Module 4
Module 4
3 ©2006 TEEX
Key parts of machines
4 ©2006 TEEX
Key parts of machines
5 ©2006 TEEX
6 ©2006 TEEX
Hazards to be Guarded
7 ©2006 TEEX
Rotating Parts
8 ©2006 TEEX
In-Running Nip Points
9 ©2006 TEEX
Reciprocating Parts
10 ©2006 TEEX
Transverse motion
11 ©2006 TEEX
Cutting action
12 ©2006 TEEX
Punching action
13 ©2006 TEEX
Shearing action
14 ©2006 TEEX
Bending action
15 ©2006 TEEX
Guarding Principles
16 ©2006 TEEX
Part Two: Safeguarding
4. Feeding/Ejection Methods
Automatic/Semi-Auto feed
Automatic/Semi-Auto ejection
Robotics
Effective Safeguarding
Enclosed shaft
end
Enclosed chain &
sprocket
First Safeguarding Strategy: Guards
Self-Adjusting Guards
The openings of these guards are
determined by the movement of the stock.
– As the operator moves the stock into
the danger area, the guard is pushed
away, providing an opening which is
only large enough to admit the stock.
– After the stock is removed, the
guard returns to the rest position.
Second Safeguarding Strategy: Devices
• Restraint
– The restraint (holdout) device utilizes
cables or straps that are attached to the
operator's hands at a fixed point
– The cables or straps must be adjusted to
let the operator's hands travel within a
predetermined safe area - there is no
extending or retracting action involved
Second Safeguarding Strategy: Devices
Second Safeguarding Strategy: Devices
• Pullback
– Pullback devices utilize a series of cables
attached to the operator's hands, wrists,
and/or arms
– This type of device is primarily used on
machines with stroking action
– When the slide/ram is up between cycles,
the operator is allowed access to the point
of operation
Identify the Action
Second Safeguarding Strategy: Devices
• Guarding by Location/Distance
– The machine or its dangerous moving parts
are positioned so that hazardous areas are
not accessible or do not present a hazard
during normal operation
– walls or other barricades (fences)
– height (above worker)
– size of stock (single end feeding,
punching)
Is this adequate guarding by location?
Another Safeguarding Strategy
• Robotics
– Machines that load and unload stock,
assemble parts, transfer objects, and
perform other tasks
– They perform work otherwise done by the
operator
– Best used in high production processes
requiring repeated routines
Robotics
Miscellaneous Aids
* Acetylene is the most commonly used fuel gas. Acetylene is very flammable
and hazardous, and can ignite at a wide range of concentrations.
* Oxygen won’t burn or explode, but it helps other objects burn at greater rates.
compressed gas can shoot through the air like a rocket if its valve is damaged
or broken.
*Storage and Handling
• Keep cylinders away from physical damage, heat, and tampering.
• Securely chain equipment to prevent falling.
• Store away from flammable and combustible materials.
• Store extra gas and oxygen cylinders separately.
• Store in an upright position.
• Close cylinder valves before moving.
• Protective caps or regulators should be kept in place.
• Roll cylinders on bottom edges to move—Do not drag.
• Allow very little movement when transporting.
*General Gas Welding Safety Tips
• Inspect equipment for leaks at all connections using approved leak-test solution.
• Inspect hoses for leaks and worn places.
• Replace bad hoses.
• Protect hoses and cylinders from sparks, flames, and hot metal.
• Use a flint lighter to ignite the flame.
• Stand to the side (away from the regulators) when opening cylinder valves.
• Open cylinder valves very slowly to keep sudden high pressures from exploding the regulators.
• Only open the acetylene cylinder valve ¼-¾ turn; leave wrench in place so the cylinder can be
quickly closed in an emergency.
• Open and light acetylene first, then open and adjust oxygen to a neutral flame.
• Follow the manufacturer's recommendations for shutting off the torch. If the guidelines are not
readily available, the commonly accepted practice is to close the oxygen valve first.
• When finished, close cylinder valves, bleed the lines to take pressure off regulators, neatly coil
hoses, and replace equipment.
• Have a fire extinguisher easily accessible at the welding site.
*Personal Protective Equipment
• Infrared radiation is a cause of retinal burning and cataracts. Protect your eyes with safety
glasses.
• Protect your body from welding spatter and optical radiation hazards with protective
clothing. Such as:
• Woolen or heavy cotton clothing
• Flame-proof apron
• Welding gloves
• Properly fitted clothing that is not frayed or worn
• Shirts should have long sleeves
• Pants should be straight legged and covering shoes when arc welding
• Fire-resistant welder’s cap or shoulder covers are needed for overhead work
• Check protective clothing equipment before each use to make sure it is in good condition.
• Keep clothes free of grease and oil.
*Proper Ventilation
* Be sure there is adequate ventilation available when welding in confined areas or where
there are barriers to air movement. Natural drafts, fans, and positioning of the head can
help keep fumes away from the welder’s face.
* VENTILATION IS SUFFICIENT IF**:
• The room or welding area contains at least 10,000 cubic feet for each welder.
• The ceiling height is not less than 16 feet.
• Cross ventilation is not blocked by partitions, equipment, or other structural barriers.
• Welding is not done in a confined space.
* **If these space requirements are not met then the area needs to be equipped with
mechanical ventilating equipment that exhausts at least 2000 cfm of air for each welder,
except where local exhaust hoods or booths, or air-line respirators are used.
*
What is Arc Welding?
96
Fumes and Gases
• Fumes and gases can be
hazardous to your health
• Keep your head out of the
fumes
• Use enough ventilation,
exhaust at the arc, or both,
to keep fumes and gases
from your breathing zone
and the general area
• See product labeling and
MSDS for ventilation and
respirator requirements
97
Electric Shock
98
Arc Rays
99
Fire and Explosion Hazards
100
Noise
101
Protective Clothing
102
Manual Handling
• Heavy materials which are not safe to handle manually must be handled by mechanical
means and this includes lifting, transporting, stacking, loading and unloading by means of
There is no doubt that machines can do many tasks more quickly and efficiently in less time
5. Incompetent operator.
1. Poorly maintained tools, equipment and machines are prone to accidents due to failure of electrical, mechanical, and
hydraulic systems that can cause serious injury to personnel and property damage.
2. Risk of load failure due to inadequate and incorrect selection of handling tools and machinery.
3. There is a risk of collision with property or personnel due to congested operating space.
4. An untrained and unauthorized machine operator can cause serious accidents and injure other personnel.
5. Risk of material failure during handling due to overloading of machines, tools and equipment.
6. Equipment can fall due to improper loading and transportation, poor rigging and lifting, and over speeding by
unauthorized operation.
7. The use of machines without guards presents a high risk of serious injury.
Dos
3. The identification number and the safe working load must be marked on all tools and hoists.
4. Check the functioning of emergency switch, limit switches and over load alarm before actually starting the operation of
lifting machines.
5. Estimate the weight, distance, and hazards before lifting the load.
10. Special care should be taken when using the forklift and other portable hydraulic equipment.
11. When lifting the load with slings, make sure that all sharp corners are padded with soft material.
15. Use an appropriate guide rope while lifting and shifting the material.
4. Don’t use the equipment for any other purpose than intended.
6. Don’t load the machines and equipment above its safe working load.
8. Don’t use equipment, tools, hoist and tackles with a missing label or tag.
10.Don’t use chemical contaminated web slings, wire sling or belt without re-inspection.
11.Don’t use a hoist, slings, chains and other lifting tools and tackles that have lost more than 10% of its
breaking strength.
Manual Handling Risk Assessment
• A manual handling risk assessment is used to identify hazards that may cause musculoskeletal injuries to workers
when they perform manual handling.
• Similar to a regular risk assessment, a manual handling risk assessment is carried out to identify and evaluate risk
factors.
• Specifically activities of lifting, putting down, carrying, moving, and handling objects during work operations.
• Once a manual handling risk assessment is completed, health and safety workers work to develop processes and
preventive measures.
• Assessing manual handling risks is crucial to protect workers from musculoskeletal disorders (MSDs), increase job
satisfaction, and improve quality of work.
How do you carry out a manual
handling risk assessment?
• Determine the task – Ask the workers how the task is done. Establish
the scope of the manual handling activity and its important stages.
This helps pinpoint the exact moment an injury may happen.
• Retrieve essential information – This includes technical information
such as load factors of TILE. Load factors to consider are the weight,
size, and shape. Another essential information is knowing what
postures will the worker be in, size of the space, number of manual
handling tasks, and the employee’s technical knowledge.
• Determine the risk factors – Find out the hazards and risk factors.
Every factor needs evidence on why it’s a potential risk for the
manual handling activity.
• Identify potential improvements – Consult with the personnel using
the objective results of the manual handling risk assessment. These
improvements should reduce or prevent injury due to manual
handling activity. HSA suggests developing a safe system of work plan
and to use equipment when possible.
• Review the changes – A staff member should do regular inspections
to check the effectiveness of the implemented improvements. Risk
assessments are a continuous process that should be updated
regularly and revised when necessary.
4 Key Areas of Manual Handling
• When performing manual handling risk assessments, the assessor
mainly focuses on the 4 key areas of manual handling which is often
referred to as the acronym TILE (Task, Individual, Load, and
Environment)
• In some safety circles, “other factors” have been identified as another
key area for evaluating manual handling risks, turning the assessment
method into TILEO (Task, Individual, Load, Environment, and Other
factors).
• Task: Manual handling tasks that are too strenuous, involves long distances, and
availability of rest and recovery.
• Individual: This involves the worker’s capabilities such as no training, lack of experience,
unfamiliar with the job, physical capabilities, and prior history of injuries.
• Load: This risk can be caused by objects that are too heavy, too large, difficult to grasp or
reach, obscures the worker’s view, and unbalanced, unstable or if its contents can move.
• Other factors: monotonous tasks at a high pace and prolonged work without resting,
among others.
Use Proper Lifting Techniques
• Avoid lifting heavy items above chest height.
• Use the “big toe” test to test the weight of the object. If you can push the item
with your toe, it is safe to move it alone. If not, ask for help.
• When picking up a heavy item from the ground, stand close to the load with your
feet shoulder-width apart.
• Squat down, bending at your knees, keeping your back as straight as possible.
• Make sure you have a firm grasp on the object before lifting. Use handles, if
available.
• If you are lifting with a partner, coordinate lifting time.
• Once the object is lifted off of the ground, carry it as close to your body as
possible to prevent the object from losing its center of gravity and falling to the
ground.
Solutions for Pulling
• Keep your feet hip-width apart.
• When bending forward to pull, drop your hips and bend your knees.
Concentrate on keeping your core muscles tight to decrease pressure
on your back.
• Always face the object you are pulling. Take small, backward steps
once you start to move.
Push Before Pulling
• It is safer to push rather than pull.
• Keep your back straight and bend your knees.
• Do not twist at your hips to push, but rather keep your core tight and
use your legs and body weight to move the object.
• Face the load squarely rather than at the top or bottom of the object.
How to Maintain hooks
1. Before use, hooks must be inspected by an experienced rigger.
2.Remove a hook from service if any of the following are in evidence:
a. Cracks, nicks or gouges
b. Twist exceeding 10 degrees from plane of unbent hook
c. Damage or malfunction to the latch
d. Throat opening exceeding 15 percent
e. Wear exceeding 10 percent of original dimension
f. Damage from heat
g. Unauthorized repairs
3.Cracks, nicks and gouges should be removed by a qualified person. Grind lengthwise, following the
contour of the hook.
4.If removing the damaged area results in a loss of more than 10 percent of the original dimension, the hook
must be replaced.
5.Never repair, alter or reshape a hook by welding, heating, burning or bending, unless approved by the
hook manufacturer.
6.When lifting, ensure the hook, not the latch, supports the load. The sling or lifting device must always be
seated properly in the bowl of the hook.
7.Never side load, back load or point load a hook. All reduce hook strength and create an unsafe condition.
Point loading can reduce hook capacity as much as 60 percent.
CLAMP Maintenance
• Routine maintenance keeps your clamps in top condition so they can live their best – and longest –
lives.
✓ No matter what type of woodworking clamps you’re using, the maintenance process begins the
moment you unwrap your shiny new friends. If your clamp has a bar, it’s important to properly prep
it before use.
✓ Next, use a clean cloth that’s been lightly dipped into mineral spirits and wipe the bar down. Do this
until all adhesive is gone and the bar is dry, with no resin coming off of it. To keep glue from sticking
during future glue-ups, apply a coat of paste wax to the bar and buff clean.
During clamp use
• Keeping your clamps clean will extend their life span and ensure your workspace (and final product) stays free of
marks or residue.
• The easiest way to prevent glue from adhering to your clamps is to use a protective layer – like painter’s tape,
packing tape, or parchment paper – between your project and your clamp
▪ Always store clamps away from heat in a secure, safe, dry place.
▪ When possible, separate clamp heads to prevent them from sticking together.