Current Tool & Machine Work General Various injuries (including potential fatalities) All staff complete safety induction programme at the start of the module. instructed in safe operation of each tool/machine. supervised at all times in the workshop. Workshop locked shut when not present. 1 5 5 issued with safety boots, overalls, eye protection, welding shield and gloves. Further PPE including hearing protection, welding aprons etc available. Use of the supplied PPE actively enforced. Emergency stops distributed around the workshop cut the power to all machines in the workshop. Power can only be reinstated once it has been reset in the s office. Guards and other safety devices on machines/tools are never defeated. Equipment is serviced and maintained as required. Faulty equipment is taken out of service until repaired satisfactorily. Equipment isolated during service or repair. Portable electric tools are 110v. Power cables are routed away from walkways. Floor marked around each machine to ensure that adequate working space maintained. Walkways kept free of obstructions. Long hair restrained and no loose clothing when using machines/tools. Specific precautions for some of the various machines used/activities in the workshop are detailed on the following pages. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 1 of 12
Welding Oxy-acetylene, MMA, MIG, TIG Burns Arc-eye from sputter Exposure to metal fume and other welding gases Electrocution Hearing damage Fire Manual handling injuries All staff Individual welding booths, including: o Welding curtain to the front. o Moveable extraction arm. o Rubber mat on the floor at the user position o Appropriate electrical outlet (with RCD); for plant. o Welding tables on wheels so that they can be moved. Tables have removable tops so they can also be used for gas cutting. o Selected shield gases piped in from outside. o Partition and benches earthed. Earthing strip so that the work piece can be earthed for welding. Appropriate PPE provided. Welders must wear long sleeve overalls, safety boots, welding apron, welding visor, welding gloves. Metal jewellery is prohibited. Larger welding gear on wheels. Extraction can be re-positioned to above the cutting tables in the main workshop. Extraction systems serviced and tested annually. Scavenger fan in the dedicated welding area extracts metal fume and welding gases not collected by the local extraction arm. Fresh air also forced into this area. Only experienced trainees allowed to use the secondary welding area. Flashback arrestors fitted to both the oxygen and acetylene cylinders. Gas torches and hoses maintained in good condition. Hoses replaced immediately if damage noticed. Current 2 5 10 Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 2 of 12
Current Compressed gas cylinders Manual handling injuries Crush injuries Fire Explosion All Staff Full and empty cylinders kept in dedicated stores. Stores locked shut. Cylinders stored upright and securely fastened with chains. Separate stores for oxygen and acetylene cylinders. Oxygen and acetylene stores well ventilated. Cylinders inspected upon arrival for damage. Cylinders colour coded and labelled with contents. 1 5 5 During use, cylinders kept on trolley. Cylinders and regulators, especially the thread, kept clean. Connected cylinders leak tested. Supply shut off at the valve when not in use. Trolleys used when moving cylinders. Safety boots compulsory when moving cylinders. Correct regulator for contents and required supply pressure used. Damaged regulators taken out of service immediately. Older/used regulators taken out of service (after roughly 4 years service). Selected shield gases piped into Workshop from manifold outside. Delivery driver drops off cylinders close to the appropriate store. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 3 of 12
Current Pyramid Roller Entrapment Entanglement Manual handling injuries Foot pedals for forward and reverse feed. Rollers only move when pedal pressed. Emergency stops, including trip wire. Motor and drive belts enclosed. 1 3 3 Machine on castors so that it can be easily moved into position. Wheels are lockable. Piece moves slowly during use. Syllabus only requires rolling of small workpieces that can be easily supported by hand. Iron Worker Entrapment Entanglement Amputation Impact injuries Moving parts enclosed and guarded. Moveable guards are interlocked. Flip guards on the outlet side of the machine. Warnings notices. Foot pedal for operation. Operation stops when pressure taken off pedal. Emergency stop. Isolator. Key removed by the instructor when not in use. Guides/stands used to support steel during use. Cut pieces fall into trolley on the other side of the machine to the user. Rubber mat placed on base of trolley to cushion impact. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 4 of 12
Brake Press Entrapment Amputation Two person operation. Second person acts as a buddy to observe the operation and warn others in the Workshop. Foot pedal for operation. Current Workpiece initially clamped in place. Light curtain ensures the user cannot get close to the lowering press. User can move in to hold the workpiece once it has been clamped. Workpiece always supported by hands beneath it. Never held with hands on top. Emergency stop. Side guarded. Guard only removed when changing top tool and bottom die. Top tool and bottom die slid into position through the side. Top tool clearance and die ratio checked before use. Access to the rear of the machine restricted. Gloves used when lifting sheet metal. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 5 of 12
Guillotine Entrapment Amputation Impact injuries Cuts & lacerations Manual handling injuries Two person operation. Second person acts as a buddy to observe the operation and warn others in the Workshop. Moving parts enclosed and blade guarded. Front table to support steel sheet. Workpiece initially clamped in place by hold down jack. Blade clearance checked before use. Foot pedal for operation. Operation stops when pressure taken off pedal. Current Cut pieces fall on the other side of the machine to the user. Light curtain at the back stops operation if someone gets to close to the rear of the machine. Emergency stops. Gloves used when lifting sheet metal. Sheet delivered direct to dedicated trolley in the Workshop and cut to size before being stored. Blades changed and set by the supplier. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 6 of 12
Current Lathe Cuts & lacerations No longer part of the course so not being used. Currently isolated. Entanglement Pedestal Drill Cuts & lacerations Entanglement Workpiece clamped in place for drilling. Sharp bits used. Adjustable bit guards. Interlocked bit guard on the Quantum drill. Pendulum guard cuts power to the machine if the workpiece spins. Eye protection worn. Emergency stop. Belt Sander Abrasions Flip down guard. Cuts Rest for the workpiece. Pinch injuries Eye protection compulsory. Emergency stop. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 7 of 12
Current Bench Grinder Abrasions Wheels changed and dressed by competent person. Cuts The side of the wheel is never used for grinding. Pinch injuries Flip down guards. Eye protection compulsory. Special, non-flickering light fitted above the grinder (more likely to see whether the wheels are turning). Power Saw Abrasions Saw room locked shut when not in use. Cuts complete theory session and demonstrated use of the power saw, before being allowed to use it themselves. Two person operation second person acts as a buddy to observe the operation. Moving parts and majority of the cutting blade enclosed. Blade changed by. Interlock ensures that the blade stops when fully lowered (i.e. when cut finished). Cutting fluid reduces likelihood of swarf being ejected. Emergency stop. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 8 of 12
Current 4 Grinder Shock, electrocution Abrasions Cuts 110v. Trigger operation stops when trigger released. Disc mounted by competent person. Disc guard. Visor worn during use. Manual Handling Back injuries Muscle strains The precautions applicable to all area, plus: Sheet delivered direct to dedicated trolley in the Workshop and cut to size before being stored. 1 3 3 Store for sheet and bar located outside the workshop, but adjacent to the roller shutter. Syllabus only requires fabrication of small workpieces that can be easily supported by hand. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 9 of 12
Housekeeping Slips, trips & falls; Fire Obstructed escape All Staff Bins located in the workshop. Bins emptied at the end of each day. Mini skip for metal waste. Mini skip moved using pallet truck or forklift truck. Workshop cleaned at the end of each day. Walkways and exits kept free of obstructions. Cupboard for each trainee under workbench (for toll box, work in progress etc.). Current 1 5 5 External storage with racking provided for metal pipe, bar and sheets. Sheet delivered direct to the Workshop and cut to size before being stored. Roller shutter Closing shutters causing crush/impact injuries Manual handling injuries All staff Visitors Motorised shutter has hold-to-run controls, so always attended when closing. As a back up to the motor, shutter can be opened easily using the pully chains. Separate door for pedestrians located beside roller shutter. Pedestrians actively encouraged to use the adjacent door, rather than the roller shutter when accessing/leaving the building. Vehicles hitting pedestrians Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 10 of 12
Current Noise Hearing damage All Staff Hearing protection available. 2 3 6 Nuisance to other building occupants Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 11 of 12
Action Plan Tool & Machine Work Recommended Controls & Actions Consider implementing a formal lock out tag out procedure when undertaking service and repair work on major items of equipment. Completion Date Person Responsible Revised 1 5 5 General Welding A monitoring programme should be undertaken to determine exposure to metal fume during welding activities. 1 5 5 The black curtain strips separating the secondary welding area from the corridor limit visibility for those exiting the welding area. Consider replacing these curtain strips with transparent alternatives. Brake Press Consider a pressure sensitive mat for the back of the brake press. The mat should be connected to the operation of the brake press (somebody could potentially stand behind the press, inside the current gate). 1 5 5 Lathe As the lathe is no longer part of the course and not being used, consider removing the lathe from the workshop. Power Saw The remote and enclosed location of this machine means that supervision is difficult. Consider relocating the power saw. Noise The noise assessment for the Training Centre was completed several years ago. Exposure to noise must be re-assessed. 1 3 3 Manager: Date: 21 st December 2015 Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 12 of 12