machine guarding for plastic sheet and roll stock extrusion osha 10-hour outreach training program...
TRANSCRIPT
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Machine Guarding
for Plastic Sheet and Roll Stock Extrusion
OSHA 10-Hour Outreach Training Program for the
Plastics Processing Industry
A Presentation of the SPI-OSHA Alliance
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Course Objectives
• Identify the types of injuries that can occur while operating plastics sheet and roll stock extrusion equipment
• Describe the possible causes of these injuries
• Identify ways to safely operate plastic extrusion equipment
• Recognize the importance of a total safety and health approach
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Reasons to Focus on Injuries in the Extrusion Process
• High injury/illness rates
• OSHA citations
• National Emphasis Program on Amputations
• Site-Specific Targeting
• High workers compensation costs
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Types of Injuries
• Fatalities
• Amputations
• Avulsions
• Fractures
• Burns
• Cuts and bruises
• Sprains and strains
• Electric shock
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Some Causes of Injuries
• Reaching around, under, over or through guards into hazardous areas
• Removing or bypassing guards
• Inadequate temperature monitoring during cleanup
• Not using LOTO procedures
• Machine/equipment malfunctions
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Causes of Injuries (cont’d)
• Lack of recognition of hazards of the job
• Lack of familiarity with the equipment
• Inadequate training, comprehension, or both
• Operating machines with missing or inoperable guards and improper or inadequate machine maintenance
• Lack of proper PPE
• Loose clothing around winding equipment
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Schematic of Extruder
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Schematic of Extrusion Process
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Risk Areas
• Feed Tubes
• Roll Stack
• Trim Knives
• Pull/Nip Rolls
• Shear
• Winder
• Grinder
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Feed Tubes
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Accident #1Third-Degree Skin Burns
• Two employees were cleaning the feed pipe for a line extruder
• Resin in the feed pipe hardened during shutdown
• Employee heated the feed pipe to soften the plastic for 30 minutes
• The employee pulled plastic plug at bottom of feed pipe
• Hot plastic sprayed out causing 2nd & 3rd degree burns
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Roll Stack
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Accident # 2Fatality
• Machine operator was threading plastic film through rolls of film extruder line when he got caught between top and bottom rolls
• Skull fracture and head trauma resulted in his death
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Trim Knives
trim knife pivoting blade guard
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Trim Knives
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Trim Knives
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Trim Knife Guarding
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Trim Knife Blade Disposal
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Pull-Roll Nips
Emergency stop pull cord
Sturdy metal mesh in guard
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Shear
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Shear
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Winder
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Accident #3Fatality
Employee was splicing plastic on new extruder winder rolls to get it started
– drawstring on hooded sweatshirt got caught in roll
– employee died by asphyxia
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Grinder Guarding
Guarding by:
•Enclosure over moving components
•Anti-kickback flaps in feed throat
•Proximity guarding – distance from feed chute to rotating knives
Proximity
Guarding
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Abrasive Wheel MachineryWork rests on offhand grinding machines must be kept adjusted closely to the wheel with a maximum opening of 1/8-inch to prevent the work piece or tool from being jammed between the wheel and the rest, which may result in wheel breakage or wheel explosion.
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Abrasive Wheel Machinery
The distance between the wheel periphery and the adjustable tongue must never exceed 1/4-inch.
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Power-Transmission Apparatus
Power-transmission apparatus (shafting, flywheels, pulleys, belts, chain drives, etc.) less than 7 feet from the floor or working platform must be guarded.
Unguarded beltand pulley
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Safety Guards and Devices
• Types of guards and devices– Movable guards with interlocks– Fixed barrier or proximity guards– Presence-sensing device
• Locations of guards– Over/around moving equipment– Around electrical hazards– Around thermal hazards– Around cut hazards
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Movable Guards with Interlocks
• Allows the electrical system to operate
• Actuated when the interlocked guard is closed or opened
• Prevents machine from operating when the guard is open Electrical Interlock Switch
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Interlocked Guard
Electrical interlock switch
Emergency stop pull cable
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Electrical Interlock Operation
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Fixed Barrier Guards
• Prevent contact with the hazard
Yellow fixed guard
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Fixed Barrier Guards
Guard over moving machine components
Wing guards
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Fixed Barrier Guards
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Presence Sensing Devices
• Safety mat
• Light curtain
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Presence Sensing Devices
Safety Mat
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Safety Guards and Devices
Light Curtain
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How to Protect Yourself
• Recognize the hazards in the job you are doing
• Understand the requirements for guarding machines
• Implement guarding solutions
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Emergency Stop Button
Know:
• Where they are located
• What they control
• When to use them
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Emergency Stop Cable
• Know:
– Where they are located
– What they control
– When to use them
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Signs and Warnings
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Colors used with Safety Signs have meaning!
DANGER
White Lettering/Red Background
WARNING
Black Lettering/Orange Background
CAUTIONBlack Lettering/Yellow
Background
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High Voltage
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Rotating Screw
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High Temperature
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High Pressure
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Crushing Fingers
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Amputated Fingers
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References for Extrusion Safety
•ANSI B11.TR3-2000 Risk Assessment and Risk Reduction - A Guide to Estimate, Evaluate and Reduce Risks Associated with Machine Tools
•ANSI B11.19-2003 Performance Criteria for Safeguarding
•ANSI/SPI B151.7-1996 Plastics Machinery - Plastics Extrusion Machines - Requirements for the Manufacture, Care and Use
•ANSI/SPI B151.5-2000 Plastic Film and Sheet Winding Machinery - Manufacture, Care, and Use
•ANSI/SPI B151.20-1999 Plastic Sheet Production Machinery - Manufacture, Care and Use
•ANSI Standards are available at the following web site: www.ansi.org
•SPI Guide to Extruded Plastic Sheet Products, www.plasticsheet.org/Guide/index.htm
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OSHA's Site-Specific Targeting (SST) Program
OSHA's Site-Specific Targeting (SST) program selects for inspection individual worksites with the nation's highest Days Away from Work Injury and Illness (DAFWII) Case Rate and Days Away, Restricted, or Transferred (DART) Rates. It is based on data reported by more than 80,000 employers surveyed by the agency.
See the OSHA Web site for the most current directive and the rates used to target inspections.
In order to verify the reliability of claims by establishments thatthey have achieved low DART rates, OSHA inspects a certain percentage of employers with low rates.
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OSHA National Emphasis Program on Amputations
On October 27, 2006, the Occupational Safety and Health Administration (OSHA) revised its national emphasis program aimed at reducing amputations in general industry workplaces. The National Emphasis Program on Amputations targets all types of machinery and equipment that are considered a high risk for causing amputations. The plastics processing industry is among the industries under scrutiny for workplace amputations.
The twenty-four states and two territories which operate their own OSHA programs are encouraged, but not required, to adopt a similar emphasis program. State Plan State information is available on OSHA’s Web site. The OSHA directive on this emphasis program is available on OSHA's Web site under Regulations and Compliance, subcategory Compliance Directives, No. CPL 03-00-003.
Under this initiative, regional and area OSHA offices will continue to conduct outreach; targeting and selection; and inspections. Area offices will obtain and use additional data to identify and add establishments where serious injuries or fatalities related to these machines have occurred.
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The Job Safety Analysis Process
The Job Safety Analysis (JSA) process is a very effective means of helping reduce incidents, accidents, and injuries in the workplace. It is a multi-step process.
•Basic Job Steps
•Potential Hazards
•Recommended Safe Job Procedures
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Summary
• Injuries can occur while operating plastics sheet and roll stock extrusion equipment
• Risk areas can be protected by safety guards and devices
• Protect yourself and operate plastic extrusion equipment safely
• Recognize the importance of a total safety and health approach
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