Machine Guarding for Injection Molding Machines

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Machine Guarding for Injection Molding Machines

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Machine Guarding for Injection Molding Machines

  1. 1. Machine Guarding for Injection Molding Machines OSHA 10-Hour Outreach Training Program for the Plastics Processing Industry A Presentation of the SPI-OSHA Alliance
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  4. 4. Course Objectives • Identify the types of injuries that can occur while operating injection molding machines • Describe the possible causes of these injuries • Identify ways to safely operate injection molding machines • Recognize the importance of a total safety and health approach
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  6. 6. Reasons to Focus on Injuries in the Injection Molding Process • High injury/illness rates • OSHA citations • National Emphasis Program • Site-Specific Targeting • High workers' compensation costs
  7. 7. Types of Injuries • Fatalities • Amputations • Avulsions • Fractures • Cuts and bruises • Sprains and strains • Burns • Electric shock
  8. 8. Some Causes of Injuries • Reaching around, under, over or through guards into hazardous areas • Removing or bypassing guards • Reaching into equipment to remove stuck or jammed material • Not using LOTO procedures • Machine/equipment malfunctions
  9. 9. Causes of Injuries (cont’d) • Lack of recognition of job hazards • Lack of familiarity with the equipment • Inadequate training, comprehension, or both • Operating machines with missing or inoperable guards and improper or inadequate machine maintenance
  10. 10. Injection Molding Machinery • Horizontal injection molding machine (HIMM) • Vertical injection molding machine (VIMM)
  11. 11. Vertical Injection Molding Machines VIMMs
  12. 12. VIMMs • Combinations of vertical and horizontal clamp and injection configurations of machines • Regardless of the configuration of the machine, basic machine guarding and good safe work practices must be applied – Point of operation – Other moving machine parts
  13. 13. VIMMs: Unique Hazards and Issues • Gravity • Plastic splatter/missing insert • Flying inserts • Unexpected bystander interventions
  14. 14. Horizontal Injection Molding Machines - HIMMs
  15. 15. HIMMs: Mechanical Hazards • Point of operation • Pinch points • Nip points • Rotating parts
  16. 16. Potential Injuries from Mechanical Hazards • Fatalities • Amputations • Avulsions • Crushing injuries • Fractures
  17. 17. Safety Guards and Devices • Types of guards and devices – Movable guards with interlocks – Fixed barrier guards – Presence-sensing devices – Mechanical safety bars • Locations of guards – Over/around moving equipment – Around electrical hazards – Around thermal hazards
  18. 18. Operator’s Gate • Equipped with redundant interlocks – Electrical – Hydraulic – Mechanical safety bar • Allows the machine to operate only when the gate is closed
  19. 19. Electrical Interlock • Allows the electrical system to operate and close the clamp • Actuated when the operator’s gate is opened or closed • Prevents clamp from closing when the operator’s gate is open
  20. 20. Electrical Interlock Operation
  21. 21. Hydraulic Interlock • Actuated by opening or closing the operator’s gate • Each hydraulic IMM requires at least one • Prevents clamp from closing when the operator’s gate is open
  22. 22. Hydraulic Interlock Operation
  23. 23. Before Activation After Activation Hydraulic Interlock Operation
  24. 24. • Prevents clamp from closing when the operator’s gate is open • Must have at least one mechanical device on all IMMs Mechanical Safety Device
  25. 25. Mechanical Safety Device Operation
  26. 26. Other Guarding • Rear guard • Top guard • Parts discharge guard • Feed opening guard • Electrical system guards • Purge guard • Injection barrel cover
  27. 27. Rear Guard • Prevents clamp from closing when interlocked rear guard is opened • Should have at least two interlocks • Prevents access to mold areas
  28. 28. Top Guard • Required if employees can reach over the top of the machine and into hazardous areas • Should be interlocked if movable
  29. 29. Top Guards (cont’d)
  30. 30. Parts Discharge Guard • Keeps employees from reaching under the operator’s gate and into hazardous areas
  31. 31. Purge Protection • Covers the nozzle and purging area • In combination with PPE, minimizes exposure to molten plastic during purging • Window allows observation through purge guard, if equipped • Should be equipped with an interlock Purge guard Safety window Barrel cover
  32. 32. Injection Barrel Cover • Protects from exposure to high voltage and high temperatures
  33. 33. Grinder Guarding Guarding by: •Enclosure over moving components •Anti-kickback flaps in feed throat •Proximity guarding – distance from feed chute to rotating knives Proximity Guarding
  34. 34. Abrasive Wheel Machinery Work rests on offhand grinding machines must be kept adjusted closely to the wheel with a maximum opening of 1/8-inch to prevent the work piece or tool from being jammed between the wheel and the rest, which may result in wheel breakage or wheel explosion.
  35. 35. Abrasive Wheel Machinery The distance between the wheel periphery and the adjustable tongue must never exceed 1/4-inch.
  36. 36. Power-Transmission Apparatus Power-transmission apparatus (shafting, flywheels, pulleys, belts, chain drives, etc.) less than 7 feet from the floor or working platform must be guarded. Unguarded belt and pulley
  37. 37. Presence Sensing Devices • Safety mat • Light curtain
  38. 38. Safety Guards and Devices Light Curtain
  39. 39. Presence Sensing Devices Safety Mat
  40. 40. How to Protect Yourself • Recognize the hazards in the job you are doing • Understand the requirements for guarding machines • Implement guarding solutions
  41. 41. Emergency Stop Know: • Where it is located • What it controls • When to use it
  42. 42. Signs and Warnings
  43. 43. Colors used with Safety Signs have meaning! DANGER White Lettering/Red Background WARNING Black Lettering/Orange Background CAUTION Black Lettering/Yellow Background
  44. 44. High Voltage
  45. 45. Rotating Screw
  46. 46. High Temperature
  47. 47. High Pressure
  48. 48. Robots • Used to automate repetitive or hazardous tasks • Must be guarded to prevent workers from entering or reaching into hazardous areas
  49. 49. The Robot
  50. 50. References for Injection Molding Safety •ANSI/SPI B151.1- 1997 Horizontal Injection Molding Machines - Safety Requirements for Manufacture, Care and Use •ANSI B11.19-2003 Performance Criteria for Safeguarding ANSI Standards are available at the following web site: www.ansi.org
  51. 51. OSHA's Site-Specific Targeting (SST) Program OSHA's Site-Specific Targeting (SST) program selects for inspection individual worksites with the nation's highest Days Away from Work Injury and Illness (DAFWII) Case Rate and Days Away, Restricted, or Transferred (DART) Rates. It is based on data reported by more than 80,000 employers surveyed by the agency. See the OSHA Web site for the most current directive and the rates used to target inspections. In order to verify the reliability of claims by establishments that they have achieved low DART rates, OSHA inspects a certain percentage of employers with low rates.
  52. 52. OSHA National Emphasis Program on Amputations On October 27, 2006, the Occupational Safety and Health Administration (OSHA) revised its national emphasis program aimed at reducing amputations in general industry workplaces. The National Emphasis Program on Amputations targets all types of machinery and equipment that are considered a high risk for causing amputations. The plastics processing industry is among the industries under scrutiny for workplace amputations. The twenty-four states and two territories which operate their own OSHA programs are encouraged, but not required, to adopt a similar emphasis program. State Plan State information is available on OSHA’s Web site. The OSHA directive on this emphasis program is available on OSHA's Web site under Regulations and Compliance, subcategory Compliance Directives, No. CPL 03-00-003. Under this initiative, regional and area OSHA offices will continue to conduct outreach; targeting and selection; and inspections. Area offices will obtain and use additional data to identify and add establishments where serious injuries or fatalities related to these machines have occurred.
  53. 53. The Job Safety Analysis Process The Job Safety Analysis (JSA) process is a very effective means of helping reduce incidents, accidents, and injuries in the workplace. It is a multi-step process. •Basic Job Steps •Potential Hazards •Recommended Safe Job Procedures
  54. 54. Summary • Injuries can occur while operating injection molding machines • Risk areas can be protected by safety guards and devices • Protect yourself and operate injection molding machines safely • Recognize the importance of a total safety and health approach
  55. 55. Do you have any Questions?

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