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. Safety boots and overalls compulsory when working in the workshop. Hearing protection, gloves and eye protection worn as required. Use of PPE actively enforced. The PPE requirements displayed at the entrance to the workshop. 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 Chemicals Fuels, Oils, lubricants, cleaning solvent, Batteries Irritation/burns to skin/eyes Dermatitis Fire, explosion Gloves and barrier creams used when handling chemicals. Hand washed when finished work with chemicals. Flammables press for storage of fuels in Jerry Cans, oils and lubricants. New batteries stored in cabinet. Battery charging carried out in well ventilated area. Parts cleaning tank never overfilled. Lid closed and pump turned off when not in use. Spills dealt with promptly. Spill absorbent provided. Wet floor signs. Used oil collected and disposed of appropriately. Plumbed in eye wash station. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 2 of 9
Identification and Assessment Form Assessment Manual Handling Back injuries Muscle strains The precautions applicable to all area, plus: Significant amount of the equipment used in the workshop on lockable castors/wheels, including: o Toolboxes o Diagnostic equipment o Engine blocks o Wheelie bins o Trolley jacks o Hydraulic oil dispensers Sack truck and hand pallet truck available. Collection tanks for waste oil emptied using compressed air. Large waste oil drum moved using fork lift. Engine oil dispensed into jug and carried to vehicle. Exhaust Gases Asphyxiation Extraction hoses placed over engine exhausts. Carbon monoxide poisoning Engines running intermittently and for short durations for testing. Engines not left running unnecessarily. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 3 of 9
Identification and Assessment Form Assessment Vehicle Lifts, Trolley Jacks, Engine Crane Crush injuries Slip, trip, fall supervises vehicles onto the lifts. Vehicles generally pushed into position. Lifting gear inspected annually. Safe working load (SWL) indicated and adhered to. Vehicle lifts: o End plates automatically flip down to prevent vehicles rolling off. o Lifts have built in air locks so they do not drop to the ground in the event of a failure. o Pressure has to be maintained on the button when lifting/lowering. Lift stops when button released. o Audible beep when lowering below one foot. o High visibility tape on the floor around the edges. Significant gaps covered by metal plates. Engine crane chained to the wall when not in use. Lights set in the floor for the 2m lift so that users do not have to use lead lamps. AG Block Engines Manual handling injuries Entanglement Burns/scalds Fixed on trolley on castors, so can be moved into position easily. Fans and belts guarded. Mesh guard surrounding the exhaust manifold. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 4 of 9
Identification and Assessment Form Assessment Other Engines Manual handling injuries Hand injuries Rolling Road Slip, trip, fall Wheel Balancer Tyre Changer Manual Handling Entanglement Impact injuries Manual handling injuries Entanglement Explosion Lifted onto bench using hoist. Engines only used for dismantling/assembly. Engines chocked to prevent them from toppling. Plates cover the rollers when not in use. High visibility tape on the floor around the edges. Damper testers within the taped/highlighted area. Two person lift used for larger/heavier wheels. Wheel secured in place by the boss. Wheel will not spin until safety hood pulled down over tyre. Wheel spins for a short duration and is never left unattended when spinning. Two person lift used for larger/heavier wheels. Wheel clamped in place. Valve core removed before removing the tyre from the rim. Lever used to start removing the tyre, head lifts off the rest as the wheel rotates. Wheel rotates slowly. Tyres inflated to recommended pressure. Tyres never over inflated. Visibly damaged tyres taken out of service and disposed. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 5 of 9
Identification and Assessment Form Assessment Battery Charging Burns to skin or eyes Explosion Batteries charge in well ventilated area. Full face shield and gloves used when topping up batteries. Plumbed in eye wash station. Compressed air Eye injuries Compressed air lines fixed to selected equipment. Skin penetration Eye protection used when using compressed air guns. Explosion Compressor located outside the workshop. Air receiver inspected annually. Supply points around the workshop, including columns dropped from the ceiling. Pedestal Drill Cuts & lacerations Eye injuries Entanglement Workpiece clamped in place for drilling. Sharp bits used. Adjustable bit guard. Gloves and eye protection worn. Emergency stop. Lockable isolator. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 6 of 9
Identification and Assessment Form Assessment Bench Grinder Coil Spring Compressor Abrasions Cuts Pinch injuries Eye injuries Impact injuries Hydraulic Press Crush Injuries Housekeeping Hoses & Cables Slips, trips & falls Fire Obstructed escape Slips, trips & falls All Staff All Staff Wheels changed and dressed by competent person. The side of the wheel is never used for grinding. Flip down guard. Gloves used when holding the work piece on the moving grinding stone. Eye protection compulsory. Lockable isolator. Guard fitted around spring during use. Guard chained in place. Foot pedal operation. Manually operated using handle. 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. Offices and store include cupboards and racking. Floor lights under selected lifts to reduce the need for lead lamps. Air lines retracted when no longer required. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 7 of 9
Identification and Assessment Form Assessment Noise Hearing damage Nuisance to other building occupants All Staff Engines running intermittently and for short durations for testing. Engines not left running unnecessarily. Hearing protection available. Hearing protection used when running diesel engines at full revs. Compressor located outside the workshop. 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 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 General Noise The noise assessment for the Training Centre was completed several years ago and must be re-assessed. Manager: Date: 18 th December 2015 Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 9 of 9