Workshop Safety Yusron Sugiarto STP MSc BACKGROUND Almost

Workshop Safety Yusron Sugiarto, STP, MSc

BACKGROUND Almost everyone working in a workshop has at some stage in his or her career suffered an injury requiring some kind of treatment or first aid. The cause may have been carelessness by the victim or a colleague, defective safety equipment, not using the safety equipment provided or inadequate protective clothing. Whatever the explanation given for the accident, the true cause was most likely a failure to think ahead. You must learn to work safely

OBJECTIVE OF WORKSHOP SAFETY Workshop safety is needed to check all the possible chances of accidents for Preventing loss of life and permanent disability of any employee, any damage to machine and material as it leads to the loss to the whole establishment It is needed to eliminate accidents causing work stoppage and production loss. It is needed to prevent accidents in industry by reducing any hazard to minimum It is needed to reduce workman’s compensation, insurance rate and all the cost of accidents.

OBJECTIVE OF WORKSHOP SAFETY It is required to educate all members regarding the safety principles to avoid accidents in industry. It is needed to achieve better morale of the industrial employees. It is required to have better human relations within the industry. It is needed to increase production means to a higher standard of living.

ACCIDENTS AND THEIR TYPES 1. Near Accident An accident with no damage or injury is called near accident. 2. Trivial An accident with very less damage is called trivial. 3. Minor Accident It is an accident with damage and injury more than trivial. 4. Serious Accident An accident with heavy damage and lot of injury is called serious accident. 5. Fatal It is an accident with very heavy damage. There may be loss of lives also.

Effect of Accidents Effect on the owner of factory Effect on worker Effect on society

Effect of Accidents Effect on the owner of factory Direct cost of an accident 1. Cost of the compensation paid to the workers. 2. Cost of the money paid for treatment. 3. Cost of the monetary value of damaged tools, equipments and materials.

Effect of Accidents Effect on the owner of factory Indirect cost of an accident 1. Cost of the lost time of injured worker. 2. Cost of the time lost by other employees. 3. Cost of the delays in production. 4. Cost of the time lost by supervisors, safety engineers etc. 5. Cost of the lowered production due to substitute worker.

Effect of Accidents Effect on worker 1. The industrial workers may get temporary or permanent disability. 2. If the industrial worker dies, his family loses the earner and the compensation never equals to his earnings. 3. Accident also affects the morale of the employees working in the manufacturing environment.

Effect of Accidents Effect on society 1. Cost of accidents is included in the products, so the society has to pay more prices for the industrial products. 2. If some industrial workers do not come under compensation act, the need for help from society is much greater. 3. Loss of production hours may causes fewer products in market. So more prices if demand is more than production

CAUSES OF ACCIDEENTS Human Causes Environmental Causes Mechanical Causes

CAUSES OF ACCIDEENTS Human Causes 1. Accidents may occur while working on unsafe or dangerous equipments or machineries possessing rotating, reciprocating and moving parts. 2. Accidents occur while operating machines without knowledge, without safety precautions, without authority, without safety devices. 3. Accidents generally occur while operating or working at unsafe speed.

CAUSES OF ACCIDEENTS Human Causes 4. Accidents may occur while working for long duration of work, shift duty etc. 5. Accidents commonly occur during use of improper tools. 6. Accidents may occur while working with mental worries, ignorance, carelessness, nervousness, dreaming etc. 7. Accidents occur because of not using personal protective devices.

CAUSES OF ACCIDEENTS Environmental Causes 1. Accidents may occur during working at improper temperature and humidity causes fatigue to the workers so chances of accidents increases with workers having fatigue. 2. The presence of dust fumes and smoke in the working area may causes accidents. 3. Poor housekeeping, blocked exits, bad plant layout etc. may cause accidents. 4. Improper ventilation in the plant may also leads to industrial accidents.

CAUSES OF ACCIDEENTS Mechanical Causes 1. Continued use of old, poor maintained or unsafe equipment may result in accidents. 2. Accidents commonly occur due to use of unguarded or improper guarded machines or equipments. 3. Unsafe processes, unsafe design and unsafe construction of building structure may lead to accidents in the plant. 4. Accidents occur due to improper material handling system and improper plant layout. 5. Accidents may occur due to not using of safety devices such as helmets, goggles, gloves, masks etc.

COMMON SAFETY METHODS Safety by construction or design Safety by position. Safety by using fixed guards. Safety by using automatic guards Safety by using distance guards Safety by workplace layout Safety by proper material handling Safety by using personal protective devices

Whenever the new tools, devices, equipments and machine are designed, they should be ensured that all their dangerous parts are either enclosed in suitable housings or provided with suitably designed safety guards in order to eliminate any chances of danger that could occur due to exposure of the dangerous parts. All control handles of machines should be carefully located to ensure adequate safety in their operation.

COMMON SAFETY METHODS Safety by construction or design Safety by position. Safety by using fixed guards. Safety by using automatic guards Safety by using distance guards Safety by workplace layout Safety by proper material handling Safety by using personal protective devices

Safety by Position The main principle involved in the method for safety by position is to design the machine in such a way that the dangerous parts are so located or placed that they are always beyond reach of the operator. It is therefore always advisable that all the dangerous parts of the machine should invariably be guarded or enclosed in the body or housing of the machines as far the design conditions permit. If it is not possible suitable external fencings must be incorporated suitably

COMMON SAFETY METHODS Safety by construction or design Safety by position. Safety by using fixed guards. Safety by using automatic guards Safety by using distance guards Safety by workplace layout Safety by proper material handling Safety by using personal protective devices

Safety by Using Fixed Guards Such fixed guards either form an integral part of the machine or are so tightly secured to them that they are not easily removable. In all cases, fixed guards are developed to have a robust and rigid construction and they should be so placed that any access to the dangerous parts of the machine is totally prevented from all directions particularly in the running condition of the machines.

Safety by Using Fixed Guards Fixed guards adjusted in position remain fixed and they are neither moved nor detached. In some cases the fixed guards are provided at a distance from the danger point. Such a provision will carry a remote feeding arrangement and, therefore, the operator will not be required to go near the dangerous points.

COMMON SAFETY METHODS Safety by construction or design Safety by position. Safety by using fixed guards. Safety by using automatic guards Safety by using distance guards Safety by workplace layout Safety by proper material handling Safety by using personal protective devices

Safety by Using Automatic Guards Automatic guard and machine operation is so linked that the part will automatically bring the guard in protecting position before the operation of the machine starts. The design of this guard is of such a kind that it automatically forces the operator to move away from the dangerous area of work before the operation starts. Such arrangement of such guard does not permit the operator access to this area again until and unless the machine stops.

COMMON SAFETY METHODS Safety by construction or design Safety by position. Safety by using fixed guards. Safety by using automatic guards Safety by using distance guards Safety by workplace layout Safety by proper material handling Safety by using personal protective devices

Safety by Using Distance Guards Distance guard helps to fence the dangerous components of machine such as bars or rails and position them at a suitable distance from the machine such that even operator by chance, extends his hands over it, his fingers, clothes or any of the body does not reach within the area of dangerous parts. For additional safety, some sort of tripping device should always be incorporated to stop the machine rapidly in case of an accident.

COMMON SAFETY METHODS Safety by construction or design Safety by position. Safety by using fixed guards. Safety by using automatic guards Safety by using distance guards Safety by workplace layout Safety by proper material handling Safety by using personal protective devices

Safety by Workplace Layout 1. A suitable layout and proper working conditions play an important role in preventing accidents which would have otherwise occurred. 2. Moving path or passage ways should be clearly marked and never be obstructed. 3. Every employee should have enough space to move and operate the machine. 4. The floor condition must be of non-skid kind. It should act as a satisfactory plane which can be easily cleaned. 5. Height of working rooms should be adequate for proper ventilation and lighting.

Safety by Workplace Layout 6. Fire walls should be used to separate various compartments. 7. Windows should have adequate size and should be in adequate numbers. 8. Illumination should be sufficient, continuous, uniform and free from glare. 9. Proper ventilation should be there in workplace. 10. Noise level should be proper if any. If it is high, use silencers to minimize the noise level.

TYPES OF SAFETY The following general types of safety are considered in the workshop 1. Safety of self. 2. Safety of job. 3. Safety of machines tools. However there are general safety precautions to be adopted while working in any workshop

Personal Protective Equipment at Work Eye protection: Serves as a guard against the hazards of impact, splashes from chemicals or molten metal, liquid droplets (chemical mists and sprays), dust, gases and welding arcs. Eye protectors include safety spectacles, eyeshields, goggles, welding filters, face shields and hoods

Personal Protective Equipment at Work Head protection: Includes industrial safety helmets to protect against falling objects or impact with fixed objects; industrial scalp protectors to protect against striking fixed obstacles, scalping or entanglement and caps and hairnets to protect against scalping and entanglement.

Personal Protective Equipment at Work Foot protection: Includes safety boots or shoes with steel toe caps; foundry boots with steel toe caps, which are heat resistance and designed to keep out molten metal; wellington boots to protect against water and wet conditions and anti-static footwear to prevent the build-up of static electricity on the wearer.

Personal Protective Equipment at Work Hand protection: Gloves of various design provide protection against a range of hazards including cuts and abrasions; extremes of temperature (hot and cold); skin irritation and dermatitis and contact with toxic or corrosive liquids. Barrier creams may sometimes be used as an aid to skin hygiene in situations where gloves cannot be used.

Personal Protective Equipment at Work Protective clothing: Types of clothing used for body protection include coveralls, overalls and aprons to protect against chemicals and other hazardous substances; outfits to protect against cold, heat and bad weather; and clothing to protect against machinery such as chain saws. Types of clothing worn on the body to protect the person include high-visibility clothing; lifejackets and buoyancy aids.

Control of Substances Hazardous to Health Hazardous substances include: • substances used directly in work activities, e. g. adhesives, paints and cleaning agents; • substances generated during work activities, e. g. fumes from soldering or welding; • naturally occurring substances, e. g. wood dust.

Control of Substances Hazardous to Health Effects from hazardous substances include: • skin irritation or dermatitis as a result of skin contact; • asthma as a result of developing allergy to substances used at work; • cancer, which may appear long after exposure to the substances which caused it. • losing consciousness as