Identification and Assessment Form Assessment 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. Restricted access to the workshop. Workshop locked shut when not present. supervised by when in the workshop. issued with safety boots, overalls, eye protection, welding shield/goggles 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. Adequate working space maintained around each machine. 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 9
Identification and Assessment Form Assessment 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. o Selected gases piped in from outside. o Earthing strips 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 systems serviced and tested annually. Flashback arrestors fitted to both the oxygen and acetylene lines. Gas torches and hoses maintained in good condition. Hoses replaced immediately if damage noticed. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 2 of 9
Identification and Assessment Form Assessment Compressed gas cylinders Manual handling injuries Crush injuries Fire Explosion All Staff Full and empty cylinders kept in dedicated stores. o Stores locked. o Stores well ventilated. o Cylinders stored upright and securely fastened with chains. o Acetylene supplied to the workshop via manifolds from the separate bottle stores. o Red exclusion zone painted on the ground outside the acetylene store (no smoking). o Intrinsically safe lights & switches in the acetylene bottle store. Delivery driver drops off cylinders close to the appropriate store. Cylinders inspected upon arrival for damage. Cylinders colour coded and labelled with contents. 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). Cylinders brought into the workshop are restrained in the upright position using chains. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 3 of 9
Identification and Assessment Form Assessment Pyramid Roller Entrapment Gloves worn when holding the sheet. 1 3 3 Entanglement Foot pedals for forward and reverse feed. Rollers only move when pedal pressed. Emergency stops, including trip wire. Motor and drive belts enclosed. 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 9
Identification and Assessment Form Assessment Brake Press Entrapment Foot pedal for operation. Amputation 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. Gate access to the rear is interlocked. 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. Gloves used when lifting sheet metal. Pedestal Drill Cuts & lacerations Entanglement Workpiece clamped in place for drilling. Bit guard for most of the drills. Sharp bits used. Gloves and eye protection worn. 2 4 8 Emergency stop on selected machines. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 5 of 9
Identification and Assessment Form Assessment Guillotine Entrapment Moving parts enclosed and blade guarded. Amputation Front table to support steel sheet. Impact injuries Workpiece initially clamped in place by hold down jack. Cuts & lacerations Manual handling injuries Blade clearance checked before use. Foot pedal for operation. Operation stops when pressure taken off pedal. Cut pieces fall on the other side of the machine to the user. Gates to the rear of the machine to prevent access. One gate is interlocked, the other gate is locked during use. Emergency stops. Lockable isolator. Gloves used when lifting sheet metal. Team lift used for larger sheets (e.g. 4 man lift for 10 x 5 x 6mm sheet). Blades changed and set by the supplier. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 6 of 9
Identification and Assessment Form Assessment Pedestal Grinder Abrasions Cuts Wheels changed and dressed by competent person. The side of the wheel is never used for grinding. 2 4 8 Pinch injuries Rest for the workpiece. Most of the grinding stones have a flip down guard. Gloves used when holding the work piece on the moving grinding stone. Eye protection compulsory. Emergency stop. Lockable isolator. Angle Notching Machine Cuts & lacerations Cutting head enclosed. Foot pedal operation. 1 3 3 Emergency stop. Lockable isolator. Belt Sander Abrasions Flip down guard. Cuts Rest for the workpiece. Pinch injuries Gloves used. Eye protection compulsory. Emergency stop. Lockable isolator. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 7 of 9
Identification and Assessment Form Assessment Power Saw Housekeeping Abrasions Cuts Slips, trips & falls; Fire Obstructed escape All Staff Noise Hearing damage All Staff Moving parts of motor, drive belt and majority of the cutting blade enclosed. Interlock ensures that the blade stops when fully lowered. Cutting fluid reduces likelihood of swarf being ejected. Emergency stop. Bins located in the workshop. Bins emptied at the end of each day. Workshop cleaned at the end of each day. Walkways and exits kept free of obstructions. Racking in the workshop for required volumes of metal pipe and bar. Shelves have lips to prevent items rolling/falling off. Required volumes of sheet metal stored in the workshop on edge in rack. External storage with racking provided for bulk storage. External store locked shut. Hearing protection available. Signs erected indicating that hearing protection compulsory. 2 3 6 Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 8 of 9
Identification and Assessment Form Action Plan Tool & Machine Work General Welding Recommended Controls & Actions Consider implementing a formal lock out tag out procedure when undertaking service and repair work on major items of equipment. Consider marking the floor to highlight walkways that must be kept free of obstructions. A monitoring programme should be undertaken to determine exposure to metal fume during welding activities. Completion Date Person Responsible Revised Pedestal Drill The bit guard was missing on one of the pedestal drills and must be replaced. Pedestal Grinder Noise The flip down guard was missing on one of the grinding stones and must be replaced. The noise assessment for the Training Centre was completed several years ago and must be repeated. 1 3 3 Manager: Date: 18 th December 2015 Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 9 of 9