Isolate/Lock off? Learning's/objectives of today: - Improve the safety standard for employees working on machinery.

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1 Isolate/Lock off? Learning's/objectives of today: - Improve the safety standard for employees working on machinery. Why do we need to do this? - As we further improve health and safety on site, our ways of working will need to change. Same Actions/Same Output. - It s legally, morally and financially correct. - Whilst we don t have many machinery accidents, when they do occur they can be very serious or even fatal.

2 Isolate/Lock off? What are we going to do? - We are going to carry out a process which looks at all the main activities we do on machinery, and this will give us a guidance on the standards we need to adopt to make sure that people don t get hurt by that machinery. Our starting point is to carry out a machinery assessment, and that is what you will learn about today. - The results of these assessments will then help us as a site to determine the level of interlock standards/isolation and lock off standards we need to adopt.

3 Isolate/Lock off? The end goal will be absolute clarity for everyone, on every machine, of when to trust an interlock and when isolation and lock off (padlock) is needed. The tool we are going to use to do this is an assessment proforma.

4 1 ST Port of Call BS 292 Possible Categories which can require additional Measures Preferred Categories Measures which can be over dimensioned. Key S Severity of injury S1 Slight (normally reversible) injury S2 Serious (normally irreversible) injury including death F Frequency and/or exposure time to the hazard F1 Seldom to quite often and/or the exposure time is short F2 Frequent to continuous and/or the exposure time is long P Possibility of avoiding the hazard P1 Possible under specific conditions P2 Scarcely possible

5 ASSESSMENT PROFORMA Machine/Line Task Clearing Jams Routine (new film) Changeovers Cleaning Deep Clean Web Bonding Programming Commissioning Other: Time Taken Severity Likelihood Frequency Total Consider the following for each task applicable, or mark N/A: Less than 5 minutes 1 Scratch 1 Very Unlikely due to distance of hazard 1 Longer minutes 3 Burn/Cut/Bruise 3 Unlikely awkward to get to hazard 3 1 per week hour 5 Severe Laceration 6 Likely hazard easily accessible 5 3 times per week 1 Above 1 hour 7 Break 30 Very Likely hazard hard to avoid 10 1 per day 2 N/A 0 Loss of Limb 50 Every 4 hours 3 Death 70 Every 1 hour 4 Every 10 minutes 5

6 ASSESSMENT PROFORMA: EXAMPLE Time Taken Severity Likelihood Frequency Machine/Line Task Total Ice Cream Machine Clearing Jams Line 3 Routine (new film) Changeovers Cleaning Deep Clean Web Bonding N/A N/A N/A N/A 0 Programming N/A N/A N/A N/A 0 Commissioning N/A N/A N/A N/A 0 Other: 0 Maintenance Consider the following for each task applicable, or mark N/A: Less than 5 minutes 1 Scratch 1 Very Unlikely due to distance of hazard 1 Longer minutes 3 Burn/Cut/Bruise 3 Unlikely awkward to get to hazard 3 1 per week hour 5 Severe Laceration 6 Likely hazard easily accessible 5 3 times per week 1 Above 1 hour 7 Break 30 Very Likely hazard hard to avoid 10 1 per day 2 N/A 0 Loss of Limb 50 Every 4 hours 3 Death 70 Every 1 hour 4 Every 10 minutes 5

7 Isolate/Lock off? Questions? Practical on the shop floor : 1 hour. Back to Classroom - for questions and feedback on assessment format. What you do next: - As a department develop a timescale plan to assess all your machines.

8 Prioritisation Machine/Line Task Time Taken Severity Likelihood of Injury Frequency of Task Artofex Mixers scrapping off mixed cream cleaning beaters Cream Tanks cleaning/ scrapping hopper cleaning/ removing the whisk fitting the whisk spindle mixers knock off mixed dough INTER-LOCK ON EACH HATCH ONLY ENGINEERS OPEN IF SEAL NEEDS REPLACIN AUGER AND PUMP Deep Clean plain chocolate kettle (9971) hand feed choc into tank clean off mixed dough or cream clean off mixed dough or cream adding ingredients raising and lowering mixer hood adding ingredients adding ingredients Butter Oil Kettle adding block of butter oil Large Diosna raising and lowering the hood locking in bowl cleaning mixer top tw6 Denester Clearing Jams tw7 Denester Clearing Jams Hygiene barrier sieving room top of scissors lift Deep Clean raising and lowering beaters cleaning cleaning Coconut Oil Kettle adding block of coconut oil unsweetened chocolate kettle (9975) pumping in chocolate Hobart Mixer locking in bowl raise and lower the beaters I INTER -LOCK ON EACH HATCH AT TOP ENGINEERS ONLY GO UP IF PROBLEM WITH TANK Hygiene Barrier Sieving Room Bottom scissors lift gate Deep Clean BOTTOM STORES COMPACTOR Deep Clean Hygiene barrier sieving room car holder doors Deep Clean GATES WITH 2 INTER-LOCKS ON EACH GATE TAKING BAGS OF PALLETS FOR SIEVING adding ingredients tipping cream/ scrapping bowl Small Diosna raising and lowering the hood logging in bowl I INTER-LOCK ON EACH DOOR PUTTING CARTS IN FOR FILLING UP OPEN AND CLO INTER-LOCK ON BUTTER CHUTE OPEN CHUTE TO UNBLOCK INTER - LOCK ON DELIVERY DOOR OPEN DOOR FOR CHOCOLATE DELIVERY cleaning cleaning INTER-LOCK ON EACH GATE OPEN AND CLOSING GATES TO PUT PALLETS ON SC I INTER-LOCK ON DOOR PUTTING WASTE IN adding ingredients Total

9 Machinery Labelling Cream Tanks The following tasks are allowed by trusting the interlock Cleaning Beaters Cleaning / scrapping hopper Cleaning / removing the whisk ALL OTHER TASKS MUST HAVE FULL ISOLATION AND LOCK OFF

10 Further Actions Access to some machines has been highlighted as high risk / high frequency. Actions to address this are Review why access is needed, consider remote access / adjustment / setting, reliability issues, timescales in the machine. Upgrade of Interlock arrangements Cost Vs Benefit analysis.

11 We have not finished yet, but learning's are You need a mixture of operatives and engineers doing the assessments. All shifts need input. Even if they do not do assessments, putting machine minders through the training has switched people on to the safety aspects.

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