Safety Measures For Power Press

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Seminar Keselamatan & Kesihatan Di IKS 17/11/2011

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Safety Measures For Power Press

  1. 1. Safety Measures for Power Press Mark (Masahiro) Komori [email_address] Komori Safety Device Lab. Co. Ltd. 1, Overview of press accident and measures in Japan 2, How to prevent press accident 3, Proposal to Malaysia
  2. 2. Masahiro Komori ( Nickname MARK), born 1950 Working for Komori Safety Device Laboratory Co., Ltd. As a Chairman Public Service : Chairman of Press Inspectors Association (JISHA) Executive of Japan Forming Machinery Association Executive of Press Safety Device Association Lecturer for JISHA Press education and Others Overseas experience Short term Expert to Singapore National Productivity Board Short term Expert to Singapore Ministry of Labor Seminar at Singapore, Korea, Taiwan, and others Technical corporation with Italy, Germany and U.S.A. SELF INTRODUCTION
  3. 3. KOMORI SAFETY DEVICE LAB. CO., LTD. Company Established 1955, Apr. Started as Metal Stamping Factory Changed to Safety Device Manufacturer from 1951 COMPANY OUTLINE Supported in 3 basic business 1, Safety Device Light Curtain, Barrier Guard, Pull-out, Area Sensor etc. Other Machinery Safety products And Consulting Machine Safety System 2, Compulsory Inspection Safety Education 3, Other Accessories Brake Stop Timer,Tonnage monitor, Forming Analysis, Production Engineering URL : http://www.komorisafety.co.jp e-mail : info@komorisafety.co.jp Singapore agent : J V Engineering +65-6267-8901
  4. 4. 1, Overview of press accident and measures in Japan      Phase 1: 1955 to 1971 Phase 2: 1972 to 1990 Phase 3; 1991 to Present situation ① ② ③ 2010 : 559 12,000->7,000 7,000->4,000 3,000->559 7000 4000 12000 1972 1990
  5. 5. Phase 1 : 1955 to 1971    After WW2, Every Press Machine must install Safety Device Phase 2 : 1972 to 1990    Safety and Health Law established Inherent Safety Measure ① Top Priority : No Hand in the Die ② Construction Code Press Machine and Safety Device ③ Compulsory Inspection System established Phase 3 : 1991 to 2010    ① Adopt ISO standards ② Risk Assessment and OSHMS ③ New regulation and construction code Preventive   measures by Phase 12,000->7,000 7,000->4,000 3,000->559 2010 :559
  6. 6. 1, Size of Company : Below 30 workers (70%) 2, Numbers of Presses : Below 30 Machines (90%) 3, Foot pedal or switch operation (80% of Full Revolution) 4, Size of Press Machine : Below 100 tons (80%) 5, Type of Clutch : Part Revolution 45%, Full Revolution 33% Hydraulic 7%, Press Brake 7% 5, Increasing Fatal Accidents at Big scale Press Machine 6, Still insufficient Safety Device, Small Protective Height 7, Many Human Error Reasons 8, Standard Operation 80%, Tool and Die Operation 20%   Trend of Press Accident Remark : Many Press Accidents Happens , following Small and Medium size factory, Below 30 presses equipped, Below 1000kN
  7. 7. Prevention of Dangers Due to a Press Machine Ordinance Article 131 TOP Priority : No Hand in the Die All the operation must use Safety Enclosure,Guard Safety Die (Die equipped with safety Guard) Small stroke Press (Below 6 mm stroke length) Automatic Feeding Press (with Safety Guard) Second Priority : Hand in the Die with Safety System Press Machine Safety Power Press Authorized M.H.L.W Interlock Guard , Two Hand Push button, Light Curtain, PSDI, Third Priority : Hand in the Die and Use Proper Safety Device Interlock Guard, Two hand push switch, Light curtain, Pullout
  8. 8. <ul><li>Promoting Press Machine Safety </li></ul><ul><li>Steps to secure the safety of press machine </li></ul><ul><li>Appropriate selection and management of safety device </li></ul><ul><li>Switching from foot-pedal to both-hand push button operation </li></ul><ul><li>Improving the safety of press machine operation </li></ul><ul><li>Using proper metal dies </li></ul><ul><li>Securing safety at the manufacturing and installation stages </li></ul>Comprehensive Measures for Press Machine Accident Prevention (Guideline 1998) Main Points (1) Promoting the safety of press machinery (2) Full implementation of press machine safety devices etc. (3) Effective measures in accordance with the situation at workplaces where press machine is installed
  9. 9. 2, How to prevent press accident <ul><li>Hardware </li></ul><ul><li>1,Danger of the Press machine </li></ul><ul><li>2,Compulsorily Inspection </li></ul><ul><li>Software </li></ul><ul><li>1, Operation Chief system </li></ul><ul><li>2, Operator Safety education </li></ul><ul><li>3, From the Top Management </li></ul>
  10. 10. Hardware 1,Danger of the Press machine <ul><li>Two types of Stopping Mechanism No stopping Mechanism ⇒ Full revolution Positive Clutch Most Dangerous but simple and cheap Machine Emergency stop Mechanism ⇒ Part revolution and Hydraulic Possible to use sensor device </li></ul>Full revolution Positive clutch Part revolution Friction clutch
  11. 11. <ul><li>Operate with Safety Measure 1,No Hand in the Die </li></ul><ul><li>Safety Enclosure, Automatic Feeding, Hand tool e.t.c. 2,Hand in the Die Select proper Safety Device </li></ul>Safety Enclosure, Automatic Feeding, Hand tool e.t.c Machine Guarding
  12. 12. <ul><li>Interlock Guard </li></ul><ul><li>Two Hand Control </li></ul><ul><li>Light Curtain </li></ul><ul><li>PSDI   (Presence Sensing Device Initiation) </li></ul><ul><li>Laser Beam (for Pressbrake) </li></ul><ul><li>Pull Out </li></ul>Kinds   of Safety Device
  13. 13. 2, Compulsorily Inspection <ul><li>Annual Inspection by Qualified Expert Inspection Agency Inside company Inspector </li></ul><ul><li>Monthly and Daily Inspection Operator Maintenance by Operation Chief </li></ul><ul><li>Use Checklist Annual Inspection Monthly and Daily Inspection </li></ul>
  14. 14. Software <ul><li>1, Operation Chief system Every 5 Presses </li></ul><ul><li>2, Operator Safety education New Operator’s education </li></ul><ul><li>3, From the Top Management </li></ul>
  15. 15. New Regulative Approach in Japan Japanese MHDL released New regulation and construction code at 2011. As follows: 1, To protect all operator from Machine with stroke edge Automatic feeding requires new protective way. Many accidents happens and some fatal accidents. Tarret Puch press ,Moving bolster, 2, Pressbrake Safety Devices Introduced from EU way 3, Guard Area must be considered not only opeator, but die setter and some other members 4, New Construction code for Press machine and Safety device
  16. 16. 3, Proposal to Malaysia <ul><li>Case Study </li></ul><ul><li>Proper Timing Inspection </li></ul><ul><li>Safety Operation </li></ul><ul><li>Safety Training </li></ul><ul><li>Legal Enforcement </li></ul><ul><li>Risk Assessment ⇒ OSHMS </li></ul>
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