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Wt4603 unit1 week2-12-09-2011

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Week 2 - Risk Assessment

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Wt4603 unit1 week2-12-09-2011

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

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