This document discusses safety measures for power presses in Japan and proposals for Malaysia. It summarizes: 1) Japan has reduced power press accidents from 12,000 in 1972 to 559 in 2010 through phased safety measures including compulsory inspections, safety devices like light curtains, and prioritizing keeping hands out of dies. 2) Recommendations for Malaysia include following Japan's example of annual inspections, operator safety training, appointing operation chiefs, and adopting new regulations for automatic feeds and pressbrakes. 3) Proposals also involve introducing proper timing for inspections, safe operations, risk assessment, and establishing an occupational safety and health management system.

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. 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. 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. 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. 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. 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. 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

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