Week 2 - Risk Assessment

2. Lecturer: Mr. Joseph Lyster

3. joseph.lyster@ul.ie

4. Notes prepared by: Mr. Joseph Lyster

7. Poor machinery guarding.

8. Poor cleaning and housekeeping arrangements.

9. Limited interest of OHS by employers/management.

10. Lack of care/respect for safety rules.

11. Poor safety culture.Department of Manufacturing & Operations Engineering

13. Consultation between employer and employees.

14. Clearly defined structure of responsibilities….

15. Employees are trained…

16. Exceeds the specific requirements of the law – manages safety not for fear of being reprimanded but for the employees.Department of Manufacturing & Operations Engineering

17. WT4603 Safety Management The Key steps of any Health & Safety Management scheme are: Policy Hazard identification Risk Assessment Control Measures. Recording Findings (Safety Statement) Monitoring, Review and Auditing Department of Manufacturing & Operations Engineering

18. WT4603 Importance of being able to Assess Risk Department of Manufacturing & Operations Engineering

19. WT4603 Required Reading Department of Manufacturing & Operations Engineering

20. WT4603 The Safety Management Process Department of Manufacturing & Operations Engineering

21. WT4603 Health & Safety Policy Department of Manufacturing & Operations Engineering

22. WT4603 Health & Safety Policy Department of Manufacturing & Operations Engineering

23. WT4603 More information can be found by consulting manufacturer’s manual Department of Manufacturing & Operations Engineering

24. WT4603 Health & Safety at Work Act 2005 Pg. 30 of Health & Safety at Work Act 2005 Department of Manufacturing & Operations Engineering

25. WT4603 Identify Hazards (Hazard Identification) Department of Manufacturing & Operations Engineering

26. WT4603 Hazards in the Workplace Department of Manufacturing & Operations Engineering

27. WT4603 Department of Manufacturing & Operations Engineering

28. WT4603 Department of Manufacturing & Operations Engineering

29. WT4603 Department of Manufacturing & Operations Engineering

30. WT4603 Department of Manufacturing & Operations Engineering

31. WT4603 Department of Manufacturing & Operations Engineering

32. WT4603 Department of Manufacturing & Operations Engineering

33. WT4603 Department of Manufacturing & Operations Engineering

34. WT4603 Department of Manufacturing & Operations Engineering

35. WT4603 Department of Manufacturing & Operations Engineering

36. WT4603 Department of Manufacturing & Operations Engineering

37. WT4603 Department of Manufacturing & Operations Engineering

38. WT4603 Department of Manufacturing & Operations Engineering

39. WT4603 Department of Manufacturing & Operations Engineering

40. WT4603 Definition: Hazard Department of Manufacturing & Operations Engineering

41. WT4603 Hazards in the Workplace Department of Manufacturing & Operations Engineering

42. WT4603 Some Possible Hazards Department of Manufacturing & Operations Engineering

43. WT4603 Common Machinery/Mechanical Hazards Department of Manufacturing & Operations Engineering

44. WT4603 Wrap Point: (Entanglement) Department of Manufacturing & Operations Engineering

45. WT4603 Shear Point and Cutting Hazards Department of Manufacturing & Operations Engineering

46. WT4603 Crush Points Department of Manufacturing & Operations Engineering

47. WT4603 Ejection Hazards Department of Manufacturing & Operations Engineering

48. WT4603 Other Hazards Department of Manufacturing & Operations Engineering

49. WT4603 Hazards Department of Manufacturing & Operations Engineering

51. Strategies will need to be developed to:

52. Reduce or eliminate risk

53. Demonstrate safe use of machine(s)

54. Teach key learning points relating to machine or process

55. Assess and record pupil learning and competence

56. Ensure adequate supervision of activitiesDepartment of Manufacturing & Operations Engineering

57. WT4603 Room Layout Department of Manufacturing & Operations Engineering

58. WT4603 Room Layout Department of Manufacturing & Operations Engineering

59. WT4603 Room Layout Department of Manufacturing & Operations Engineering

60. WT4603 Room Layout Department of Manufacturing & Operations Engineering

61. WT4603 Assess Risk (Risk Assessment) Department of Manufacturing & Operations Engineering

62. WT4603 Department of Manufacturing & Operations Engineering

63. WT4603 Hierarchy of Risk Control Eliminate the Hazard Completely. Substitute Hazard with a safer alternative. Isolate the Hazard. Use engineering controls to reduce risk at the source (Guarding). Provide training on how to avoid risks. & if all that fails… Use PPE. Department of Manufacturing & Operations Engineering

64. WT4603 Risk Assessment Department of Manufacturing & Operations Engineering

66. means anything that can cause harm (eg chemicals,electricity, working from ladders, etc)

67. Risk

68. is the chance, high or low, that somebody will beharmed by the hazard.Department of Manufacturing & Operations Engineering

69. WT4603 Importance of being able to Assess Risk Department of Manufacturing & Operations Engineering

71. Minor Injury/Ill Health ( minor cuts, abrasions etc.)

72. Injury/Ill Health (burns, sprains, minor fractures etc.)

73. Serious Injury/Ill Health (breaks, deafness etc.)

74. Major Injury/Ill Health (amputations, cancer, multiple breaks etc.)

75. Fatality (one or more fatalities)Department of Manufacturing & Operations Engineering

77. Skills

78. Training

79. Experience

80. Attitude

81. Motivation

82. Risk perception

83. Mental condition

84. Physical condition

85. Accident pronenessDepartment of Manufacturing & Operations Engineering

86. WT4603 Risk Magnitude Department of Manufacturing & Operations Engineering

87. WT4603 Department of Manufacturing & Operations Engineering

88. WT4603 Factors Effecting Likelihood of Occurrence Department of Manufacturing & Operations Engineering

89. WT4603 Department of Manufacturing & Operations Engineering

90. WT4603 Risk Magnitude Matrix Department of Manufacturing & Operations Engineering

91. WT4603 Risk Magnitude Matrix: Severe Cut/Amputation from Bandsaw Department of Manufacturing & Operations Engineering

92. WT4603 Department of Manufacturing & Operations Engineering

93. WT4603 Department of Manufacturing & Operations Engineering

94. WT4603 Which Poses the Greatest Risk? Department of Manufacturing & Operations Engineering

95. WT4603 Department of Manufacturing & Operations Engineering

96. WT4603 Department of Manufacturing & Operations Engineering

97. WT4603 Department of Design & Manufacturing Technology

98. WT4603 Department of Design & Manufacturing Technology

99. WT4603 Department of Design & Manufacturing Technology

100. WT4603 Department of Design & Manufacturing Technology

101. WT4603 Department of Design & Manufacturing Technology

102. WT4603 Risk Assessment Template Department of Design & Manufacturing Technology

103. WT4603 Department of Design & Manufacturing Technology

104. WT4603 Department of Design & Manufacturing Technology

105. WT4603 Department of Design & Manufacturing Technology

106. WT4603 Department of Design & Manufacturing Technology

107. WT4603 Department of Design & Manufacturing Technology

108. WT4603 Department of Design & Manufacturing Technology

109. WT4603 Department of Design & Manufacturing Technology

110. WT4603 Department of Design & Manufacturing Technology

111. WT4603 Department of Design & Manufacturing Technology

112. WT4603 Department of Design & Manufacturing Technology

113. WT4603 Department of Design & Manufacturing Technology

114. WT4603 Department of Design & Manufacturing Technology

115. WT4603 Department of Design & Manufacturing Technology

116. WT4603 Department of Design & Manufacturing Technology

117. WT4603 Department of Design & Manufacturing Technology

118. WT4603 Department of Design & Manufacturing Technology

119. WT4603 Department of Design & Manufacturing Technology

120. WT4603 Department of Design & Manufacturing Technology

121. WT4603 CLASSROOM MANAGEMENT: Health & Safety… Department of Design & Manufacturing Technology

123. Close monitoring of students using machinery.

124. Students must not be permitted to use equipment while unsupervised.

125. It is the responsibility of the schools to ensure that the machines are not accessible to unauthorised persons

126. Cleaners

127. Visitors

128. Unsupervised students.Department of Manufacturing & Operations Engineering

129. WT4603 Supervision & Access Department of Manufacturing & Operations Engineering

131. When the competent person (supervisor) is not in the work area.

132. Before cleaning out any blockage.

133. Before the machine is cleaned.

134. Before any maintenance work is carried out on the machine.

135. Before guards are adjusted.

136. Before tools or accessories are adjusted or changed.

137. Before removing waste or swarf.

138. When a machine is awaiting repair or maintenance.Department of Manufacturing & Operations Engineering

139. WT4603 Supervision & Access Department of Manufacturing & Operations Engineering

141. 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.

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

143. 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.Department of Manufacturing & Operations Engineering

144. WT4603 CE Mark 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. Department of Manufacturing & Operations Engineering

146. The letters "CE" are the abbreviation of French phrase "ConformitéEuropéene" which literally means "European Conformity".

147. The term initially used was "EC Mark" and it was officially replaced by "CE Marking" in the Directive 93/68/EEC in 1993.Department of Manufacturing & Operations Engineering

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

150. Also an offence to reduce the visibility of the “CE” Marking on a machine.Department of Manufacturing & Operations Engineering

151. WT4603 CE Mark The existance of the “CE” marking on a piece of machinery should indicate that its manufacturer has met all relevant standards and requirements. Department of Manufacturing & Operations Engineering

152. WT4603 CE Mark Never assume that machinery is safe just because it has a “CE” marking Department of Manufacturing & Operations Engineering

154. Not give rise to any additional hazard.

156. Not restrict more than necessary the view of the operating cycle of the equipmentDepartment of Manufacturing & Operations Engineering

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

159. If necessary, machines should be moved to accommodate this safe operational area.Department of Manufacturing & Operations Engineering

160. WT4603 Lighting Department of Manufacturing & Operations Engineering

161. WT4603 Emergency Isolators and Emergency Stops Department of Manufacturing & Operations Engineering

163. Location

164. Colour

165. Flush mounted

166. Mushroom head

167. Turn release

168. Key releaseDepartment of Manufacturing & Operations Engineering

171. Push BarDepartment of Manufacturing & Operations Engineering

172. WT4603 Emergency Stop Some machines may have two stopping devices. Hand Operated Foot/Knee Operated Department of Manufacturing & Operations Engineering

173. WT4603 Push Sticks Department of Manufacturing & Operations Engineering

174. WT4603 Material Preparation Department of Manufacturing & Operations Engineering

175. WT4603 Maintenance of Machinery Department of Manufacturing & Operations Engineering

176. WT4603 Preventative Maintenance Department of Manufacturing & Operations Engineering

177. WT4603 Maintenance Records Department of Manufacturing & Operations Engineering

178. WT4603 Inspection of Machinery Department of Manufacturing & Operations Engineering

179. WT4603 Inadvertent Starting Department of Manufacturing & Operations Engineering

180. WT4603 Machinery Rundown Time Department of Manufacturing & Operations Engineering

181. WT4603 A brief look at Safety Signage Emergency/Permission Mandatory/Action Warning/Caution-Danger Regulatory/Prohibited Department of Manufacturing & Operations Engineering

182. WT4603 Week2: Lab 1 & 2 Table Department of Design & Manufacturing Technology

183. WT4603 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. 242 740 Department of Design & Manufacturing Technology

184. WT4603 Surface Planer Department of Design & Manufacturing Technology

185. WT4603 1 9 8 2 7 3 4 6 5 Surface Planer 10 11 12 Department of Design & Manufacturing Technology

187. Note infeed and outfeed table.

188. Square to infeed using right angle square.

189. Use red lock handles to open and adjust fence.

190. Lock gently when fence is perpendicular to infeed table.Infeed Table Department of Design & Manufacturing Technology

192. Maximum recommended material removal is 1-2mm/pass

193. Dept stop to be set at 2mm

194. Open infeed lock handle

195. Turn wheel to left to drop table to 2mm

196. Lower you drop, the more the planer cutting block is exposed

197. Close infeed lock handle when required dept is achieved.

198. * Do not adjust outfeed table level, this is for maintenance purposes only*Department of Design & Manufacturing Technology

200. Width of material + 10mm is recommended

201. This results in 10mm blade exposure - Safety

202. Adjust lock handle to wind in or out guide fence

203. Lock in appropriate position242 + 10 Department of Design & Manufacturing Technology

205. Guard set for face edge = handle flat – no blade exposureDepartment of Design & Manufacturing Technology

207. Cupping

208. Bowing

209. Twist

210. Knots

211. Loose grain

212. 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.Department of Design & Manufacturing Technology

214. Select appropriate face side and face edge based on inspection

215. Preliminary surface marking using an ‘X’ with no less than a HB pencil

216. Ensure extraction gate valve is open and extraction is on

217. Proceed to plane material – face side and face edge only!Gate Valve locate on extractor pipe just above surface planer X X Department of Design & Manufacturing Technology

219. Hand positionsDept of Hand Dept of Hand Ensure Guard Guide is in a vertical position to plane face side Department of Design & Manufacturing Technology

220. WT4603 Department of Design & Manufacturing Technology

221. WT4603 Note Hand Positions in relation to material Department of Design & Manufacturing Technology

223. Hand positionDept of Hand Dept of Hand Ensure Guard Guide is in a horizontal position to plane face edge Department of Design & Manufacturing Technology

224. WT4603 Note Hand Positions in relation to material Split second blade Exposure Blade guard flat onto table Department of Design & Manufacturing Technology

225. WT4603 Thicknesser Department of Design & Manufacturing Technology

226. WT4603 1 2 3 4 Thicknesser Department of Design & Manufacturing Technology

227. WT4603 Lab sequence – Thicknesser Step 1: Unlock twist release stop mechanism Press green button to start Allow machine to build up, this can be determined by noise consistency When noise is consistent flip delta switch to on position Feed rate, i.e. Speed at which material is passed, is set. Adjust table height as required Feed material as directed Delta Switch Stop/Start Twist Release Stop Display Panel Thicknesser Bed Adjustment Control Feed Rate Control Department of Design & Manufacturing Technology

228. WT4603 Bandsaw Department of Design & Manufacturing Technology

229. WT4603 The bandsaw Department of Design & Manufacturing Technology

230. See you all next week! Next week: Machine Provision Risk assessment Week 3 ripsaw labs WT4603 Department of Design & Manufacturing Technology