practical machinery safeguarding

Practical Machinery Practical Machinery SafeguardingSafeguarding

Nigel DavyNigel Davy

Machinery GuardingMachinery GuardingRecognise machinery hazardsRecognise machinery hazardsBe aware of common Be aware of common machinery guarding issuesmachinery guarding issuesDo this systematicallyDo this systematicallyIdentify when improvements Identify when improvements are requiredare requiredSelect the appropriate safety Select the appropriate safety devicesdevicesBe aware of the standardsBe aware of the standardsImplement the correct Implement the correct management system for the management system for the equipment.equipment.

Types of machineTypes of machineHow the machines are How the machines are usedusedWhat to look forWhat to look forMachinery hazardsMachinery hazardsPUWER & EHSRPUWER & EHSR


What can go wrongWhat can go wrongGuarding arrangementsGuarding arrangementsMaintenanceMaintenanceEffective interlock guardsEffective interlock guardsEffective fixed guardsEffective fixed guards


Overview of legal Overview of legal requirementsrequirementsSupply Regs vs. PUWERSupply Regs vs. PUWERRisk assessmentRisk assessmentBS EN StandardsBS EN StandardsTaking into useTaking into use


Machinery guardingMachinery guardingWhat to look forWhat to look forObservationObservation


Risk reductionRisk reductionApply appropriate Apply appropriate safeguardssafeguardsMake user aware of Make user aware of residual risksresidual risksDesignDesignSafety distances Safety distances Minimum gapsMinimum gapsGuard typesGuard typesGuarding systemsGuarding systemsPotential guard failuresPotential guard failuresCategories of safety Categories of safety control systemscontrol systemsControls & isolationControls & isolation


Machinery Directive EHSRMachinery Directive EHSRPUWER requirementsPUWER requirementsLOLER, PSR, EaW, NoiseLOLER, PSR, EaW, NoiseStandardsStandards

AABBCC

Specific standardsSpecific standardsAssessmentAssessmentDesignDesignReach distancesReach distancesControl systemsControl systems


Statutory inspectionStatutory inspectionElectrical testingElectrical testingSSoWSSoW

Normal productionNormal productionOther regular tasksOther regular tasksAbnormal circumstancesAbnormal circumstances

Isolation & lock offIsolation & lock offTrainingTrainingPre start checksPre start checksInspections & auditsInspections & auditsMaintenanceMaintenance

TasksTasksSafety devicesSafety devices

Conveyor

Tooling

Motor & drive

Infeedconveyor nip

Infeed reach in

Reach in & down

Access from underneath

Outfeed conveyor nip

End access

Direct sideaccess

Outfeed reach in

Conveyor

Tooling

Motor & drive

What do we need from this guard?

What is it protecting?

What do we need from this guard?

What is it protecting?

Need for time delay?

How often will

it be opened?

What type of interlock

will be needed?

Infeedconveyor nip

Infeed reach in

Reach in & down

Access from underneath

Outfeed conveyor nip

End access

Direct sideaccess

Outfeed reach in

How do I start & stop it?

Emergency stop

& isolator!

Where do the controls need to be?

Who needs access to the

controls?

PUWER PUWER A few sneaky bitsA few sneaky bits

Specific RisksSpecific RisksThe way equipment is used, The way equipment is used,

repaired, adjusted etc.repaired, adjusted etc.

PUWERPUWERA few more sneaky bitsA few more sneaky bits

Information and instructionsInformation and instructionsAdequate health and safety informationAdequate health and safety informationWritten instructions if appropriateWritten instructions if appropriate

Same for supervisors & managersSame for supervisors & managersInformation & instruction to include:Information & instruction to include:--

Conditions in which & methods by which it may be Conditions in which & methods by which it may be usedusedForeseeable abnormal situations and actions requiredForeseeable abnormal situations and actions requiredConclusions drawn from experience with the Conclusions drawn from experience with the equipmentequipment

PUWERPUWEROne more sneaky bitOne more sneaky bit

Regulation 22 Regulation 22 –– Maintenance operationsMaintenance operationsMaintenance operations involving a risk to health Maintenance operations involving a risk to health or safety to be carried out while equipment is or safety to be carried out while equipment is shut down.shut down.If not:If not:--

Carried out without exposing the person to riskCarried out without exposing the person to riskOROR appropriate measures to be taken to protect the appropriate measures to be taken to protect the personperson

THIS IS AN IMPORTANT REGULATION!THIS IS AN IMPORTANT REGULATION!

Machinery Guarding Machinery Guarding

What can go wrong?What can go wrong?

Machinery GuardsMachinery Guards

A guard is not a guard A guard is not a guard when when ………………………………………………………………………………

A guard is not a guard when A guard is not a guard when ……....

It is not fittedIt is not fittedIt has been removedIt has been removedIt is too looseIt is too looseIt is not fixed properlyIt is not fixed properlyIf fixed it can be removed If fixed it can be removed by handby handIt is brokenIt is brokenIt has been defeatedIt has been defeatedIt has been modified It has been modified incorrectlyincorrectly

It is not properly It is not properly maintainedmaintainedIt is removed and the It is removed and the machine is runningmachine is runningThe interlock is defectiveThe interlock is defectiveThe interlock is The interlock is incorrectly adjustedincorrectly adjustedDoes not prevent contactDoes not prevent contactNot the correct dimensionNot the correct dimensionIt has been overriddenIt has been overridden

MaintenanceMaintenance

Is it really guarded?Is it really guarded?

Flowrap MachineFlowrap Machine

Is the guard effective?Is the guard effective?

Could you touch the sealing jaws?Could you touch the sealing jaws?

Machinery Guarding Issues Machinery Guarding Issues

ItIt’’s all right Nigel!s all right Nigel!ItIt’’s Interlocked!s Interlocked!

Is the interlock effective?Is the interlock effective?

Fixed GuardsFixed Guards

Is the guard effective?Is the guard effective?

A few general issuesA few general issues

BlockagesBlockages

Reach InReach In

ConveyorsConveyors

Hazard/Danger ZoneHazard/Danger Zone

Any space within or around machinery in Any space within or around machinery in which a person can be exposed to a which a person can be exposed to a hazard.hazard.

PUWER Reg.11 PUWER Reg.11 –– Danger ZoneDanger Zone““Any zone in or around machinery in which Any zone in or around machinery in which a person is exposed to risk from contact a person is exposed to risk from contact with a dangerous part of machinery with a dangerous part of machinery or a or a

rotating stock barrotating stock bar””

Intended use of machineIntended use of machine

Use of a machine in accordance with the Use of a machine in accordance with the information provided by the manufacturer information provided by the manufacturer

in the instructions for usein the instructions for use

Routine production operationRoutine production operation

&&

All All foreseeable abnormal foreseeable abnormal situationssituations

Reasonably foreseeable misuseReasonably foreseeable misuseUse of a machine in a way not intended by the designer, but whicUse of a machine in a way not intended by the designer, but which may h may result from result from readily predictablereadily predictable human behaviour.human behaviour.

? Standing on a machine to reach in?? Standing on a machine to reach in?

? Use of an interlocked door to stop a machine rather than walk ? Use of an interlocked door to stop a machine rather than walk to a to a switch panel?switch panel?

? Failure to isolate because isolation facilities are not readil? Failure to isolate because isolation facilities are not readily available?y available?

? Short cuts during cleaning and clearing blockages?? Short cuts during cleaning and clearing blockages?

Hazard IdentificationHazard Identification

Need to identify every hazard, this is a critical first step.Need to identify every hazard, this is a critical first step.If you have not identified the hazards you cannot control If you have not identified the hazards you cannot control them.them.Must include all types of use, including:Must include all types of use, including:--

Normal operationNormal operation

CleaningCleaningAdjustingAdjustingMaintaining Maintaining Clearing blockagesClearing blockagesSetting up Setting up Dismantling & reassemblyDismantling & reassembly

We often forget these!

GuardingGuarding

Machinery GuardingMachinery Guarding

Practical TipsPractical Tips

Look underneathLook underneath

Look at the sidesLook at the sides

Look at the topLook at the top

Look at the Look at the infeed and outfeedinfeed and outfeed

Look at the motors & drivesLook at the motors & drives

Look at the controlsLook at the controls

Which buttons do I press Which buttons do I press to to

start and stop it?start and stop it?

Look at the Look at the Emergency Stop SwitchesEmergency Stop Switches

Look at the isolation facilitiesLook at the isolation facilities

Look at the conveyorsLook at the conveyors

Look between the machinesLook between the machines

Pop Out RollersPop Out Rollers

Do they Do they ““pop outpop out””??

Look beside the machinesLook beside the machines

Look at the safety devicesLook at the safety devices

Look at the access pointsLook at the access points

Look at the way Look at the way we use the machinewe use the machine

Look at the abnormal Look at the abnormal uses of the machineuses of the machine

Abnormal CircumstancesAbnormal Circumstances

•• CleaningCleaning•• AdjustingAdjusting•• Clearing blockagesClearing blockages•• BreakdownsBreakdowns•• MaintenanceMaintenance•• ObservationsObservations

•• Opening or removing guardsOpening or removing guards

Loading and AdjustingLoading and Adjusting

Cleaning or Clearing BlockagesCleaning or Clearing Blockages

Maintenance ActivitiesMaintenance Activities

ObservingObserving

Practical Machinery GuardingPractical Machinery Guarding

A few tips!A few tips!

practical machinery safeguarding

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