Module 4- ISE

MCN 401
 MACHINERY SAFEGUARD

• Machine guards are the first line of defense against injuries caused by machine operation.

• Each machine must have adequate safeguards to protect operators and other employees in the

immediate work area from hazards

Principle of machine guarding
 Prevent contact: The safeguard must prevent hands, arms, and any other part of a
worker's body from making contact with dangerous moving parts. A good
safeguarding system eliminates the possibility of the operator or another worker
placing parts of their bodies near hazardous moving parts.
 Secure: Workers should not be able to easily remove or tamper with the
safeguard.Guards and safety devices should be made of durable material that will
withstand the conditions of normal use. They must be firmly secured to the machine.

 Protect from falling objects: The safeguard should ensure that no objects can fall
into moving parts. A small tool which is dropped into a cycling machine could easily
become a projectile that could strike and injure someone.
 Principle of machine guarding
 Create no new hazards: A safeguard defeats it's own purpose if it creates a hazard of its
own such as a jagged edge, or an unfinished surface which can cause a laceration. The
edges of guards, for instance, should be rolled or bolted in such a way that they eliminate
sharp edges.

 Create no interference: Any safeguard which impedes worker from performing the job
quickly and comfortably should not be used. Proper safeguarding actually enhance
efficiency since it can relieve the workers apprehensions about injury.

 Allow safe lubrication: If possible, one should be able lubricate the machine without
removing the safeguards. Locating oil reservoirs outside the guard, with a line leading
to the lubrication point, will reduce the need for the operator maintenance worker to enter
the hazardous area.
 Machine Guarding

All machines consist of three fundamental areas: the point of operation, the power
transmission device, and the operating controls.
 The point of operation is where work is performed on the material, such as cutting,
shaping, boring, etc
 The power transmission apparatus is all components of the mechanical system
which transmit energy to the part of the machine performing the work. These
components include pulleys, belts, connecting rods, chains, gears
 A mechanical or electrical power control shall be provided on each machine to
make it possible for the operator to off the power from each machine without
leaving his position at the point of operation.
• Machine operators often need to come into close proximity to points of operation in the

course of their work. In those cases, machine guards can be installed to prevent hands or

other body parts from accidentally getting caught in those moving parts.

• When a solid guard would impede the operator's productivity or cannot be installed,

optical sensing technologies such as safety light curtains can act as a safeguard at the point

of operation.
 Methods of Safeguarding
There are five (5) general types of machine safeguards that can be used to protect workers and personnel in the

immediate vicinity of machinery. They are:

1. Guards - are barriers that prevent access to dangerous areas of machines.

• Guards can be made of, such as metal, plastic, or wood, and are typically attached to the

machine using screws, brackets or clamps.

• Common guard types include door guards, gate guards, and fence guards. Guards must be

properly installed and maintained to be effective.

• Improperly installed or maintained guards can create hazards themselves or may fail to

protect workers from hazards.

Methods of Safeguarding
2. Safety Devices :

• It may stop the machine if a hand or any part of the body is inadvertently placed
in the danger area;

• restrain or withdraw the operator's hands from the danger area during operation;

• require the operator to use both hands on machine controls, thus keeping both
hands and body out of danger,

• provide a barrier which is synchronized with the operating cycle of the machine
to prevent entry to the danger area during the hazardous part of the cycle.
Methods of Safeguarding
3. Automated Feeding and Ejection Mechanisms:

• Feeding and ejection methods generally do not require the operator to place his
or her hands in the danger area.

• In some cases, no operator involvement is necessary after the machine is set up.

• Properly designed ejection methods do not require operator involvement after

the machine starts functioning.
Methods of Safeguarding
4. Machine Location or Distance :

• To consider a part of a machine to be machine guarded by location, the dangerous

moving part of a machine must be positioned so that those areas are not
accessible or do not present a hazard to a worker during the normal operation of
the machine.

• This may be accomplished by locating a machine so that the hazardous parts of

the machine are located away from operator work stations or other areas where
employees walk or work.
Methods of Safeguarding
5. Miscellaneous Aids –
• these methods can be used to protect both operators and people in the immediate vicinity of
operating machinery.
• Examples include shields to contain chips, sparks, sprays or other forms of flying debris;
holding tools that an operator can use to handle materials going into the point of operation;
and awareness barriers to warn about hazards in the area people
 MACHINE SAFEGUARD DEVICES

A safety device may perform one of several functions:

o It may stop the machine if a hand or any part of the body is inadvertently placed in the danger

area

o restrain or withdraw the operator's hands from the danger area during operation

o require the operator to use both hands on machine controls thus keeping both hands and body

out of danger

o provide a barrier which is synchronized with the operating cycle of the machine in order to
Presence-Sensing Devices:
o Presence-sensing devices use a system of light or radiofrequency sources and controls
o They can interrupt the machine's operating cycle
o if the light or electric field is broken, the machine stops and will not cycle.

Photoelectric presence-sensing device:

When the light beam is broken:
o either the machine will not begin to work, or
o if the working has begun, the stopping mechanism will be activated so that it stops
before the operator's hand can enter the danger zone.
Electromechanical sensing device:
o This device has a probe or contact bar which descends to a predetermined distance when the
operator initiates the machine cycle.
o If there is an obstruction preventing it from descending its full predetermined distance, the
control circuit does not actuate the machine cycle.
Pullback devices:
o Pullback devices use a series of cables attached to the operator's hands, wrists, and/or arms.
o This type of device is primarily used on machines with stroking action.
o When the slide/ram is up between cycles, the operator is allowed access to the point of
operation.
o When the slide/ram begins to cycle by starting its descent, a mechanical linkage automatically
assures withdrawal of the hands from the point of operation.
Restraint Devices
o The restraint (holdout) device uses cables or straps that are attached to the operator's hands at a
fixed point.
o The cables or straps must be adjusted to let the operator's hands travel only within a
predetermined safe area.
o There is no extending or retracting action required because the hands are never allowed to
extend into the danger area.
o Consequently, hand-feeding tools are often necessary if the operation involves placing material
into a dangerous area.
Safety Trip Controls
o Safety trip controls provide a quick means for deactivating the machine in an emergency
situation.
o A pressure-sensitive body bar, when depressed, will deactivate the machine.
o If the operator or anyone trips, loses balance or is drawn toward the machine, applying pressure
to the bar will stop the operation.
o The positioning of the bar, therefore, is critical. It must stop the machine before a part of the
employee's body reaches the dangerous area.
o Unfortunately, it may be easy to defeat the body bar by going under it into the danger zone.
Two-Hand Control Devices
o The two-hand control device requires constant, concurrent pressure by the operator to activate
the machine.
o This kind of control requires a part- revolution clutch, brake, and a brake monitor if used on a
power press.
o With this type of device, the operator's hands are required to be at a safe location (on control
buttons) and at a safe distance from the danger area while the machine completes its closing
cycle.
Two-Hand Trip Devices
o The two-hand trip device requires concurrent application of both the operator's control buttons
to activate the machine cycle, after which the hands are free.
o This device requires the joint operation of two trigger buttons located away from the "danger
zone" of the press.
o To be effective, both two-hand controls and trips must be located so that the operator cannot
use two hands or one hand and another part of his/her body to trip the machine.
 TYPES OF GUARDS

Guards are barriers which prevent access to danger areas. There are four general types of guards:

1. Fixed

2. Interlocked

3. Adjustable guards

4. Self-adjusting
 1. Fixed guards

• Fixed guards are permanently attached to the machine or tool, don't have any moving
parts, and can't be moved while the machine is in use.
• They're most often used to enclose the point of operation, or other hazards that the
operator doesn't need to interact with, like fan blades or flywheels.
• Because fixed guards are permanent features of the machine, they must be disassembled
and removed to perform any kind of adjustment or maintenance.
• It may be constructed of sheet metal, screen, wire cloth, bars, plastic, or any other
material that withstand any impact it may receive and to endure prolonged use.
• This guard is usually preferable to all other types because of its relative simplicity and
permanence.
• Safeguarding Action: Provides a barrier
Advantages

i. Can be constructed to suit many specific applications.

ii. In-plant construction is often possible.

iii. Can provide maximum protection.

iv. Usually requires minimum maintenance.

v. Can be suitable to high production, repetitive operations.

Disadvantages
 May interfere with visibility.

 Can be limited to specific operations.

 Machine adjustment and repaired often require its removal, thereby

necessitating other means of protection for maintenance personnel.
 2. Interlocked
• Interlocking guards, also known as automatically shut off or disengage the power source when
the guard is open or removed.

• These are barrier situations where operators need to be able to open the guard or access the
guarded parts of the machine, such as when clearing guards particularly useful in jams.

• These guards allow safe access to interior parts of the machine without requiring a total
disassembly.

• Safeguarding Action: Shuts off or disengages power and prevents starting of machine when
guard is open; should require the machine to be stopped before the worker can reach into the
danger area
 Advantages & Disadvantages
Advantages
 Can provide maximum protection.

 Allows access to machine for removing jams without time consuming removal of fixed
guards.

Disadvantages
 Requires careful adjustment and maintenance.

 May not be easy to disengage jams.

3. Adjustable guards
• Adjustable guards, like fixed guards, are permanent, but they can be adjusted to allow the machine to handle
different sizes of material.

• They must be manually adjusted and locked into place, so all employees who will operate adjustable guards
must be trained on their use.

• If improperly adjusted or locked, adjustable guards can fail to prevent contact with moving parts, causing
serious or even fatal injury.

• Safeguarding Action: Provides a barrier that may be adjusted to facilitate a variety of production operations.
 Advantages & Disadvantages
Advantages
 Can be constructed to suit many specific applications.
 Can be adjusted to admit varying sizes of stock.

Disadvantages
 Hands may enter danger area - protection may not be complete at all times.
 May require frequent maintenance and/or adjustment.
 The guard may be made ineffective by the operator.
 May interfere with visibility.
 4. Self-adjusting
• Self-adjusting guards serve the same purpose as adjustable guards, but automatically adapt to
the size of the material.

• When the machine is at rest, these guards sit all the way down.

• When the machine is in use, the operator feeds material into the machine, which opens the
guard just enough to let the material in.

• Safeguarding Action: Provides a barrier that moves according to the size of the stock entering
the danger area.
Advantages & Disadvantages

Advantages
 Off-the-shelf guards are often commercially available.

Disadvantages:
 Does not always provide maximum protection.

 May interfere with visibility.

 May require frequent maintenance and adjustment.

SAFETY IN TURNING

 Metal turning lathes, particularly centre or engine lathes, are commonly used for machining metal parts.

 In a lathe, the workpiece is held in the chuck and rotated about its axis at a uniform speed

 A workpiece secured in a chuck is turned against a cutting tool which cuts metal from the workpiece.

 Parts are created by turning the workpiece in one or both ends of the lathe, and changing its shape using tools

with specific cutting edges.

General Lathe Safety

• All stock must be properly secured in the lathe chuck or mounted before the machining process starts. Use the

correct sized clamp or vise for the stock being machined.

 Turn the chuck or faceplate by hand to ensure there is no danger of the work striking any part of the

lathe.

 Check to ensure the cutting tool will not run into the chuck or lathe dog. If possible, feed away from

the chuck or lathe dogs.

 When using wood, do not mount a split workpiece or one containing knots.
Before Starting the Lathe

 Before starting the lathe, ensure the spindle work has the cup center imbedded; tail, stock and tool

rests are securely clamped; and there is proper clearance for the rotating stock.

 Prior to starting the lathe, ensure that small diameter stock does not project too far from the chuck

without support from the tail stock center.

While in Operation

 When roughing stock, do not force the cutting tool in the work piece or take too big a cut.

 The operator must always be aware of the direction and speed of the carriage or cross- feed prior
to engaging the automatic feed.

 When an operator has finished working on the lathe, and before leaving the lathe for any reason,
the power must be shut off and the machine must come to a complete stop.
 Stop the machine immediately if odd noise or excessive vibration occurs.
The Chuck

 Never leave the key in the chuck. Do not let go of the key until it is free of the chuck and secured

in its proper holding place.

 Never attempt to run the chuck on or off the spindle head while engaging the power.

 Do not stop the rotation of the chuck by reversing the power to the lathe unless tapping holes.
Turning Speed

 Select turning speed carefully. Large diameter stock must be turned at a very low speed. Always

use the lowest speed to rough out the stock prior to final machining.

 The correct speed and feed for the specific material and cutting tool must be used. Stop the

machine before making adjustments or measurements.

SAFETY IN GRINDING

 All types of grinding machines, whether pedestal, bench mounted, free-standing or portable, can be

potentially hazardous if they are not well maintained and used correctly.

 In addition to the common hazards of flying particles, dust and sparks, shattering abrasive wheel while in

motion, it can cause severe injury to both the user and others.
Safety measures
 Guards must be provided and adjusted properly as per the manufacturer’s manual. Replace
damaged guards because if an abrasive wheel breaks while rotating, it can cause a serious injury.
 Before use, check the manufacturer's stated running speeds, or markings on the grinder, and
grinder wheel for the maximum speed that it can be used.

 Clean and service grinders according to manufacturers recommendations. Record all maintenance
for grinders.
 Ensure that a machine will not operate when unattended.

 Wear safety glasses or goggles, or a face shield (with safety glasses or goggles) to protect against
flying particles. Gloves, aprons, metatarsal safety boots, hearing protection, and respiratory
protection may be required, depending on the work.
Safety measures

 Ensure the floor around the work area is clean.

 Do not use wheels that are cracked or those that excessively vibrate.

 Do not operate grinder on wet surface.

 Keep the power cord away from the grinding wheel and the material being ground.

 Make sure the work area is clear of flammable materials and that combustible dust is not allowed

to accumulate.
Safety measures

 Never adjust the workpiece or work mounting devices when the machine is operating

 Do not exceed recommended depth of cut for the wheel or machine.

 Remove workpiece from grinding wheel before turning machine off.

 Use proper wheel guards on all grinding machines

 SAFETY IN GAS-WELDING (CUTTING)

• gas welding process uses gases like acetylene and oxygen to produce flames.

• Acetylene is flammable and hazardous.

• It has the ability to ignite and condense.

• Whilst, oxygen helps other substances to burn faster.

• It does not catch fire but can explode if exposed to fire.

1. Personal protective equipment

• Eye goggles or safety glasses should use to protect the eye from infrared radiation.

• Protecting clothing such as flameproof apron, gloves, cap or helmet, and booth should
be wear before welding.

• The apron should be well fitted to avoid fraying.

• The shirt should be long sleeves and trousers should be long enough to cover the top
of the booth.

• Protective clothing should be free from oil or grease.

• All these clothing should be in good condition before operators or

• students use them.

 2. Storage and Handling Safety

• Cylinders should not be exposed to heat and should be securely chained to prevent from falling.

• They should be kept away from flammable and combustible materials, same as in upright (vertical)
position.

• They should be store in a well-ventilated area, Acetylene and oxygen cylinders should be store
separately.

• It should not be a drag, but rolling on a slow movement on bottom edges.

• Valves on cylinders should be close before moving.

• Regulators and protective caps should be kept in place.

• Keep hands off grease or oil when opening or closing valves and regulators
 3. Environmental safety

• Iindustries or shops where gas welding is used should have proper ventilation, lighting,
walkways, store, escape route, safety poster, etc.

• The floor should be kept clean, free from water grease, and oil.

• Fire extinguishers should be easily accessible and welded jobs should be properly stored.
 4. Operation and equipment safety
• Flame arrestors must be fitted in acetylene and oxygen cylinder lines.
• One of them should be fitted beside the low-pressure regulator and the other near the touch.
• Higher pressure should release on oxygen than acetylene to avoid acetylene flame from
going back.
• However, acetylene should not be used when welding at a pressure exceeding 1bar of
atmosphere gauge to avoid explosion.
• Whenever a backfire occurs, the oxygen valve should be close first and acetylene should
follow immediately.
• It should be rectified before operations continue.
• In case of flashback(explosion in gas hose), the first thing to do is to set bot cylinder valve
apart.
• Whenever a flashback occurs, all hoses should be replaced with new ones.
 SAFETY IN ARC-WELDING (CUTTING)

• Arc welding is a type of welding process using an electric arc to create heat to melt and

join metals.

• A power supply creates an electric arc between a consumable or non-consumable

electrode and the base material using either direct (DC) of alternating (AC) currents.
 Welding tools & Equipment Safety

 All welding machine should be properly ground/earthed connection must need.

 Welding machine switch board and fuse should be proper

 Do not over load and heat welding machine.

 If any abnormal sound, then call the expert and get it rectified

 Electrode holder insulation is must.

 Personal safety

 Welder has to protect eyes from - welding infra-red rays, ultra violet light,

flying sparks, spatter, hot slag partial, and hot electrode stub.

 In helmet and head screen special filter glass must befitted.

 Welder must wear lather apron, Hand glove, Leg guards, Safety boots.

 Welder must protect from welding fumes, Gases, dusts.

 All welder must aware about Health protection and ventilation.

 List of Recommended Welding Safety Gear:

 Earplug or muffs when the noise is high

 Leather safety boots

 Leather gloves.

 Safety glasses or a welding helmet with a cover plate: the cover plate's
opaqueness is important and dependent on the kind of materials being welded.
 Respirators for protection from the toxic perfumes

 Do not operate the welder if any of the clothing is wet.

 A person who uses a pacemaker is advised not to do the welding.

 SAFETY IN MILLING MACHINE

- Milling refers to the process of removing material from a workpiece with the help of rotary cutters.

- The process of milling helps in flattening, tapering, curving or carving the workpiece with irregular
patterns at various angles by using a rotating cutter that has different types of abrasive edges.

- A typical milling machine comprises of a milling machine spindle that is powered by a motor and
that causes the milling cutter to revolve

- the other important component of a milling machine is its worktable which can be adjusted to feed
the workpiece to the cutter as required.
Safety precautions for Milling Machine

1. Never operating unaccompanied

Operating intentional safety slip. We must always have at least one additional person around at the
work site to rush one another to medical assistance if the need arises.

2. Pre-inspecting the machine

Prior to commencing the milling operation, the milling machine should be inspected thoroughly for
the presence of any damaged parts or malfunctioning components. If any such components are
found, they should be replaced by experienced personnel. Moreover, the machine must never be
tended to or serviced, when power is connected.
 Safety precautions for Milling Machine

3. Wearing adequate safety gear

The operator must wear adequate safety gear before beginning operation. Must-have safety
essentials around milling machines include safety glasses to protect the eyes from any stray
particles that might accidentally fly into them, damaging the vision partially or completely and
ear protection to protect any hearing loss from surreptitiously settling in.

4. Keeping away from revolving cutter

While operating a milling machine, the adequate distance must be maintained from the
revolving cutter. Extra care must be taken when dismantling or setting the milling cutter up; it
must be held using a spare cloth to prevent its sharp edges from cutting through the skin.
Safety precautions for Milling Machine

5. Removing chips

Always use a brush and a rake to remove chips from the work- piece to avoid
being cut or scraped in the hands.

6. Using cutting oil with care

The use of cutting oil is required to facilitate the milling action. The cutting oil
may splash back at the operator- to prevent this, use splash guards. If the
cutting oil scatters on the floor, we might slip and accidentally strike the milling
machine; this must be avoided at all times and the floor must be kept clean.
 MATERIAL HANDLING

• Material handling is the movement, protection, storage and control of materials and products
throughout manufacturing, warehousing, distribution, consumption and disposal.

• As a process, material handling incorporates a wide range of manual, semi-automated and

automated equipment and systems that support logistics and make the supply chain work.

• Material handling involves movements of material mechanically or manually in batches or one

by one within the plant. Movement may be horizontal, vertical or a combination of the two.

• Design and operation of an efficient production plant requires a good and effective material

handling system for moving the materials from one stage of production to another.
 Safety in material handling:

• According to National Safety Council ,

∙ Avoid lifting materials from the floor or while seated.

∙ Make use of available handling aids.

∙ Refrain from using sudden or jerky movements

∙ Never lift a load over an obstacle.

∙ Perform lifts in areas with adequate footing, space and lighting

∙ Modify objects and redesign jobs to make moving easier.

∙ Seek assistance from co-workers.

 Stay in good physical shape.

∙ Begin lifts close to the body.

∙ Use containers made of lighter materials.

∙ Reduce load sizes when possible.

∙ Do not twist or bend while lifting objects.

∙ Ensure repetitive, heavy and bulky lifts are not performed.

∙ Keep lifts between shoulder and knuckle height.

∙ Use conveyors, slides or chutes to eliminate pushing or pulling.

 TYPES OF MATERIAL HANDLING EQUIPMENTS
• 4 types.

1. Transporting : Transport equipment is used to move materials from one location to another.

o This could be moving a material between workspaces or from a loading dock to a storage facility.

o This saves workers from having to lift and transport heavy materials which is time consuming, and
potentially dangerous.
Types of transporting equipment includes:

Conveyors - These are used when material is frequently moved between specific points over a
fixed pathway when there is a sufficient flow volume.

Cranes - These are used to transport materials over horizontal and vertical paths. Cranes are
more flexible than conveyors as they can handle a variety of shapes and weights. This increases
productivity and makes best use of floor space.
• Industrial trucks - These are used to move materials over variable paths. These transportation devices
can include small hand-operated trucks, pallet jacks, and various kinds of forklifts. Trucks can also
be manual or powered operation can either be walk or ride. This requires a user to manually push
them or to ride along on the truck.

• Manual handling equipment - These are often used to move smaller pieces of equipment where larger

tools would struggle. They include pallet trucks, trolleys, and sack trucks .
 2. Storage
Storage equipment is used to store materials in a factory or warehouse before they are transported
elsewhere.

• They could be stored for a period of time due to temporary pauses during transportation or for long-
term storage to allow the buildup of stock.

• These types of equipment aim to make material easily accessible, and maximize the use of space. If
materials are stacked directly on the floor, then storage equipment is not necessary. However, it
makes sense to stack products at different heights to make the most out of space.

• Factories and warehouses usually have rows of shelves, each packed with different materials.

• Storage handling equipment includes pallet racking, stacking frames, shelving, and mezzanine
flooring.
3.Positioning Equipment

• This equipment is used to handle materials at a specific location and move into the correct position for
subsequent, handling, transporting, or storage.

• This enhances productivity as the machine can handle large volumes of material, rather than relying
on an employee to move everything into position by hand. Moreover, this reduces the chance of
damage to materials due to human error or a lack of attention.

It can also help to reduce fatigue and hazards when handling materials which are heavy and awkward .
Examples of positioning equipment include material lifts, electric chain hoists, glass suction lift, and
barrow chains.