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Safe Use of Machinery

1. IN THIS SECTION 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 9 9 9 10 9 11 Choosing a guard Basic rules for guard design Guarding of operational and non operational parts Choosing the material for guards Servicing and maintenance considerations Guards for exposed rotating cutting machinery Pulleys and drives Rotating shafts and rollers Conveyors bulk handling Press brakes Robotics SECTION 09 CHOOSING THE RIGHT GUARD Choosing the right guard for the machine will create a physical barrier between a worker and the dangerous parts of the machinery When choosing guards careful attention to design and layout and the use of the machine can remove many health and safety hazards and can prevent health issues and injuries occurring Note the flowchart does not take other protective devices such as two hand controls into account START HERE Are hazards present Is access required by operators maintenance staff or cleaners Does opening the guard cause the hazard to stop before access Is constant access required Can presence sensing systems be used appropriately If competent person verifies the machinery can t be guarded agree on safe systems of work Flowchart 7 Choosing a guard NO NO NO NO NO Guards not needed Fixed guards as gt AS 4024 1601 gt AS 4024 1 1801 1803 Use movable gua
2. Figure 14 Examples of cutting hazards 3 4 10 STABBING AND PUNCTURING HAZARDS The human body can be pierced by flying objects Figure 15 shows some ways operators can be injured by stabbing and puncturing hazards For example gt a loose tool in a lathe broken tooling on a press gt an abrasive wheel breaking up gt swarf 25 26 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY gt timber from a bench saw molten metal from a die casting machine sparks from welding gt a bolt from an explosive powered tool debris thrown by rotary mowers and hedge cutters The human body can also be pierced by rapidly moving parts of machinery or pieces of material For example the needle of a sewing machine the drill of a drilling machine the arm of a robot Injection of fluids through the skin can cause tissue damage similar to stabbing Figure 15 Examples of stabbing and puncture hazards by flying objects or moving parts of machinery ERGONOMIC HAZARDS Ergonomic hazards come about through the way the operator interacts with the machine Sometimes machinery is not always designed for how an operator must use the machine For example operators may have to overreach reach above shoulder height hold awkward postures and use repetitive or forceful movements Having to work this way can cause damage to nerves muscles and tendons
3. EE DUTIES OF MANUFACTURERS AND SUPPLIERS OF MACHINERY Manufacturers and suppliers of machinery should take all practicable steps to make sure it is designed manufactured and tested so it will not harm anyone during gt installation gt use gt repair gt dismantling gt cleaning Manufacturers and suppliers are responsible for gt safety in design eg if they cannot find the parts specified by the designer they must find others of the same standard building the machine to meet the design requirements testing the machinery HSE Regulations 67 describes the duties of manufacturers and suppliers of plant EE SUPPLYING MACHINERY Under section 18A of the HSE Act a person who hires leases sells or otherwise supplies another person with a machine to be used in a workplace has legal duties SECTION 02 RESPONSIBILITIES AND DUTIES FOR MACHINERY People who hire lease or loan machinery must find out whether it will to be used in a workplace and if so how it will be used They must ensure that the machinery has been designed made and maintained to be safe for its intended use People who sell or supply machinery that can be used in a workplace must take all practicable steps to make sure it has been designed made and maintained to be safe for any known intended use or any reasonably expected use If a seller or supplier agrees to install or arrange a machine section 18A 3 of the H
4. Ergonomic hazards can cause serious harm to operators but they do not need to These hazards can be removed at the design stage 3 5 1 MANUAL HANDLING By considering how and when a machine is used you can reduce the risk of injury This includes how well the working environment is set up are frequently used displays instruments or control panels where operators can reach safely while keeping correct posture what type of machinery is used does the equipment expose anyone to too much vibration noise or emissions or does it need physical force to work how work is organised how much work needs to be done How urgent is the work How many breaks do operators get How long are the breaks what physical demands are put on the person using the machinery is the work repetitive Does it require awkward movements or postures Does the operator have to work in extreme temperatures Check whether tasks require repetitive movement or there is a risk of musculoskeletal injuries and gradual process disease More information can be found in WorkSafe NZ s Code of Practice for Manual Handling SECTION 03 IDENTIFY ASSESS AND CONTROL HAZARDS 3 5 2 LAYOUT AND DESIGN Good layout makes any guarding better at keeping people safe Machines that are poorly placed or too close together can be unsafe even if guarded When designing layout avoid congestion points or worker movements near hazardous machi
5. gt Have the control measures isolated or minimised the risk from the hazard as intended Have the control measures made any new hazards Have the control measures made any existing hazards worse In order to answer these questions you may need to gt talk with workers supervisors and any health and safety representatives measure levels of exposure eg take noise measurements where a noise source was identified refer to manufacturers instructions monitor incident reports contact industry associations unions government bodies or health and safety consultants When deciding when to monitor and review control measures consider the level of risk high risk hazards need more frequent assessments the type of work practices or machinery involved whether new methods tasks equipment hazards operations procedures rosters or schedules have been introduced whether the environment has changed gt any indication that risks are not being controlled KEEPING DOCUMENTS AND RECORDS Documenting your chosen control measures helps show you have met your legal obligations Keep records to track what has been done and what is planned effective record keeping can save time and money The level of documentation should be appropriate for the level of risk and control measures 61 62 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Notes
6. 75 76 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Notes 1 APPENDICES IN THIS SECTION 11 1 Definitions 11 2 Example of hazard checklist 11 3 Sample job safety analysis JSA 11 4 Summary of the AS 4024 Safety of machinery series 11 5 Example risk assessment process 11 6 Flowcharts 11 7 More information DEFINITIONS Please note some these definitions are based on the Health and Safety in Employment Act 1992 HSE Act but should not replace legal advice All practicable steps is defined in the HSE Act Briefly it means doing what is reasonably able to be done in the circumstances taking into account the severity of any injury or harm to health that may occur the degree of risk or probability of that injury or harm occurring how much is known about the hazard and the ways of eliminating reducing or controlling it the availability effectiveness and cost of the possible safeguards Current state of knowledge is what is known about the hazard or risk including actual or potential harm and ways of eliminating isolating or minimising the risk Dynamic forces are forces resulting from movement of an object in this case movement of a machine Functional validation of a machine is the process of testing that a safety related device performs as the designer intended
7. BUSINESS CASE The concept stage of a project is the best time to get things right With thorough research planning and consultation many hazards can be eliminated before a machine is designed purchased installed or modified 6 4 1 HEALTH AND SAFETY IN THE BUSINESS CASE Once the need for new machinery or a change to existing machinery is identified adding health and safety into the business case will help to assess hazards and risks This can also help avoid budget blow outs unpleasant surprises and costly retrofitting A thorough business plan includes at least the following elements outlined in sections 6 4 2 to 6 47 of this guideline 6 4 2 RETURN ON INVESTMENT ROI A return on investment ROI assessment should incorporate health and safety implications For example two different machines can get the same results One machine costs 10 000 more but is insulated and does not make enough noise to damage hearing If the cheaper machine was purchased the company would have to spend 15 000 on hearing protection and hearing monitoring for operators The machine that is 10 000 more expensive will actually save the company 5000 in safety equipment and health checks 6 4 3 CAPITAL EXPENDITURE CAPEX Some businesses incorporate health and safety costs in the CAPEX sign off process A senior manager responsible for health and safety ensures an assessment is done and any risks addressed before the machine is purc
8. FLOWCHARTS START HERE A Concept stage Define the need What will the machine be used for see Flowchart 5 and Flowchart 6 OR Redesign or modify existing plant and machinery Validation Take into account gt Performance gt Layout decide how gt Cost to eliminate see Flowchart 2 and 3 gt Safety specifications any potential gt Lighting hazards gt Hazards like noise Assess Hazard And Risk and dust assessment gt Personnel gt Legislation gt Current state of knowledge SECTION 11 APPENDICES Consult with A staff experts and others to Identify hazards see Flowchart 4 Isolation guards and guarding systems see Flowchart 7 and Appendix 11 4 Eliminate hazards where possible Guarding options not available verified by competent person Minimise by a safe system of work see Flowchart 8 Flowchart 1 Get it right from the start overview of safe use of machinery guideline START HERE Hazard identification by Task analysis gt Process analysis Physical inspection Best practice guidelines guides and standards gt Accidents and incidents Failure mode analysis gt Maintenance records gt HAZOP Hazard and Operability Analysis Chemicals Ergonomics Mechanical Organisational Electrical hazards Occupational health hazards Other hazards Flowchart 2 Common machinery hazards gt
9. gt Are operators and maintenance workers adequately trained familiar with the operation and set up of machinery and able to demonstrate safety features 2 ASSESS THE LEVEL OF RISK FOR IDENTIFIED HAZARDS gt Gather information about the hazard s Consult with relevant people including workers Work out the likelihood of an injury or harm occurring Consider how many people are likely to be exposed to the hazard and for how long Take into account different situations or conditions that might exist at the workplace and could increase risk such as changes to operations inspection cleaning maintenance servicing and repairs and new or inexperienced workers gt Use the information you have gathered to assess the potential consequences of any injury or harm occurring from the hazard s for example whether people die or suffer major minor or negligible injuries gt Rate the risk by using the risk rating table below to work out the level of risk associated with each hazard 3 CONTROL MEASURES Once the risk has been assessed where required choose control measures to eliminate the risk See section 4 of this guideline for options to control hazards 4 RESIDUAL RISK The risk may then be assessed after taking into consideration how much the hazard controls will prevent harming workers RISK RATING TABLE Likelihood of injury or Consequences of injury or harm to health A Extreme immediate action
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11. points and the drive mechanism are usually the best way to guard conveyors Large conveyors such as stockpilers generally need both carry idlers and return idlers guarded where they are under high tension and accessible This should be done to an appropriate standard such as AS 1755 Conveyors Safety Requirements AS 4024 3610 Conveyors General Safety Requirements or equivalent Note the interlocking lid that flips down amp closes over the auger Interlocking mechanism Interlocking mechanism Figure 32 Typical guard for head and tail section of a conveyor 9 9 3 ELECTRICAL ISOLATION LOCK OUT AND TAG OUT Electrical isolation safeguards which prevent access during most phases of machinery life may not be effective when hazardous areas need to be accessed such as during maintenance and set up Because of this conveyors should have appropriate drive power isolation whether its power source is electrical hydraulic pneumatic or mechanical A lock out and tag out system should secure isolation 9 9 4 START AND STOP CONTROLS Each conveyor start location needs a clearly labelled stop control If any part of the conveyor operation cannot be seen from the start control there must be a visible or audible signal to warn people nearby 9 9 5 EMERGENCY STOP CONTROLS A lanyard type pull wire emergency stop is the best emergency stop for exposed belt conveyors where workers must a
12. Machinery can injure people by gt crushing gt cutting gt shearing gt puncturing abrading burning tearing gt stretching Common injuries include amputation gt crushing electric shock hearing loss ill health from hazardous chemicals or lack of oxygen WorkSafe New Zealand has identified a number of trends where employers have been prosecuted for injuries and fatalities to staff and contractors through using machinery These trends are gt no guarding on machines at all letting operators reach into dangerous parts of the machine guards not securely fastened and easily removed while the machine is in use openings in the guards where the operator can easily reach through to dangerous parts operators able to remove guards for maintenance and not replacing them interlocked guards that can open while parts are still moving or running down mechanisms from interlock switches can be removed to override the guards single light beam safeguard devices can be switched off closed limit switches which are not used causing interlock switches to be overridden interlock guards used as a shortcut to start the machine BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY ineffective lock out and isolation of power systems supporting systems failure such as when pneumatic or hydraulic systems lose pressure and allow a ram to fall FED AUSTRALIAN
13. Solvents gt Layout and gt Oils and design lubricants gt Reach gt Hydrocarbons gt Fixing gt Projectiles gt Lubrication gt Interlocking gt Trapping gt Impact gt Projectiles gt Entanglement gt Fatigue gt Shiftwork Z Gontact gt Workload gt Nipping Lack of safety Stability culture Shock Electromagnetic gt EMF radiation Noise gt Laser burn gt Dust gt Radio supply gt Fumes gt Earthing gt Radiation gt Fuse gt Heat gt Lightning gt Vibration gt Biological gt Fibres gt Confined space gt High pressure gt Stored energy Regular review and make changes if necessary gt Training staff gt Personal protective equipment gt Safe operating procedures Y Involve staff experts health and safety reps inhouse expertise Assess each hazard and associated risks Develop hazard controls 93 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Operator controls Personal Start protective equipment Normal gt Stop 5 HR A START HERE Operation Emergency stop n 9 Hazards T hele gt Training and xia supervision Hazard identification b i d Tool setting gt Safe operating gt Task analysis pay and procedures gt Process analysis gt Physical inspection Usual use gt Failure mode Irregular gt HAZOPs _ Hazards Operator response Assess each hazard Accidents and who it
14. assess and control hazards 3 2 1 HAZARD IDENTIFICATION METHODS Once you have identified all machinery you can identify their hazards A good hazard identification process is key to hazard management You can identify hazards using Physical inspections Inspect the machinery and assess where someone could get injured or caught in the machinery Task analysis Identify the hazards involved in each task This should include what happens when there is a blockage or the machine needs cleaning or maintenance gt Process analysis Identify hazards at each stage of the production process gt Best practice guidelines and standards Hazard and operability analysis HAZOP Accident investigation analysis Identify hazards and causes of harm from investigations involving similar types of work Hazard identification and management should be completed and monitored regularly to make sure control measures are working and no new hazards have been introduced See Appendix 1 for a sample hazard checklist 19 20 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY EXAMINE COMPANY RECORDS AND MANUFACTURERS INSTRUCTIONS TO SEE IF THEY REVEAL ANY HAZARDS List the plant in your workplace Develop checklists and a worksheet to use when physically inspecting the workplace Inspect the workplace and talk to people who work with plant Record hazards identified Figure 3 Processes are used together to
15. develop measures to eliminate isolate or minimise hazards before an injury or incident occurs when SECTION 08 GUARDING TYPES MINIMISE gt new machinery is introduced gt changes are made to existing machinery gt changes are made to how they work 8 3 3 TRAINING INFORMATION Employers must train workers supervisors and others so they can use hazard control measures and work safely 8 3 4 SUPERVISION Operators and workers must be supervised by a competent person to make sure hazard control measures are used correctly 8 3 5 MAINTENANCE Work procedures should identify any maintenance needed to keep control measures effective Looking at maintenance of control measures is an important part of the implementation process So maintenance can be done safely consider the ease of accessing parts ensuring machinery parts are safe to maintain gt ease of handling gt designing machinery to reduce the range of tools and equipment needed for maintenance 8 3 6 PERSONAL PROTECTIVE EQUIPMENT Employees may need personal protective equipment when working with machinery that makes heat fumes noise or other hazards Personal protective equipment must be provided by the employer and maintained and replaced when required Standards New Zealand have a range of guidance relating to personal protective equipment 59 60 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY 8 3 7 FIRST AID Every wo
16. parts or from exploding out of the machine Do guards allow safe comfortable and easy Yes No use of the machine Can the machine be maintained without Yes No removing the guard Can the existing guards be improved Yes No Are there safe procedures in place and a way to shut down the machine if something out of Yes No the ordinary happens like a blockage Mechanical hazards point of operation Is a guard on the machine at every point of operation where there is a hazard NES NO Does the guard keep the operator s hands Yes No fingers and body out of the danger area Have the guards been tampered with Yes No or removed Is there a more practical or better guard Yes No How can point of operation hazards Yes No be removed Are the tools used for placing and removing material the right length type and size to keep Yes No an operator s hands out of the machine Operator controls Are start and stop controls in easy reach of Mes No the operator If there is more than one operator station are separate controls placed where operators can Yes No see the entire operation Are controls including foot controls guarded against being turned on accidentally 00 Are controls labelled clearly with their function Yes No 80 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Are controls similar in type and arrangement Yes No to other similar machines in the plant Are emergency stop controls easily reached and cle
17. such as lock out tag out These types of controls rely on extensive instruction information training and supervision Minimising a hazard can stop injuries but it is the least effective option because it relies more on human behaviour maintenance programmes and supervision In the long term minimisation can also be more expensive because it needs time and ongoing oversight by managers and employers and additional costs of personal protection eg hearing protection When a hazard can only be minimised section 10 of the HSE Act requires employers to monitor employees exposure to the hazard and monitor their health Employers can only monitor employee s health with their informed consent Because minimisation relies on human behaviour hazard management needs to consider the actions of the people who install or dismantle machines gt operate machines and equipment maintain or repair machines gt clean machines 37 38 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY With changes in technology and cost of solutions over time measures to eliminate and or isolate a hazard may become practicable Duty holders should continue to assess significant hazards that are being minimised in order to determine whether there are other methods to control them For example replace with a newer machine that eliminates or isolates the hazard 5 3 1 AS 4024 SAFETY OF MACHINERY SERIES Duty holders should us
18. 10 Use of machinery the employee SECTION 02 RESPONSIBILITIES AND DUTIES FOR MACHINERY Designers manufacturers suppliers and employers all have responsibilities to ensure machinery is safe to use Figure 1 shows who has health and safety responsibilities for each phase or aspect of the machine s life cycle Responsibility of designers manufacturers and suppliers Responsibility of employers x Q x s t x A 9 WS X9 19 5 AB AD ANO y a VS 13 aA LE 4 19 43 o Ne 2 Ao EO C 2 3 LA o x VS o A3 VE NC 3 3 Figure 1 Division of health and safety responsibilities during machine s life cycle EX DESIGN AND MANUFACTURING GET IT RIGHT FROM THE START The best time to make machinery safe is at the design stage Designers of machinery must take all practical steps to ensure that what they design does not become a hazard to anyone building installing using maintaining or repairing it Designers manufacturers and suppliers of machinery and personal protective equipment have legal duties these are explained in HSE Regulations 66 to 69 Equipment designs should meet relevant New Zealand and international standards Figure 2 summarises the designer s responsibilities which are to ensure machinery gt is ergonomically sound has conveniently placed power controls gt will not be a source of harm meets relevant New Zealand and overs
19. Health and Safety Representatives SECTION 11 APPENDICES 101 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Notes 102 SECTION 11 APPENDICES Notes 103 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Notes 104 DISCLAIMER WorkSafe NZ has made every effort to ensure that the information in this guideline is reliable but we make no guarantee of its accuracy or completeness and do not accept any liability for any errors WorkSafe NZ may change add to delete from or otherwise amend the contents of this guideline at any time without notice Except for the logos of WorkSafe NZ this copyright work is licensed under a Creative Commons Attribution Non commercial 3 0 NZ licence To view copy of this licence visit http creativecommons org licenses by nc 3 0 nz In essence you are free to copy communicate and adapt the work for non commercial purposes as long as you attribute the work to WorkSafe NZ and abide by the other licence terms MORE INFORMATION Information examples and answers to your questions about the topics covered here can be found on our website www worksafe govt nz on the Safe use of machinery project page or by calling us free on 0
20. SPECIFIC USER INFORMATION Written information for the user should include the machine s intended use gt a description of the machine s controls especially emergency stops operating instructions including start up preparations process change over and shutting down common faults and any reset instructions the user may need any guards or protective safety devices for particular hazards safety sign descriptions and details any prohibited uses or likely misuse any hazards the manufacturer could not eliminate any personal protective equipment that needs to be used gt any training that is needed 8 4 2 MACHINERY INFORMATION A wide range of information sources can be used to help identify hazards including employee and health and safety representative participation and involving those working with the machinery Australian Australia New Zealand New Zealand or European standards manufacturer s instructions and advice maintenance logs of machinery documentation of safe work practices and their effectiveness injury or incident information and hazard alerts gt relevant reports from occupational health and safety agencies unions employer and professional bodies gt articles from health and safety journals gt safety information from safety authorities on the Internet ED SAFE SYSTEMS OF WORK A safe system of work is a formal work procedure developed
21. Whether commissioning or designing a new machine or changing an existing machine this is the chance to get rid of significant hazards WorkSafe NZ recommends eliminating hazards at the start of the commissioning or purchase process The flowcharts also cover identifying hazards risk assessments choosing appropriate guarding and how to develop a safe system of work The aim is to create a safe working environment and safe systems of work for anyone working with or near machinery Use the individual flowcharts to scope the design or to modify of a piece of machinery The key is identifying and assessing all hazards caused by the machine and its use which then must be eliminated isolated or minimised If you cannot eliminate or isolate them work through the hierarchy of guarding options see section 5 of this guideline before moving to minimising the hazard Minimisation includes gt using personal protective equipment monitoring employee health and the environment using safe operating procedures gt training using safe systems of work The flowcharts are collated together in section 11 6 and also appear in the appropriate section of this guideline START HERE A Concept stage Take into account Define the need gt Performance What will the machine gt gt Layout be used for gt Cost see Flowchart 5 and gt Safety specifications Flowchart 6 gt Lighting gt Ha
22. affects and incidents gt Emergency associated risks Maintenance records planning and A esponse gt Best practice resp guidelines guides and gt naela standards a ae ees Develop hazard a a controls gt Blockage Cleaning gt Personal gt Lock out protective eguipment Maintenance gt Interlock Mente Repair De energising 9 gt Insulation gt Training gt Safe operating procedures Flowchart 3 Identify operational hazards to use machinery safely START HERE Assess the hazard for significance and assess the risk i r Monitor and review WES Is the hazard gt Consequence severit d a lt y Review if something changes controlled gt Likelihood exposure and the risk frequency see mitigated Appendix 11 5 for risk rating YES Evaluate controls NO through Risk probability regular review gt Low Medium High and update gt Who is exposed to the or change if isk required gt Current state of knowledge Keep records Guarding gt Interlocks Develop priority of Is the hazard gt Training actions for each hazard controlled No gt PPE Installation and and the risk commissioning a gt Information and mitigated signage gt Procedures Identify controls Involve Audit and review staff and use internal gt Monitor or external advice Select and environment and engineers health and put in place or health controls safety consultants see Flowcharts 7 and 8 gt Supervision g
23. after a systematic examination of a task to identify all the hazards It defines safe ways to work so hazards and risks are minimised When hazards cannot be completely eliminated or isolated you may need to use a safe system of work An competent person must agree that a safe system of work is the only way to control a hazard In this case a competent person is someone with current knowledge and understanding of gt AS 4024 and other relevant standards the guards and other safety devices how to use guards and other devices on that type of machine A safe system of work should never be used as the main hazard control without first assessing whether the hazards can be eliminated or isolated with guarding either provided by the manufacturer or retro fitted to existing machinery Workers need extra training more supervision and other protective measures when using a safe system of work These also need to be documented ES MONITORING AND REVIEWING EFFECTIVENESS OF CONTROL MEASURES Once control measures are in place they must be regularly monitored and reviewed To do this it is useful to ask the following questions Have control measures been implemented as planned gt If control measures have not been implemented why not and what is happening in the meantime gt Are the control measures being used correctly SECTION 08 GUARDING TYPES MINIMISE gt Are the control measures working
24. are mechanical methods to control hazards other ways to minimise risk might still be needed such as safe work systems or protective clothing and equipment see section 8 3 Do not use only non mechanical control measures to control hazards They rely on human behaviour and need commitment management and enforcement to work effectively EE OTHER CONTROL MEASURES There are control measures that minimise the risk of harm that can be used with machine guarding Some of these control measures are systems and others are activity based such as maintenance 8 3 1 DEVELOPING WORK PROCEDURES Work procedures are needed to make sure that hazard control measures are effective All work procedures must define responsibilities for management supervisors and workers have systems to make sure appropriate guarding is bought and correctly installed explain how workers will be trained and supervised to make sure the machinery is only used with the guarding in place require workers to follow the work procedures have arrangements to maintain the machine and guards gt have a system for workers to report malfunctions or problems with machinery have emergency procedures and training for staff on what to do 8 3 2 CONSULTATION AND COMMUNICATION Involving workers and health and safety representatives in hazard management is essential They are most likely to know about the hazards of their work They can help
25. can t then isolated and if that isn t practicable controls should be put in place to minimise the hazard If it is not a significant hazard the employer must still take all practicable steps to ensure the equipment is safe for employees to use EE RISK ASSESSMENT Use flowchart 4 to work through the hazard and risk assessment process This is the process to assess hazards select controls and to assess whether these methods have reduced or eliminated the risk of harm occurring To manage risks effectively an assessment of how likely a hazard is to cause harm must occur and if it does how badly someone can be hurt This helps prioritise which hazards need to be dealt with first 33 34 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Any risk assessment should cover where which and how many workers could be injured or harmed how often this is likely to occur how serious any injuries might be For example with hazards from moving rotating or reciprocating machinery first assess how likely it is that a worker could get caught entangled or nipped and then determine how serious any injury might be Risk factors to consider during the risk assessment include gt visibility how easy is it to see the hazard gt orientation for example a feed screw that is low and horizontal could entangle hair ties and jewellery A screw in a different place or angle would pose a different risk gt
26. identify hazards Critically inspect each piece of machinery and how it is used to identify where someone could be harmed by gt any parts moving and stationary gt processes gt procedures gt workplace activities gt related danger zones For more information see gt the machinery factsheets on WorkSafe NZ s Safe Use of Machinery page at www worksafe govt nz gt Flowcharts 2 and 3 in this guideline gt Figure 3 above for an example of one process to identify hazards EE MACHINERY HAZARDS In this guideline hazards are split into two categories machanical hazards and operational hazards This section covers the main hazards caused by the machinery itself Many pieces of machinery use force and motion to cut bend join or shape materials This force and motion can harm people Some of the ways people can be hurt are covered in this section Machines and machinery parts in the figures section are unguarded to show the hazards and danger zones Flowchart 2 shows the most common types of machinery hazards MECHANICAL HAZARDS 3 4 1 PRIME MOVERS Prime movers are devices that turn energy into motion to power a machine Prime movers include gt water turbines gt electric generators gt electric motors gt electric rotary converters the head and tail race of water wheels motors powered by burning fuel such as coal petrol or natural gas Every flywheel directly connecte
27. include Goods machinery will meet all relevant New Zealand safety laws Goods machinery will meet the following standards eg AS 4024 Safety of Machinery series For more information see WorkSafe NZ s Position Paper for the Safe Use of Machinery Exceptions to section 18 A of the HSE Act are goods that are second hand or sold as is As is means without promises or warranties as to quality durability or fitness with the buyer carrying all risks Buyer beware INSTALLING MACHINERY The installer must thoroughly identify and assess all hazards and determine the machine s limits using the latest AS 4024 1 or other equivalent standard An engineer must decide what safety category the machine falls into and what guards it needs so it meets AS 4024 The engineer needs relevant experience and knowledge of machine guarding and the requirements of AS 4024 13 14 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY The manufacturer must validate that the design of all safety features in control components and control systems meet the standards of sections 1501 and 1502 of AS 4024 If the manufacturer cannot do this an engineer with relevant experience and knowledge must inspect the machine and validate that it meets AS 4024 The machinery must be installed according to the manufacturer s instructions If the person selling or supplying machinery agrees to install it the law says they must
28. induction for new staff and covering people on leave People management gt Matching the worker to the task gt Training for competency gt Effective supervision gt Use maintenance and replacement of personal protective equipment gt Visitor management Safe system of work must be approved by the authorised duty holders and a competent person Regular auditing and recommended changes Emergency management gt Procedures in place for emergencies gt Information and signage gt Equipment accessible gt Staff trained competent and capable gt Processes in place for blockages and out of the ordinary events eg power outages Agree on safe system of work that takes into account and controls the hazards Flowchart 8 Developing and maintaining a safe system of work for specific tasks Human factors gt Shiftwork gt Fatigue gt Repetitive activities gt Incentives bonuses gt Shift length and breaks No guarding options available Verified by a competent person Consultation with staff health and safety reps and internal experts about any changes 73 74 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Flowchart 8 gives details of the key factors that should be considered when developing a safe system of work Apart from assessing guarding options for machinery all workplaces must have safe systems of work in place for tasks and processes
29. machinery gt Do people need to work in enclosed areas where the atmosphere could be harmful such as pits tanks or storage vessels What equipment or materials need to be carried to do the job Where and when is access needed to use maintain and clean the machine How will people get safe access such as from a walkway gantry elevated work platform ladder What work will be carried out with the machine Will people be near or exposed to any mechanical or non mechanical hazards when they access the machine Has consultation occurred with employees or contractors about how they intend to gain access and what equipment and work platform or structure is best suited for the intended task 3 10 2 CONFINED SPACE Larger machinery and equipment can have enclosed areas that are difficult to get to In confined spaces oxygen levels may be low or there may be harmful levels of gas vapour or dust 29 30 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Normal START HERE Operation Hazards Hazard identification by Task analysis Process analysis Physical inspection gt Failure mode HAZOPs Irregular gt Accidents and A incidents gt Maintenance records gt Best practice guidelines guides and standards Cleaning Maintenance Repair Operator controls gt Personal gt Start protective gt Stop equipment gt Monitoring gt Emergency stop Traini d S Lab
30. take all practicable steps to install or arrange the machinery so it is safe for its intended use HSE Act section 18A 3 EX USE OF MACHINERY THE EMPLOYER Employers are responsible for the health and safety of their employees and any other people who can be harmed by the actions or inactions of their employees Employers must as far as practicable gt keep workers safe from hazards at work by identifying and managing hazards gt make sure work done is safely gt provide protective clothing and equipment gt train and supervise workers so they can work safely gt provide an accident reporting system and follow up on any accidents injuries or near misses gt develop procedures for dealing with emergencies If an employer can only minimise a hazard they must monitor the environment and the health of employees 2 6 1 TRAINING AND SUPERVISION OF MACHINE OPERATORS The employer or person in control of the workplace must not let anyone use a machine unless they have had training on gt the actual and potential hazards of the machine gt all the precautions to be taken gt Unless the machine operator can operate the machine safely then the employer or person in control should have the operator closely supervised by someone with the skills Employees must be supervised and trained by a competent person section 13 HSE Act When training people to use machinery a trainer must explain g
31. that take into account gt hazards and controls human factors gt emergency management gt people management the work environment gt correct use of tools and plant ETE PARTICIPATION AND CONSULTATION For the safe system of work to be robust anyone who could come in contact with the machine should be consulted This includes gt operators gt supervisors health and safety representatives maintenance staff in house engineers any health and safety experts ITE HAZARD MANAGEMENT Before a safe system of work can be put in place employers must identify and assess all hazards such as the work environment eg layout lighting ventilation human factors eg people s capabilities shift work fatigue the use and maintenance of personal protective equipment Then they must develop a way to control each hazard such as gt safe operating procedures gt job or task safety analysis gt effective and safe maintenance cleaning and blockages procedures gt procedures for unexpected events like power outages UE COMPETENCY OF OPERATORS AND SUPERVISORS Any operator using a safe system of work must be competent to do the job and be supervised by a competent person Employers must have a training programme in place that works for gt new employees gt existing employees gt employees on leave when the safe system of work was introduced TY EMERGEN
32. to access the machine when setting it Design and install the guard so a tool is needed to remove and replace it Figure 30 Fixed guard for a pulley and drive preventing access to transmission machinery 65 66 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY ROTATING SHAFTS AND ROLLERS Interlocked guards are preferable for rotating shafts and rollers such as gt couplings gt spindles gt fan shafts gt ironing rollers Guards should stop loose clothing and long hair getting caught in rotating shafts In addition to a guard it may be appropriate to tell operators not to wear loose clothing such as long sleeved shirts or jackets and tie long hair back or wear a head covering Fixed Guard ANAT AAA A AD T f 4 12174 A ADA A L 7 AVN Na f 24 ART ie 7 APTA TIT lt La TIRAS AC NAAA MAN T MM 2 NV wae Figure 31 Fixed guard on rotating shaft or coupling CONVEYORS BULK HANDLING Conveyors move materials from one place to another Types include belt screw and bucket conveyors 9 9 1 HAZARDS The main hazards of a conveyor are the many in running nip points which can entangle crush and abrade people The drive system can also pose risks of entanglement or abrasion 9 9 2 CONTROL MEASURES Fixed guards that enclose in running nip
33. up The inching control should be a hold to run type so the machine stops immediately when the control is released Employers should maintain and keep machinery in sound operating condition at all times They can manage the maintenance using gt preventive maintenance schedules gt regular inspections unsafe condition reports ask for employee feedback MODIFYING MACHINERY The manufacturer s and designer s instructions should be referred to before modifying any plant Modifications should be only be completed by a competent person who has knowledge and experience of AS 4024 and the type of machine or plant Any modifications must be validated so the design of all safety features in control components and control systems meet the standards of sections 1501 and 1502 of AS 4024 If the manufacturer cannot do this an engineer with relevant experience and knowledge must inspect the machine and validate that it meets AS 4024 EE DECOMMISIONING MACHINERY Any decommissioning and dismantling of machinery must be undertaken as per the manufacturer s instructions and completed by a competent person FET USE OF MACHINERY THE EMPLOYEE When using machinery an employee is responsible for their own health and safety not harming others through their actions or inaction following any safe work procedures their employer has in place identifying and reporting hazards and controlling them w
34. 24 1 Series Safety of machinery gt AS 4024 1101 Terminology General gt AS 4024 1201 General principles Basic terminology and methodology gt AS 4024 1202 General principles Technical principles gt AS 4024 1301 Risk assessment Principles of risk assessment gt AS 4024 1302 Risk assessment Reduction of risks to health and safety from hazardous substances emitted by machinery Principles and specifications for machinery manufacturers gt AS 4024 1401 Safety of machinery Part 1401 Ergonomic principles Design principles Terminology and general principles SECTION 11 APPENDICES gt AS 4024 1501 Design of safety related parts of control systems General principles AS 4024 1502 Design of safety related parts of control systems Validation AS 4024 160 Design of controls interlocks and guarding Guards General requirements for the design of fixed and movable guards AS 4024 1602 Interlocking devices associated with guards Principles for design and selection gt AS 4024 1603 Design of controls interlocks and guards Prevention of unexpected start up AS 4024 1701 Human body measurements Basic human body measurements for technological design AS 4024 1702 Human body measurements Principles for determining the dimensions required for openings for whole body access into machinery gt AS 4024 1703 Principles for determining the dimensions required for access openings AS 4024 1704 Human
35. 800 030 040 WorkSafe New Zealand 56 The Terrace PO Box 165 Wellington 6140 Phone 64 4 897 7699 Fax 64 4 415 4015 0800 030 040 www worksafe govt nz ISBN 9780478425154 online VY WorkSafeNZ ISBN 9780478425147 print WORK New Zealand Government NEW ZEALAND
36. CY PROCEDURES Emergency procedures must be in place and staff trained to use them This includes information signage and emergency equipment FU WHEN GUARDING IS NOT AN OPTION A workplace cannot opt for a safe system of work that does not include guarding to control a hazard without first considering all possible guarding controls TY AGREEMENT AND SIGN OFF Once agreement is reached on what a safe system of work is for a machine the duty holders employer or principal must approve it along with a competent person and document it ETE COMPETENT PERSON Before designing a safe system of work a competent person must establish that all possible guarding options were considered they must explain why none could be used and give advice on the residual risks that remain The competent person must also be consulted and approve the safe system of work EU REVIEWING Every safe system of work needs regular reviewing to take into account gt advances in technology gt incidents or accidents any new hazards identified new industry standards and guidance whether the hazards are still controlled monitoring of the environment and or health of operators SECTION 10 SAFE SYSTEMS OF WORK Any proposed changes should involve anyone previously consulted on the safe system of work The system and any changes need testing before they are included in the safe working system and approved by the duty holder
37. Emergency stop devices should not be the only method used to control hazards They are only a backup for other control measures They should be red with a yellow background Do not use emergency stops to lock out the machine because the actuators can separate from the contacts If this happens the control will show the machine is off but it is actually on 55 56 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Do a hazard assessment when choosing an emergency stop device and consider whether part of the machine still needs to work in an emergency situation what other safety features still need to work such as pressure release valves whether the stop introduces any new hazards what level of integrity any associated circuitry needs Make sure emergency stop devices gt are prominent and clearly and durably marked gt are immediately accessible to each user of the machine have red handles bars or push buttons labelling can also be used gt are not affected by electrical or electronic circuit failure Other considerations include whether stop devices should be easily seen in contrast to their surroundings the best access for workers ideally they are near where someone can be trapped in the machine the environment the machine is used in eg whether the device is exposed to dust chemicals temperature extremes or vibration the number of emergency stop devices ne
38. Group control is a control that protects more than one person in the vicinity of the machine in addition to the operator Harm a means illness injury or both and b includes physical or mental harm caused by work related stress Hazard a means an activity arrangement circumstance event occurrence phenomenon process situation or substance whether arising or caused within or outside a place of work that is an actual or potential cause or source of harm and SECTION 11 APPENDICES b includes i a situation where a person s behaviour may be an actual or potential cause or source of harm to the person or another person and ii without limitation a situation described in subparagraph i resulting from physical or mental fatigue drugs alcohol traumatic shock or another temporary condition that affects a person s behaviour Inching means limited motion of machinery where dangerous parts of machinery are exposed during cleaning setting adjustment or feeding material and depending on the machine and industry may include the terms jog crawl and pulse lonising radiation is radiation with enough energy so that during an interaction with an atom it can remove tightly bound electrons from the orbit of an atom causing the atom to become charged or ionised Examples are x rays and gamma rays Machine life cycle is the process beginning with design continuing through manufacture sale transport in
39. MAY 2014 New Zealand Government BEST PRACTICE GUIDELINES 4 WORIK NEW ZEALAND s ACKNOWLEDGEMENTS WorkSafe New Zealand WorkSafe NZ would like to thank Safe Work Victoria for letting us use content and images from their publication Machinery and Equipment An Introduction July 2007 Ist edition WorkSafe NZ would also like to thank the Western Australian Commission for Occupational Safety and Health and the Mining Industry Advisory Committee for letting us use content and images from their Code of Practice for Safeguarding of Plant and Machinery 2009 Some of the text in that Code was originally published by Workplace Health and Safety Queensland and is copyright to the State of Queensland 2006 We are reproducing it with permission Illustrations for Figures 30 31 and 32 are reproduced with the permission of the Queensland Department of Justice and Attorney General JAG JAG owns the copyright for these illustrations WorkSafe NZ would like to thank Dulux NZ Myriad Engineering Ltd and Ferndale Furniture Ltd for letting us photograph their workplace to illustrate good practice for safe use of machinery in this guideline This guideline is aimed at employers engineers designers manufacturers and distributors of machinery WorkSafe New Zealand has also developed a set of factsheets for specific machinery Though relevant to employers these factsheets are mostly aimed at operators and employees TABLE
40. OCESS The best time to eliminate hazards is at the machinery design stage This section covers some of the common hazards that can be eliminated through design The section also outlines the principles of including health and safety in the design process The design process usually begins with the buyer or employer wanting a piece of machinery to meet business needs and or modifications a manufacturer seeing an opportunity to meet an industry need gt a supplier seeing a gap in the market a supplier looking for other products to promote At this point the designer should get advice from safety experts people who might use it and engineers to help design a safe machine Machinery must be designed that does not hurt anyone at any point in the process of its manufacture installation use maintenance or repair Designers must consider how the machinery can injure people working with it Injuries include amputation and crush injuries workplace stress and fatigue manual handling injuries occupational illness from fumes dust noise radiation ELIMINATE HAZARDS THROUGH DESIGN Common hazards that can be eliminated through design include mechanical hazards hazards made by the shape relative location mass and stability movement and strength of machine parts gt electrical hazards contact with or distance from live parts suitability of insulation static electricity
41. OF CONTENTS INTRODUCTION 1 1 1 2 Australian Standard AS 4024 Using the flowcharts in the guideline RESPONSIBILITIES AND DUTIES FOR MACHINERY 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 Design and manufacturing get it right from the start Duties of manufacturers and suppliers of machinery Supplying machinery Choosing and buying Installing machinery Use of machinery the employer Inspection and Maintenance Modifying machinery Decommisioning machinery Use of machinery the employee IDENTIFY ASSESS AND CONTROL HAZARDS 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 Hazard management Identify hazards Machinery hazards Mechanical hazards Ergonomic hazards Chemicals and fumes Organisational hazards Electrical safety of machinery Environmental and occupational health hazards Other hazards Operational hazards HAZARD AND RISK ASSESSMENT 4 1 4 2 Risk assessment Adequate information knowledge and experience ala 10 12 13 TS 14 lS 16 16 16 19 19 20 20 26 27 27 28 28 29 30 33 34 CONTROLLING MACHINERY HAZARDS 5 1 5 2 5 3 5 4 Eliminate hazards Isolate hazards Minimise hazards Matrix of guarding controls ELIMINATE HAZARDS AT THE DESIGN PROCESS 6 1 6 2 6 3 6 4 6 5 6 6 Eliminate hazards through design Reliability of safety functions Designing for safety throughout the life cycle Concept stage hea
42. ON 08 GUARDING TYPES MINIMISE If access to machinery is required and it is not practical to stop it employer principal or duty holders must ensure that the machine is fitted with operating controls that allow controlled movement there are written procedures to be followed for inspections repairs maintenance alteration and cleaning gt people working on the machine carry out the work in accordance with the written procedures 8 1 10 COMPETENT PERSON FOR PLANNED ISOLATION The competent person must be the key person to gt stop and isolate the machine minimise any risks associated with identified hazards including telling any workers who may be affected by isolating the machine The competent person must make sure gt all energy sources are de energised and isolated using an isolation device and locked out using a lock out device gt all energy isolating devices are activated and all switches and valves are in the off or safe position to stop any attempts to activate the machine stored energy is released or restrained including for example completing the cycle of a flywheel releasing steam and bleeding valves an out of service tag is fixed to the machine and danger tags are fixed to the energy sources and operating controls tests are in place to de energise and isolate the energy sources to make sure the machine cannot be re energised the machinery is isolated befor
43. SE Act says they must take all practical steps to install or arrange the machine so it is safe for its intended use Health and safety legislation requires people to make sure others are safe at work It also protects people using machinery and equipment 2 3 1 INFORMATION FOR SUPPLIERS AND PURCHASERS HIRERS Manufacturers and suppliers must give thorough and easy to understand instructions on how to use the machine safely see HSE Regulations 67 3 4 People who make and supply protective clothing and equipment have similar duties see HSE Regulations 69 4 amp 5 Any instructions must explain gt hazards linked to the machine how to install the machine safely gt how to operate the machine safely safe ways to clean and adjust the machine how to maintain and repair the machine regular replacement of parts of the machine that wear how to safely take the machine out of service and take it apart gt any other relevant matters The supplier or the purchaser or hirer must understand and follow the information EX CHOOSING AND BUYING Machinery that is designed from the outset to remove hazards should reduce costs for employers due to less need to purchase personal protective equipment install extraction systems for fumes or particles install extra guarding Buyers and hirers can include conditions about the safety of the machinery in the purchase contract Examples
44. STANDARD AS 4024 Duty holders should use the Australian Standard AS 4024 Safety of machinery series as the standard that gives the current state of knowledge for the safeguarding of machinery and plant It should be referred to by duty holders as the primary standard against which to benchmark Employers suppliers manufacturers and designers can work to other standards but they need to show that they can reach the same level of safety or better in the circumstances in which they are used Employers must make sure anyone they engage for advice on machine guarding and safety is a competent person and is experienced at working with and using AS 4024 or equivalent or higher standards Based on key information from AS 4024 this guideline advises employers and other duty holders on managing machinery hazards This guideline is the key reference for what safety looks like when using machinery This guideline is part of a suite of guidance for the use of machinery For further information refer to WorkSafe NZ s Safe Use of Machinery page at www worksafe govt nz USING THE FLOWCHARTS IN THE GUIDELINE This guideline has a series of flowcharts that cover the key concepts around machinery safety The flowcharts work through the processes for commissioning manufacturing or purchasing machinery and how hazards can be eliminated at this point The design stage is the best time to control the hazards associated with machinery
45. STEM OF WORK FOR PRESS BRAKES On occasions it may not be possible to perform work with the guarding system in place Removal of or turning off a guard should only occur if the guard makes it impracticable to perform close work or jobbing and a hazard and risk assessment is carried out by a competent person A safe system of work must be developed in conjunction with the employer and operators and approved by a competent person with appropriate knowledge and experience of machine safety In cases where guarding of any moving parts of the plant does not eliminate risks of entanglement or where it is not practicable to guard the parts people must not operate or pass close to the moving part unless a safe system of work is in place to reduce the risks Additional training experience and higher levels of supervision and other protective measures may be required and will need to be documented For more information on safe systems of work see section 10 in this guideline 9 10 4 CLOSED TOOL METHOD The closed tool method of reducing the press brake s opening to 6mm limits the risk of introducing a part of the body into this hazardous zone The distance between the point of the upper tool and the top of the bottom die is where the 6mm is measured from Where possible the closed tool method should be used with a safety light curtain a laser beam device or a two hand control device ED ROBOTICS Using robots can remove the
46. a 93eJos lt e uoneledald lt L Jequunu uonduosep xse1 de1s dais ASEL A9NSSI a uesea D 1equinu ysr 82 SECTION 11 APPENDICES I have read understand and agree to the procedure and controls documented Person s performing the work Date RISK RATING TABLE Likelihood of injury or Consequences of injury or harm to health harm to health Ee eee Extreme immediate action 83 84 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY EE SUMMARY OF THE AS 4024 SAFETY OF MACHINERY SERIES AS 4024 is the Australian Standard for managing machinery hazards The standard is available in four series Their organisation is shown in the chart below Organisation of AS 4024 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 mos 1 1 1 1 1 1 1 1 1 1 1 1 SECTION 11 APPENDICES Series 1 or to use its full title AS 4024 7 Safety of Machinery series has 26 Parts under the eight headings in the diagram above The 26 Parts are European EN and Internationally based ISO safety and design standards with some modifications to meet Australia s safety practices and regulations The series gives designers manufacturers suppliers employers and users of machinery guidelines to help reduce the risks of working with or near machinery Designers manufacturers suppliers employers and users of common manufacturing machinery not li
47. aining Employees may elect a health and safety representative for their workplace The health and safety representative is someone that staff can go to and discuss any problems around health and safety The health and safety representative will work with the employer to find a solution In larger workplaces employees representatives may be elected onto the health and safety committee that also includes representatives of the employer Where employee health and safety representatives are elected they are entitled to paid leave to attend approved training courses If an employee has genuine concerns about health and safety they have the right to refuse unsafe work HSE Act section 28A This should only happen when other avenues to deal with the problem have not been successful During the time the employee s concerns are being investigated he or she may need to perform other duties in the workplace For more information see WorkSafe NZ s factsheets Health and safety representatives Employers must involve employees in health and safety Employees have to help ensure and safe and healthy workplace 17 18 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Notes IN THIS SECTION 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 Hazard management Identify hazards Machinery hazards Mechanical hazards Er
48. anticipated work practices including less obvious ones such as gt maintenance inspection repair and cleaning practices for example a screw conveyor is behind closed panels but when it jams a worker may open the panel and stick their hand in infrequent or one off tasks required on the machine When assessing the risk take into consideration whether the danger zone can be reached the likelihood of a worker putting fingers hands arms feet or legs into places where they do not normally go when the machine is running Figure 16 An example of visibility risk factor When the top part of the machine lowers it comes to rest on supports on each corner so only a small area on the underneath of the top may be a hazard Key for arrows gt Solid red arrows where a part of the body could be drawn into a nip point Grey arrows movement of machine parts EE ADEQUATE INFORMATION KNOWLEDGE AND EXPERIENCE Risk assessment is not an absolute science it is a best estimate made on the basis of available information As such the people doing risk assessments need the right information knowledge and experience of the work environment and work processes They need to talk to workers and health and safety representatives who can advise on the particular hazards and risks for different machinery The AS 4024 Safety of machinery series has more information on risk assessment
49. are in HSE Regulation 11 3 9 4 OPERATING SPEEDS AND DANGEROUS VIBRATION No machine should be driven or used at an unsafe speed Where a designer or manufacturer recommends a working speed for a machine do not go any faster Maintain machines so there is no dangerous vibration when the machine is working or when moving parts and cutters are run at idle or full speed 3 9 5 MACHINERY STABILITY AND SECURITY All machinery must be secured to the floor or other structure so that it cannot tip become unstable or create any other hazards unless it is designed to be portable 3 9 6 WEIGHT OF GUARDING Large machinery may need a lot of guarding which needs to be removed for maintenance access Design guards to come off easily and be handled by one person Well placed handles make removing lifting and handling easier and reduce the risk of manual handling injuries Where practical use cranes or other lifting devices to move heavy guards EET OTHER HAZARDS 3 10 1 ACCESS HAZARDS Operators and employees need safe access into on and around machinery Workers need a stable work platform that is right for the work they need to do The operator should be able to keep good posture while working The platform must give a sure footing a safe working environment and prevents falls it is at height When designing safe access to machinery think about who what where when and how Who will be working on or around the
50. arly identified es Mo Is the machine wired so it must be manually re started if power is cut and Yes No then put on again Are gears sprockets pulleys or flywheels guarded teede Are there any exposed belts or chain drives Yes No Are there any exposed sets key ways Yes No collars etc Are all hazardous moving parts guarded Mes No including auxiliary parts Are start and stop controls in easy reach Yes No of the operator lf there is more than one operator are there Yes No separate controls Are other hazards like noise fumes and vibrations identified and managed GERE Have special guards enclosures or personal protective equipment been provided Yes No to protect workers from exposure to hazardous substances Have hazards associated with layout repetitive movements and workload been Yes No identified and managed Is the machine regularly tagged and tested If so how often Yes No Are there loose conduit fittings Yes No Is the power supply correctly fused and protected Yes No Do workers occasionally get minor shocks Yes No while using any of the machines SECTION 11 APPENDICES Are operators and skilled workers trained and competent to use the guards Yes No Are production workers trained in where the guards are Yes No how they give protection what hazards they protect against Are operators supervised by competent staff Yes No Have workers been trained in what to do if
51. body access to machinery Gives the smallest size an opening can be when someone has to go through it to access machinery There may be extra requirements for mobile machinery Use this standard to help design openings such as for people to walk upright through or climb via a vertical ladder Sizes are also given for users wearing personal protective equipment or carrying an injured person Principles for determining the dimensions required for access openings Gives minimum sizes for access openings in machinery Additional space needs are also given There may be extra requirements for mobile machinery Use this standard to help design access openings for putting body parts into a machine It allows for different postures such as standing or crouching Anthropometric data Gives the human body measurements needed to calculate the size of access openings in machinery The measurements come from European surveys Use AS 40241701 for information on how to source human body measurements Safety distances and safety gaps AS 4024 1801 AS 4024 1802 AS 4024 1803 Safety distances to prevent danger zones being reached by the upper limbs Gives the minimum safety distances between a barrier and a danger zone of a machine to stop anyone over three years old reaching the danger zone with their arms Only use this standard when distance alone can remove the hazard This standard does not protect against radiation or substances coming out o
52. body measurements anthropometric data gt AS 4024 1801 Safety distances to prevent danger zones being reached by the upper limbs AS 4024 1802 Safety distances and safety gaps Safety distances to prevent danger zones being reached by the lower limbs gt wAS 4024 1903 Displays controls actuators and signals Ergonomic requirements for the design of displays and control actuators Control actuators AS 4024 1907 Safety of machinery Displays controls actuators and signals System of auditory and visual danger and information signals gt AS 4024 2601 Safety of machinery Design of controls interlocks and guarding Two hand control devices Functional aspects and design principles AS 4024 2801 Safety of machinery Safety distances and safety gaps Positioning of protective equipment with respect to the approach speed of parts of the human body gt AS 4024 3 Safety of machinery Part 3 Manufacturing and testing requirements for electro sensitive systems Optoelectronic devices gt AS 4024 4 Safety of machinery Part 4 Installation and commissioning requirements for electro sensitive systems Pressure sensitive devices gt AS 4024 3001 Safety of machinery Materials forming and shearing Mechanical power presses gt AS 4024 3002 Safety of machinery Materials forming and shearing Hydraulic power presses gt AS 4024 3101 Safety of machinery Materials cutting Milling machines including boring machin
53. ccess the belt area while the conveyor is in use such as when placing and removing parcels at a transport depot The lanyard type means wherever someone is working on the conveyor they can reach the emergency stop Emergency stop controls should be manually reset before the conveyor can be restarted from its normal start control 9 9 6 ACCESS PROVISIONS The machine design should let people do routine adjustment and lubricate and maintain the machine without removing guards or much taking apart Wherever practical people should be able to lubricate and maintain the machine from outside the danger area If people need access to the danger area such as for machine setting use safe isolation procedures 9 9 7 TRAINING Make sure people working around conveyors are trained on how to use the machinery and are aware of the potential hazards 9 9 8 MORE INFORMATION AS 1755 Conveyors Safety Requirements and AS 4024 3610 or equivalent give more information on minimum safety requirements for the design installation and guarding of conveyors and conveyor systems and training PRESS BRAKES A press brake is a variable stroke machine generally limited to straight bending and forming of material such as sheet metal and heavy gauge material SECTION 09 CHOOSING THE RIGHT GUARD 9 10 1 HAZARDS For press brakes the main hazards are the die sets mounted to the main moving beam and table coming together to fo
54. circular and band saws gt drills and drill chucks gt cutters in metal working machines including the blades of guillotines and the tools of power presses gt beaters Then consider non operational parts such as chains and sprockets belts and pulleys gt gears including rack and pinion sets shafts plain or threaded flywheels Revolving shaft Vee belt amp enclosed pulley drive fully enclosed Shaft end closed Chain amp sprocket drive fully enclosed Figure 28 Examples of machine guards isolating various hazards EX CHOOSING THE MATERIAL FOR GUARDS There are four main considerations when choosing material to make a guard strength and durability use of non metallic materials in corrosive environments effects on machine reliability a solid guard may cause the machine to overheat gt visibility there may be operational and safety reasons for needing a clear view of the danger area control of other hazards eg the use of a material that will not eject molten metal SERVICING AND MAINTENANCE CONSIDERATIONS When designing guards consider what safe procedures are needed for their removal for repair clearing jams and breakdowns Servicing matters to consider include following documented safe work procedures including manufacturers instructions proximity to hot or sharp parts cool down or warm up periods gt run down period
55. crushed by or entangled with the robot including being crushed between a rapidly rotating robot arm and barriers close by SECTION 09 CHOOSING THE RIGHT GUARD gt Control errors These come from faults in the control system of the robot such as software electrical interference programme corruption and sub controls associated with the electrics hydraulics and pneumatics Human error These can happen during programming teaching maintenance and repair working close to the robot or at loading or unloading stations Failure or malfunction Electrics hydraulics and pneumatics can all create hazards when they fail Biological or chemical hazards These can happen when robots are used to reduce the risks from hazardous or infectious processes Workers may risk inhaling or absorbing hazardous substances In this case the work process needs close attention along with any breakdown or emergency procedures that may be needed such as for spillage contamination or breach of the system Environmental hazards These include dust vapours fumes lasers noise radiation and flammable and explosive atmospheres that can cause serious harm such as burns and inhaling or absorbing hazardous substances and hearing loss 9 11 2 CONTROL MEASURES Industrial robots can be made safe using one or more guarding and presence sensing devices Control measures include enclosing the robot gt restricting access
56. ct more than one person whereas individual controls can only protect one person at a time If hazards can t be eliminated there are a number of options to isolate operators from machinery When deciding which guarding methods to use consider practicality and how the operator will use the machine Many factors determine the choice of guard Depending on the situation a combination of two or more guards may be needed to keep workers safe SECTION 05 CONTROLLING MACHINERY HAZARDS HIERARCHY OF CONTROLS GROUP CONTROLS INDIVIDUAL CONTROLS ul a Design or modify machine to eliminate the hazard 2 gt Eliminate by substitution t ELIMINATE gt Eliminate human interaction eg automate handling gt Eliminate pinch points gt Increase clearances or remove forces Fixed guard gt Safe by position Interlock guard ISOLATE Interlock distance bars AE NN Failsafe interlocking mE LESS DESIRABLE Table 1 Matrix of guarding controls 40 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Notes IN THIS SECTION 6 1 6 2 6 3 6 4 6 5 6 6 Eliminate hazards through design Reliability of safety functions Designing for safety throughout the life cycle Concept stage health and safety in the business case Construction of machinery Validation and verification SECTION 06 ELIMINATE HAZARDS AT THE DESIGN PR
57. d 7 1 2 INTERLOCKED GUARDS Interlocked guards work by cutting power to the machine when the guard is opened They are a good guard to use when a machine needs to be accessed often If parts keep moving when the machine is not working you must use a type of guard that cannot be opened until all parts have stopped moving or fit devices that stop the machinery Any brakes fitted to machinery must be well maintained Use a suitable anti freefall device with interlocked rise and fall guards on machine tools that can injure if they freefall under gravity Power operated guards should work with a minimum of force so they do not create a trapping hazard Where it is not possible to reduce the closing force of a guard fit a safety trip device to the leading edge of the guard that will stop and reverse the guard if it contacts an object like a hand With barriers like fences there is a danger that machines can start when someone is close to them such as when an interlocked door accidentally closes and the machine re starts To avoid this hazard fit devices to stop an interlock door or gate closing accidentally such as a spring or gravity latch which need a deliberate action from someone to close the door 49 50 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Interlocked guards must be designed so that any failure or loss of power does not expose people to danger The design also needs to consider the possibil
58. d supervision by a competent Safe system of work must be approved by the SECTION 11 APPENDICES power outages Agree on safe system of work that takes into Consultation with staff health and Take into account person in authorised duty account and safety reps and place for all holders and a controls the internal experts gt Advances in staff including competent person hazards about any technology induction for changes gt Incidents or new staff and accidents covering people gt Any new hazards identified gt New industry standards and guidance on leave Regular auditing and gt Whether hazards recommended changes are still controlled gt Keeping records Flowchart 8 Developing and maintaining a safe system of work for specific tasks 98 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY EFE MORE INFORMATION This list of standards is included for general guidance only and is not inclusive of all standards Readers should check the latest version of a standard at the time of use New Zealand has performance based legislation and there is a duty on designers manufacturers suppliers importers sellers and employers to take all practicable steps to eliminate isolate and or minimise hazards Complying with the requirements of an appropriate best practice standard may be considered as taking all practicable steps to ensure safety of machinery and plant Evidence of failure to comply with the req
59. d for a drop saw Fixed guard for a pulley and drive preventing access to transmission machinery Fixed guard on rotating shaft or coupling Typical guard for head and tail section of a conveyor Press brake with fixed guards and a presence sensing light curtain Robot cell showing Levels 1 2 and 3 11 12 20 22 22 22 25 25 25 24 24 25 25 25 26 54 SE 55 49 50 50 54 54 55 55 56 58 64 65 65 66 66 68 70 INTRODUCTION SECTION 01 INTRODUCTION The Best Practice Guidelines for the Safe Use of Machinery outlines the hazards that come with using machinery in the workplace potential injuries and how best to control these hazards It gives duty holders advice on how to use machinery safely and meet their duties under the Health and Safety in Employment Act 1992 HSE Act and the Health and Safety in Regulations 1995 HSE Regulations When using this guideline consider the unique demands of your workplace and industry there may be other hazards and risks not covered in this guideline The HSE Act and HSE Regulations place responsibilities on many different persons including machinery and plant designers manufacturers suppliers installers and operators employers and owners of machinery These people are called duty holders Duty holders must take all practicable steps to make sure machinery in the workplace is designed safely and is adequately guarded to reduce the risk of injuries or harm
60. d to a prime mover and every moving part of a prime mover should be securely guarded unless it is safe because of its position or construction It must be safe for everyone in the workplace Prime movers also include motors powered by burning solid liquid or gas fuels such as coal petrol or natural gas START HERE Hazard identification by Task analysis Process analysis Physical inspection gt Best practice guidelines guides and standards gt Accidents and incidents gt Failure mode analysis gt Maintenance records gt HAZOP Hazard and Operability Analysis Chemicals Ergonomics Mechanical Organisational Electrical hazards Occupational health hazards Other hazards SECTION 03 IDENTIFY ASSESS AND CONTROL HAZARDS gt Solvents gt Oils and lubricants gt Hydrocarbons gt Fatigue gt Shiftwork gt Workload gt Lack of safety culture gt Noise gt Dust gt Fumes gt Radiation gt Heat gt Vibration gt Biological gt Fibres gt Layout and design gt Reach gt Fixing gt Projectiles gt Lubrication gt Interlocking gt Trapping Assess gt Impact each hazard and gt Projectiles gt Entanglement gt gt Nipping gt Stability Develop hazard controls gt Shock Electromagnetic gt EMF radiation gt Laser burn gt Radio supply gt Earthing gt Fuse gt Lightn
61. dangerous There is no longer a reasonably foreseeable risk of injury to any person employed or working in the place of work even a person who is careless or inattentive while in the vicinity of a machine or using a machine Shall and must are used in this guideline in places where there is a legal requirement to achieve the desired result Should is used in this guideline as a way of indicating a preference It does not indicate a mandatory requirement as other alternatives may achieve an equivalent result Supplier is anyone who sells or hires out machinery They have a number of legal responsibilities Swarf is metal removed from a workpiece during machining It may be in the form of small chips tightly curled strips or long ribbons Transmission machinery is a mechanism that transfers movement from the prime mover to the machine It can be a shaft wheel drum pulley system of fast and loose pulleys gearing coupling clutch driving belt chain rope band or other device Validation is the process of confirming that all required steps of the safety life cycle are tested implemented working and verified SECTION 11 APPENDICES EFE EXAMPLE OF HAZARD CHECKLIST SAFE USE OF MACHINERY CHECKLIST Guarding requirements Do guards stop workers touching dangerous moving parts Yes No Are guards firmly secured and not ves No easily removable Do guards stop objects falling into the moving Yes No
62. done by the person in charge of the validation once the risk reduction methods have been put in place on the machine It should include descriptions of how the machine was made safe to operate and any minor hazards remaining should be noted If new hazards have appeared as a result of any modifications these must be noted and controlled 6 6 4 SAFETY DESIGN CONTROL AND SOFTWARE VALIDATION Validation must also check the design of controls and how the software functions SECTION 06 ELIMINATE HAZARDS AT THE DESIGN PROCESS 6 6 5 INSTALLATION VALIDATION This can include gt gt gt gt physical inspection of machine review of guarding design check that reach distances meet the ergonomics of machine guarding requirements electrical inspection hydraulic inspection pneumatic inspection ensure components are fit for purpose system architecture meets the needs of risk assessment and safety requirement specifications inspection of components for things like damage and correct mounting check that wiring and piping match drawings and are labelled correctly 6 6 6 FUNCTIONAL SAFETY VALIDATION Each safety feature is individually tested and validated for example each emergency stop is pressed and what happens is compared to what the safety requirement specifications say is supposed to happen 6 6 7 ESSENTIAL HEALTH AND SAFETY REQUIREMENTS VERIFICATION Assess the machinery for other hazards Flowc
63. e person usually a manager to hold the key at all times This person must also make sure the gate is not opened until the machine is switched off isolated and has stopped Only use locked guards and gates if after diligent trials there are no practical alternatives Senior management in association with staff should also write approve and monitor any safe operating procedures and monitor the effectiveness of the safety process as a temporary means to minimise the hazards SECTION 08 GUARDING TYPES MINIMISE Isolation hold cards and lock out devices see section 8 1 11 of this guideline can also be used so a machine is not accidentally restarted 8 1 6 ADJUSTABLE GUARDS Adjustable guards are made up of a fixed guard with adjustable elements that are moved to suit each task They can be self adjusting guards that are forced open by the entry of work distance guards barriers that can be moved to a safe distance from the danger zone Guards that move out of the way for each operation automatic guards need special care Hazards can be created between the guard and machine gt person gt work piece Staff need full training on using and adjusting these guards These guards are only effective when the people use them correctly Figure 25 The self adjusting guard over the cutting wheel swings back as the cutting wheel cuts through steel 8 1 7 EMERGENCY STOP DEVICES
64. e any inspection repair maintenance alterations cleaning or withdrawal happens 57 58 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY The competent person who isolated the machinery must be the one to remove the lock out equipment and make the machine operational again A procedure should be in place where this is not possible such as where work is done over a number of shifts or the worker has gone home sick If the competent person cannot complete all steps in a planned isolation they must make sure a competent person develops written procedures and that these are followed by the person doing the work 8 111 ISOLATION HOLD CARDS AND LOCK OUT DEVICES Chains clasps and locks are examples of devices that can be used to isolate machinery Isolation devices must be reliable and clear Each lock should be strong enough to take physical abuse either intentional or unintentional be made of material suitable for the environment have only one key and one owner who is responsible for it Master or spare keys should be kept in a designated place away from the workplace and under the control of an competent person There must be strict procedures about when to use spare keys They must only be used in an emergency after thorough safety checks are done Lock out and tag out cards should be used together and be attached to the power controls of isolated machinery This reduces the chance of someone star
65. e one control down gt need to be held to run so the machine stops immediately when the control is released gt be spaced well apart and shrouded so one arm cannot run both controls The rear and sides of the machine should be guarded by fixed guards to prevent stop access by other people 8 1 4 PRESSURE SENSITIVE MATS Pressure sensitive mats are designed to cut the machine s power if someone steps on them to access a dangerous part Only use pressure sensitive mats when you cannot use physical barriers or other methods of isolating people from hazards Pressure sensitive mats use a number of well spaced electrical or fluid switches or valves in a mat The mat covers any entries to a restricted space Pressure on the mat stops the automatic operation of the machine You should design the guard so no one can step over or around it into a restricted area Operate and maintain pressure sensing safeguard systems to the manufacturers instructions Keep records of any maintenance inspection commissioning and alteration to a presence sensing system as well as any test results Make sure workers and health and safety representatives can access the records Because pressure sensitive mats do not usually show any visible sign of failure use a control system that shuts down the machine if a mat fails Figure 24 Pressure mat enclosing a robot 8 1 5 LOCKED GUARDS AND GATES Locking guards and gates need a responsibl
66. e reel such as the tool of a broaching machine and gt reaching between rotating and fixed parts the part being broached such as flywheels and the machinery bed Screw or worm conveyors and their casings mixers extruder screw and barrel the edge of an abrasive wheel or an incorrectly adjusted work rest SECTION 03 IDENTIFY ASSESS AND CONTROL HAZARDS Figure 12 Shear hazards between two machine parts Figure 13 Shear hazards between a machinery part and a work piece 3 4 9 CUTTING HAZARDS Cutting hazards exist at the point where wood metal or other materials are cut Figure 14 shows some ways operators can be injured by shearing hazards Many kinds of tools create cutting hazards band and circular saws boring or drilling machines gt planing and tenoning machines milling machines cutting edges of milling tools water jet cutting high energy lasers moving sheet material in a machine gt abrasive wheels cutting edges of endless band cutting machines reciprocating knives and saws gt revolving cutting tools Cutting hazards may involve rotating reciprocating or sideways motion Danger exists at the cutting point where a finger arm or body part can be injured Flying chips or scrap material can strike the head particularly in the eyes or face The danger is worse if the person caught cannot move away from the cutter
67. e systems to identify and deal with such factors when they can affect workplace safety Shift work can be hazardous because it disrupts normal rest patterns Employees need enough recovery time outside work so they can be safe and productive at work Along with enough sleep breaks during work hours are important to maintain an employee s physical and mental well being See WorkSafe NZ s Stress and Fatigue Reducing Their Impact Advice for Employers and Employees guide for more information ELECTRICAL SAFETY OF MACHINERY The wiring and fittings of machinery connected to the mains or similar must meet all legal requirements and must be installed by a registered electrician A certified professional third party must do all tagging and testing in line with electrical regulations All portable or handheld machinery that gets power from electricity should be used with an isolating transformer or residual current device where needed Get specific advice from the electricity supplier on the best device to use EE ENVIRONMENTAL AND OCCUPATIONAL HEALTH HAZARDS When reviewing machinery for non mechanical hazards consider how machinery can affect the area around it A thorough hazard identification process needs to consider the effect environmental factors such as lighting heat and cold have on workers when using machinery 3 9 1 WORKING AT HEIGHT People need a suitable work platform to reduce the risk of fa
68. e the AS 4024 Safety of Machinery series as the standard that gives the current state of knowledge in relation to safeguarding machinery and plant It should be referred to by duty holders as the primary standard against which to benchmark Employers suppliers manufacturers and designers can work to other standards but they need to show that they can reach the same level or better of safety in the circumstances in which they are used The level of familiarity with AS 4024 will depend on the responsibilities of the duty holder For instance when buying new machinery or hiring machinery the employer must make sure any machinery purchased or hired meets AS 4024 or equivalent or higher standards The employer must make sure that any competent person they hire to give advice or services on machine guarding or safe use of machinery is experienced in using AS 4024 or equivalent or higher standards However an engineer maintaining and repairing machinery and or installing guarding should be very familiar and experienced with AS 4024 and be able to readily access a copy See Section 11 4 for a summary of the AS 4024 Safety of Machinery series ED MATRIX OF GUARDING CONTROLS Table 1 covers options for eliminating hazards the types of guards and methods that isolate workers from hazards and examples of how hazards can be minimised The controls are split into two categories individual and group controls Group controls prote
69. eas standards gt will be safe for its intended purpose during manufacture and during its operating life gt is safe when it is decommissioned and disposed of 11 12 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Design is ergonomically sound DUTIES OF DESIGNERS Design will not be the cause of source of harm if the following occurs Provides information and instructions that are comprehensible Power controls shall be conveniently placed Used for the purpose for which it was designed Installed adjusted used cleaned maintained repaired an and comprehensive to manufacturers Manufactured in accordance with design The use for which the plant has been designed A How to install adjust use clean maintain repair and dismantle the plant in accordance with the d dismantled designer s instructions in accordance with the designer s Figure 2 Summary of the duties of designers of mach instructions Any other matters about which the manufacturer needs information from the designer in order to be able to carry out the manufacturer s duties inery Designers should provide thorough and easy to understand information and instructions to the manufacturer about how to build the machine so it meets the design criteria The designer also needs to give information on the right way to install operate adjust maintain and repair the machine
70. ed to keep every part of a person away from any hazard To stop trapping any fixed barriers should be at least 500mm from the robot work envelope extreme reach of the robot arm and tooling Design and place presence sensing devices such as photoelectric curtains to detect if anyone enters a restricted space or danger area Level 2 The device must stop the automatic operation of the robot when entry is detected Operation must also stop if this device fails You can use laser scanners or pressure sensitive mats as a back up safety protection for high risk machinery in areas inside the primary light curtain This way the system cannot restart while someone is inside the area protected by a light curtain 9 11 3 ADDITIONAL CONTROL MEASURES Because robots are highly technical and programmable consider extra safeguards beyond just guarding moving parts These include making sure only competent people can access and start the robot system gt no one can access the robot through or by removing associated equipment such as conveyors transfer systems loading stations or trolleys If people have to enter the robot cell Level 2 while the robot is working the control system should make sure the robot runs with reduced force The robot also needs a sensor to stop it immediately if it hits someone Safe operating procedures also minimise some of the risks of working with robotics A safe work system needs procedures f
71. eded if the machine is large several devices or pull wires may be needed a manual way to reset an emergency stop device gt a regular testing routine to check the device still works Figure 26 The green line shows the emergency stop cord on the rollers that act as a trip guard Badly placed emergency stop devices may slow shutdown in an emergency and encourage dangerous practices such as reaching across moving parts gt failing to shut down machinery when there is a problem allowing one worker to start the machine while another is in a dangerous location like cleaning a machine When there is more than one device use a safe procedure so machinery cannot restart during maintenance or other temporary situations such as a blockage of product A lock out and tag out system is essential to isolate the machine from a power source to stop accidental start up When servicing emergency stop devices actuators can separate from contacts meaning the machine appears to be off but because of the fault it is still on This why emergency stops are unsafe to use as a means of lock out 8 1 8 COLOUR CODING It is good practice to paint safety guard posts or frames yellow and any mesh black so it can be seen through more easily and staff do not need to open the guards for observation as much So workers can easily see when a guard is out of place it is good practice to gt use high visibility
72. een a rotating surface and another surface moving along it such as a power transmission belt and its pulley a chain and its chain wheel a rack and its pinion running nips between a rotating surface and another surface moving along it where material like metal paper cable rope runs onto a reel drum or shaft gt nips between rotating and fixed parts which can shear crush or abrade such as spoked hand wheels flywheels and Screw conveyors 3 4 4 CRUSHING HAZARDS Figure 6 shows some ways operators can be injured through crushing hazards that can happen when part of the body is caught between a fixed and moving part of a machine such as the bed and tool of a power press between two moving parts of a machine such as the support arms of a scissor lift platform between a moving part of a machine and a fixed structure such as a counterweight and the floor Figure 6 Examples of crushing hazards SECTION O3 IDENTIFY ASSESS AND CONTROL HAZARDS 3 4 5 IMPACT HAZARDS Impact hazards are caused by objects that strike the body but do not enter it Figure 7 shows some ways operators can be injured by impact hazards Examples include the rotating arm of a robot the reciprocating bed of a metal planing machine and the arms of a wool scouring machine Impact hazards are different from crush hazards even though the machines involved may be the same Impact hazard
73. els raining an supervision gt Safe operating procedures gt Tool setting adjusting and calibration gt Usual use Assess each hazard who it affects and associated risks Operator response gt Emergency planning and response gt Breakdowns and unplanned a Develop hazard maintenance controls gt Blockage gt Personal gt Lock out protective gt Interlock equipment gt De energising z Monitoring gt Insulation gt Training gt Safe operating procedures Flowchart 3 Identify operational hazards to use machinery safely For more information refer to the Australian Standard AS 2865 Confined spaces 3 10 3 HOUSEKEEPING Mess can cause slips trips and falls Avoid injuries by gt keeping work areas walkways and other access paths clear and clean gt clearly marking walkways and no go areas gt preventing spills which can cause slips Design machinery and work processes to minimise oil loss or spillage Clean up spills as soon as possible and avoid any oily residues on the floor Provide a rough anti slip floor where this is not practical ED OPERATIONAL HAZARDS Flowchart 3 shows the more common hazards associated with machine operations Apart from the hazards associated with the normal running of the machine the flowchart also covers hazards associated with cleaning maintenance and repair along with irregular hazards To keep people safe during inspections cleaning
74. em Non industrial robot applications include undersea military and space robots tele operated manipulators prosthetics and other aids for the physically impaired micro robots smaller than 1mm gt surgery or healthcare gt service or consumer products AS 4024 4 1998 SAFEGUARDING OF MACHINERY INCLUDES Pressure sensitive devices AS 4024 4 Safeguarding of machinery Installation and commissioning requirements for electro sensitive systems Pressure sensitive devices Explains the requirements to install and commission pressure sensitive fixed mats floors edges and bars that will be used with plant and machinery You will need to adapt or extend this standard if safety devices are to be used in other situations such as protecting children or in exposed places with wide temperature limits SECTION 11 APPENDICES EFI EXAMPLE RISK ASSESSMENT PROCESS The process can be used to identify hazards assess their risks and identify controls to implement in relation to safeguarding of machinery and plant This risk management process is outlined below 1 IDENTIFY POTENTIAL HAZARDS THESE MAY INCLUDE gt drawing in or trapping hazards entanglement hazards shearing hazards cutting hazards impact hazards gt crushing hazards stabbing and puncturing hazards gt friction and abrasion hazards gt hot or cold hazards gt ejection hazards gt other contact hazards gt noi
75. ents in the following publications gt AS 4024 1801 Safety Distances to Prevent Danger Zones Being Reached by the Upper Limbs AS 4024 1802 Safety Distances and Safety Gaps Safety Distances to Prevent Danger Zones Being Reached by the Lower Limbs 7 2 1 DANGER ZONE SEPARATION DISTANCES Use Table 2 above to assess the risk in equipment and the design and positioning of guards The minimum separation distances are based on people with long arms hands and fingers The gaps are based on people over 14 years old with small fingers and hands The separation values are more conservative than values calculated from the Ergonomics of Machine Guarding Guide Where needed more information is in AS 4024 1801 Safety of Machinery Part 1801 Safety Distances to Prevent Danger Zones Being Reached by the Upper Limbs 2mm 20mm 850mm 2 700mm The anthropometric data used in this standard was based on information available when the standard was developed Better sources may become available If your workforce is significantly different from the general population you may need to take your own measurements If someone can fit an arm through a gap the hazard assessment should also consider any smaller openings inside the machinery If the arm can be bent at the elbow the minimum separation distance from the elbow to any danger zone should be 550mm the wrist the minimum separation distance from the wrist to a
76. es Safety requirements gt AS 4024 3301 Safety of machinery Robots for industrial environments Safety requirements gt AS 4024 3610 Conveyors Safety requirements AS 4024 4 Safeguarding of machinery Part 4 Installation and commissioning requirements for electro sensitive systems Pressure sensitive devices AS 60204 1 Safety of machinery Electrical equipment of machines General requirements AS 62061 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems 99 100 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY European Standards gt IEC 61496 1 Safety of machinery Electro sensitive protective equipment Part 1 General requirements and tests gt IEC 61496 2 Safety of machinery Electro sensitive protective equipment Part 2 Particular requirements for equipment using active opto electronic protective devices AOPDs gt IEC 61496 3 Safety of machinery Electro sensitive protective equipment Part 3 Particular requirements for active opto electronic protective devices responsive to diffuse reflection AOPDDR gt BS EN 1756 1 Tail lifts Platform lifts for mounting on wheeled vehicles Safety requirements Tail lifts for goods BS EN 1756 2 Tail lifts Platform lifts for mounting on wheeled vehicles Safety requirements Tail lifts for passengers WORKSAFE NZ PUBLICATIONS Approved Codes of Practice Approved Code o
77. es and specification for machinery manufacturers Gives principles for controlling risks to health from the emission of hazardous substances from machinery 85 86 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Ergonomic principles AS 4024 1401 Design principles Terminology and general principles Specifies the ergonomic design principles and terminology to be used by designers DESIGN PARAMETERS Design of safety related parts of control systems AS 4024 1501 AS 4024 1502 General principles Gives safety requirements and guidance on the principles to be used in the design of the safety features of machinery control systems Categories are specified and the characteristics of the safety functions are described Validation Specifies the conditions and procedures to be followed for the validation by both analysis and testing of safety functions provided and safety category achieved by the safety related parts of control systems using the design rationale including risk analysis provided by the designer When validating programmable electronic systems this standard does not give complete requirements and needs the use of other standards such as the AS 61508 series Design of controls interlocks and guarding AS 4024 1601 AS 4024 1602 AS 4024 1603 AS 4024 1604 Guards General requirements for the design and construction of fixed and moveable guards Specifies requirements for the design and construc
78. f the machine Safety distances to prevent danger zones being reached by the lower limbs Gives safety distances to keep people s legs out of danger zones of machinery Only use these distances when distance alone can remove the hazard and there is no chance that someone can reach the hazard with their arms Minimum gaps to prevent crushing of parts of the human body Gives minimum gaps in machinery to stop parts of the body being crushed 87 88 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY DISPLAYS CONTROLS ACTUATORS AND SIGNALS Ergonomic requirements for the design of displays and control actuators AS 4024 1901 AS 4024 1902 AS 4024 1903 General principles for human interaction with displays and control actuators Gives general principles to design displays and controls so operators can use the machine efficiently Displays Gives the ergonomic requirements for visual audible and tactile displays on machines It helps you choose design and place any displays to avoid ergonomic hazards Control actuators Helps you design choose and place manual control actuators to suit the needs of the task and the operators Indication marking and actuation AS 4024 1904 AS 4024 1905 AS 4024 1906 AS 4024 1907 Requirements for visual auditory and tactile signs Explains how to give safety information using sight sound and touch It sets out a system of colours signs markings and other ways to show ha
79. f Practice for cranes Approved Code of Practice for operator protective structures on self propelled mobile mechanical plant Approved Code of Practice for power operated elevating work platforms Approved Code of Practice for the management of noise in the workplace Approved Code of Practice for load lifting rigging Code of Practice for manual handling Guidelines and guides An introduction to the safe use of machinery gt Small business guide to the Health and Safety in Employment Act 1992 Guidance notes for electrical interlocking for safety in industrial processes Ergonomics of machine guarding guide First aid for workplaces A good practice guide Keeping safe at work A guide for employees Managing health and safety A guide for employers A principal s guide to contracting to meet the Health and Safety in Employment Act 1992 and its summary Health and safety in contracting situations Management of Substances Hazardous to Health A guide to completing an assessment in your workplace Guidelines for the provision of facilities and general safety in commercial and industrial premises Stress and fatigue Reducing their impact Advice for employers and employees Best Practice Guidelines for the use of elevating work platforms in the horticultural industry Best Practice Guidelines for working at height in New Zealand Factsheets Employers must involve staff in health a
80. factors and methodology see AS 40241301 and AS 4024 1501 in particular SECTION 04 HAZARD AND RISK ASSESSMENT Gather information about each hazard identified Think about how many people are exposed to each hazard and for how long Likelihood How likely is it that a hazardous event will occur within the life of the machine 1 See matrix in Appendix 11 5 Use the information to Consequence assess the likelihood and What might be the consequences of the consequence of each hazard hazardous event or situation Use the risk table to work out the risk associated with each hazard See the risk matrix in Appendix 11 5 Figure 17 Risk assessment explains one process for assessing risks and hazards RISK RATING TABLE Likelihood of injury or Consequences of injury or harm to health harm to health Insignificant Moderate Major Catastrophic no injuries first aid and extensive fatalities or medical injuries treatment Extreme immediate action Figure 18 A example risk rating table 35 36 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Notes 05 CONTROLLING MACHINERY HAZARDS IN THIS SECTION 5 1 5 2 5 3 5 4 Eliminate hazards Isolate hazards Minimise hazards Matrix of guarding controls SECTION 05 CONTROLLING MACHINERY HAZARDS Employers and principals are responsible for making s
81. gonomic hazards Chemicals and fumes Organisational hazards Electrical safety of machinery Environmental and occupational health hazards Other hazards Operational hazards SECTION 03 IDENTIFY ASSESS AND CONTROL HAZARDS Making sure hazards do not cause harm or injury is the basis of health and safety in any workplace This section covers the basics of hazard management and the common hazards that are found when working with or near machinery EX HAZARD MANAGEMENT Planning a safe approach to a job can help identify the hazards of working with machinery The hazard management process includes hazard identification hazard assessment decide if the identified hazards are significant gt hazard control either by eliminating isolating or minimising the hazard gt a safety plan or hazard register documenting this information hazard monitoring including workplace exposure monitoring or health monitoring of workers a schedule to update the safety plan ES IDENTIFY HAZARDS The first step in the hazard management process is to identify hazards anything that could injure or harm someone Do a workplace inspection to identify all machinery used Include common items that may not normally be thought of as machines Also consider how other workplace items such as chairs and heaters can affect the use of machinery Sections 7 10 of the HSE Act outline the process to identify
82. gt architecture drawings Concept and gt components design stage gt guarding see Flowchart 5 Software validation if required Installation or modification Installation inspection and validation and commission machine Functional validation test function behaviour Validation Document Flowchart 6 Validation and verification 95 96 START HERE Are hazards present YES Is access required by operators maintenance staff or cleaners YES Does opening the guard cause the hazard to stop before access YES Is constant access required YES Can presence sensing systems be used appropriately If competent person verifies the machinery can t be guarded agree on safe systems of work Flowchart 7 Choosing a guard NO NO NO NO NO BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Guards not needed Fixed guards as gt AS 4024 1601 gt AS 4024 1 1801 1803 Use movable guard with guard locking to the appropriate category level see AS 4024 1501 AS 4024 1602 Use movable guard with interlock to the appropriate category level see AS 4024 1501 Consider the environment and choose the right device eg twohanded controls with a hold to run and slow speed function and safety trip devices AS 4024 2601 and IEC 61496 series Note the flowchart does not take other protective devices such as two hand controls into account Series 1 General safet
83. harts 11 7 More information 63 64 64 64 65 65 65 66 66 67 69 74 74 74 74 74 74 Us 743 TU 79 82 84 91 93 98 TABLES 1 2 Matrix of guarding controls Separation distances and gaps FLOWCHARTS O Ui R WN j b W N H Get it right from the start overview of safe use of machinery guideline Common machinery hazards Identify operational hazards to use machinery safely Assess hazard and risks eliminate hazards where possible Concept stage health and safety in the business case Validation and verification Choosing a guard Developing and maintaining a safe system of work for specific tasks Get it right from the start overview of safe use of machinery guideline Common machinery hazards Identify operational hazards to use machinery safely Assess hazard and risks eliminate hazards where possible Concept stage health and safety in the business case Validation and verification Choosing a guard Developing and maintaining a safe system of work for specific tasks 39 51 21 50 55 44 46 65 WS 93 93 94 94 95 95 96 97 FIGURES O O VI R W N ki j j hb W N H 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 Division of health and safety responsibilities during a machine s life cycle Summary of the duties of designers of machinery Processes are used togethe
84. harts 2 and 3 can help in this assessment 47 48 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Notes IN THIS SECTION 7 1 Types of guards that isolate the hazard 7 2 Machine guarding and ergonomics SECTION 07 GUARDING TYPES ISOLATE This section covers the types of machine guarding available and the situations where it is generally used Depending on the situation a combination of two or more safeguards may be needed to keep workers safe TYPES OF GUARDS THAT ISOLATE THE HAZARD 7 1 1 FIXED GUARDS Fixed guards are physical barriers that keep people out of dangerous areas during normal use maintenance or cleaning The need to adjust drive belts and transmission chains other machinery parts can affect guard design Fixed guards can be permanent welded into or part of the body of the machine removable but they can only be removed when the machine is stopped with a special tool that is not easily available to operators Do not use wing nuts wedge inserts or anything that can be undone with the fingers Barriers or fences held securely in place with fasteners or other suitable devices can stop access to dangerous areas Machine guards should be made of substantial materials such as sheet steel wire mesh that cannot be easily damaged Figure 19 Example of a fixed guar
85. hased SECTION 06 ELIMINATE HAZARDS AT THE DESIGN PROCESS 6 4 4 LEGAL REQUIREMENTS Anyone buying or modifying machinery to be used in a place of work has legal duties The person putting together the business case should check what laws apply to their business All businesses must comply with the HSE Act and the HSE Regulations 6 4 5 SAFETY AND OPERATIONAL STANDARDS The business case should address health and safety and consider the following the WorkSafe NZ Position Paper on the Safe Use of Machinery the AS 4024 Safety of Machinery series any standards relating to the equipment eg if there is a conveyor refer to AS 7755 Conveyors Safety Requirements gt any relevant WorkSafe NZ approved codes of practice guidelines guides and factsheets the current state of knowledge from industry associations manufacturers and other sources involvement of health and safety representatives union representatives if applicable operators cleaners maintenance staff and engineers 6 4 6 IDENTIFY ASSESS AND CONTROL HAZARDS By doing a detailed hazard identification process before starting hazards can be eliminated at the design stage Use Flowcharts 2 and 3 to identify the most common machinery hazards While removing hazards is the best option not all hazards can be eliminated If hazards cannot be eliminated consider how they can be isolated Flowchart 7 can help choose the right guarding so
86. hat work cold metal or material partly of cold metal You can use the principles in AS 4024 1 for work with hot metal and tongs but you may not be able of apply them fully Read this standard with AS 40241 series This standard also covers presses intended for use with cold metal but are also used in a similar way to work other sheet materials like cardboard plastic rubber or leather and metal powder The requirements in this standard take account of the intended use This standard presumes access to the press from all directions deals with the hazards and gives safety measures for the operator and other people This standard also applies to accessories that are vital to the press 89 90 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Milling machines including boring machines AS 4024 3101 Safety of machinery Materials cutting Milling machines including boring machines Safety requirements Gives the safety requirements and measures to design build supply install take apart transport and maintain milling and boring machines Robots for industrial environments AS 4024 3301 Robots for industrial environments Safety requirements Gives requirements and guidelines to design build and use industrial robots and robot systems safely It describes some hazards of working with robots and how to avoid them While this standard does not cover non industrial robots the safety principles can be used for th
87. heat radiation and results of overloads or short circuits heat hazards contact with high temperature objects or materials noise and vibration hazards radiation hazards both ionising for example x rays and gamma rays and non ionising for example electric and magnetic fields radio waves microwaves infrared and ultraviolet radiation materials and substances hazards hazards made used or released by machinery or from the construction materials gt ergonomic hazards poor machine set up leading to injuries and operational errors maintenance hazards when guarding is removed or switched off for cleaning maintenance or access to the area around a machine gt slips trips and falls hazards flooring surface and access gt work environment hazards environmental conditions such as temperature weather or lighting 41 42 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY 6 1 1 INHERENTLY SAFE DESIGN MEASURES Experience shows that protective measures built into the design are more likely to stay effective even when well designed safeguarding fails an error is made or safety procedures are not followed Hazard identification is the first step in the design process Examples of safe design that eliminates particular hazards rather than relying on safeguards to prevent harm include putting oil filters and grease nipples on the opposite side of a machine to its hot parts gt
88. here possible gt using all guarding keeping their work areas clear clean and tidy wearing and using all protective equipment and clothing gt alerting their supervisor to any machinery faults or maintenance needs gt telling their supervisor about any illness or condition that could stop or limit their ability to work with machinery to keep others safe and help supervisors allocate work Machine operators should check that the machinery they use is in sound working order report immediately any problems to their supervisor gt use any safety devices guards appliances protective devices and any other methods used to make the machinery safe Where there is a risk of entanglement with machinery people should tie long hair back close to the head not wear loose clothing 2 10 1 EMPLOYEE PARTICIPATION IN HEALTH AND SAFETY Employees are often in the best place to know the hazards of their job and how they could be injured For example product might back up in the machine and need clearing which could be hazardous if the machine is still running SECTION 02 RESPONSIBILITIES AND DUTIES FOR MACHINERY Everyone benefits when employees are involved in developing health and safety systems and when those systems are part of the daily life in the workplace The HSE Act gives employees the right to participate in health and safety issues at work and gives them access to information and tr
89. idated by a competent person Validation confirms that all steps of the safety life cycle were implemented and verified Designers can find information on reducing safety system failure through good design and typical failure modes in 4S 4024 1502 Safety of Machinery Part 1502 Design of Safety Related Parts of Control Systems Validation DESIGNING FOR SAFETY THROUGHOUT THE LIFE CYCLE Different hazards exist at different stages of a machine s life cycle many of these can be reduced or removed through thoughtful design SECTION 06 ELIMINATE HAZARDS AT THE DESIGN PROCESS 6 3 1 MANUFACTURE The making of machinery is the first phase of the life cycle Examples of removing or controlling hazards include replacing spoked gears with gears with a solid disc to get rid of a shear hazard building housing around obvious hazards rather than having to fit guards after manufacture HSE Regulation 66 describes the duties of designers of plant 6 3 2 TRANSPORT Moving the machine to where it will be installed is the next important step An example of removing a transport hazard is a metal lathe is to be delivered fully assembled and is much heavier at one end The designer notes the chance for the lathe to slip out of its lifting slings so they incorporate lifting eyes for the slings in positions that mean the lathe can be lifted in a horizontal position 6 3 3 INSTALLATION Once a machine is safely de
90. ing gt Confined space gt High pressure gt Stored energy Flowchart 2 Common machinery hazards 3 4 2 TRANSMISSION MACHINERY Transmission machinery takes energy from a prime mover to the part of a machine where it is used Every part of any transmission machinery should be securely fenced unless because of its position or construction it is safe Figure 4 shows some ways operators can be injured by this type of machinery Transmission machinery can include gears shafts pulleys and belts chains and sprockets or friction drives All transmission machinery should have a device in every room or workplace to cut the power to the machinery Key for arrows Solid red arrows where a part of the body could be drawn into a nip point White or grey arrows movement of machine parts 21 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY y d Figure 4 Examples of where operators can be injured by unguarded transmission machinery Figure 5 Drawing in hazards between counter rotating parts 3 4 3 DRAWING IN OR TRAPPING HAZARDS Injuries can be caused when a part of the body is drawn into a nip point Figure 5 shows some ways operators can be injured by drawing in and trapping hazards such as gt in running nips between two counter rotating parts like meshing gears rolling mills mixing rolls press rolls gt in running nips betw
91. ing hazards or when started after inactivity They can include information on how to break down the machine for safe storage 6 3 7 DISPOSAL People breaking down machines for scrap can face significant hazards These include energy stored in springs and pressure devices hazardous substances that are part of the machine 43 44 START HERE Get it right at the start Establish the need for new plant or modifying existing plant Develop a business case Define machine safety specifications and operational requirements Identify hazards see Flowcharts 2 and 5 Eliminate hazards through safe design BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY gt Return on investment Capital expenditure gt Production Operations input gt Do need this machine gt How often do use it Legislation gt Standards AS4024 and machine specific standards see Appendix 11 4 WorkSafe NZ Approved Codes of Practice ACOP and Guidelines Current state of knowledge Consultation with users health and safety reps and internal expertise WorkSafe NZ s Safe Use of Machinery page for advice on specific machinery Complete business case with the information gathered Develop project plan including health and safety requirements Business case is accepted Flowchart 5 Concept stage Health and safety in the business case CONCEPT STAGE HEALTH AND SAFETY IN THE
92. ion and or mechanical extraction Remove any contaminants made as part of the work at the source Any mechanical extraction must pull contaminants away from workers breathing zone not through it If it is not practical to completely remove or isolate the hazardous substance you must minimise any risk of harm to the employee To minimise a hazard s effects an employer can monitor employees exposure to the hazard monitor employees health with their informed consent gt provide protective clothing and equipment such as breathing equipment or dust masks and make sure they are used EZ ORGANISATIONAL HAZARDS For machine guarding to work well employers must understand how materials move through the site understand all safe operating procedures for the machinery develop instructions on how to use machinery safely including maintenance and cleaning train workers to work safely New technology new machinery or changes to machinery can introduce new hazards At these times always complete a hazard assessment and consult with workers 27 28 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY 3 7 1 FATIGUE AND SHIFT WORK Employers must take measures to prevent fatigue causing harm such as when employees must drive or use dangerous machinery Employers are not responsible for anything outside work that reduces an employee s ability to cope or leads to fatigue But they must hav
93. ires employers to make sure machinery is safe to clean maintain and repair Procedures must be put in place for these activities to be performed safely and workers must be trained to follow them Isolation tag out cards and lock out devices should also be used as described in section 8 1 11 of this guideline Any other hazard present should also have the appropriate control applied to stop people being harmed If it is essential for the cleaning maintenance or repair procedure that the machine stays in operation then employers should gt only have power going to the part of the machine that must be in motion gt adequately train anyone working in this hazardous situation gt establish and follow a safe work system gt regularly review any safe work systems gt reduce the speed of any dangerous parts to as slow as practical with reduced power force or step by step operation with a limited movement control device gt restrict access to and control of danger areas to one person gt have emergency stop controls within immediate reach 15 16 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY gt use a portable inching control with E stop or local inching allowing full sight of controlled elements and danger area Mid position pendants are better than jogging or inching machinery using a hold to run control The machine should run at the slowest practical operating speed for cleaning loading and setting
94. ity of someone being inside the area enclosed by the guard when someone tries to start the machine Only after doing a risk assessment can you know what type of safety device to install with the guard and the level of integrity of the related control circuitry If needed more information is available AS 4024 1501 Safety of Machinery Part 1501 Design of Safety Related Parts of Control Systems General Principles for Design we Perimeter fence guard Figure 20 Perimeter fence guard with fixed panels and interlocking access door Emergency Stop button Interlocking guard Interlocking mechanism Figure 21 Food mixer with an interlocking guard 7 1 3 SAFE BY POSITION This method of hazard management relies on putting dangerous machinery parts out of reach of people The problem with this method is that people can often use ladders furniture or machine parts to reach the hazard This method needs policies and practices in place to make sure that the protection is not compromised When deciding how far away to put dangerous machinery also consider how maintenance people will get access such as by ladder scaffold or mobile elevating work platform 7 1 4 TRIP GUARDS When other guarding methods are not practical you can use trip guards A trip guard is designed to cut the power if someone reaches into a dangerous part of a machine However if this system fails the
95. livered it needs to be installed For example to reduce hazards during installation design a large machine to be delivered in modules that are put in place by a crane Then installers do not need to work at height or handle heavy items by hand 6 3 4 COMMISSIONING The designer can build in test points for instruments and alarms so a machine or parts of machinery cannot be energised by mistake 6 3 5 OPERATION Designers must design machinery and plant that is safe to use Some examples of designing machinery for safe operation consider the type of seating an operator may use and the ease of using the controls from the seat if an operator needs to move around a large machine provide a portable emergency stop button gt give easy and safe access to areas that need regular maintenance Access will be needed for cleaning lubrication and adjustment Maintenance considerations include routine adjustments people should be able to do these with the machine stopped but without needing to remove safeguards or take apart any of the machine when frequent access is needed use interlocked guards when access is difficult consider self lubrication or central lubrication for parts gt positive lock off devices to stop the machine restarting accidentally particularly if a machine was shut down in error 6 3 6 STORAGE Manufacturers and designers should make sure machinery can be stored without creat
96. lling from machinery Working safely at height may need gt fixed or permanently installed access platforms gt mobile elevating work platforms gt temporary platforms For more information see WorkSafe NZ s Best Practice Guidelines for Working at Height in New Zealand 3 9 2 LIGHTING Make sure the work area is well lit Poor lighting can be a hazard Sometimes the machine or guards can block normal lighting so extra local light is needed Also put local lighting in regular maintenance areas that are poorly lit such as inside some electrical compartments where electrical isolation is needed for access For more information refer to AS NZS 1680 2 4 Interior lighting Part 24 Industrial tasks and processes 3 9 3 NOISE Employers must take all practicable steps to reduce any risk of harm to people from machinery noise Machinery noise should be eliminated or through isolation kept to a level that does not damage hearing Where this is not practical employers should isolate people from excessive noise Where neither option is practical employers must put systems in place to make sure people exposed to the noise are unlikely to suffer harm SECTION 03 IDENTIFY ASSESS AND CONTROL HAZARDS For more information on controlling noise refer to WorkSafe NZ s Approved Code of Practice for the Management of Noise in the Workplace Noise limits for an 8 hour day peak noise levels and protective measures
97. lth and safety in the business case Construction of machinery Validation and verification GUARDING TYPES ISOLATE 7 1 7 2 Types of guards that isolate the hazard Machine guarding and ergonomics GUARDING TYPES MINIMISE 8 1 8 2 8 3 8 4 8 5 8 6 8 7 Power controls Other guarding requirements Other control measures Providing information on machinery Safe systems of work Monitoring and reviewing effectiveness of control measures Keeping documents and records 57 S S7 38 41 42 42 44 45 45 49 50 55 59 59 60 61 61 61 ED CHOOSING THE RIGHT GUARD 9 1 9 2 9 3 9 4 9 5 9 6 9 7 9 8 9 9 9 10 9 11 Choosing a guard Basic rules for guard design Guarding of operational and non operational parts Choosing the material for guards Servicing and maintenance considerations Guards for exposed rotating cutting machinery Pulleys and drives Rotating shafts and rollers Conveyors bulk handling Press brakes Robotics ED SAFE SYSTEMS OF WORK 10 1 Participation and consultation 10 2 Hazard management 10 3 Competency of operators and supervisors 10 4 Emergency procedures 10 5 When guarding is not an option 10 6 Agreement and sign off 10 7 Competent person 10 8 Reviewing ED APPENDICES 11 1 Definitions 11 2 Example of hazard checklist 11 3 Sample job safety analysis JSA 11 4 Summary of the AS 4024 Safety of machinery series 11 5 Example risk assessment process 11 6 Flowc
98. lution If guarding is not possible hazards must be minimised Flowchart 8 covers the minimum requirements for a safe system of work 6 4 7 PROJECT PLAN Once the business case is accepted a project plan is usually developed Health and safety implications and information about hazard management should be included in the project plan CONSTRUCTION OF MACHINERY All machinery should be soundly built Machinery should also be built so it is free from dangerous vibrations when in use This includes any cutter fitted to a machine running at full speed or at idle VALIDATION AND VERIFICATION In the flowchart 6 the left hand column specifies steps in the process of ensuring the safety of a machine The right column lists procedures carried out to test and ensure the safety of a machine Verification did we build it right Validation did we build the right thing 6 6 1 VALIDATION IS IT CORRECT SAFE AND FIT FOR PURPOSE Safety validation is a documented examination of the machine and its processes The examination must be done to national or international guidelines or standards The examination compares the actual status of the machine or work with what it should be Anyone doing a validation needs extensive knowledge of the equipment and how it should work The person must be competent to compare the machine s safety features and performance to the planned results established by the safety requi
99. more traditional hazards of working with machinery They can do high risk work such as in the biotechnology field It is wrong to think that robotic operations are safe just because there is little or no worker interaction Hazards when using robotics can come from gt errors during use gt ejection of materials trapping points gt failures and malfunctions Hazards can also come up during installation repair and maintenance There may also be biological chemical or environmental hazards A hazard assessment should be done to ensure workers safety during all phases of the machinery s life and use Follow a hazard management process with reference to the manufacturer s instructions during installation or commissioning testing start up repair and maintenance 9 11 1 HAZARDS AND RISKS Robots have inherent dangers Some of the hazards of industrial robot use include Impact Robots can move at high speed in an unexpected direction either in a straight line or circular directions The robot can also eject work pieces off cuts or molten metal Workers are at risk from being hit by the robot or parts of the work Trapping points These can be made by the robot s movement or other equipment such as work carriages pallets or transfer mechanisms With the robot itself trapping points are found on the arm of the robot between the arm and the column and between the arm and fixed objects Workers can be
100. nd safety Employees have to help ensure a safe and healthy worksite gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet gt Factsheet Factsheet Band saws Beam saws CNC Woodworking machines CNC machining centre CNC turret punch Dough brakes Dough dividers Circular saw benches General principles of machine guarding Guarding of conveyors Information installation operation and maintenance Fixed hand held grinders Four siders Injection blow moulding Jig saws Metal cutting shears Metal turning lathes Metalworking guillotines Mitre saws Mortisers Overhand planing Paper cutting guillotines Pendulum saws Plastics extrusion Plastics granulator Platen press Power presses Press brake machine guarding Punch amp shear Radial arm saws Rise amp fall saws Rotary printing press Screw conveyor Tenoners Thicknessers Three roll bending machines Vertical spindle moulder
101. nery make sure people can use clean and maintain the machinery without being harmed make space for any waste materials to gather before they are cleared they should not clutter walkways or work areas note the movements of trucks materials and people mark out walkways and create vehicle movement areas gt mark out no go areas so people can stay away from dangerous machinery Check how close moving parts are to other machinery and fixtures in buildings 3 5 3 REACH AND GUARDING The main point of machine guarding is to stop workers reaching past the guard into the machine When deciding on the best way to guard a machine consider how a worker uses and interacts with a machine ergonomic principles More information on ergonomics is in section 7 2 of this guideline CHEMICALS AND FUMES Many chemicals used with machinery can harm workers Assess all chemicals for hazardous health effects Put appropriate controls in place to stop or control people s exposure In some cases you may need to monitor the environment or workers health to make sure exposure to the chemicals is not affecting their health For more information refer to the substance s safety data sheet available from your supplier 3 6 1 CONTROL OF AIRBORNE HAZARDS VENTILATION Protect workers at all times from inhaling steam fumes dust and other airborne contaminants in the workplace You can use ventilation filtrat
102. nimum distances for sensing or actuating devices of protective equipment to a danger zone The safety distances are based on hand or arm approach speeds and the response time of the machine These devices are a trip devices defined in AS 40241201 specifically electro sensitive protective equipment pressure sensitive mats including those used to start the machine b two hand control devices defined in AS 4024 1201 Mechanical power presses AS 4024 3001 Materials forming and shearing Mechanical power presses Gives the safety requirements and measures to design build and supply mechanical presses that work cold metal or material partly of cold metal You can use the principles in AS 4024 1 for work with hot metal and tongs but you might not be able to apply them fully Read this standard with AS 40241 series This standard also covers presses intended for work with cold metal but are used in a similar way to work other materials like cardboard plastic rubber or leather and metal powder The requirements in this standard take account of intended use This standard presumes access to the press from all directions and gives the safety measures for both the operator and other people This standard also applies to accessories that are vital parts of the press Hydraulic power presses AS 4024 3002 Materials forming and shearing Hydraulic power presses Gives the safety requirements and measures for hydraulic presses t
103. ny danger zone should be 250mm 7 2 2 LOCATION OF DISTANCE GUARDS Distance guards should be at least 1600mm tall and at least 900mm away from the danger zone further or higher if there is a projectile hazard If the guard is between 1000mm and 1600mm tall it must be at least 1500mm away from the danger zone No guards should be less than 1000mm high 51 52 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Notes 08 GUARDING TYPES MINIMISE IN THIS SECTION 8 1 8 2 8 3 8 4 8 5 8 6 8 7 Power controls Other guarding requirements Other control measures Providing information on machinery Safe systems of work Monitoring and reviewing effectiveness of control measures Keeping documents and records SECTION 08 GUARDING TYPES MINIMISE This section details the type of guarding and control options that will only minimise the likelihood of harm occurring These controls should only be used if the hazard cannot be eliminated or isolated These guarding options generally protect more than one person and are called group controls Pictures in this section show guards in yellow and emergency stop buttons in red EX POWER CONTROLS The power control is the device on a machine that controls the flow of energy to the prime mover This energy may be gt electricity hydraulic oil under pressu
104. or entry including who can access the robot to do identified tasks maintenance and repair Inspecting and maintaining a robot can present different hazards from working with the robot Assess all hazards for risks SECTION 09 CHOOSING THE RIGHT GUARD Staff must be trained to control the hazards of working with industrial robot machines Inadequate training can increase risks at most stages of robot operation 9 11 4 CONTROL SYSTEMS Robots usually have programmable electronic start and control systems These should be protected from unauthorised access such as by putting them in a lockable cabinet or room Make and place controls so people cannot accidently start the robot This can be done a number of ways including shrouding guarding gating or appropriate positioning If people can access the robot it must be isolated from its power source For more information see AS 62061 Safety of machinery Functional Safety of Safety Related Electrical Electronic and Programmable Electronic Control Systems AS 4024 3301 Safety of machinery Robots for industrial environments Safety requirements 9 11 5 MASTER SWITCHES Robots should have master switches to cut power to any moving part of the robot This can be the same device as an emergency stop You should be able to lock the master switch in the isolating position so it needs to be manually reset 71 72 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Note
105. placing lubrication points away from moving parts Avoid creating hazards by considering gt visibility of working areas from the control position shape of and spacing between components reducing sharp edges enabling effective working positions and ease of access to controls limiting forces or emissions Find more information on inherently safe design in AS 4024 1202 Safety of machinery Part 1202 General Principles Technical Principles 6 1 2 STABILITY ASPECTS When designing the machine s stability consider the shape of the base weight distribution dynamic forces gt vibration gt oscillations gt the surface the machine sits on gt external forces gt earthquakes gt wind loadings 6 1 3 TECHNICAL INFORMATION The designer must develop technical information for the supplier and buyer from standards codes and calculations The information should cover gt forces which may be applied to material used in construction gt management of emissions including noise fumes and dust gt tests and procedures to ensure continued safe operation of the machine RELIABILITY OF SAFETY FUNCTIONS The designer must consider gt the reliability of all machinery parts gt use of safety failure modes of components gt duplication or redundancy of safety features gt automatic monitoring of faults The designs of safety related parts of control systems need to be val
106. r to identify hazards Examples of where operators can be injured by unguarded transmission machinery Drawing in hazards between counter rotating parts Examples of crushing hazards Examples of impact hazards Friction and abrasion hazards Contact with single rotating surface Catching on projections or in gaps Catching between rotating and fixed parts Shear hazards between two machine parts Shear hazards between a machinery part and a work piece Examples of cutting hazards Examples of stabbing and puncture hazards by flying objects or moving parts of machinery An example of visibility risk factor When the top part of the machine lowers it comes to rest on supports on each corner so only a small area on the underneath of the top may be a hazard Risk assessment explains one process for assessing risks and hazards A example risk rating table Example of a fixed guard Perimeter fence guard with fixed panels and interlocking access door Food mixer with an interlocking guard Example of a photoelectric light curtain used as a trip guard Example of a two hand control Pressure sensing mat enclosing a robot The self adjusting guard over the cutting wheel swings back as the cutting wheel cuts through steel The green line shows the emergency stop cord on the rollers that act as a trip guard Shows various types of tag out and lock out devices that can be used Examples of machine guards isolating various hazards Self adjusting guar
107. rd with guard locking to the appropriate category level see AS 4024 1501 AS 4024 1602 Use movable guard with interlock to the appropriate category level see AS 4024 1501 Consider the environment and choose the right device eg twohanded controls with a hold to run and slow speed function and safety trip devices AS 4024 2601 and IEC 61496 series Series 1 General safety requirements Series 2 Controls and appropriate speeds gt Two handed controls Series 3 Requirements for specific machines Mechanical and hydraulic power presses gt Milling machines gt Industrial robots Series 4 Electro sensitive safety devices gt Pressure sensitive devices Flowchart 7 details how to make decisions EE CHOOSING A GUARD around the most appropriate guard taking into account whether the machine parts Machine guarding options in order require access of preference gt if access is not needed during normal Sections 7 11 of the HSE Act describe a operation maintenance or cleaning use a way to identify hazards manage health permanently attached physical barrier and safety issues and follow up on health gt if access is needed during normal operation and safety matters maintenance or cleaning use an interlocked physical barrier 63 64 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY if opening the guard stops the hazard before access use a moveable guard
108. re gt compressed gas The power control should be able to stop the flow from all energy sources Interlocks and labels should clearly indicate where there is more than one energy source and stop all sources of energy to the prime movers HSE Regulation 66 requires that plant and power control placement are designed with ergonomic principles The power controls should be gt able to open all energy sources such as all phases of a three phase electrical supply gt built and shrouded so the machine cannot be started accidentally gt clearly identified with labels giving information on when and how to start the machine gt convenient to use and placed using sound ergonomic principles away from dangerous parts gt fail safe in case the energy supply is cut gt lockable in the off position when a person at the controls might not be able to see staff working on the machine refer also to section 8 1 11 of this guideline gt showing the direction of the movement of the controls which match up to the motion of the moving parts gt unable to be locked out in the on position gt unable to indicate off position if it is in fact in the on position Hydraulic controls should be either dead man or hold to run type with anti tie down so that if the control is released the machine stops moving When a machine s power falls to a low level or stops completely exposing parts of the machine this can crea
109. re is no physical barrier to stop people touching dangerous parts All safety trip guards should be hardwired to the machine control and power brake systems EZ MACHINE GUARDING AND ERGONOMICS Ergonomic principles cover how a worker uses and works with a machine Making sure workers cannot reach past the guarding into the machine is a key part of machine guarding and isolating the people from hazards Typical ergonomic principles include gt the nature of operator postures and movements gt the ease of physical operation gt the effects of noise and temperature gt the lighting environment gt the clarity and location of manual controls gt the design of dials markings and displays PART OF BODY ANY APERTURE OR OPENINGS IN THE MACHINERY GAP MAXIMUM SIZE OF SECTION 07 GUARDING TYPES ISOLATE MINIMUM SEPARATION DISTANCE FROM DANGER ZONE Fingertip 4mm Finger 6mm Arm 20mm Arm reaching above head Table 2 Separation distances and gaps Reach is limited by the length of arms fingers and hands legs and feet The distance a person can reach sets the minimum height for some guards or the minimum distance of barriers from the hazard The average size and reach of humans is used to set design criteria There will be some people the very tall or very slender whose size means they are not fully protected by the standard measurements given Protect these people using the more restricted measurem
110. rement specifications and risk assessment 45 46 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY SAFE USE OF MACHINERY PROCESS START HERE Identify hazards see Flowcharts 2and 3 Risk assessment see Flowchart 4 Safety requirement specifications Concept and design stage see Flowchart 5 Installation or modification and commission machine Validation Flowchart 6 Validation and verification VERIFICATION AND OR VAILIDATION Post measures Risk assessment Verify the following safety requirement specifications gt architecture drawings gt components guarding Software validation if required Installation inspection and validation Functional validation test function behaviour Document Validation verifies that the safety design was put in place correctly and checks that the machine works safely and meets the safety requirement specifications Depending on the machine validation can include reviewing machine risks examining mechanical guarding examining safety related control circuits eg electrical pneumatic hydraulic examining safety related software functional validation examining essential health and safety requirements eg noise ergonomics 6 6 2 VALIDATION STEPS The following are some recommended steps to take to complete the validation process 6 6 3 RISK ASSESSMENT AFTER MODIFICATIONS AND CHANGES This is
111. repairs maintenance and emergencies gt use isolation procedures whenever people need to enter the danger area around machinery for maintenance and repair make sure workers understand cleaning repair maintenance and emergency procedures SECTION 03 IDENTIFY ASSESS AND CONTROL HAZARDS put in place a regular inspection regime to identify any problems with machinery and guards identify and assess any other hazards specific to inspections cleaning repair maintenance and emergencies take special precautions when workers cannot be seen or where there are multiple operating switches if dangerous parts need to move while a guard is open for example setting fault finding or maintenance use safe operating procedures such as speed as slow as practical and two hand hold to run inching controls with pendant to minimise hazards and the risk of injury HSE Regulation 17 requires employers must make sure machinery is safe to clean maintain and repair Procedures must be put in place for these activities and workers trained to follow them 31 32 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Notes 04 HAZARD AND RISK ASSESSMENT IN THIS SECTION 4 1 Risk assessment 4 2 Adequate information knowledge and experience SECTION 04 HAZARD AND RISK ASSESSMENT Hazard and risk asse
112. ric drills lifts escalators tractors hand trolleys cranes and other lifting gear to arc welding gear Prime mover means an engine motor or other appliance that provides mechanical energy derived from steam water wind electricity gas gaseous products or any other source It includes any device which converts stored or potential energy into movement or mechanical energy Risk means a combination of probability and the degree of possible injury or damage to health in a hazardous situation Safe by position means so positioned that any person cannot reach or gain access to the dangerous parts Safety requirement specifications is the means by which the hazards of a machine or process are controlled to reduce risks of harm to those working at or near the machine or process Safe operating procedures are written instructions that detail the steps that will be performed during a given procedure including information about hazards and how these hazards will be controlled Safe system of work means a formal procedure which results from systematic examination of a task in order to identify all the hazards It defines safe methods to ensure that hazards are eliminated or risks minimised Safety life cycle refers to the safety of the machine its assembly its functioning and decommissioning at the end of its life Securely fenced means so guarded that the arrangements provided ensure that the dangerous part is no longer
113. rkplace should have first aiders and first aid supplies Employers should put first aid provisions in place based on the types of accidents injuries and illnesses that could occur in the workplace For more information see WorkSafe NZ s First Aid for Workplaces A Good Practice Guide EX PROVIDING INFORMATION ON MACHINERY Employers must give staff this information in a way workers can easily understand it be aware of language and literacy issues Employers may also need to give information to others who enter the workplace including cleaners visitors and contract staff This could be a machinery instruction handbook or other written instructions that include gt a publication date and revision details if the information has been redrafted or updated any transport handling or storage requirements including the machine s dimensions weight and lifting points information about installation and connecting to a power source including any assembly information and power supply requirements Specific information about an individual machine should include gt a detailed description of the machine including any fittings guards or protective safety devices reference to any machinery safety standards used in its design including any mandatory requirements eg conformance declaration verification of design gt details of any emissions eg noise fumes dust the machine makes when running 8 4 1
114. rm the product the work piece and the press frame coming together in the fold forming process The impact from both can have a pinching crushing cutting or shearing motion which creates a risk to the operator of being crushed or cut Drive belts on press brakes have in running nip points which present a risk of entanglement and abrasion Hydraulic hoses may leak or burst causing slip hazards and workers getting sprayed with hydraulic fluids under pressure 9 10 2 CONTROL MEASURES The front dies of a press brake and its sides and rear require guarding Three forms of guarding for the front of the dies on a press brake are gt a fixed guard gt interlocked guard gt a light or presence sensing system Where workers have to hold or stabilise the material or need frequent access to closing dies presence sensing devices may be required to ensure safe operation Presence sensing devices may be light curtains or light beams Automatic stops should also be guarded and back gauging equipment is recommended Presence sensing devices cameras light curtains or light beams may not protect the operator in all circumstances 67 68 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Guarding Guarding Emergency stop button Light beams from presence sensing system Shrouded controls Figure 33 Press brake with fixed guards and a presence sensing light curtain 9 10 3 SAFE SY
115. s 10 SAFE SYSTEMS OF WORK IN THIS SECTION 10 1 Participation and consultation 10 2 Hazard management 10 3 Competency of operators and supervisors 10 4 Emergency procedures 10 5 When guarding is not an option 10 6 Agreement and sign off 10 7 Competent person 10 8 Reviewing SECTION 10 SAFE SYSTEMS OF WORK In this guideline a safe system of work means the steps which if followed will minimise the hazard arising from doing a specific task or set of tasks as far as practicable START HERE Identify hazards and other hazards that may occur by using a safe system of work Correct use of tools and plant gt Safe operating procedures gt Job safety analysis gt Effective and safe maintenance cleaning programmes gt Monitoring of environment and or operator health Review system s effectiveness regularly Take into account gt Advances in technology gt Incidents or accidents gt Any new hazards identified gt New industry standards and guidance gt Whether hazards are still controlled gt Keeping records Good work environment gt Safe layout gt Enough lighting ventilation gt Comfortable temperature gt Noise and fumes managed gt Information and signage Training and supervision by a competent person in place for all staff including
116. s gt lock out provisions or permission for guard removal enough room to do tasks without risk of injury or strain gt stored energy in the machine or materials being processed any additional hazards from maintenance procedures such as testing while the machine is unguarded a dry run or trial run working at heights use of solvents maintaining or updating service records Maintenance considerations include where servicing is needed how much servicing is needed what kind of servicing is needed how often servicing needs to be done GUARDS FOR EXPOSED ROTATING CUTTING MACHINERY Exposed rotating cutting machinery includes cut off saws milling machines SECTION 09 CHOOSING THE RIGHT GUARD gt friction cutting equipment gt boring equipment Hazards arise from the exposed blades and risks include cutting people or entanglement Guards or visors that move must stay close to the work piece The cutter s teeth can be exposed if the visor is not attached to the fixed guard gt in a poor position jams in the open position Figure 29 Self adjusting guard for a drop saw EX PULLEYS AND DRIVES Pulleys and drives are used in many machines Nip points are the main hazard They must be guarded so no one can get entangled Interlocked guards are preferable for pulleys and drives In some cases a hinged section may be appropriate
117. s and other projecting items such as keys set screws and cotter pins are typical projection hazards Fan blades spoked wheels such as pulleys sprockets gear wheels and flywheels mixer and beater arms and spiked cylinders create gap related hazards Figure 11 Catching between rotating and fixed parts 3 4 8 SHEARING HAZARDS Shearing trims or shears metal or other material with a powered knife or slide Shear points are found where stock is inserted held and withdrawn Figures 12 and 13 show some ways operators can be injured by Figure 10 Catching on projections or in gaps x shearing hazards Parts of the human body can be sheared touching moving materials in motion such as in centrifuges tumble driers and dough between two machine parts such as mixers or swarf the table of a metal planing machine reaching between counter rotating parts shaper and its bed such as gear wheels rolling mills the table and blade of a guillotine or reaching between a rotating part and ROWE press another part moving along it such as a gt nip points between connecting rods or power transmission belt and its pulley a links and rotating wheels or between parts chain and chain wheel a rack and pinion a that move back and forth conveyor belt and any of its pulleys a rope between a machine part and a work piece and its storag
118. s involve the inertia of the body while crush hazards involve trapping the body between two machine parts or between a machine part and a fixed structure Figure 7 Examples of impact hazards 3 4 6 FRICTION AND ABRASION HAZARDS Friction burns can be caused by smooth parts operating at high speed Figure 8 shows some ways operators can be injured by friction and abrasion hazards Examples of friction or abrasion hazards include the sides of a grinding wheel the belt of a belt sanding machine material running onto a reel or shaft gt a conveyor belt and its drums gt pulleys and fast moving ropes or belts Figure 8 Friction and abrasion hazards 3 4 7 ENTANGLEMENT HAZARDS Entanglement is when someone is caught in a machine by loose items such as clothing gloves ties jewellery long hair cleaning rags bandages or rough material being fed into the machine Figures 9 10 and 11 show some ways operators can be injured by entanglement with machinery Contact that can lead to entanglement includes touching a single rotating surface such as plain shafting couplings spindles chucks lead screws mandrels or rotating work pieces including plain bar material Figure 9 Contact with single rotating surface 23 24 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY gt catching on projections or in gaps Belt fastener
119. se hazards gt release of hazardous substances gt hazards related to location of the machine or plant hazards related to systems of work associated with the machine or plant gt concurrent hazards Questions to ask to identify hazards Where fixed guards are provided are they of substantial construction and secured into position while machinery is in operation Where interlocked guards are provided do they prevent operation of the machinery when open and are the guards prevented from opening while the machinery is in operation Where a presence sensing system is used does it operate as intended and stop the machinery when light beams or sensors are interrupted Do guards protect against hazards at the rear and sides of machinery Are pre operational checks conducted to ensure safety features are in working order Are adequate isolation procedures provided for maintenance Are manufacturers manuals available Are machine controls protected to prevent unintentional operation clearly marked and within easy reach of the operator gt Are warning signs and decals clearly visible Where it is not practical to provide guarding and people are required to operate or pass close to dangerous moving parts is a safe system of work in place to reduce risks 91 92 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY gt s it practical to provide a higher level of guarding than currently provided
120. sible Flowchart 4 offers a method of assessing the risk each hazard poses so appropriate control measures can be developed Flowchart 5 Building health and safety into the business case A thorough safety and hazard assessment at the concept stage can eliminate many hazards This flowchart works through the basics of including health and safety into a business case Flowchart 6 Validation of machine safety This flowchart works through the process of validation making sure that all required steps of the safety life cycle are tested Flowchart 7 Choosing a guard The flowchart gives the hierarchy of machine guarding using the standard AS 4024 Safety of Machinery series Flowchart 8 Developing and maintaining a safe system of work for specific tasks This flowchart describes the minimum needed to put a safe system of work in place for a specific task or set of tasks 10 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Notes 02 RESPONSIBILITIES AND DUTIES FOR MACHINERY IN THIS SECTION 2 1 Design and manufacturing get it right from the start 2 2 Duties of manufacturers and suppliers of machinery 2 3 Supplying machinery 2 4 Choosing and buying 2 5 Installing machinery 2 6 Use of machinery the employer 2 7 Inspection and maintenance 2 8 Modifying machinery 2 9 Decommisioning machinery 2
121. ssment is a process to determine how significant a hazard is and what harm it could cause START HERE Assess the hazard for significance and assess the risk Monitor and review Is the hazard gt Consequence severit YES repos b y Review if something changes controlled gt Likelihood exposure and the risk frequency see mitigated Appendix 11 5 for risk rating YES Evaluate controls NO through Risk probability regular review gt Low Medium High and update gt Who is exposed to the or change if isk required risk gt Current state of Keep records knowledge gt Guarding gt Interlocks Develop priority of Is the hazard gt Training actions for each hazard controlled NO gt PPE Installation and and the risk commissioning mitigated gt Information and i signage gt Procedures Identify controls Involve gt Audit and review staff and use internal gt Monitor or external advice Select and environment and engineers health and put in place or health controls safety consultants see Flowcharts 7 and 8 gt Supervision gt Workplace culture gt Staffing levels Flowchart 4 Assess hazard and risks eliminate hazards where possible Every identified hazard must be assessed to see ifitis a significant hazard something that could cause serious harm If it is a significant hazard it must be controlled using the hierarchy of controls A significant hazard should be eliminated if it
122. stallation test use and maintenance ending in disassembly and disposal Machinery is a collective term for machines and their parts A machine is considered to be any apparatus that has interrelated parts and is used to perform work machines may include an engine motor or other appliance that provides mechanical energy derived from compressed air the combustion of fuel electricity gas gaseous products steam water wind or any other source and includes a any plant by or to which the motion of any machinery is transmitted and b a lifting machine a lifting vehicle a machine whose motive power is wholly or partly generated by the human body and a tractor 77 78 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Non ionising radiation is in the electromagnetic spectrum where there is insufficient energy to cause ionisation It includes electric and magnetic fields radio waves microwaves infrared ultraviolet and visible radiation Plant includes a appliance equipment fitting furniture implement machine machinery tool and vehicle and b part of any plant the controls of any plant and anything connected to any plant It is a general name for machinery equipment appliance implement or tool and any component or fitting or accessory of these It can include things as diverse as presses in a foundry excavators and trucks in mining and photocopiers in an office It can range from elect
123. sted above can find specific guidance in AS 1755 Conveyors Safety Requirements AS 1788 series Abrasive Wheels gt AS 1473 series Wood Processing Machinery People looking for more information about electro sensitive safety devices beyond what is in AS 4024 Series 4 should find it in IEC 61496 series Electro sensitive Protective Equipment AS 4024 1 2006 SAFETY OF MACHINERY INCLUDES SAFETY PRINCIPLES Terminology and principles AS 4024 1101 Terms and definitions Gives users a set of terms and definitions that are used in other machinery safety standards as well as in discussions of machinery safety AS 4024 1201 Basic terminology and methodology Specifies the basic terminology and methodology to be used by designers to achieve safety of machinery AS 4024 1202 Technical principles Defines the technical principles needed to design safe machinery Does not deal with injury to domestic animals property or the environment Risk assessment AS 40241301 Principles of risk assessment Specifies principles for doing a risk assessment so the knowledge and experience of the harm related to machinery is gathered together to help assess risks during all phases in the life of machinery Gives guidance on the information needed to carry out risk assessments and a brief outline of some of the techniques available AS 4024 1302 Reduction of risks to health and safety from hazardous substances emitted by machinery Principl
124. system can stop the machine If the beam is too far away someone can stay inside the protected area without interrupting the light beam You can use extra protection such as extra light beams curtains safety mats or laser scanners to monitor the area inside the light curtain You can use photoelectric safety devices with other types of guard to make a safe zone where an operator has to access the machine frequently As photoelectric systems can fail without visible warning any failure must not put a user at risk Photoelectric safety devices should meet and be installed to high performance standards such as the International Electrotechnical Commission standard EC 61496 Safety of Machinery Electro Sensitive Protective Equipment 8 1 2 AUTOMATIC PUSH AWAY GUARDS With this type of guarding a barrier moves towards the user when they approach the hazard making them step back out of reach of the hazard If push away guards are not carefully designed and maintained then they too can become a hazard Users need thorough training to safely use machinery guarded like this 8 1 3 TWO HAND CONTROLS Figure 23 Example of a two hand control Only use this method to isolate people from machinery hazards as a last resort Even when used properly two hand controls only protect the machine operator not other people who may be near Two hand controls should gt need to be turned on together so people cannot tap
125. t Workplace culture gt Staffing levels Flowchart 4 Assess hazard and risks eliminate hazards where possible 94 SECTION 11 APPENDICES START HERE Get it right at the start Establish the need for new plant or modifying existing plant gt Return on investment Capital expenditure gt Production Operations input gt Do need this machine Develop a business case i gt How often do luse it gt Legislation Define machine gt Standards AS4024 and machine sare NE specific standards see Appendix 11 4 an opera gt WorkSafe 2 Approved Codes of requirements 8 o gt Practice ACOP and Guidelines Current state of knowledge Consultation with users health and safety reps and internal expertise Identify hazards WorkSafe NZ s Safe Use of Machinery see Flowcharts 2 and 3 page for advice on specific machinery Eliminate hazards Complete business A A Develop project plan E Business case is i through case with the accepted including health and safe design information gathered safety requirements Flowchart 5 Concept stage Health and safety in the business case SAFE USE OF MACHINERY PROCESS VERIFICATION AND OR VAILIDATION START HERE Identify hazards see Flowcharts 2and 5 Risk assessment Post measures see Flowchart 4 Risk assessment Safety Verify the following requirement gt safety requirement specifications specifications
126. t how to check and adjust the machine before starting it how to stop and start the machine gt how the machine works gt what the machine does gt location and operation of other controls gt actual and potential hazards and appropriate ways to control them gt purpose of guards and other safety devices gt correct use and adjustment of guards gt correct work methods to be used gt how to recognise faults that could cause harm gt limitations and capabilities of the machine gt emergency procedures Take manufacturer s instructions into consideration when developing training programmes for operators 2 6 2 SAFE USE OF MACHINERY RESPONSIBILITIES RESTRICTIONS FOR YOUNG PEOPLE Employers must take all practicable steps to stop anyone under the age of 15 years old working or helping with work with machinery No one under the age of 15 years old should be in an area where gt goods are being prepared or manufactured for trade or sale gt construction work or forestry work is done SECTION 02 RESPONSIBILITIES AND DUTIES FOR MACHINERY Unless they are gt in a public access area under the direct supervision of an adult gt on a guided tour of the area in an area only used for the sale of goods or services Minimum ages in health and safety legislation gt 12 years old for trained drivers of agricultural tractors and implements HSE Regulation 61 gt 15 years old for most du
127. te a significant hazard when the power is restored The machine should need the deliberate operation of the power control to start the dangerous parts If the machine operator cannot see the whole machine a warning device must alert people either visually by sound or both before the machine restarts 8 1 1 PHOTOELECTRIC SAFETY DEVICES Photoelectric safety devices use light beams that stop machines working when the light beam is broken This method is often used when fixed or interlocked mechanical guards are not practical However if the system fails there is no physical barrier to stop people being exposed to the hazard Photoelectric devices can be set to control how much anyone can enter a restricted space such as a hand but not the arm or an arm but not the body 53 54 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Shrouded g controls Guarding Figure 22 Example of a photoelectric light curtain used as a trip guard Single light beams are not normally suitable because people can reach around the light beam and access the hazard You can use a number of light beams so there are no gaps that people can reach through around under or over When any of the beams are broken the power is cut Consider carefully what distance a light beam curtain is placed from the hazard If it is too close someone can reach through the light curtain to danger faster than the control
128. they notice guards that are damaged missing Yes No or inadequate Is protective equipment and clothing needed Yes No Is it right for the job in good condition kept VEIS clean and stored when not in use Is the operator dressed safely for the job no loose fitting clothing or jewellery Yes No Do technicians engineers or operators have up to date instructions on the machines they Yes No service or clean Do staff or contractors lock out machines from all energy sources before starting repairs Yes No or cleaning Is the maintenance equipment properly guarded Yes No Where several maintenance staff are working on the same machine are multiple lock out Yes No devices used Is the machinery properly maintained and kept clean Yes No Is all machinery securely placed and anchored due Yes No to prevent tipping or other movement Is the machine laid out so it does not create hazards to operators or others in Yes No the workplace Is there enough clearance around and between machines to allow safe operation set up servicing material handling and waste removal Yes No 81 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY 452 JOJ S OO 1284402 esf lt BUIDUBLUWOD se pajejos USIH KJx221109 juaudinba aansug lt sainpadoid uonejosi MOJJO lt splezey dl dijs Jo ag lt sjulod youd JO eg lt Suonejosi BUIDUBLULUOD UBIH soled poe329jje
129. ties except those in retail or office areas HSE Regulations 54 to 60 gt 16 years old for work between 10pm and 6am unless special conditions apply HSE Regulations 58 and 58F gt 18 years old to operate amusement devices Amusement Devices Regulations 1978 20 a EX INSPECTION AND MAINTENANCE The employer or principal must have an inspection and maintenance programme in place This programme must ensure a competent person regularly inspects tests and maintains the machine s guards and safety control system This ensures the safety system s reliability and integrity When developing maintenance and repair programmes refer to the manufacturer s instructions Maintenance and repair programmes should specify gt where servicing is needed gt how much servicing is needed gt what type of servicing is needed gt how often it needs to be serviced gt who is responsible for maintaining repair and maintenance programmes gt how defects will be fixed gt what standards are used for performance testing and evaluation Programmes should be reviewed regularly to ensure their effectiveness Develop implement and maintain an accurate record of maintenance done and maintenance programmes 2 7 1 CLEANING AND MAINTENANCE OF MACHINERY Employers should take all practicable steps to make sure any hazardous machinery has stopped before any cleaning or maintenance is done HSE Regulation 17 requ
130. ting the machinery inadvertently The cards must clearly state that under no circumstances should the machinery be connected to the power source or be started until the hold card is removed by the person named on the tag out card Include advice on the tag out card of the actual or potential danger where appropriate Tag and lock Multiple locks Valve lock and tag Figure 27 Shows various types of tag out and lock out devices that can be used Lock out devices make sure people are out of the danger area before a machine can be started They are mechanical locking mechanisms used to physically lock machinery controls so they cannot be used Use lock out devices when people have to work on or inside machinery and are out of sight of other people in the workplace Anyone who has to work in a hazardous area should have a lock out device that identifies who is protected by the device The lock used with these devices should be durable and must only have one key held by the operator Tag out cards are sometimes referred to as danger tags restricted use tags and warning tags Use a tag out card with lock out devices and isolation to improve staff safety EE OTHER GUARDING REQUIREMENTS The duty holder must ensure that fences or guards are constantly maintained of substantial construction for their intended purpose gt kept in position while the machinery is used Even when there
131. tion of fixed and movable guards that protect people from mechanical hazards in machinery Principles for design and selection Specifies principles for the design and selection of interlocking devices used with guards The principles are independent of the energy sources used on the machine Prevention of unexpected start up Gives ways to stop unexpected machine start up to use at the design stage including energy isolation and dissipation Applies to all forms of energy including those external to the machine such as wind gravity and electro magnetic Emergency stop Principles for design Explains what an emergency stop needs to do and gives the design principles regardless of the energy source used to control the functions It does not apply to hand guided machines hand held portable machines or to machines where having an emergency stop would not reduce the risk to anyone ERGONOMICS SECTION 11 APPENDICES Human body measurements AS 4024 1701 AS 4024 1702 AS 40241703 AS 4024 1704 Basic human body measurements for technological design Gives information and descriptions of anthropometric human body measurements that ergonomists and designers of workplaces can use to compare population groups Use this standard to help design work stations where people stand sit or reach controls or other items There are pictures to help Principles for determining the dimensions required for openings for whole
132. turning the robot off when people are near Designers manufacturers and suppliers of robotic systems have the same obligations as designers manufacturers and suppliers of other machinery HSE Regulations 66 and 67 and section 18A of the HSE Act 69 70 BEST PRACTICE GUIDELINES SAFE USE OF MACHINERY Level 3 in touch with the robot Horizontal amp vertical light curtains Level 2 where the robots move Level 1 perimeter guard Figure 34 Robot cell showing Levels 1 2 and 3 Robot safety has different hazards and precautions in each of the three levels around a robot workstation 1 Level 1 is the workstation perimeter usually a physical barrier guarded with an interlock gate and possibly with presence sensing devices 2 Level 2 is within the workstation where the robot moves Here safety systems should detect if someone is present usually with presence sensing devices 3 Level 3 is contact with the robot A safety system should detect a person touching the robot and stop it moving immediately using safety trip devices or sensors Fixed or distance guards at Level 1 are practical as long as the guard does not interfere with the mechanism of the robot Someone should have to use tools to remove the guards to enter the restricted danger area Guards or fences should be placed so people cannot reach into a restricted area Any openings for feeding material in should be design
133. uirements of the best practice standard may be used as evidence in proceedings for an offence under the HSE Act Some standards listed may be out of date and not available The hierarchy for application of standards are that if there is no New Zealand Standard for a subject the first appropriate standard to use is an Australian standard If there is no Australian standard for the subject the next most relevant standards are ISO European or British standards If there is no such standard available then refer to the American Canadian or other recognised relevant standards The criteria will also be which standard or guideline can provide the latest current state of knowledge and good practices about the safety of a plant or process Legislation Electricity Act 1992 gt Electricity Safety Regulations 2010 and Electrical Codes of Practice ECP Health and Safety in Employment Act 1992 Health and Safety in Employment Regulations 1995 Standards gt AS 1121 4 Agricultural tractor power take offs Guards for power take off PTO drive shafts Strength and wear tests and acceptance criteria gt AS NZS 1680 1 Interior and workplace lighting General principles and recommendations AS NZS 1680 2 4 Interior lighting Part 24 Industrial tasks and processes AS 1755 Conveyors Safety requirements gt AS NZS 1680 1 Interior and workplace lighting General principles and recommendations AS 2865 Confined spaces AS 40
134. ure the hazards associated with machinery are controlled in the workplace so they do not harm workers and operators Sections 8 10 of the HSE Act outline a hierarchy of controls that must be used when a significant hazard has been identified The hierarchy consists of three steps eliminate isolate or minimise the hazard If employers cannot eliminate or isolate the hazard because it is not practicable to do so they must minimise it EX ELIMINATE HAZARDS With elimination the hazard or hazardous work practice is removed from the workplace With machinery this may involve employers changing processes and machinery so workers are not exposed to significant hazards Hazards can be eliminated at the design stage too see section 6 of this guideline ES ISOLATE HAZARDS If elimination is not practicable the significant hazard must be isolated This involves isolating or separating the hazard or hazardous work practice from those who may be harmed by it These usually protect everyone around the machine which is known as a group control They can be fixed guards interlocked guards or safe by position ES MINIMISE HAZARDS If it is not practicable to eliminate or isolate the hazard then the likelihood of it causing harm must be minimised Minimisation provides a framework of expected behaviours such as rotation of staff to reduce exposure to a hazard personal protective equipment or a documented safe system of work
135. with guard locking interlock and safety switches of an appropriate category level Category levels are outlined in AS 4024 and a summary can be found in Flowchart 7 of this guideline If constant access is needed gt use a safety interlock system that meets the appropriate rating in its failsafe control category a hazard and risk assessment determines what failsafe category is needed gt add extra protections to minimise hazards such as safety trip devices accessible emergency stops slow speed and or two hand hold to run control devices If there is no practicable way to guard a hazard a safe system of work must be put in place see section 1O of this guideline EXD BASIC RULES FOR GUARD DESIGN The basic rules for guard design are gt use materials of suitable strength and good quality gt use the right guard Custom designed is best poorly designed or inappropriate guards can cause injuries the environment and the needs of operators and maintenance workers affect how well a guard works If a guard is used from another machine check carefully that it gt is not faulty fits the target machine is strong enough for the new use gt controls the risk ES GUARDING OF OPERATIONAL AND NON OPERATIONAL PARTS When deciding what needs to be guarded look at operational and non operational parts of the machine Start with obvious operational parts such as gt rollers mills gt saws
136. y requirements Series 2 Controls and appropriate speeds gt Two handed controls Series 3 Requirements for specific machines gt Mechanical and hydraulic power presses gt Milling machines gt Industrial robots Series 4 Electro sensitive safety devices gt Pressure sensitive devices START HERE Identify hazards and other hazards that may occur by using a safe system of work Correct use of Good work People Emergency Human factors tools and plant environment management management gt Shiftwork gt Safe operating gt Safe layout gt Matching the gt Procedures gt Fatigue procedures gt Enough worker to in place for gt Repetitive gt Job safety lighting the task emergencies activities analysis ventilation gt Training for gt Information gt Incentives gt Effective gt Comfortable competency and signage bonuses and safe temperature gt Effective gt Equipment gt Shift length maintenance gt Noise and supervision accessible and breaks cleaning fumes gt Use gt Staff trained programmes managed maintenance competent and gt Monitoring of gt Information and capable environment and signage replacement gt Processes and or of personal in place for No guarding operator health protective blockages options available equipment and out of Verified by a gt Visitor the ordinary competent management events eg person Review system s effectiveness regularly Training an
137. yellow paint for the guard that is different from the machine s colour gt paint surfaces behind the guard a bright or contrasting colour like blue or red 8 1 9 LOCK OUT SYSTEMS AND ISOLATION PROCEDURES Lock out systems are used to safely isolate machinery from its power source They are used when someone needs to inspect repair maintain alter or clean the machine or when it is to be withdrawn for assessment or repair The method used to isolate depends on the type of machinery Employers should develop these safe operating procedures with employees Once a procedure has been put in place it should be strictly obeyed Employers must make sure there is a safe system to isolate all machinery from power sources They must have procedures to prepare a machine for the application of isolation devices locks and tags train and instruct workers in the system so they are competent to isolate or lock out and tag out machinery gt give supervision to make sure that isolation procedures are followed Workers trained in the safe system of isolation for machinery must make sure the system is followed at all times If the machine is powered by electricity the employer or principal should have a qualified electrician remove and keep the fuses Where other sources of power are used the parts that are removed to achieve isolation should also be kept in a place where they can not be accessed by other workers SECTI
138. zards and help in emergencies Requirements for marking Gives rules on markings on machines for identification gt safe use gt preventing hazards from incorrect connections Requirements for the location and operation of actuators Gives the safety requirements for actuators run by hand or other body part It applies to both single actuators and groups of actuators System of auditory and visual danger and information signals Gives a series of danger and information signals both sight and sound that indicate urgency and can be differentiated from each other This standard does not apply to signals covered by specific standards or conventions such as fire alarms public transport or navigation signals POSITION OF TWO HAND CONTROLS amp SAFETY SENSORS Two hand control devices AS 4024 2601 Design of controls interlocks and guarding Two hand control devices Functional aspects and design principles Gives the safety requirements for two hand controls This standard helps you design and choose two hand control devices using a risk assessment It helps stop work arounds and faults It also gives standards for two hand control devices with a programmable electronic system SECTION 11 APPENDICES Safety distances and safety gaps AS 4024 2801 Safety distances and safety gaps Positioning of protective equipment with respect to the approach speed of parts of the human body Explains how to work out the mi
139. zards like noise and dust gt Personnel oR gt Legislation gt Current state of knowledge a Redesign or modify y existing plant and 5 m gt Isolation guards and guarding systems see Flowchart 7 and Appendix 11 4 Y SECTION 01 INTRODUCTION Consult with A staff experts and others to decide how to eliminate any potential hazards Identify hazards see Flowchart 2 and 3 Assess Hazard And Risk assessment see Flowchart 4 Eliminate hazards where possible Regular review and make changes Guarding options if necessary not available verified by competent person Minimise by a safe gt Training staff Involve staff experts health and safety reps inhouse expertise system of work Personal see Flowchart 8 protective equipment Safe operating procedures Y Flowchart 1 Get it right from the start overview of safe use of machinery guideline 1 2 1 SUMMARY OF FLOWCHARTS Flowchart 1 Get it right from the start gt This flowchart shows the overview of safe use of machinery process It summarises the process and shows how each flowchart links with the others Flowchart 2 Common machinery hazards A summary of the common machinery hazards Flowchart 3 Identify operational hazards to use machinery safely The common operational hazards are identified in this flowchart Flowchart 4 Assess hazard and risks eliminate hazards where pos

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