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MAINTENANCE OF MACHINERY, GUARDS AND
EQUIPMENT
Safety and Health Officer Certificate Programme
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Session/LessonPlansTiming (minutes) Learning Objective Main tasks / Process Resources / tools
5 Title Standard Operating Procedures for Power Press Machine Slide 1
5 Index Contents of the presentation Slide 2
15 Introduction
The main purpose of guideline
Limitation
How to use the guideline
Slide 3, 4and 5
10 Slide 6-15
10 Slide 16 - 25
BREAK (30 MIN)
45 Slide 26 - 35
10 Slide 36 - 49
10 Slide 50 - 48
BREAK (LUNCH)
20 Slide 49 +
Video duration (15 min)10 Slide 50
15 Slide 51
30 Slide 52
BREAK (30 MIN)
120
Total Time
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OBJECTIVES
• State the definition of maintenance
• List 3 maintenance requirements
• Explain 4 types of maintenance
• List 4 hazards during maintenance activities
• List 12 safety measures related to maintenance works
• List 6 factors that influence the frequency of maintenance
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SCOPE
• Definition• Necessity for maintenance• Types of maintenance• Selection and frequency• Common accidents during maintenance works• Safety measures• Conclusion
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DEFINITION
MAINTENANCE
“Work that is carried out to ensure plant* remains at acceptable standards”
* plant – as defined in the Occupational Safety and Health Act 1994
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NECESSITY FOR MAINTENANCE
• To ensure smooth-running of plant operations
• To ensure safety of plant operations
• To minimize the possibility of injury or harm
• To increase workplace cleanliness for safety purposes
• To demonstrate compliance with safety regulations
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TYPES OF MAINTENANCE
• Preventive Maintenance
• Statutory Preventive Maintenance
• Breakdown Maintenance
• Online Maintenance
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PREVENTIVE MAINTENANCE
• Conduct maintenance regularly according to already set schedules
• Replace and restore faulty equipment according to schedule
• Keep maintenance and repair records
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PREVENTIVE MAINTENANCE
Conducted to prevent faulty equipment or equipment failures that may result in:
• Work disruption
• Accidents
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STATUTORY PREVENTIVE MAINTENANCE
• Conducted in compliance with provisions of the Factories and Machinery Act 1967 (required by the regulations)
• Machinery inspection as per FMA 1967 provisions
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STATUTORY PREVENTIVE MAINTENANCE
Types of Machinery:• Steam generating machinery• Boilers, autoclaves, steam generators• Pressure vessels• Lifting machinery• Lifts, cranes and machinery that requires
certification of fitness• Prime movers
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METHODS OF STATUTORY PREVENTIVE MAINTENANCE
As per regulatory requirements, such as:
• Keeping maintenance records
• Appointing registered firms (lifts, boilers, cranes)
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BREAKDOWN MAINTENANCE
Conducted when machinery encounters a problem or is damaged, and is unable to operate.
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BREAKDOWN MAINTENANCE
Why?
• Fulfill / address company policy• Reduces cost (rather than buy a new one)• Machinery does not have to be regularly
stopped (only when needed)• Allows the option of repairing or
disposing of the machinery
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ONLINE MAINTENANCE
Conducted while machine is in operations
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ONLINE MAINTENANCE
Why?Not practical to stop machine operationsSome maintenance works/processesrequires machine to be in operations forthe purpose of:•Cleaning•Repair works•Coordination•Trouble shooting
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SELECTION OF METHOD
The selection of which maintenance method to adopt is dependent on the:
•Type of process
•Type of machinery
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FREQUENCY OF MAINTENANCE
Frequency is dependent on:
• Age of machinery• Machinery damage records• Conditions of the machine operations• Manufacturer instruction/suggestion/ recommendation• Statutory requirements• Company policyThe frequency and nature of maintenance should be determined through risk assessment, taking full account of: the manufacturer's recommendations
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FREQUENCY OF MAINTENANCE
Also the frequency and nature of maintenance should be determined through risk assessment, taking full account of:
• the manufacturer's recommendations• the intensity of use • operating environment (eg the effect of temperature,
corrosion, weathering)• user knowledge and experience • the risk to health and safety from any foreseeable
failure or malfunction
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COMMON ACCIDENTS DURING MAINTENANCE
Exposure to hazardous materials including chemical substances
Contact with moving elements/ materials/parts
Falls• from same level• from higher level
Crushed by falling object
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MAINTENANCE SAFETY
Measures to be Taken
• Safety training for relevant workers and personnel
• Formulate safe work procedures• Implement safe system of work• Supervision of work to be undertaken• Formulate rules and guidelines for
maintenance works
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MAINTENANCE SAFETY
Measures to be taken (Cont.)
• Implement permit to work system• Implement proper worker selection• Use of safety signages• Provide uniforms and appropriate PPE• Use of suitable tools/equipment
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WHO CAN UNDERTAKE MAINTENANCE WORK
Maintenance work should only be undertaken by those who:
• are competent to do the work• have been provided with sufficient information,
instruction and training• in some cases, may be best undertaken by the
manufacturer or specialist contractors• but, in many cases, maintenance can be done in-
house by suitably trained, competent staff
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CONCLUSION
• The purpose of maintenance is to: Ensure smooth-running and safety of plant, workplace
and equipment operations Prevent accidents with improved workplace cleanliness
and housekeeping
• There are four types of maintenance methods that may be adopted.
• Selection of method is based on the machinery, equipment or process used in operations
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Complete the puzzle
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Down2. uniform and scheduled maintenance
4. maintenance to a machine in operation
5. regulatory maintenance with certificate of fitness
7. required for maintenance staff
9. required during maintenance work
10. maintenance machine depends on its ________
12. certicate of fitness for unfired pressure vessels
14. CF for Boilers
Across1. the last hierarchy of control measures
3. Is it a problem ? Fix it
6. right ____ for the job
8. PPE for dust
11. maintenance records
13. measures during maintenance
15. hazard during maintenance
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3/8/2016 Copyright@NIOSH 2005
REFERENCE
• http://ehs.research.uiowa.edu/machine-and-equipment-guarding-procedures
• https://www.osha.gov/SLTC/etools/machineguarding/additional_considerations.html