wt4603 unit1 week2-12-09-2011

WT4603 Wood Processing Safety & PracticeAUTUMN 2011Lecture Unit 1

Machine Provision, Hazard Identification, Risk Assessment & Week 2 Labs Lecturer: Mr. Joseph Lyster [email protected] Notes prepared by: Mr. Joseph Lyster Notes available on www.slideshare.net/WT4603

mailto:[email protected]

http://www.slideshare.net/WT4603

Department of Manufacturing & Operations Engineering

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• Section 8(2)e of the 2005 (Now 2007) Act states that it is the duty of every employer“to provide systems of work that are planned, organised, performed and maintained so as to be, so far as is reasonably practicable, safe and without risk to health.”

• Health and safety management is a practical and systematic approach to identifying hazards and evaluating the extent of associated risk

Health & Safety Management


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Can be identified by:▫High accident/injury rates.▫Poor machinery guarding.▫Poor cleaning and housekeeping arrangements.▫Limited interest of OHS by employers/management.▫Lack of care/respect for safety rules.▫Poor safety culture.

Unsafe Workplaces


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Can be identified by:

•Regular inspection of workplace•Consultation between employer and employees.•Clearly defined structure of responsibilities….•Employees are trained…•Exceeds the specific requirements of the law –

manages safety not for fear of being reprimanded but for the employees.

Safe Workplaces


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The Key steps of any Health & Safety Management scheme are:

1. Policy2. Hazard identification3. Risk Assessment4. Control Measures.5. Recording Findings (Safety Statement)6. Monitoring, Review and Auditing

Safety Management


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Importance of being able to Assess Risk


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Required Reading


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The Safety Management Process


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Health & Safety Policy


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More information can be found byconsulting manufacturer’s manual


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Health & Safety at Work Act 2005

Pg. 30 of Health & Safety at Work Act

2005


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Identify Hazards (Hazard Identification)


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Hazards in the Workplace


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Definition: Hazard


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Hazards in the Workplace


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Some Possible Hazards


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Common Machinery/Mechanical Hazards


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Wrap Point: (Entanglement)


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Shear Point and Cutting Hazards


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Crush Points


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Ejection Hazards


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Other Hazards


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Hazards


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• You will need to develop a template for your lesson risk assessment.• Strategies will need to be developed to:

Reduce or eliminate risk Demonstrate safe use of machine(s) Teach key learning points relating to machine or process Assess and record pupil learning and competence Ensure adequate supervision of activities

Classroom Risk Assessment:


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Room Layout


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Assess Risk (Risk Assessment)


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A. Eliminate the Hazard Completely.B. Substitute Hazard with a safer alternative.C. Isolate the Hazard.D. Use engineering controls to reduce risk at the source

(Guarding).E. Provide training on how to avoid risks.& if all that fails…F. Use PPE.

Hierarchy of Risk Control


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Risk Assessment


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• Hazard • means anything that can cause harm (eg

chemicals, electricity, working from ladders, etc)

• Risk • is the chance, high or low, that

somebody will be harmed by the hazard.

Difference Between A Hazard & Risk


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Importance of being able to Assess Risk


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• Consequences

▫Minor Injury/Ill Health ( minor cuts, abrasions etc.)▫ Injury/Ill Health (burns, sprains, minor fractures etc.)▫Serious Injury/Ill Health (breaks, deafness etc.)▫Major Injury/Ill Health (amputations, cancer, multiple breaks

etc.)▫Fatality (one or more fatalities)

Risk Assessment Considerations


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▫Knowledge▫Skills▫Training▫Experience▫Attitude

▫Motivation▫Risk perception▫Mental condition▫Physical condition▫Accident proneness

Factors Effecting Likelihood & OccurrenceIndividual Factors


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Risk Magnitude


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Factors Effecting Likelihood of Occurrence


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Risk Magnitude Matrix


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Risk Magnitude Matrix: Severe Cut/Amputation from Bandsaw


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Which Poses the Greatest Risk?


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Department of Design & Manufacturing Technology

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RISK ASSESSMENTLocation: SR2-047 Date: 24-09-2010 Assessment Carried out by: Mr. Joe LysterAssessment of: PILLAR DRILL CE Marking (Machines): Yes □ No □Page 1 of 1 Assessment Review Date: 24-09-2010

HAZARD RISK MAGNITUDE PERSONS AT RISK EXISTING CONTROLS REQUIRED CONTROLS PERSONS RESPONSIBLE TARGET DATE

Weekly etc…


Risk Assessment Template

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RISK ASSESSMENTLocation: SR2-047 Date: 24-09-2010 Assessment Carried out by: Mr. Joe LysterAssessment of: PILLAR DRILL CE Marking (Machines): Yes □ No □Page 1 of 1 Assessment Review Date: 24-09-2010


1. Entanglement

2. Violent Ejection

3. Piece Spinning4. Electric Shock Hazards5. Cuts

6. Inadvertent Starting7. Space around Machine8. Tripping/Slipping9. Pinch Point

10. Falling Table

11. Noise Levels

12. Crushing


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1. ENTANGLEMENTSEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D

Highly Unlikely Trivial Tolerable Tolerable Moderate Moderate

Quiet Unlikely Tolerable Tolerable Moderate Moderate Substantial

Likely Tolerable Moderate Moderate Substantial Substantial

Quite Likely Moderate Moderate Substantial Substantial Intolerable

Highly Likely Moderate Substantial Substantial Intolerable Intolerable


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2. VIOLENT EJECTIONSEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D







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3. PIECE SPINNINGSEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D







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4. ELECTRIC SHOCKSEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D







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5. CUTSSEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D







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6. INADVERTENT STARTING

SEVERITYSlightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D







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7. SPACE AROUND MACHINE

SEVERITYSlightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D







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8. TRIPPING/SLIPPINGSEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D







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9. PINCH POINTSEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D







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10. FALLING TABLESEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D







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11. NOISE LEVELSSEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D







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12. CrushingSEVERITY

Slightly Harmful

Moderately Harmful

Quite Harmful

Very Harmful

Extremely Harmful

LIKELIHOO

D







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RISK ASSESSMENTLocation: SR2-047 Date: 24-09-2010 Assessment Carried out by: Mr. Joe Lyster

Assessment of: PILLAR DRILL CE Marking (Machines): Yes No □□̷Page 1 of 1 Assessment Review Date: 24-09-2010


1. Entanglement Intolerable User of Machine Securing Clothes/Hair Chuck Guard Teacher/Students 24-09-2010

2. Violent Ejection Moderate All in Class Spring Loaded Chuck Chuck Guard Teacher/Students 24-09-2010

3. Piece Spinning Moderate All in Vicinity Clamp Correct Clamping Teacher/Students 24-09-2010

4. Electric Shock Hazards Moderate User of Machine Inspection of

EquipmentRegular Inspection of electrical components

Teacher/Students 24-09-2010

5. CutsModerate User of Machine Training

Exclusion zones marked clearly in

relation to work areaTeacher/Students 24-09-2010

6. Inadvertent Starting Moderate All in Vicinity Lockable Isolator

SwitchLock isolator in the off position when not in

useTeacher/Students 24-09-2010

7. Space around Machine Substantial User of Machine Nothing

Safe work area exclusion zone marked

around machineTeacher/Students 24-09-2010

8. Tripping/Slipping Moderate User of Machine Nothing Sign posts Teacher/Students 24-09-2010

9. Pinch Point Substantial User of Machine Nothing Chuck Guard Teacher/Students 24-09-2010

10. Falling Table Moderate User of Machine Pillar Post Lock Handle Correct Locking/Clamp Teacher/Students 24-09-2010

11. Noise Levels Trivial All in Class Nothing PPE & Sign posts Teacher/Students 24-09-2010

12. Crushing Intolerable All in Vicinity Nothing Secure Fixing Teacher/Students 24-09-2010


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CLASSROOM MANAGEMENT:

Health & Safety…


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• Students should only work in a high risk area when it is fully under the control of a person competent to work in and supervise that area.

• Close monitoring of students using machinery.• Students must not be permitted to use equipment while

unsupervised.• It is the responsibility of the schools to ensure that the

machines are not accessible to unauthorised persons▫Cleaners▫Visitors▫Unsupervised students.

Supervision & Access

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Power operated equipment and tools should be locked in the “OFF” position in the following situations:▫When left unattended for any period of time.▫When the competent person (supervisor) is not in the work

area.▫Before cleaning out any blockage.▫Before the machine is cleaned.▫Before any maintenance work is carried out on the machine.▫Before guards are adjusted.▫Before tools or accessories are adjusted or changed.▫Before removing waste or swarf.▫When a machine is awaiting repair or maintenance.


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Machines not to be used while pupils are in the classroom:

• Spindle Moulder• It is recommended that the use of the circular saw and planer

thicknesser machines while the students are in the classroom should be strictly prohibited.

• All preparatory work involving these machines should take place before class.

• May not be achievable immediately but plans should be made to try…in the interim control measures should be put in place to reduce exposure to as low levels as possible.



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The CE Marking is not a mark indicating conformity to a standard but rather a mark indicating conformity to the legal requirements of EU Directives.

CE Mark


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• CE Marking is the symbol as shown on the top of this page. • The letters "CE" are the abbreviation of French phrase

"Conformité Européene" which literally means "European Conformity". • The term initially used was "EC Mark" and it was

officially replaced by "CE Marking" in the Directive 93/68/EEC in 1993.

CE Mark


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• Machinery must bear the “CE” mark in order to be deemed in compliance with these regulations.

• Must not add to machinery – must be there… criminal offence to try to add it.

• Also an offence to reduce the visibility of the “CE” Marking on a machine.

CE Mark


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The existance of the “CE” marking on a piece of machinery should indicate that its manufacturer has met all relevant standards and requirements.

CE Mark


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Never assume that machinery is safe just because it has a “CE” marking

CE Mark

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Machine guards must:▫ Be of robust construction.▫ Not give rise to any additional hazard.▫ Not be easily removed or rendered inoperative.

(Removed with the use of a tool)▫ Be situated a sufficient distance from the danger zone.▫ Not restrict more than necessary the view of the operating cycle of the

equipment

Guarding

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• An assessment of each workshop should be carried out in order to determine the safe operational area around each machine.

• Hard wearing and clearly visible markings should be set down on the floor to indicate these safe operation areas.

• If necessary, machines should be moved to accommodate this safe operational area.

Exclusion Zones

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Lighting

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Emergency Isolators and Emergency Stops

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Start/Stop• Are there appropriate start / stop controls ?• Location• Colour• Flush mounted• Mushroom head

▫ Turn release▫ Key release

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Stop control must have priority over the Start control.

Start Control Flush Recessed

Stop Control Mushroom Head Push Bar

Start/Stop


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Some machines may have two stopping devices.

Hand Operated

Foot/Knee Operated

Emergency Stop


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Push Sticks


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Material Preparation


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Maintenance of Machinery


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Preventative Maintenance


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Maintenance Records


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Inspection of Machinery


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Inadvertent Starting


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Machinery Rundown Time


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A brief look at Safety Signage

Mandatory/Action

Regulatory/Prohibited

Emergency/Permission

Warning/Caution-

Danger

Week2: Lab 1 & 2•Table

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Week 2: Lab 1 & 2• Machine Exposure:▫ Surface Planer▫ Planer Thicknesser▫ Bandsaw

• Material Process – Component A:▫ Each student will receive an unprocessed plank of red deal measuring 750 x 245 x

50 (mm)

▫ Aim of week 2 labs is to square the material to a clean workable condition of required dimension.

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740

242


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Surface Planer


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Surface Planer 1 Guide Fence

2 Infeed Table

3 Isolator

4 Infeed Dept Adjustment Wheel

5 Start/Stop Control

6 Infeed Adjustment Lock Handle

7 Blade Guard

8Blade Guard Clamp/Release Mechanism

9 Outfeed Table

10 Guide Fence Adjustment Wheel

11 Guard Guide

12 Guide Fence Lock Handle

2

1

3

4

57

9

8

6

11

12

10


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Step 1:Isolate machine

Step 2: Squaring guide fence• Set up surface planer guide fence @ 90⁰ to

table surface• Note infeed and outfeed table. • Square to infeed using right angle square.• Use red lock handles to open and adjust fence.• Lock gently when fence is perpendicular to

infeed table.

Infeed Table

Out feed Table


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Step 3: Setting infeed dept• This machine is calibrated in metric.• Maximum recommended material removal is 1-

2mm/pass• Dept stop to be set at 2mm• Open infeed lock handle• Turn wheel to left to drop table to 2mm• Lower you drop, the more the planer cutting

block is exposed• Close infeed lock handle when required dept is

achieved.• * Do not adjust outfeed table level, this is for

maintenance purposes only*

Infeed Infeed


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Step 4: Setting the guide fence width• Minimum blade exposure• Width of material + 10mm is recommended• This results in 10mm blade exposure - Safety• Adjust lock handle to wind in or out guide fence• Lock in appropriate position

242 + 10

242 + 10


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Step 5: Guard adjustment• Guard set for face side = handle up – 10mm

blade exposure• Guard set for face edge = handle flat – no blade

exposure


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Step 6: Material Inspection• Inspect material for the following defects

• Cupping• Bowing• Twist• Knots• Loose grain

• Example - if material is bowed, set the bowed face to the surface planer table surface and process. Material should never be run through hump side down.


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Step 7: Determining face side and face edge• Use machine surface to check square• Select appropriate face side and face edge

based on inspection• Preliminary surface marking using an ‘X’ with

no less than a HB pencil• Ensure extraction gate valve is open and

extraction is on• Proceed to plane material – face side and face

edge only!Gate Valve locate on extractor pipe just above surface planer

X X


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Step 8: Planing face side• Material position • Hand positions

Ensure Guard Guide is in a vertical position to plane face side

Dept of Hand Dept of Hand


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Note Hand Positions in relation to material


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Step 9: Planing face edge• Material position• Hand position

Ensure Guard Guide is in a horizontal position to plane face edge

Dept of Hand Dept of Hand


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Note Hand Positions in relation to material

Split second blade ExposureBlade guard flat onto table


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Thicknesser


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Thicknesser

1

2

4

3

1 Extractor Pipe

2 Control Panel

3 Adjustment Lever

4 Thicknesser Bed


• Lab sequence – Thicknesser• Step 1:

1. Unlock twist release stop mechanism2. Press green button to start3. Allow machine to build up, this can be determined by

noise consistency4. When noise is consistent flip delta switch to on position5. Feed rate, i.e. Speed at which material is passed, is set.6. Adjust table height as required7. Feed material as directed

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Delta Switch

Twist Release Stop

Display Panel

Feed Rate Control

Stop/Start

Thicknesser Bed Adjustment

Control

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Bandsaw


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The bandsaw


See you all next week!•Next week:▫Machine Provision▫Risk assessment▫Week 3 ripsaw labs

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wt4603 unit1 week2-12-09-2011

Education

joseph lyster

notes available

lecture unit

hazard identification

machine provision

risk assessment week