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 and supervised. supervised by when in the workshop. Safety boots and overalls compulsory when working in the workshop. Gloves, hearing protection and eye protection worn as required. Use of 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 12
Identification and Assessment Form Assessment Welding Oxy-acetylene, Oxy-propane, MIG, TIG, MMA Burns Arc-eye from sputter Exposure to metal fume and other welding gases All staff Individual welding booths for MIG & TIG, 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 benches on wheels so that they can be moved. Appropriate PPE provided. Welders must wear long sleeve overalls, safety boots, welding apron, welding visor, welding gloves. Metal jewellery is prohibited. 2 5 10 Electrocution Hearing damage Fire Manual handling injuries Oxy-acetylene & oxy-propane equipment used at open benches: o Moveable extraction arms located at each bench. o Curtains on frames used to shield passers by. o Oxygen & Acetylene piped in from outside. o Local on/off valves and flashback arrestors on both lines. Larger welding gear on wheels. Extraction systems serviced and tested annually. 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 12
Identification and Assessment Form Assessment Compressed gas cylinders Manual handling injuries Crush injuries All Staff Full and empty cylinders kept in well ventilated store. Store locked. Cylinders stored upright. Oxygen and acetylene cylinders segregated in the store by a block partition. Fire Cylinders inspected upon arrival for damage. Explosion 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. Cylinders that are brought into the workshop either left on the trolley, or chained in the upright position. 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). Oxygen & acetylene piped in from manifold outside. Shield gases kept on the trolley with the welding plant. Delivery driver drops off cylinders close to the appropriate store. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 3 of 12
Identification and Assessment Form Assessment Sheet Metal & Bar Hand injuries Manual handling injuries Crush injuries Gloves worn when handling sheet metal. Team lift used when moving larger sheets. Sheets stored on end, behind barrier. Racking for storing bar. Pedestal Drill Cuts & lacerations Entanglement Workpiece clamped in place for drilling. Interlocked bit guard. Sharp bits used. Gloves and eye protection worn. Grinding Stone Abrasions Wheels changed and dressed by competent person. Cuts The side of the wheel is never used for grinding. Pinch injuries Flip down guard for each stone. Gloves used when holding the work piece on the moving grinding stone. Eye protection compulsory. Emergency stop. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 4 of 12
Identification and Assessment Form Assessment Belt Sander Abrasions Flip down guard. Cuts Rest for the workpiece. Pinch injuries Gloves used. Eye protection compulsory. Emergency stop. Power Saw Abrasions Moving parts of motor, drive belt and majority of the cutting blade enclosed. Cuts Interlock ensures that the blade stops when fully lowered. Cutting fluid reduces likelihood of swarf being ejected. Emergency stop. Chop Saw Cuts & lacerations Amputation Spring loaded guard around the blade. Retracts for cutting, and returns when blade lifted. Trigger operation. Machine stops if pressure on the trigger released. Entanglement Hose Cutter Cuts & lacerations Blade enclosed during operation. pushed down to cut the hose. Guard lifts automatically as the lever is Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 5 of 12
Identification and Assessment Form Assessment Vehicle Access Crush injuries following impact with vehicles Staff Ramp up to the roller shutter railed on both sides. Pedestrians use the door beside the roller shutter. Overturning vehicle Exhaust Gases Asphyxiation Extraction hoses placed over engine exhausts. Carbon monoxide poisoning Engines running intermittently and for short durations. Engines not left running unnecessarily. Nederman arms in the Diesel Room. Hoses & Cables Slips, trips & falls All Staff Floor lights under selected lifts to reduce the need for lead lamps. Air lines retracted when no longer required. Lead lamps removed and wound up when no longer required. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 6 of 12
Identification and Assessment Form Assessment Vehicle Lifts & Trolley Jacks Crush injuries Overturning vehicles Lifting gear inspected annually. Safe working load (SWL) indicated and adhered to. Vehicle lifts: o Vehicle parked on ramp with handbrake on. Chocks also used with larger vehicles on the 4-post lift. 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 Holder plates secured together when using the vibrating plates for testing the suspension. Axle stands used once vehicle lifted to required height by trolley jack. Vibrating Plate & Alignment Tester Slip, trip, fall Sunk into the floor. Edges highlighted. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 7 of 12
Identification and Assessment Form Assessment Chemicals Fuels, Oils, lubricants, hydraulic fluid, cleaning solvent, Batteries Irritation/burns to skin/eyes Dermatitis Fire Nitrile gloves used when handling oils, lubricants & hydraulic fluid. Hands washed regularly. Barrier creams available. Extracted Oil Store. Piston pumps fitted to the large drum for siphoning off oil. Flammables press for storage of fuels in Jerry Cans, oils and lubricants. New batteries stored in cabinet. Dedicated room for battery charging. Parts cleaning tank located in extracted Oil Store. 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. Battery Charging Burns to skin or eyes Explosion Extraction system. Full face shield, apron and gloves used when topping up batteries. Eye wash located in the room. Emergency shower in the main workshop. 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 on selected units. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 8 of 12
Identification and Assessment Form Assessment Hydraulics / Brakes Displays Manual handling injuries Fixed on trolley on castors, so can be moved into position easily. Other Engines, Gearboxes etc. Manual handling injuries Hand injuries Stored on pallet and moved into position using forklift or hand pallet truck. Lifted onto bench using crane & slings. Engines & gearboxes only used for dismantling/assembly. Engines & gearboxes chocked to prevent them from toppling. Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 9 of 12
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 Vacuum o Workbenches o MIG welding plant o Jacks and engine lifts. o Wheelie bins o Spill kit in wheelie bin Trolleys used for moving gas cylinders. AG Block engines on trolleys. Other engines stored on pallets, moved into position using the forklift or a hand pallet truck. Drum grab for moving oil drums. Piston pumps fitted to large drums for siphoning off oil. Motorised roller shutter. Chain for manual operation if the motor fails. Dust Respiratory irritation Electric sanders connected to extraction during use. Eye protection used Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 10 of 12
Identification and Assessment Form Assessment Compressed air Compressed air lines fixed to selected equipment. Skin penetration Eye protection used when using compressed air guns. Explosion Air receiver inspected annually. Supply points around the workshop, including columns dropped from the ceiling. Housekeeping Slips, trips & falls; Fire Obstructed escape All Staff 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. Cupboards and racking for storage. Points for power and services such as compressed air, located throughout the workshop to minimise trailing cables. 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. Compressor located in a sound enclosure. 2 3 6 Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 11 of 12
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 Welding A monitoring programme should be undertaken to determine exposure to metal fume during welding activities. The oxygen and acetylene points are roughly at head height. To stop passers by walking into them, ensure that the benches are left under the supply points. Hoses & Cables Consider installing floor lights under selected lifts to reduce the need for lead lamps. Chemicals Ensure that the drums for waste oil are clearly labelled. Fuels, Oils, lubricants, cleaning solvent, Batteries s, lacquers The drums for the waste oil should be placed on a bunded pallet. In the event of a leak the oil would be retained in the bund, rather than spilling all over the floor. Noise The noise assessment for the Training Centre was completed several years ago, and must be repeated. Manager: Date: 18 th December 2015 Produced by: Oak Leaf Safety Ltd. Ver: 1/2015 Page 12 of 12