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Wt4603 unit1 week2-12-09-2011

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Week 2 - Risk Assessment

Week 2 - Risk Assessment

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  • 1. WT4603Wood Processing Safety & PracticeAUTUMN 2011Lecture Unit 1
    • Machine Provision, Hazard Identification, Risk Assessment & Week 2 Labs
    • 2. Lecturer: Mr. Joseph Lyster
    • 3. joseph.lyster@ul.ie
    • 4. Notes prepared by: Mr. Joseph Lyster
    • 5. Notes available on www.slideshare.net/WT4603
  • WT4603
    Health & Safety Management
    • Section 8(2)e of the 2005 (Now 2007) Act states that it is the duty of every employer
    “to provide systems of work that are planned, organised, performed and maintained so as to be, so far as is reasonably practicable, safe and without risk to health.”
    • Health and safety management is a practical and systematic approach to identifying hazards and evaluating the extent of associated risk
    Department of Manufacturing & Operations Engineering
  • 6. WT4603
    Unsafe Workplaces
    Can be identified by:
    • High accident/injury rates.
    • 7. Poor machinery guarding.
    • 8. Poor cleaning and housekeeping arrangements.
    • 9. Limited interest of OHS by employers/management.
    • 10. Lack of care/respect for safety rules.
    • 11. Poor safety culture.
    Department of Manufacturing & Operations Engineering
  • 12. WT4603
    Safe Workplaces
    Can be identified by:
    • Regular inspection of workplace
    • 13. Consultation between employer and employees.
    • 14. Clearly defined structure of responsibilities….
    • 15. Employees are trained…
    • 16. Exceeds the specific requirements of the law – manages safety not for fear of being reprimanded but for the employees.
    Department of Manufacturing & Operations Engineering
  • 17. WT4603
    Safety Management
    The Key steps of any Health & Safety Management scheme are:
    Policy
    Hazard identification
    Risk Assessment
    Control Measures.
    Recording Findings (Safety Statement)
    Monitoring, Review and Auditing
    Department of Manufacturing & Operations Engineering
  • 18. WT4603
    Importance of being able to Assess Risk
    Department of Manufacturing & Operations Engineering
  • 19. WT4603
    Required Reading
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    The Safety Management Process
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    Health & Safety Policy
    Department of Manufacturing & Operations Engineering
  • 22. WT4603
    Health & Safety Policy
    Department of Manufacturing & Operations Engineering
  • 23. WT4603
    More information can be found by
    consulting manufacturer’s manual
    Department of Manufacturing & Operations Engineering
  • 24. WT4603
    Health & Safety at Work Act 2005
    Pg. 30 of Health & Safety at Work Act 2005
    Department of Manufacturing & Operations Engineering
  • 25. WT4603
    Identify Hazards (Hazard Identification)
    Department of Manufacturing & Operations Engineering
  • 26. WT4603
    Hazards in the Workplace
    Department of Manufacturing & Operations Engineering
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    Department of Manufacturing & Operations Engineering
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    Department of Manufacturing & Operations Engineering
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    Department of Manufacturing & Operations Engineering
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    Department of Manufacturing & Operations Engineering
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    Department of Manufacturing & Operations Engineering
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    Department of Manufacturing & Operations Engineering
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    Definition: Hazard
    Department of Manufacturing & Operations Engineering
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    Hazards in the Workplace
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    Some Possible Hazards
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    Common Machinery/Mechanical Hazards
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  • 44. WT4603
    Wrap Point: (Entanglement)
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    Shear Point and Cutting Hazards
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    Crush Points
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    Ejection Hazards
    Department of Manufacturing & Operations Engineering
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    Other Hazards
    Department of Manufacturing & Operations Engineering
  • 49. WT4603
    Hazards
    Department of Manufacturing & Operations Engineering
  • 50. WT4603
    Classroom Risk Assessment:
    • You will need to develop a template for your lesson riskassessment.
    • 51. Strategies will need to be developed to:
    • 52. Reduce or eliminate risk
    • 53. Demonstrate safe use of machine(s)
    • 54. Teach key learning points relating to machine or process
    • 55. Assess and record pupil learning and competence
    • 56. Ensure adequate supervision of activities
    Department of Manufacturing & Operations Engineering
  • 57. WT4603
    Room Layout
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  • 58. WT4603
    Room Layout
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  • 59. WT4603
    Room Layout
    Department of Manufacturing & Operations Engineering
  • 60. WT4603
    Room Layout
    Department of Manufacturing & Operations Engineering
  • 61. WT4603
    Assess Risk (Risk Assessment)
    Department of Manufacturing & Operations Engineering
  • 62. WT4603
    Department of Manufacturing & Operations Engineering
  • 63. WT4603
    Hierarchy of Risk Control
    Eliminate the Hazard Completely.
    Substitute Hazard with a safer alternative.
    Isolate the Hazard.
    Use engineering controls to reduce risk at the source (Guarding).
    Provide training on how to avoid risks.
    & if all that fails…
    Use PPE.
    Department of Manufacturing & Operations Engineering
  • 64. WT4603
    Risk Assessment
    Department of Manufacturing & Operations Engineering
  • 65. WT4603
    Difference Between A Hazard & Risk
    • Hazard
    • 66. means anything that can cause harm (eg chemicals,electricity, working from ladders, etc)
    • 67. Risk
    • 68. is the chance, high or low, that somebody will beharmed by the hazard.
    Department of Manufacturing & Operations Engineering
  • 69. WT4603
    Importance of being able to Assess Risk
    Department of Manufacturing & Operations Engineering
  • 70. WT4603
    Risk Assessment Considerations
    • Consequences
    • 71. Minor Injury/Ill Health ( minor cuts, abrasions etc.)
    • 72. Injury/Ill Health (burns, sprains, minor fractures etc.)
    • 73. Serious Injury/Ill Health (breaks, deafness etc.)
    • 74. Major Injury/Ill Health (amputations, cancer, multiple breaks etc.)
    • 75. Fatality (one or more fatalities)
    Department of Manufacturing & Operations Engineering
  • 76. WT4603
    Factors Effecting Likelihood & Occurrence
    Individual Factors
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  • 86. WT4603
    Risk Magnitude
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  • 88. WT4603
    Factors Effecting Likelihood of Occurrence
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  • 89. WT4603
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  • 90. WT4603
    Risk Magnitude Matrix
    Department of Manufacturing & Operations Engineering
  • 91. WT4603
    Risk Magnitude Matrix: Severe Cut/Amputation from Bandsaw
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  • 92. WT4603
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  • 93. WT4603
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  • 94. WT4603
    Which Poses the Greatest Risk?
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  • 95. WT4603
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  • 102. WT4603
    Risk Assessment Template
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  • 121. WT4603
    CLASSROOM MANAGEMENT: Health & Safety…
    Department of Design & Manufacturing Technology
  • 122. WT4603
    Supervision & Access
    • Students should only work in a high risk area when it is fully under the control of a person competent to work in and supervise that area.
    • 123. Close monitoring of students using machinery.
    • 124. Students must not be permitted to use equipment while unsupervised.
    • 125. It is the responsibility of the schools to ensure that the machines are not accessible to unauthorised persons
    • 126. Cleaners
    • 127. Visitors
    • 128. Unsupervised students.
    Department of Manufacturing & Operations Engineering
  • 129. WT4603
    Supervision & Access
    Department of Manufacturing & Operations Engineering
  • 130. WT4603
    Supervision & Access
    Power operated equipment and tools should be locked in the “OFF” position in the following situations:
    • When left unattended for any period of time.
    • 131. When the competent person (supervisor) is not in the work area.
    • 132. Before cleaning out any blockage.
    • 133. Before the machine is cleaned.
    • 134. Before any maintenance work is carried out on the machine.
    • 135. Before guards are adjusted.
    • 136. Before tools or accessories are adjusted or changed.
    • 137. Before removing waste or swarf.
    • 138. When a machine is awaiting repair or maintenance.
    Department of Manufacturing & Operations Engineering
  • 139. WT4603
    Supervision & Access
    Department of Manufacturing & Operations Engineering
  • 140. WT4603
    Supervision & Access
    Machines not to be used while pupils are in the classroom:
    • Spindle Moulder
    • 141. It is recommended that the use of the circular saw and planer thicknesser machines while the students are in the classroom should be strictly prohibited.
    • 142. All preparatory work involving these machines should take place before class.
    • 143. May not be achievable immediately but plans should be made to try…in the interim control measures should be put in place to reduce exposure to as low levels as possible.
    Department of Manufacturing & Operations Engineering
  • 144. WT4603
    CE Mark
    The CE Marking is not a mark indicating conformity to a standard but rather a mark indicating conformity to the legal requirements of EU Directives.
    Department of Manufacturing & Operations Engineering
  • 145. WT4603
    CE Mark
    • CE Marking is the symbol as shown on the top of this page.
    • 146. The letters "CE" are the abbreviation of French phrase "ConformitéEuropéene" which literally means "European Conformity".
    • 147. The term initially used was "EC Mark" and it was officially replaced by "CE Marking" in the Directive 93/68/EEC in 1993.
    Department of Manufacturing & Operations Engineering
  • 148. WT4603
    CE Mark
    • Machinery must bear the “CE” mark in order to be deemed in compliance with these regulations.
    • 149. Must not add to machinery – must be there… criminal offence to try to add it.
    • 150. Also an offence to reduce the visibility of the “CE” Marking on a machine.
    Department of Manufacturing & Operations Engineering
  • 151. WT4603
    CE Mark
    The existance of the “CE” marking on a piece of machinery should indicate that its manufacturer has met all relevant standards and requirements.
    Department of Manufacturing & Operations Engineering
  • 152. WT4603
    CE Mark
    Never assume that machinery is safe just because it has a “CE” marking
    Department of Manufacturing & Operations Engineering
  • 153. WT4603
    Guarding
    Machine guards must:
    • Be of robust construction.
    • 154. Not give rise to any additional hazard.
    • 155. Not be easily removed or rendered inoperative.
    (Removed with the use of a tool)
    • Be situated a sufficient distance from the danger zone.
    • 156. Not restrict more than necessary the view of the operating cycle of the equipment
    Department of Manufacturing & Operations Engineering
  • 157. WT4603
    Exclusion Zones
    • An assessment of each workshop should be carried out in order to determine the safe operational area around each machine.
    • 158. Hard wearing and clearly visible markings should be set down on the floor to indicate these safe operation areas.
    • 159. If necessary, machines should be moved to accommodate this safe operational area.
    Department of Manufacturing & Operations Engineering
  • 160. WT4603
    Lighting
    Department of Manufacturing & Operations Engineering
  • 161. WT4603
    Emergency Isolators and Emergency Stops
    Department of Manufacturing & Operations Engineering
  • 162. WT4603
    Start/Stop
    Department of Manufacturing & Operations Engineering
  • 169. WT4603
    Start/Stop
    Stop control must have priority over the Start control.
    Start Control
    Stop Control
    Department of Manufacturing & Operations Engineering
  • 172. WT4603
    Emergency Stop
    Some machines may have two stopping devices.
    Hand Operated
    Foot/Knee Operated
    Department of Manufacturing & Operations Engineering
  • 173. WT4603
    Push Sticks
    Department of Manufacturing & Operations Engineering
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    Material Preparation
    Department of Manufacturing & Operations Engineering
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    Maintenance of Machinery
    Department of Manufacturing & Operations Engineering
  • 176. WT4603
    Preventative Maintenance
    Department of Manufacturing & Operations Engineering
  • 177. WT4603
    Maintenance Records
    Department of Manufacturing & Operations Engineering
  • 178. WT4603
    Inspection of Machinery
    Department of Manufacturing & Operations Engineering
  • 179. WT4603
    Inadvertent Starting
    Department of Manufacturing & Operations Engineering
  • 180. WT4603
    Machinery Rundown Time
    Department of Manufacturing & Operations Engineering
  • 181. WT4603
    A brief look at Safety Signage
    Emergency/Permission
    Mandatory/Action
    Warning/Caution-Danger
    Regulatory/Prohibited
    Department of Manufacturing & Operations Engineering
  • 182. WT4603
    Week2: Lab 1 & 2
    Table
    Department of Design & Manufacturing Technology
  • 183. WT4603
    Week 2: Lab 1 & 2
    Machine Exposure:
    Surface Planer
    Planer Thicknesser
    Bandsaw
    Material Process – Component A:
    Each student will receive an unprocessed plank of red deal measuring 750 x 245 x 50 (mm)
    Aim of week 2 labs is to square the material to a clean workable condition of required dimension.
    242
    740
    Department of Design & Manufacturing Technology
  • 184. WT4603
    Surface Planer
    Department of Design & Manufacturing Technology
  • 185. WT4603
    1
    9
    8
    2
    7
    3
    4
    6
    5
    Surface Planer
    10
    11
    12
    Department of Design & Manufacturing Technology
  • 186. WT4603
    Step 1:
    Isolate machine
    Out feed Table
    Step 2: Squaring guide fence
    • Set up surface planer guide fence @ 90⁰ to table surface
    • 187. Note infeed and outfeed table.
    • 188. Square to infeed using right angle square.
    • 189. Use red lock handles to open and adjust fence.
    • 190. Lock gently when fence is perpendicular to infeed table.
    Infeed Table
    Department of Design & Manufacturing Technology
  • 191. WT4603
    Infeed
    Infeed
    Step 3: Setting infeed dept
    • This machine is calibrated in metric.
    • 192. Maximum recommended material removal is 1-2mm/pass
    • 193. Dept stop to be set at 2mm
    • 194. Open infeed lock handle
    • 195. Turn wheel to left to drop table to 2mm
    • 196. Lower you drop, the more the planer cutting block is exposed
    • 197. Close infeed lock handle when required dept is achieved.
    • 198. * Do not adjust outfeed table level, this is for maintenance purposes only*
    Department of Design & Manufacturing Technology
  • 199. WT4603
    242 + 10
    Step 4: Setting the guide fence width
    • Minimum blade exposure
    • 200. Width of material + 10mm is recommended
    • 201. This results in 10mm blade exposure - Safety
    • 202. Adjust lock handle to wind in or out guide fence
    • 203. Lock in appropriate position
    242 + 10
    Department of Design & Manufacturing Technology
  • 204. WT4603
    Step 5: Guard adjustment
    • Guard set for face side = handle up – 10mm blade exposure
    • 205. Guard set for face edge = handle flat – no blade exposure
    Department of Design & Manufacturing Technology
  • 206. WT4603
    Step 6: Material Inspection
    • Inspect material for the following defects
    • 207. Cupping
    • 208. Bowing
    • 209. Twist
    • 210. Knots
    • 211. Loose grain
    • 212. Example - if material is bowed, set the bowed face to the surface planer table surface and process. Material should never be run through hump side down.
    Department of Design & Manufacturing Technology
  • 213. WT4603
    Step 7: Determining face side and face edge
    • Use machine surface to check square
    • 214. Select appropriate face side and face edge based on inspection
    • 215. Preliminary surface marking using an ‘X’ with no less than a HB pencil
    • 216. Ensure extraction gate valve is open and extraction is on
    • 217. Proceed to plane material – face side and face edge only!
    Gate Valve locate on extractor pipe just above surface planer
    X
    X
    Department of Design & Manufacturing Technology
  • 218. WT4603
    Step 8: Planing face side
    • Material position
    • 219. Hand positions
    Dept of Hand
    Dept of Hand
    Ensure Guard Guide is in a vertical position to plane face side
    Department of Design & Manufacturing Technology
  • 220. WT4603
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  • 221. WT4603
    Note Hand Positions in relation to material
    Department of Design & Manufacturing Technology
  • 222. WT4603
    Step 9: Planing face edge
    • Material position
    • 223. Hand position
    Dept of Hand
    Dept of Hand
    Ensure Guard Guide is in a horizontal position to plane face edge
    Department of Design & Manufacturing Technology
  • 224. WT4603
    Note Hand Positions in relation to material
    Split second blade Exposure
    Blade guard flat onto table
    Department of Design & Manufacturing Technology
  • 225. WT4603
    Thicknesser
    Department of Design & Manufacturing Technology
  • 226. WT4603
    1
    2
    3
    4
    Thicknesser
    Department of Design & Manufacturing Technology
  • 227. WT4603
    Lab sequence – Thicknesser
    Step 1:
    Unlock twist release stop mechanism
    Press green button to start
    Allow machine to build up, this can be determined by noise consistency
    When noise is consistent flip delta switch to on position
    Feed rate, i.e. Speed at which material is passed, is set.
    Adjust table height as required
    Feed material as directed
    Delta Switch
    Stop/Start
    Twist Release Stop
    Display Panel
    Thicknesser Bed Adjustment Control
    Feed Rate Control
    Department of Design & Manufacturing Technology
  • 228. WT4603
    Bandsaw
    Department of Design & Manufacturing Technology
  • 229. WT4603
    The bandsaw
    Department of Design & Manufacturing Technology
  • 230. See you all next week!
    Next week:
    Machine Provision
    Risk assessment
    Week 3 ripsaw labs
    WT4603
    Department of Design & Manufacturing Technology