastMediumRiskbeforeworkstarts.Thereshouldnotbeanyinterimriskcontrolmeasures.RiskcontrolmeasuresshouldnotbeoverlydependentonPPE.Ifpracticable,thehazardshouldbeeliminatedbeforeworkstarts.Managementreviewisrequiredbeforeworkstarts.4.MachineSafetyStep4:IdentifytheneedforadditionalcontrolWhatistherisklevelwiththeconsiderationofexistingcontrols?HighriskmustbereducedtoatleastmediumriskbeforestartupofworkWhethertherisklevelcanbefurtherreducedtoAsLowAsReasonablyPractical(ALARP)?4.MachineSafetyStep5:AssigntheresponsiblepersonResponsiblepersonshallbeassignedforeachidentifiedactivityTimeframefortheactivitycanalsobedecidedResponsiblepersonshallensuretheeffectiveclosureoftheactivity4.MachineSafetyHIERARCHYOFHAZARDSCONTROL4.MachineSafety4.2ControlMeasuresTypesofhazardscontrolmeasuresMachineguardingUsingdevices,e.g.sensor,gates,etcDistanceUseofautomaticorsemi-automaticfedandejection/robotsUseoffeedingtoolsTraining,Procedures(LOTO),etcPPE4.MachineSafetyTypesofmachineguardingFixedguardInterlockedguardAdjustableguardSelf-adjustingguard4.MachineSafetyMachineGuardFixedGuardofMachineSource:MachineGuarding,OSHAOfficeofTrainingandEducation4.MachineSafetyMachineGuardInterlockedguardonrevolvingdrumInterlockedGuardofMachineSource:MachineGuarding,OSHAOfficeofTrainingandEducation4.MachineSafetyMachineGuardBandsawbladeadjustableguardAdjustableGuardofMachineSource:MachineGuarding,OSHAOfficeofTrainingandEducation4.MachineSafetyMachineGuardCirculartablesawself-adjustingguardSelf-adjustingGuardSource:MachineGuarding,OSHAOfficeofTrainingandEducation4.MachineSafetyDevicesPullbackDeviceSource:MachineGuarding,OSHAOfficeofTrainingandEducation4.MachineSafetyDevicesSource:MachineGuarding,OSHAOfficeofTrainingandEducationRestraintDevice4.MachineSafetyDevicesTripwireCableSource:MachineGuarding,OSHAOfficeofTrainingandEducationSafetyTripwireCable4.MachineSafetyDevicesTwo-handControlSource:MachineGuarding,OSHAOfficeofTrainingandEducation4.MachineSafetyTwo-handControlTwo-handControlDevices4.MachineSafetyDevicesTwo-handControlTwo-handControl4.MachineSafetyDevicesGateOpenGateClosedSource:MachineGuarding,OSHAOfficeofTrainingandEducationGates4.MachineSafetyDevicesSensorPictureSource:ConceptsandTechniquesofMachineSafeguarding,U.S.DepartmentofLabor,OSHA3067,1992(Revised)4.MachineSafetyDevicesSensorPictureSource:ConceptsandTechniquesofMachineSafeguarding,U.S.DepartmentofLabor,OSHA3067,1992(Revised)4.MachineSafetySafeguardbyDistanceSource:MachineGuarding,OSHAOfficeofTrainingandEducation4.MachineSafetyAutomaticFeedRobotAutomaticFeedandRobotSource:MachineGuarding,OSHAOfficeofTrainingandEducation4.MachineSafetyProtectiveShieldSource:MachineGuarding,OSHAOfficeofTrainingandEducation4.MachineSafetyHoldingToolsSource:MachineGuarding,OSHAOfficeofTrainingandEducation4.MachineSafetyHoldingToolsSource:ConceptsandTechniquesofMachineSafeguarding4.MachineSafetyEmergencySwitchEmergencyswitchisprovidedwhenemergencystoppingofmachineisnecessary,andhence,theswitchshall:Beeasilyaccessibletotheoperator;andBedesignedforunexpectedactivationWhennecessary,buddysystemshallbeconsidered.4.MachineSafetyEmergencySwitchEmergencySwitchesforDifferentUsesPictureSource:4.MachineSafetyTwo-handControlEmergencySwitchDevices4.MachineSafetyPowerTrucksWhileusingpowertrucksformaterialtransportation,thefollowingcouldbeapplied:DonotblockthevisionNopassengersallowedWraptheloadfromfallingLimitthespeedConsiderdooraccesscontroltominimizetheimpacttopedestriansReferto“SafeOperationofForklift”fordetails.4.MachineSafetyLockout/TagoutProcedureLOTOisusedtocontroltheunexpectedreleaseofenergy:ElectricitySteamGasPhysicalLockout/Tagout4.MachineSafetyLockout/TagoutDevicesPhysicalLockout/TagoutPictureSource:/wiki/Lock_and_tag4.MachineSafetyLockout/TagoutDevicesPhysicalLockoutforCircuitBreakerPictureSource:.au4.MachineSafetyPhysicalLockout/TagoutDevicesPictureSource:.auLockout/TagoutDevices4.MachineSafetyLockout/Tagout(LOTO)ProcedureWhatmustbeincludedintheLOTOProcedure?Astatementonhowtousetheprocedures;Stepstoshutdown,isolate,block,andsecuremachines;Stepsdesignatingthesafeplacement,removal,andtransferofLOTOdevicesandidentifyingwhohasresponsibilityfortheLOTOdevices;andRequirementstodetermineandverifytheeffectivenessoflockoutdevices,tagoutdevices,andotherenergy-controlmeasures.4.MachineSafetyWhatmustworkersdobeforemaintenanceactivities?Prepareforshutdown;Shutdownthemachine;Disconnectorisolatethemachinefromtheenergysource(s);Applythelockoutortagoutdevice(s)totheenergy-isolatingdevice(s);Release,restrain,orrendersafeallpotentialhazardousstoredorresidualenergy.Regularlyinspecttoavoidre-accumulationofenergyifnecessary.Verifytheisolationandde-energizationofthemachine.Lockout/Tagout(LOTO)Procedure4.MachineSafetyWhatmustworkersdobeforeremovingLOTOdeviceandreenergizethemachine?Lockout/Tagout(LOTO)ProcedureStep1:Inspectmachinesortheircomponentstoassurethattheyareoperationallyintactandthatnonessentialitemsareremovedfromthearea;andStep2:Checktoassurethateveryoneispositionedsafelyandawayfrommachines.4.MachineSafetyWhatarethelimitationsfortagoutdevices?Lockout/Tagout(LOTO)ProcedureAtagoutdeviceisaprominentwarningofthehazards;Tagsdonotprovidethephysicalrestraintofalock;Tagsmayevokeafalsesenseofsecurity;Therefore,lockoutdevicesisconsideredmoresecureandmoreeffectivethantagoutdevicesinprotectingemployeesfromhazardousenergy.4.MachineSafetyTrainingBeforeusinganymachine,youshould:Betrainedbyqualifiedperson/agentClarifyanydoubtonmachineusageHavethecorrectcertificate,ifrequiredbylawInspectthemachineforgoodcondition(orinspectedbyqualifiedpersons)Donotoperatemachineunlessauthorized4.MachineSafetyPPEBeforeusinganymachine,youshouldensurethat:ProperPPEisusedtoconducttheworkThePPEisingoodconditionPropertraininghasbeengivenonhowtousePPE4.MachineSafetyErgonomicsSomebasictipstoimproveergonomics:UseequipmenttoaidmaterialhandlingUsecorrectmaterialhandlingpositionMaintaincomfortablepositionwhenworkingDotheworkwithpropertoolsRefertoMaterialHandlingforMetalworkingIndustryformoredetailsaboutergonomichazardcontrol.4.MachineSafetySource:ErgonomicsGuidelinesforManualMaterialHandling,CDC,NIOSHErgonomics4.MachineSafetyErgonomicsSource:ErgonomicsGuidelinesforManualMaterialHandling,CDC,NIOSH4.MachineSafetyUseToolswithBetterGripSource:EasyErgonomics:AGuidetoSelectingNon-PoweredHandTools,CDC,NIOSHErgonomics4.MachineSafetySelecttheCorrectToolfortheJobSource:EasyErgonomics:AGuidetoSelectingNon-PoweredHandTools,CDC,NIOSHErgonomics4.MachineSafetyAdopttheCorrectPostureSource:EasyErgonomics:AGuidetoSelectingNon-PoweredHandTools,CDC,NIOSHErgonomics4.MachineSafetySelecttheCorrectToolSource:EasyErgonomics:AGuidetoSelectingNon-PoweredHandTools,CDC,NIOSHErgonomics4.MachineSafetySafePracticesThefollowingpracticesshallbeobservedatalltimes:Alwaysusethesafetyd