ISE Module 4 - Industrial Safety Engineering PDF

101908/C0700D – INDUSTRIAL SAFETY ENGINEERING MODULE 4 – SAFETY HAZARDS IN MACHINES Emi Elizabeth Jobi Assistant Professor Department of Civil Engineering RSET ...

101908/C0700D – INDUSTRIAL SAFETY ENGINEERING MODULE 4 – SAFETY HAZARDS IN MACHINES Emi Elizabeth Jobi Assistant Professor Department of Civil Engineering RSET  INDUSTRIAL SAFETY ENGINEERING SYLLABUS Module 4 – Safety Hazards in Machines Machinery safeguard – Point-of-Operation, Principle of machine guarding -types of guards and devices. Safety in turning, and grinding. Welding and Cutting – Safety Precautions of Gas welding and Arc Welding. Material Handling – Classification – safety consideration – manual and mechanical handling. Handling assessments and techniques – lifting, carrying, pulling, pushing, palletizing and stocking. Material Handling equipment – operation & maintenance. Maintenance of common elements – wire rope, chains slings, hooks, clamps. Hearing Conservation Program DEPARTMENT in ENGINEERING, OF CIVIL Production industries. RSET 2  INDUSTRIAL SAFETY ENGINEERING MACHINERY SAFEGUARD DEPARTMENT OF CIVIL ENGINEERING, RSET 3  INDUSTRIAL SAFETY ENGINEERING MACHINERY SAFEGUARD Moving machine parts have the potential to cause severe workplace injuries, such as crushed fingers or hands, amputations, burns, or blindness. Safeguards are essential for protecting workers from these preventable injuries. Any machine part, function, or process that may cause injury must be safeguarded. When the operation of a machine or accidental contact injure the operator or others in the vicinity, the hazards must be eliminated or controlled. DEPARTMENT OF CIVIL ENGINEERING, RSET 4  INDUSTRIAL SAFETY ENGINEERING Point-of-Operation The area on a machine where work is actually performed upon the material being processed The point of operation of machines whose operation exposes an employee to injury, shall be guarded. The guarding device shall be in conformity with any appropriate standards In the absence of applicable specific standards, it shall be so designed and constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle. Special hand tools can be used for placing and removing material ▫ To permit easy handling of material without the operator placing a hand in the danger zone ▫ To supplement protection provided. DEPARTMENT OF CIVIL ENGINEERING, RSET 5  INDUSTRIAL SAFETY ENGINEERING Point-of-Operation Some of the machines which usually require point of operation guarding: Guillotine Shear cutters s DEPARTMENT OF CIVIL ENGINEERING, RSET 6  INDUSTRIAL SAFETY ENGINEERING Point-of-Operation Some of the machines which usually require point of operation guarding: Alligator Power shears presses DEPARTMENT OF CIVIL ENGINEERING, RSET 7  INDUSTRIAL SAFETY ENGINEERING Point-of-Operation Some of the machines which usually require point of operation guarding: Milling Power machines saws DEPARTMENT OF CIVIL ENGINEERING, RSET 8  INDUSTRIAL SAFETY ENGINEERING Point-of-Operation Some of the machines which usually require point of operation guarding: Jointer Forming rolls and calendars s DEPARTMENT OF CIVIL ENGINEERING, RSET 9  INDUSTRIAL SAFETY ENGINEERING Point-of-Operation Some of the machines which usually require point of operation guarding: Portable power tools DEPARTMENT OF CIVIL ENGINEERING, RSET 10  INDUSTRIAL SAFETY ENGINEERING Principle of Machine Guarding If the various types of mechanical motion are clearly understood, the dangerous parts of any machinery can be identified and such parts or combination of parts of machinery which contribute to dangers should be guarded The guard shall effectively eliminate dangers from parts of machinery in motion and work in process. Effective guarding is an essential factor in efficiency and productivity. The correct elimination of dangerous conditions enables machinery operators to work with speed and efficiency DEPARTMENT OF CIVIL ENGINEERING, RSET 11  INDUSTRIAL SAFETY ENGINEERING Principle of Machine Guarding (Contd…) No allowance should be made on the assumption of carefulness by workers in avoiding accidents from machinery in motion Intrinsic safety should be a basic feature of machinery design and installation. Where the design features do not safeguard dangerous parts, provision should be made to facilitate appropriate guarding. DEPARTMENT OF CIVIL ENGINEERING, RSET 12  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 1. Fixed Guards This type of guard should be provided in every practicable case as the preferred method of attaining secure fencing The guard should by nature of its design and construction, prohibit access to the dangerous parts of machinery and should remain in position after installation Adjustments ▫ Fixed guards may be adjustable to accommodate different sets of tools or various kinds of work. ▫ Once adjusted they should remain fixed and there should be neither movement nor detachment of them ▫ The means DEPARTMENT OF CIVILof adjustment ENGINEERING, – remote from the danger zone RSET and in no way reduce the effectiveness of the guard ▫ Adjustment should only be made when the machine is at rest 13  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 1. Fixed Guards (Contd…) Where for the purpose of production, for example to remove some obstruction or for maintenance, a fixed guard or a portion of the fixed guard is removable without the use of special tools, it should incorporate a lock to ensure that it cannot be removed while the machine is in motion. Adjustment should only be made while machine is at rest Opening for the work to be fed through the guard into the machine should be sufficient only for the size of the work-piece; it should not allow a person to gain access to the dangerous parts The effectiveness of any fixed guard should always be judged by a test to see that finger tips cannot reach beyond a safe limit DEPARTMENT OF CIVIL ENGINEERING, RSET 14  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 1. Fixed Guards DEPARTMENT OF CIVIL ENGINEERING, RSET 15  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 1. Fixed Guards DEPARTMENT OF CIVIL ENGINEERING, RSET 16  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 2. Interlocking Guards It should be used on a machine as the first alternative, if a fixed guard cannot be used. The interlocking system may be either mechanical or electrical or a combination of both All parts of the interlocking system should as far as possible be incorporated in the design of the machine for which this type of guarding is to be used. If practicable, these guards should be designed for sequential operations They must guard the dangerous part before the machinery can be operated, maintain the guarding until the dangerous part comes to rest and shall be failsafe DEPARTMENT OF CIVIL ENGINEERING, RSET 17  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 2. Interlocking Guards (Contd…) Hydraulic or pneumatic systems used to operate certain types of machines, including presses, may be employed for interlocking guards. In such cases, however, the guards have to be carefully designed to ensure safety Where limit switches or microswitches are used for interlocking purposes, the switches should be positively opened and closed by the guard member Sometimes sudden braking of the rotating parts which have considerable inertia may not be practicable. In such cases a time delay device may be included in the interlocking arrangements so that the guard should open only when the rotating part has come to rest. DEPARTMENT OF CIVIL ENGINEERING, RSET 18  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 2. Interlocking Guards Interlocking Guards DEPARTMENT OF CIVIL ENGINEERING, RSET 19  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 3. Automatic Guards This type of guard should only be used where neither fixed nor interlocking guards are practicable to safeguard a particular danger area Automatic guards should operate to remove any part of a person exposed to danger to a position of safety Automatic guards should function independently of the operator and its action should repeat as long as the machine is in motion The mechanism of automatic guards should be carefully adjusted in relation to the movement and physical characteristics of the dangerous parts, and frequently examined to ensure that the safeguard is properly maintained and used. DEPARTMENT OF CIVIL ENGINEERING, RSET 20  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 3. Automatic Guards DEPARTMENT OF CIVIL ENGINEERING, RSET 21  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 4. Trip Guards Trip guards should be so arranged that an approach by a person beyond a safe limit causes the guard to move and the machinery to stop and/or reverse its motion before any part of the person can reach the dangerous part They are recommended to be used on machines which are normally in continuous motion where the hands (or other parts of a person) have temporarily to enter a space swept by the dangerous part or where entangling in an article or material which is being fed to a machine may occur They can also be used where a person may be injured by being pulled against or through the feed opening of a fixed guard DEPARTMENT OF CIVIL ENGINEERING, RSET 22  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 4. Trip Guards DEPARTMENT OF CIVIL ENGINEERING, RSET 23  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 5. Two-Hand Control Device and Two-Hand Control System This device is not a guard but safety of the operator is achieved by keeping both the hands of the operator engaged away from the danger area If more than one person are to work on a machine this device should be provided for each operator Two push buttons or two levers be so interlocked mechanically, electrically or both that it is necessary to operate both the push buttons or levers simultaneously to start the operation of machine, and in the case of more than one device provided on a machine it should be necessary to operate all the push buttons/levers simultaneously to start the operation of the machine DEPARTMENT OF CIVIL ENGINEERING, RSET 24  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices Two-Hand Control Device and Two-Hand Control System Two-hand control should be located in such a position that after leaving the control button/lever, the hand of the operator cannot reach the point -of operation before the closing movement of the parts has stopped. This safety distance between the control button/lever from the point-of-operation is determined on the assumption that the speed of the hands moving from button/lever to the point-of-operation is 1.6 m/s DEPARTMENT OF CIVIL ENGINEERING, RSET 25  INDUSTRIAL SAFETY ENGINEERING Types of Guards and Devices 5. Two-Hand Control Device and Two-Hand Control System DEPARTMENT OF CIVIL ENGINEERING, RSET 26  INDUSTRIAL SAFETY ENGINEERING GENERAL REQUIREMENTS OF MECHANICAL GUARDS Guards should be so designed, constructed and used that they will ▫ provide positive protection ▫ prevent access to the danger zone during operations ▫ cause the operator no discomfort or inconvenience ▫ operate automatically or with minimum effort ▫ not interfere with efficient operation of the machine ▫ be suitable for the job and the machine ▫ not weaken the structure of the machine ▫ preferably constitute a built-in feature DEPARTMENT OF CIVIL ENGINEERING, RSET 27  INDUSTRIAL SAFETY ENGINEERING GENERAL REQUIREMENTS OF MECHANICAL GUARDS Guards should be so designed, constructed and used that they will ▫ provide for machine oiling, inspection, adjustment and repairs ▫ be constructed strongly enough to resist normal wear and shock ▫ be durable, resistant to fire and corrosion and easily repaired ▫ withstand long use with minimum maintenance ▫ not constitute a hazard by themselves such as splinters, pinch points, shear points, sharp corners, rough edges or other sources of accidents ▫ protect against operational contingencies, not merely against normally expected hazards. DEPARTMENT OF CIVIL ENGINEERING, RSET 28  INDUSTRIAL SAFETY ENGINEERING GENERAL REQUIREMENTS OF MECHANICAL GUARDS Material for guards ▫ preferable material under most circumstances should be metal ▫ Framework of guards should be generally made from structural sections, pipes, strapping, bar or rod ▫ Paneling material should be generally solid sheet metal, expanded or perforated metal or wire mesh ▫ The use of plastic or safety glass, where visibility is required, is recommended ▫ Guards made of wood may be used but they have limited application due to their lack of durability and strength and relatively high maintenance cost and flammability DEPARTMENT OF CIVIL ENGINEERING, RSET 29  INDUSTRIAL SAFETY ENGINEERING GENERAL REQUIREMENTS OF MECHANICAL GUARDS All guards should be securely fastened to the machine or to the floor, wall or ceiling or any other rigid fixed structure and should be kept in place whenever the machinery is operating Exception may be made in the case of transparent chip guards or splash guards which may be adjustable or provided with magnetic base as they may need to be shifted during the course of work. DEPARTMENT OF CIVIL ENGINEERING, RSET 30  INDUSTRIAL SAFETY ENGINEERING Machine Safety https://www.youtube.com/watch?v=XKopBrybSU E DEPARTMENT OF CIVIL ENGINEERING, RSET 31  INDUSTRIAL SAFETY ENGINEERING Turning DEPARTMENT OF CIVIL ENGINEERING, RSET 32  INDUSTRIAL SAFETY ENGINEERING Turning Most common lathe machining operation During the turning process, a cutting tool removes material from the outer diameter of a rotating workpiece The main objective of turning is to reduce the workpiece diameter to the desired dimension. DEPARTMENT OF CIVIL ENGINEERING, RSET 33  INDUSTRIAL SAFETY ENGINEERING Hazards in turning The primary hazards of lathes are contact with rotating parts and contact at the point of operation An operator can be pulled into the lathe from working too close, or wearing gloves, loose clothing, loose hair, or jewelry Trapping spaces are also created between the cutting tool, its mounting, and the workpiece or chuck Projected parts or material such as chuck keys, unsecured workpieces, flying chips and coolant also strike or present hazards to the operator. DEPARTMENT OF CIVIL ENGINEERING, RSET 34  INDUSTRIAL SAFETY ENGINEERING Hazards in turning DEPARTMENT OF CIVIL ENGINEERING, RSET 35  INDUSTRIAL SAFETY ENGINEERING Safety in turning https://www.youtube.com/watch?v=0X1nZwOZH6 M DEPARTMENT OF CIVIL ENGINEERING, RSET 36  INDUSTRIAL SAFETY ENGINEERING Safety in turning Do not remove any guards, or other devices Always use the flip down clear guard to protect against flying chips or work pieces Make sure that that spindle nose cover is on the machine when a chuck is not in use. This protects operators from point of operation contact Make sure to always put the collet closer guard down before starting the lathe. This protects the users from rotational hazards Do not operate the lathe unless you are trained and authorized to operate the machine Move the carriage back to a safe distance when loading or unloading parts and measuring the work If performing service and maintenance activities follow lock out tag out procedures DEPARTMENT OF CIVIL ENGINEERING, RSET 37  INDUSTRIAL SAFETY ENGINEERING Safety in turning Be sure the work and holding device are firmly attached Turn spindle by hand using the hand wheel, with lathe turned OFF, to be sure there is no danger of striking any part of the lathe Keep machine clear of tools. Tools must not be placed on the ways of the lathe top lathe before making any measurements, adjustments, or cleaning Support all work solidly. Do not permit small diameter work to project too far from chuck (not over 3X the work's diameter) without support DEPARTMENT OF CIVIL ENGINEERING, RSET 38  INDUSTRIAL SAFETY ENGINEERING Safety in turning If work must be repositioned or removed from the lathe. Move cutting tool clear of work to prevent any accidental injuries You should always be aware of direction of travel and speed of carriage before you engage automatic feed Chips are sharp. Do not attempt to remove them with your hand when they become “stringy” and build up on tool post or work piece. Stop machine and remove them with pliers DEPARTMENT OF CIVIL ENGINEERING, RSET 39  INDUSTRIAL SAFETY ENGINEERING Safety in turning Stop lathe immediately if any odd noise or vibration develops. If you cannot locate source of the trouble, get help from instructor. Under no circumstance should the lathe be operated until the problem has been corrected Remove sharp edges and burrs from work before removing it from the lathe Always wear safety glasses Always wear closed toe shoes that protect the top of your foot Do not wear any rings or dangling jewelry Long hair needs to be tied up or put into a bun DEPARTMENT OF CIVIL ENGINEERING, RSET 40  INDUSTRIAL SAFETY ENGINEERING Grinding Grinding is a type of abrasive machining process which uses a grinding wheel as cutting tool. Types of grinding machines ▫ Portable power tools such as angle grinders, die grinders and cut-off saws ▫ Stationary power tools such as bench grinders and cut-off saws ▫ Stationary hydro- or hand- powered sharpening stones DEPARTMENT OF CIVIL ENGINEERING, RSET 41  INDUSTRIAL SAFETY ENGINEERING DEPARTMENT OF CIVIL ENGINEERING, RSET 42  INDUSTRIAL SAFETY ENGINEERING Hazards in grinding All types of grinding machines, whether pedestal, bench mounted, free-standing or portable, can be potentially hazardous if they are not well maintained and used correctly Hazards ▫ flying particles ▫ dust and sparks ▫ shattering abrasive wheel while in motion can cause severe injury to both the user and others. https://www.youtube.com/watch?v=pf_5IM28-6s DEPARTMENT OF CIVIL ENGINEERING, RSET 43  INDUSTRIAL SAFETY ENGINEERING Safety in grinding Grinders shall be equipped with the ‘dead man switch’. Self- modification of the toggle Switch to function as a ‘dead man switch’ is strictly prohibited as the tool may not have been designed to be used in that manner and maybe a poor decision from an ergonomic perspective. All handheld grinding machines shall be complete with handle or commonly known as the ‘T’ bar. Removal of the handle during use is strictly prohibited. Each grinding machine shall be fitted with its correct guard as supplied by the manufacturer. The guard shall cover a minimum of 70% of the circumference of the rotating disc. Unbreakable glass / plastic screen shall be fit on all pedestal/static grinding machines which can be adjusted to protect against flying particles. All pedestal/static grinding machines must have an efficient starting and stopping device, which is easily accessible. Each grinding machine shall be inspected regularly before use, and colour coded DEPARTMENT OF CIVIL ENGINEERING, RSET 44  INDUSTRIAL SAFETY ENGINEERING Safety in grinding Abrasive wheels, grinding or cutting discs without the manufacturer’s maximum RPM marked shall not be used. RPM (rotation per minute) of the wheel shall be more than a grinding machine if machine RPM exceeds than a wheel can break easily. Grinding and cutting discs are different in the manufacture and shall therefore only be used for its intended purpose. Cutting wheel is only allowed for cutting do not do grinding using cutting wheel, chances of breaking. They shall be stored separately and physically identified to avoid selection error. Proper PPE, including double eye protection such as the use of goggles underneath of a shatter-resistant face shield and an inhalation mask such as dust mask, Leather gloves shall be worn by all personnel operating grinding machines. Work areas around pedestal / static abrasive wheels equipment shall be kept clear of obstructions to reduce the risk of tripping hazards. Screens shall be erected by fire blanked around welding/grinding works to prevent flying sparks showering nearby personnel/equipment. DEPARTMENT OF CIVIL ENGINEERING, RSET 45  INDUSTRIAL SAFETY ENGINEERING Safety in grinding Cables shall be run neatly in a manner and shall hang on insulated hangers that do not cause tripping hazards. When changing the grinding disc of the grinder, the power source shall be isolated and the plug physically removed. Expiry year of shall be visible on the disk. Do not use an expired grinding disk. & do not use a wheel without an expiry date. Subjected Work-pieces shall be secured using proper clamps. Holding the workpiece onto one hand while performing grinding operations is strictly prohibited. Due to the possibility of a wheel disintegrating during start-up, employees shall be briefed not to stand directly in front of the wheel as it accelerates to full operating speed. Worn out / damaged, grinding or cutting disc shall be replaced. When changing the disc, proper tools shall be use. All worn out / damaged, grinding or cutting disc shall be returned to the stores at the end of each shift to ensure that they are dispose of properly. The power source shall be isolated and the plug physically removed while not in operation. DEPARTMENT OF CIVIL ENGINEERING, RSET 46  INDUSTRIAL SAFETY ENGINEERING Safety in Welding and Cutting https://www.youtube.com/watch?v=XKjxKpLL7XE DEPARTMENT OF CIVIL ENGINEERING, RSET 47  INDUSTRIAL SAFETY ENGINEERING Safety Precautions of Gas welding and Arc Welding https://www.youtube.com/watch?v=YskH4MHBQ Fw https://www.youtube.com/watch?v=JRtELTkfUq4 DEPARTMENT OF CIVIL ENGINEERING, RSET 48  INDUSTRIAL SAFETY ENGINEERING MATERIAL HANDLING DEPARTMENT OF CIVIL ENGINEERING, RSET 49  INDUSTRIAL SAFETY ENGINEERING MATERIAL HANDLING The movement, protection, storage and control of materials and products throughout manufacturing, warehousing, distribution, consumption and disposal Incorporates a wide range of manual, semi-automated and automated equipment and systems that support logistics and make the supply chain work Their application helps with: ▫ Forecasting ▫ Resource allocation ▫ Production planning ▫ Flow and process management ▫ Inventory management and control ▫ Customer delivery ▫ After-sales support and service DEPARTMENT OF CIVIL ENGINEERING, RSET 50  INDUSTRIAL SAFETY ENGINEERING MATERIAL HANDLING Objectives To improve customer service To reduce inventory To shorten delivery time To lower overall handling costs in manufacturing, distribution and transportation DEPARTMENT OF CIVIL ENGINEERING, RSET 51  INDUSTRIAL SAFETY ENGINEERING Manual and Mechanical Handling Manual Handling involves workers physically lifting and manipulating the respective materials themselves, Mechanical Handling involves the use of special machines and lifting equipment to perform the task. Both methods can be used effectively to move materials DEPARTMENT OF CIVIL ENGINEERING, RSET 52  INDUSTRIAL SAFETY ENGINEERING Manual Handling Little-to-no cost If a pile of heavy pallets or drums needs moving from point A to point B, the employer may ask one or more workers to perform this task Places workers at a higher risk of injury – money in the long run DEPARTMENT OF CIVIL ENGINEERING, RSET 53  INDUSTRIAL SAFETY ENGINEERING Mechanical Handling Involves the use of special lifting machines and equipment to lift, move and manipulate heavy objects Little-to-no risk of worker injury Machines can perform many of the same tasks as human workers, only faster and more efficiently More work accomplished in less time Boost productivity levels in the workplace DEPARTMENT OF CIVIL ENGINEERING, RSET 54  INDUSTRIAL SAFETY ENGINEERING Types of Equipment Source: OSHA Source: TEEX-Harwood Conveyors Powered Industrial Trucks DEPARTMENT OF CIVIL ENGINEERING, RSET 55  INDUSTRIAL SAFETY ENGINEERING Types of Equipment Source: TEEX Source: OSHA Cranes Sling s DEPARTMENT OF CIVIL ENGINEERING, RSET 56  INDUSTRIAL SAFETY ENGINEERING Hazards Associated with Materials Handling Factors contributing to injuries: ▫ Weight and bulkiness of objects ▫ Bending, twisting, turning movements Source of photos: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 57  INDUSTRIAL SAFETY ENGINEERING Hazards Associated with Materials Handling Hazards: ▫ Improper operation of equipment ▫ Accumulated materials or clutter Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 58  INDUSTRIAL SAFETY ENGINEERING Hazards Associated with Materials Handling ▫ Unsafe conditions of materials or containers ▫ Flammability or toxicity of some materials Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 59  INDUSTRIAL SAFETY ENGINEERING Hazards Associated with Materials Handling ▫ Weight of materials ▫ Binding ties or other devices that secure bundles or bound materials Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 60  INDUSTRIAL SAFETY ENGINEERING Hazards Associated with Materials Handling ▫ Falling objects ▫ Lifting, pushing, pulling, or otherwise manually moving large, heavy items Source: OSHA Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 61  INDUSTRIAL SAFETY ENGINEERING Hazards Associated with Materials Handling ▫ Improperly stacked materials ▫ Struck-by or caught-in/-between hazards Source TEEX - Harwood Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 62  INDUSTRIAL SAFETY ENGINEERING Hazards Associated with Materials Handling Types of injuries commonly reported: ▫ Back injuries ▫ Sprains, strains, tears ▫ Soreness and pain ▫ Bruises and contusions ▫ Cuts, lacerations, punctures, crushing, and amputations Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 63  INDUSTRIAL SAFETY ENGINEERING Hazards Associated with Materials Handling Examples of events or exposures leading to injuries: Contact with objects and equipment ▫ Transportation incidents ▫ Exposure to harmful substances or environments Source: OSHA Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 64  INDUSTRIAL SAFETY ENGINEERING Hazards Associated with Materials Handling ▫ Falls, slips, trips, or loss of balance Source: OSHA ▫ Repetitive motion ▫ Overexertion Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 65  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards Moving materials manually: ▫ Use devices to assist with holding loads ▫ Wear PPE ▫ Use proper lifting technique ▫ Seek help for oversized loads ▫ Use blocking materials Source of photos: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 66  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards Overhead and gantry cranes: ▫ Never move a load over co workers or allow co- workers to walk underneath ▫ Return the load block to its designated location after use ▫ Do not leave the load Source: OSHA block low enough for someone to runOFinto DEPARTMENT CIVIL ENGINEERING, RSET 67  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards Do not leave unused slings suspended on a crane hook Store wall-mounted cranes against the wall Continuously observe equipment for any sign of problems during operation. Don’t allow yourself to become distracted. DEPARTMENT OF CIVIL ENGINEERING, RSET 68  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards Operated only by thoroughly trained and qualified workers Source: UA DEPARTMENT OF CIVIL ENGINEERING, RSET 69  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards Eliminate/reduce crane hazards by: ▫ Knowing  Load  Capacity of the crane Source: TEEX - Harwood  When the load is safe to lift ▫ Always checking crane load chart and never exceed load limits Source: TEEX - Harwood DEPARTMENT OF CIVIL ENGINEERING, RSET 70  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards Inspection of crane by a qualified person ▫ Modified, repaired, or adjusted ▫ Post-assembly ▫ At least every 12 months ▫ Equipment not in regular use Visual inspection by a Source: OSHA competent person ▫ Prior to each shift DEPARTMENT OF CIVIL ENGINEERING, RSET 71  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards Slings ▫ Connects a crane hook to a load ▫ Proper selection ▫ Inspection Source of photos: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 72  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards ▫ Reduce sling hazards by:  Lubricating  Not shortening with knots, bolts, or other devices, or kink legs  Keeping clear of loads  Avoiding sudden movement DEPARTMENT OF CIVIL ENGINEERING, RSET 73  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards Forklifts Main causes of injuries ▫ Forklift overturns ▫ Forklift striking workers on foot Forklift toppled sideways possibly due to shift in center of gravity. Source: OSHA ▫ Persons crushed by forklifts ▫ Persons falling from forklifts DEPARTMENT OF CIVIL ENGINEERING, RSET 74  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards Illegal forklift operators ▫ Anyone under 18 ▫ Anyone not properly trained Source of photos: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 75  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards ▫ Driving the forklift  Obstructed vision  Travel path  Approaching people  Elevated platform  Seat belts and ROPS  Raising/lowering forks  Safe distance Source of photos: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 76  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards ▫ Elevating workers with forklift  Standing on forks  Lifting personnel  Approved lift platform  Restraining means Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 77  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards ▫ Driving forklift on grades/ramps  Use extreme caution  No turns  Tilting and raising load  Point load up the incline Source of photos: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 78  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards ▫ Forklift operating speed  Tip-overs  Turning  Avoiding collisions  Wet and slippery floors  Ascending/descending  Obstructed vision Source of photos: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 79  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards ▫ Avoiding excess weight  Do not exceed weight capacity of forklift.  Center loads and secure to keep from shifting to maintain balance of weight Source of graphics: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 80  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards ▫ Use of dock boards for loading/uploading  Bridging space  Securing portable dock boards  Handholds for dock boards Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 81  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards ▫ Exiting the forklift  Set brake, lower forks/lifting carriage, neutralize controls  Stand-up type forklift ▫ Riding the forklift  No passengers allowed  Exception – seat is provided Source of photos: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 82  INDUSTRIAL SAFETY ENGINEERING Preventing Hazards ▫ Avoiding struck-by/crushed-by  Don’t jump from an overturning, sit-down type forklift.  Stay with the truck, hold on firmly, and lean in the opposite direction of the overturn. Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 83  INDUSTRIAL SAFETY ENGINEERING Employer Requirements Comply with OSHA standards related to materials handling, including: ▫ Training requirements ▫ Inspection requirements Source of photos: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 84  INDUSTRIAL SAFETY ENGINEERING Employer Requirements Comply with manufacturers’ requirements and recommendations for materials handling equipment. Source : OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 85  INDUSTRIAL SAFETY ENGINEERING Recognizing Hazards Identify potential hazards and possible solutions: Source: OSHA DEPARTMENT OF CIVIL ENGINEERING, RSET 86  INDUSTRIAL SAFETY ENGINEERING Recognizing Hazards Identify potential hazards and possible solutions: Source: OSHA Source: TEEX - Harwood DEPARTMENT OF CIVIL ENGINEERING, RSET 87  INDUSTRIAL SAFETY ENGINEERING Recognizing Hazards Identify potential hazards and possible solutions: Source of photos : OSHA - Source of photos : TEEX UFCW Harwood DEPARTMENT OF CIVIL ENGINEERING, RSET 88  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Lifting Carrying Pulling Pushing Palletizing Stacking DEPARTMENT OF CIVIL ENGINEERING, RSET 89  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Lifting and carrying Caution: This technique may be effective only if loads are small, light- Keep the load close to your body and lift by pushing up weight, with your legs. and can easily fit between the knees. 90 DEPARTMENT OF CIVIL ENGINEERING, RSET  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Lifting and carrying Lean the sack Slide the sack Slide the sack As you stand up, keep onto your up onto your onto the other the sack close to your kneeling leg. kneeling leg. leg while body. keeping the sack close to your body. DEPARTMENT OF CIVIL ENGINEERING, RSET 91  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Pushing and Pulling DEPARTMENT OF CIVIL ENGINEERING, RSET 92  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Pushing and Pulling Factors That Affect Pushing and Pulling DEPARTMENT OF CIVIL ENGINEERING, RSET 93  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Pushing and Pulling Set stance and pace ▫ keep their feet away from the load as much as possible ▫ Speed should not be faster than walking speed Choose and maintain handling devices ▫ Handle heights should be between the worker’s shoulder and waist. ▫ Devices should be well maintained with wheels that run smoothly. ▫ When you buy new trolleys, etc., make sure they are of good quality with large-diameter wheels made of suitable material and with casters, bearings, etc., that will last with minimum maintenance. DEPARTMENT OF CIVIL ENGINEERING, RSET 94  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Pushing and Pulling (Contd…) Calculate force ▫ Roughly, the amount of force that needs to be applied to move a load over a flat, level surface using a well-maintained handling aid is at least 2% of the load weight. ▫ For example, if the load weight is 400 kg, then the force needed to move the load is 8 kg. ▫ The force needed will be larger if conditions are not perfect (e.g., wheels not in the right position or a device that is poorly maintained, the ground or floor surface is not smooth). DEPARTMENT OF CIVIL ENGINEERING, RSET 95  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Pushing and Pulling (Contd…) Compensate for slopes ▫ Pushing and pulling forces on slopes greatly increase ▫ Employees should get help from another worker whenever necessary ▫ Eg:- if a load of 400 kg is moved up a slope of 1 in 12 (about 5°), the required force is over 30 kg in ideal conditions – good wheels and a smooth slope. ▫ This is above the guideline weight for men and well above the guideline weight for women. DEPARTMENT OF CIVIL ENGINEERING, RSET 96  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Pushing and Pulling (Contd…) Adjust for uneven surfaces ▫ Moving an object over soft or uneven surfaces requires higher forces ▫ On an uneven surface, the force needed to start the load moving could increase to 10% of the load weight Push instead of pull when possible ▫ It is easier to maintain proper body mechanics when pushing, versus pulling a heavy item. DEPARTMENT OF CIVIL ENGINEERING, RSET 97  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Pushing and Pulling (Contd…)  Summary Factors that effect pushing and pulling: ▫ Human factors ▫ Task factors ▫ Cart/Equipment factors ▫ Floor/Ground factors Set stance and pace Choose and maintain handling devices Calculate force Compensate for slopes Adjust for uneven surfaces Push instead of pull when possible DEPARTMENT OF CIVIL ENGINEERING, RSET 98  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Palletizing The act of placing products on a pallet for shipment or storage in logistics supply chains DEPARTMENT OF CIVIL ENGINEERING, RSET 99  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Palletizing (Contd…) Multiple smaller products are converted into a single load that can be moved as one unit Products are stacked in a pattern that maximizes the amount of product in the load by weight and volume while being stable enough to prevent products from shifting, toppling, or crushing each other The goal is to prevent motion among the smaller units DEPARTMENT OF CIVIL ENGINEERING, RSET 100  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Palletizing (Contd…) Semi-automated palletizers with an ergonomic work platform allow employees to slide cases into place at a fast rate DEPARTMENT OF CIVIL ENGINEERING, RSET 101  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Palletizing (Contd…) Palletizing Techniques: ▫ Fill Boxes Fully ▫ Distribute Weight ▫ Stack Boxes Tightly ▫ Fill Gaps ▫ Wrap Tightly DEPARTMENT OF CIVIL ENGINEERING, RSET 102  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Stacking DEPARTMENT OF CIVIL ENGINEERING, RSET 103  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Stacking (Contd…) Stacking materials can be dangerous if workers do not follow safety guidelines Hazards ▫ Crushing of workers, causing injury or even death due to falling materials and collapsing loads ▫ Back injuries due to improper lifting techniques ▫ Struck-by material or equipment hazards ▫ Caught-in or pinch point material handling injuries ▫ Damage to racking systems and inventory ▫ Injuries due to incorrectly cutting ties or securing devices DEPARTMENT OF CIVIL ENGINEERING, RSET 104  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Stacking Stacking Techniques ▫ Stack loads on a level surface, straight and even ▫ Place heavier loads on lower or middle shelves ▫ Maintain good housekeeping ▫ Keep aisles and passageways clear ▫ Use proper lifting techniques DEPARTMENT OF CIVIL ENGINEERING, RSET 105  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Stacking Drums, barrels and kegs ▫ Stack symmetrically ▫ Place planks, sheets of plywood dunnage, or pallets between each tier ▫ If stored on their sides, block the bottom tiers to keep them from rolling. DEPARTMENT OF CIVIL ENGINEERING, RSET 106  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Stacking Lumber ▫ It should be stacked in such a way that is stable and self- supporting ▫ Remove all nails from used lumber before stacking ▫ Stack and level lumber on solidly supported bracing ▫ Stack lumber no more than 16 ft high if it is handled manually, and no more than 20 ft if using a forklift. DEPARTMENT OF CIVIL ENGINEERING, RSET 107  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Stacking Boxed materials ▫ Band or secure them with cross-ties or shrink wrap ▫ Interlocking boxes will create a more stable stack ▫ For stability, boxes can be placed on a pallet which will also make them easier to move. DEPARTMENT OF CIVIL ENGINEERING, RSET 108  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Stacking Bags and bundles ▫ Stack in interlocking rows to keep them secure ▫ Stack bagged material by stepping back the layers ▫ To remove bags from the stack, start from the top row first DEPARTMENT OF CIVIL ENGINEERING, RSET 109  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Stacking Pipes and bars ▫ Do not store in racks that face main aisles to avoid creating a hazard to passersby when removing supplies ▫ Unless they are in racks, stack and block poles, structural steel, pipe, bar stock and other cylindrical materials DEPARTMENT to preventRSET OF CIVIL ENGINEERING, 110  INDUSTRIAL SAFETY ENGINEERING Handling Assessments and Techniques Stacking Bricks ▫ Stack loose bricks no more than 7 ft in height ▫ When brick stacks reach a height of 4 ft, taper them back 2 inches for every foot of height above the 4-foot level. DEPARTMENT OF CIVIL ENGINEERING, RSET 111  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment Devices that help a warehouse function by moving and storing goods. 4 types 1. Storage and Handling Equipment 2. Bulk Material Handling Equipment 3. Industrial Trucks 4. Engineered Systems DEPARTMENT OF CIVIL ENGINEERING, RSET 112  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 1. Storage and Handling Equipment This is the simplest type Place to store the material in between receiving it and shipping it Includes ▫ shelves and racks ▫ Bins, drawers, stacking frames, flow racks, cantilever racks, and mezzanines They are often designed to utilize vertical space so the warehouse can hold more items DEPARTMENT OF CIVIL ENGINEERING, RSET 113  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 1. Storage and Handling Equipment (Contd…) Bin Rack Drawer Flow rack DEPARTMENT OF CIVIL ENGINEERING, RSET 114  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 1. Storage and Handling Equipment (Contd…) Stacking frames Cantilever racks Mezzanines DEPARTMENT OF CIVIL ENGINEERING, RSET 115  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 2. Bulk Material Handling Equipment Storing, transportation and control of materials in loose bulk form Example ▫ Silo - a large cylinder that can hold stuff like grain DEPARTMENT OF CIVIL ENGINEERING, RSET 116  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 2. Bulk Material Handling Equipment (Contd…) ▫ Stackers and reclaimers  Large machines that are used to dump things into piles or to pick them back up again DEPARTMENT OF CIVIL ENGINEERING, RSET 117  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 2. Bulk Material Handling Equipment (Contd…) ▫ Hoppers  It stores material and can release an exact quantity out the bottom. DEPARTMENT OF CIVIL ENGINEERING, RSET 118  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 2. Bulk Material Handling Equipment (Contd…) ▫ Grain elevators  Buildings used to store grain  They include a series of buckets on a track that automatically transports grain to the top of the building where it can be funneled into different silos. DEPARTMENT OF CIVIL ENGINEERING, RSET 119  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 2. Bulk Material Handling Equipment (Contd…) ▫ Bucket elevators  Similar to a grain elevator  this device features buckets that transport large amounts of material. DEPARTMENT OF CIVIL ENGINEERING, RSET 120  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 2. Bulk Material Handling Equipment (Contd…) ▫ Conveyor Belts  Moving belts that transport material  They can be combined into more complicated conveyor systems which are considered engineered systems. DEPARTMENT OF CIVIL ENGINEERING, RSET 121  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 2. Bulk Material Handling Equipment (Contd…) ▫ Dump Trucks  A type of industrial material transport vehicle. DEPARTMENT OF CIVIL ENGINEERING, RSET 122  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 2. Bulk Material Handling Equipment (Contd…) ▫ Screw Conveyor A screw-shaped device inside a tube that turns to move material. DEPARTMENT OF CIVIL ENGINEERING, RSET 123  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 2. Bulk Material Handling Equipment (Contd…) ▫ Rotary car dumper  A device that turns a rail car to dump out its contents. DEPARTMENT OF CIVIL ENGINEERING, RSET 124  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 3. Industrial Trucks These are vehicles or equipment that move materials Examples ▫ Hand trucks  Also called dollies  They are simple, L-shaped devices that let you carry material at a tilt DEPARTMENT OF CIVIL ENGINEERING, RSET 125  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 3. Industrial Trucks (Contd…) ▫ Side-loaders  These are used to load materials in narrow aisles where other trucks may be too wide DEPARTMENT OF CIVIL ENGINEERING, RSET 126  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 3. Industrial Trucks (Contd…) ▫ Pallet trucks  Hand-operated or electric devices that slide into pallets to move them DEPARTMENT OF CIVIL ENGINEERING, RSET 127  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 3. Industrial Trucks (Contd…) ▫ Walkie stackers  These transport and lift pallets like a forklift  They don’t include a place for the operator to ride in  They come in both powered or manual versions. DEPARTMENT OF CIVIL ENGINEERING, RSET 128  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 3. Industrial Trucks (Contd…) ▫ Order pickers  These vehicles lift a worker off the ground so they can grab high packages. DEPARTMENT OF CIVIL ENGINEERING, RSET 129  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 3. Industrial Trucks (Contd…) ▫ Forklifts  Operational vehicles used to lift and transport heavy items DEPARTMENT OF CIVIL ENGINEERING, RSET 130  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 4. Engineered Systems This type of material handling equipment involves more complicated systems with multiple components, usually warehouse automation. This category of equipment is the most complicated and expensive, often incorporating elements from the other categories into wider more expansive systems These systems require a lot of time and research before making an investment. Make warehouses more efficient Basically anything that moves materials around the warehouse so workers don’t have to. DEPARTMENT OF CIVIL ENGINEERING, RSET 131  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 4. Engineered Systems Examples ▫ Automated Guided Vehicles (AGVs) DEPARTMENT OF CIVIL ENGINEERING, RSET 132  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 4. Engineered Systems Examples ▫ Robotic delivery systems DEPARTMENT OF CIVIL ENGINEERING, RSET 133  INDUSTRIAL SAFETY ENGINEERING Material Handling Equipment 4. Engineered Systems Examples ▫ Automated Storage and Retrieval System (AS/RS) DEPARTMENT OF CIVIL ENGINEERING, RSET 134  Hazards in Mechanical Material Handling 1. Use of equipment and machinery without valid OSHA inspection certificates. 2. Inadequate and wrong selection of handling tools and machines. 3. Mechanical damage and faulty equipment. 4. Congested space for operation. 5. Incompetent operator. 6. Overloading of machines, tools and equipment. 7. Loading and transporting unbalanced materials. 8. Poor rigging and lifting. 9. Over speeding and unauthorized operation 10.Use of machines without machine guard.  Risk in Mechanical material handling 1. Poorly maintained tools, equipment and machines are prone to accidents due to failure of electrical, mechanical, and hydraulic systems that can cause serious injury to personnel and property damage. 2. Risk of load failure due to inadequate and incorrect selection of handling tools and machinery. 3. There is a risk of collision with property or personnel due to congested operating space. 4. An untrained and unauthorized machine operator can cause serious accidents and injure other personnel. 5. Risk of material failure during handling due to overloading of machines, tools and equipment. 6. Equipment can fall due to improper loading and transportation, poor rigging and lifting, and over speeding by unauthorized operation. 7. The use of machines without guards presents a high risk of serious injury.  Dos 1. Use lifting tools and hoists of adequate capacity. 2. Only authorized persons should use the equipment and machines. 3. The identification number and the safe working load must be marked on all tools and hoists. 4. Check the functioning of emergency switch, limit switches and over load alarm before actually starting the operation of lifting machines. 5. Estimate the weight, distance, and hazards before lifting the load. 6. Store lifting tools and hoists in a designated location. 7. Use appropriate personal protective equipment 8. Keep the speed slow while approaching at destinated location. 9. Stay alert and maintain eye contact on load and nearby man movement. 10.Special care should be taken when using the forklift and other portable hydraulic equipment. 11.When lifting the load with slings, make sure that all sharp corners are padded with soft material. 12.Barricade the area where the lifting operation is performed. 13.Use appropriate plate clamps to lift metal plates. 14.Use beam clamps for lifting beams. 15.Use an appropriate guide rope while lifting and shifting the material. 16.Apply an appropriate protective coating to keep tools in good condition.  Don’ts 1. Don’t use faulty tools and tackles. 2. Don’t stand under a suspended load. 3. Don’t lift the metal plates by using web slings only. 4. Don’t use the equipment for any other purpose than intended. 5. Don’t allow personnel to move underneath lifted load. 6. Don’t load the machines and equipment above its safe working load. 7. Don’t use makeshift arrangement for lifting the material. 8. Don’t use equipment, tools, hoist and tackles with a missing label or tag. 9. Don’t drag chains, ropes or cables on the floor. 10.Don’t use chemical contaminated web slings, wire sling or belt without re-inspection. 11.Don’t use a hoist, slings, chains and other lifting tools and tackles that have lost more than 10% of its breaking strength.  INDUSTRIAL SAFETY ENGINEERING HEARING CONSERVATION PROGRAM DEPARTMENT OF CIVIL ENGINEERING, RSET 150  INDUSTRIAL SAFETY ENGINEERING Effects of Noise Exposure Noise ▫ Generated during processes, operations and work activities ▫ One of the most common occupational health hazards Noise Induced Deafness (NID) ▫ Prolonged exposure to excessive noise can cause noise induced hearing loss DEPARTMENT OF CIVIL ENGINEERING, RSET 151  INDUSTRIAL SAFETY ENGINEERING Detrimental effects of excessive noise exposure Tinnitus (ringing in the ear) Acoustic trauma (temporary or permanent hearing loss due to sudden exposure to very loud noise.) Disruption of job performance Annoyance Extra-auditory effects DEPARTMENT OF CIVIL ENGINEERING, RSET 152  INDUSTRIAL SAFETY ENGINEERING HEARING CONSERVATION PROGRAM (HCP) To protect exposed employees from the adverse effects of noise, every workplace with a noise hazard should implement a comprehensive Hearing Conservation Program (HCP), as part of the company’s workplace safety and health program. The objective of the HCP is to minimize the risk associated with workplace noise exposure and to prevent NID. DEPARTMENT OF CIVIL ENGINEERING, RSET 153  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 1. Noise Monitoring 2. Noise Control 3. Audiometric Testing (test your ability to hear sounds) 4. Audiometric Test Requirements 5. Audiometer Calibration 6. Training 7. Record Keeping DEPARTMENT OF CIVIL ENGINEERING, RSET 154  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 1.NOISE MONITORING Noise monitoring is done to identify work locations where hazardous noise levels exists. Employee exposures to noise monitored periodically with ▫ Sound Level Meter (area noise level) ▫ Noise Dosimeter (personal noise exposure level) DEPARTMENT OF CIVIL ENGINEERING, RSET 155  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 1.NOISE MONITORING (Contd…) Noise Level and Allowable Exposure Time NOISE LEVEL ALLOWABLE NOISE LEVEL ALLOWABLE EXPOSURE EXPOSURE TIME TIME 85 Decibels 8 hours 90 Decibels 4 hours 100 Decibels 1 hour 105 Decibels 30 minutes 110 Decibels 15 minutes 115 Decibels 0 DEPARTMENT OF CIVIL ENGINEERING, RSET 156  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 2. NOISE CONTROL After the noise hazard has been identified and evaluated, the next step of risk assessment involves the reduction of the noise risk to an acceptable level through the application of reasonably practicable controls. DEPARTMENT OF CIVIL ENGINEERING, RSET 157  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 3. AUDIOMETRIC TESTING Audiometric testing monitors an employee’s hearing over time. It also provides an opportunity for employers to educate employees about their hearing and the need to protect it. The employer must establish and maintain an audiometric testing program. DEPARTMENT OF CIVIL ENGINEERING, RSET 158  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 3. AUDIOMETRIC TESTING (Contd…) The important elements of the program include baseline audiograms, annual audiograms, training and follow up procedures. There are two types of audiograms required in the Hearing Conservation Program (HCP): ▫ Base line audiogram ▫ Annual audiogram DEPARTMENT OF CIVIL ENGINEERING, RSET 159  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 3. AUDIOMETRIC TESTING (Contd…) Audiogram Graph showing the results of a pure-tone hearing test. It will show how loud sounds need to be at different frequencies for you to hear them. The audiogram shows the type, degree, and configuration of hearing loss. DEPARTMENT OF CIVIL ENGINEERING, RSET 160  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 3. AUDIOMETRIC TESTING (Contd…) Base line audiogram It is the reference against which future audiograms are compared in order to determine the extent to which an employee's hearing is deteriorating. If it is not conducted properly, it will not reflect the employee's true threshold, and any changes between baseline and future tests may be masked. DEPARTMENT OF CIVIL ENGINEERING, RSET 161  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 3. AUDIOMETRIC TESTING (Contd…) Annual audiogram Employers must provide annual audiograms within 1 year of the baseline audiogram to identify any deterioration to an employee’s hearing ability. This enables employers to initiate protective follow-up measures before hearing loss progresses. DEPARTMENT OF CIVIL ENGINEERING, RSET 162  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 4. AUDIOMETRIC TEST REQUIREMENTS Accurate audiometric results help to ensure correct interpretation of findings and correct diagnosis. Acoustic environment ▫ The background noise level can interfere and affect the accuracy of the test results. Therefore testing should be conducted in a proper booth where the background noise level does not exceed the permissible levels. DEPARTMENT OF CIVIL ENGINEERING, RSET 163  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 5. AUDIOMETER CALIBRATION The functional operation of the audiometer shall be checked daily and the audiometer calibration shall be checked acoustically annually as per the standards. DEPARTMENT OF CIVIL ENGINEERING, RSET 164  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 7. TRAINING Training and education are necessary for employees to understand the importance of protecting their hearing. Training Topics must include: ▫ Effects of Noise on Hearing. ▫ Purpose of hearing protectors. ▫ Advantages and Disadvantages of different types of hearing protectors. ▫ Attenuation of different types of hearing protectors. ▫ Purpose of audiometric testing. DEPARTMENT OF CIVIL ENGINEERING, RSET 165  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 8. RECORD KEEPING The objective of record keeping is to document HCP activities. ▫ Types of Records a) HCP policy statement b) Records of noise monitoring c) Records of risk assessment d) Noise Control Plan kept available for at least three years. DEPARTMENT OF CIVIL ENGINEERING, RSET 166  INDUSTRIAL SAFETY ENGINEERING ELEMENTS OF HEARING CONSERVATION PROGRAM 8. RECORD KEEPING (Contd…) e) Documentation of noise control solutions. f) Documentation of employees' training. g) Records of audiometric calibration data. h) Records of program evaluation. ▫ The records should include  the names of the personnel who performed the HCP tasks,  date of the records and,  results DEPARTMENT OF CIVIL ENGINEERING, RSET 167  INDUSTRIAL SAFETY ENGINEERING Noise Control Methods 1. Engineering Controls 2. Administrative controls 3. Personal Protection-Hearing Protectors DEPARTMENT OF CIVIL ENGINEERING, RSET 168  INDUSTRIAL SAFETY ENGINEERING Noise Control Methods 1. Engineering controls Engineering controls are physical means that limit the hazard. These include structural changes to the work environment or work processes. Some examples are: ▫ Reduce the driving force of vibrating surfaces. ▫ Reduce the sound radiation from vibrating surfaces. ▫ Reduce noise transmitted through the air by complete enclosure of noise surfaces. ▫ Enclosure of noisy machines to minimize the noise transmitted to the employees. DEPARTMENT OF CIVIL ENGINEERING, RSET 169  INDUSTRIAL SAFETY ENGINEERING Noise Control Methods 2. Administrative controls Administrative controls are any arrangements or procedures that limit the daily noise exposure of employees by control of the work or production schedule. Some examples are: ▫ Shortening the length of time an employee is exposed to excessive noise by job rotation ▫ Scheduling machine operating times. DEPARTMENT OF CIVIL ENGINEERING, RSET 170  INDUSTRIAL SAFETY ENGINEERING Noise Control Methods 3. Personal protection-Hearing protectors Employers must provide hearing protectors to all workers exposed to 8-hour Time- Weighted Average (TWA) noise levels of 85 db or above. This requirement ensures that employees have access to protectors before they experience any hearing loss. DEPARTMENT OF CIVIL ENGINEERING, RSET 171  INDUSTRIAL SAFETY ENGINEERING Noise Control Methods 3. Personal protection-Hearing protectors (Contd…) Attenuation of different types of hearing protectors ▫ Ear plugs will reduce noise by as much as 30 decibels. ▫ Ear canals is used when individual is unable to use traditional ear plugs and it will reduce noise by as much as 30 decibels. ▫ Ear Muffs will reduce noise by as much as 15-30 decibels and it is used in conjunction with ear plugs when exposed to high noise levels. DEPARTMENT OF CIVIL ENGINEERING, RSET 172 Thank you…