LEARNING MATERIAL

Farm Machine and Equipment Maintenance Worker

Index:

1) Introduction to the FLP Farm Machine and Equipment

Maintenance Worker.

2) Occupational Health and Safety.

3) Environmental care and waste disposal.

4) Use of tools and tool care.

5) Lifting equipment and aids.

6) Measuring instruments and units.

7) Fasteners

8) Metalwork tools and equipment and their use.

9) Basic Hand Skills.

10) Gas cutting and welding.

11) Arc welding.

12) Identify farm machines and equipment.

13) Routine Maintenance.

1) Introduction to the FLP Farm Machine and Equipment maintenance Worker.

This foundational learning program is intended to

Occupational Health and Safety.

INDEX

1. INTRODUCTION TO OCCUPATIONAL HEALTH AND SAFETY ACT

2. DEFINITIONS

3. DUTIES IN TERMS OF THE ACT

4. BASIC CRITERIA OF THE HEALTH AND SAFETY SYSTEM

5. COMPLIANCE WITH THE SET STANDARD

6. OCCUPATIONAL HEALTH

7. ERGONOMICS

8. MACHINE GUARDS

9. LOCK-OUTS

10. LADDER AND SCAFFOLDS

11. POLLUTION

12. OFFENCES AND PENALTIES

13. OFF THE JOB, HYGIENE, HEALTH AND SAFETY

1. INTRODUCTION TO THE OCCUPATIONAL HEALTH AND SAFETY ACT

It is a well established principle in our law that an employee has an implicit right to work in a safe working environment. Conversely, the employer has an obligation to ensure that his employees are not exposed to safety hazards. Infringements constitute criminal offences.

The legislation was at first unsophisticated and very much prescriptive. The Act (commonly known as Factories Act), was largely ineffective as the penalties for non-compliance were marginal and responsibility vested in the so-called, factory engineer. These inefficiencies resulted in promulgation of the Machinery and Occupational Safety Act No. 6 of 1983 (MOSACT) which repealed the old Factories Act.

The MOSACT initially was less prescriptive and made provision for more serious penalties. As time went by, new regulations were issued in terms of the MOSACT and this Act evolved into a very complex legislative framework. The MOSACT further made management responsible for employees safety and the Chief Executive Officer became the focus point of the employers safety program. This position was re-enforced by the 1991 amendment to the Machinery and Occupational Safety Act.

It was clear that the MOSACT was more effective than the Factories Act, but it still did not address Occupational Health issues. The Minister of Labour realised that health is as important as safety and accordingly consulted with various Trade Unions, Employer Organisations, State Departments and other relevant entities with the view to incorporating health into safety legislation. This led to the publishing of various draft bills on Occupational Health and Safety which culminated in the promulgation of the Occupational Health and Safety Act No. 85 of 1993 (OHS-Act).

The OHS-Act is regarded, generally, as very progressive and in touch with the needs of both the employer and his employees. For the first time, it is accepted that Occupational Health and Safety should be addressed by both the employer and his employees. Employees are now part of the Occupational Health and Safety management program and they are responsible for ensuring that they participate in the advancement of Occupational Health and Safety of all employees and non-employees who may be affected by their work activities.

The Act caters for constant interaction between employees and management with the view to ensuring a high standard of Occupational Health and Safety at the workplace.

The OHS-Act further makes provision for an obligation on behalf of management and employees to ensure that any other persons whose health and safety may be affected by the employers activities are not endangered. As you will note, the Act has extended both the employer and his employees duties to such an extent that they can no longer be oblivious to Occupational Health and Safety in the workplace.

2. DEFINITIONS

Incident

Unplanned, uncontrolled and undesired event caused by an unsafe act and/or unsafe condition, which results in any loss or potential loss.

Safe

Free from hazard

Hazard

A source of/or exposure to danger

Danger

Anything which may cause injury or damage to person or property

Unsafe act

Any deviation from a set working standard

Unsafe condition

Any deviation from a mechanical and/or environmental set standard

Employer

Any person who employs or provides work for any person and remunerates that person

Employee

Any person who is employed by or works for an employer who receives or is entitled to receive any remuneration or who works under the direction or supervision of an employer or any other person

Workplace

Any place where work is performed

Employment

Employment or employed as an employee

First aid injury

Superficial injury which was sustained that does not need medical attention by a qualified doctor or hospital and the person is able to carry on with his work after the qualified first aider attended to the injury

More than first aid

Any injury that requires the attention of a medical practitioner because the person is not able to continue with his work due to the injury

3. DUTIES IN TERMS OF THE ACT

SECTION 16

EXECUTUVE APPOINTMENT

The Chief Executive Officer, is overall responsible and accountable for the health and safety of all employees under his direction

He may delegate duties and responsibilities to other members of his staff under, and according to Section 16 of the OHS-Act

The above people in turn may on CEOs instruction delegate responsibilities to others under their direction, but the CEO remains accountable for the program status. This may extend to appointments in terms of Section 16 of the Act, and would be determined by the application of the term reasonably practicable.

SECTION 8

GENERAL DUTIES OF EMPLOYERS REGARDING THE HEALTH AND SAFETY OF THEIR EMPLOYEES

What are the general duties of employers to the employees (including Health and Safety Representative)?

Every employer shall provide and maintain, as far as is reasonably practical, a working environment that is safe and without risk to the health and safety of his employees. To achieve this the employer has to do the following:

Provide a plant, machinery and working systems that are safe and without risk to the health of employees

Take steps to eliminate or mitigate hazards to the safety and health of employees before resorting to personal protective equipment

Ensure what is necessary to provide for safety and absence of risk to the health of employees when using, handling, storing, etc. of articles or substances

Determine what measures should be taken in order to protect the health and safety of persons in a workplace

Provide information, instructions, training and supervision that may be necessary to ensure the health and safety of his employees

Prevent any employee from performing hazardous work is the prescribed measures have not been taken

Take measures to ensure that every person in his employ conforms to the relevant requirements of the legislation

Enforce the measures that may be necessary in the interest of health and safety

Ensure that those in a supervisory capacity are trained to understand the hazards of the task in hand an that they have the authority to ensure that adequate measures are taken and implemented

Ensure that employees know and understand what is expected of them and why as well as what actions they should take while carrying out their duties and tasks (e.g. operating procedures)

SECTION 9

DUTIES OF EMPLOYER TO PERSONS OTHER THAN THEIR EMPLOYEES

Conduct the undertaking in such a manner as to ensure, as far as is reasonably practical, that all persons other than employees are not exposed to hazards to health and safety.

Elements of the abovementioned to be discussed:

This section relates to all persons, and makes no distinctions between persons entering the premises with, or without permission, or with, or without being accompanied by an employee. The aspects pertaining to visitors, contractors, casual employees and trespassers, will be addressed at a later stage during this course

This section is wide enough to include neighbours of the site as well as persons residing some distance away from the site, who are able to prove that the activities of the site are adversely affecting their health and safety

The environmental legislation has assumed greater importance during the last decade in South Africa, to such an extent that the environment in itself, may be regarded as a legal person in its own right. This aspect carries considerable weight, due to the fact that should any person be able to indicate that the activities of an organisation, adversely affects the environment in any way, the organisation would have to disprove this

It has become normal practice in industry, to require visitors and contractors to sign an indemnity clause, prior to entering the site. In terms of such indemnities, the visitor or contractor undertakes to be responsible for their own health and safety. Considering that Section 9 does not provide an option to exclude the responsibility brought about by the section, as do sections 10 and 37, the contention has been made that such indemnity clauses are contrary to the legislation and therefore, invalid. This aspect will be discussed in more detail, at a later stage.

Under the terms of current legislation, the employer (CEO) is responsible to making sure that any contractors and their employees, who are working on the premises carry out all their tasks in compliance with legislation.

Contractors must be informed of any hazards which may be in the area that they are in. They must be given training on any hazards on the site. They must also have and use all the necessary PPE and any other safety equipment to prevent exposure to themselves and/or anyone else.

It is best to have a written agreement drawn up so that both parties know what is required. All hazards have been identified and appropriate steps taken to prevent any incident.

SECTION 14 & 15

WHAT ARE THE GENERAL DUTIES OF EMPLOYEES AT WORK?

You should take care not to harm yourself or other people around you or interfere with their safety and health

Co-operate with your employer or other persons on the premises to ensure that all comply with their duties or legal requirements

Carry out all health and safety related instructions given to you and obey the health and safety rules and procedures laid down for the workplace or task

Report any hazardous situations or conditions to your Health and Safety Representative or employer

Report any incident which may affect your health and safety to the Health and Safety Representative for your area or to the employer before the end of the shift

WHAT ARE THE GENERAL DUTIES OF EMPLOYERS TO THEIR HEALTH AND SAFETY REPRESENTATIVES?

The employer must allow time during working hours for the Health and Safety Representative to inspect the workplace. The employer must also provide assistance and training that may be required by the Health and Safety Representative to carry out his functions successfully

It is important that the employer view the Health and Safety Representative as an important part of the team in all efforts to create and maintain a safe workplace which is free of risk to health and safety.

Where activities could create a risk to the safety and health of employees, the employer shall keep the Health and Safety Representative for that are informed of the actions taken to prevent exposure to the hazard. He must minimize such exposure, and keep Health and Safety Representatives informed of the occupational hygiene programme, as well as any biological monitoring and medical surveillance necessary.

The employer has to inform the involved Health and Safety Representative beforehand of inspections, investigations or formal enquiries planned by inspectors. The employer also has to inform the Health and Safety Representative concerned of the occurrence of an incident/accident in his section of the workplace as soon as possible. The employer may suppose that the Health and Safety Representative is aware of this incident/accident, but it still remains his responsibility to ensure that the Health and Safety Representative is officially informed of such an accident/incident.

SECTION 17

FUNCTIONS OF THE SAFETY HEALTH AND ENVIRONMENTAL REPRESENTATIVES

What are the functions of Health and Safety Representatives?

A Health and Safety Representative may perform the following functions in respect of the workplace or section of the workplace for which he has been designated, namely:

Examine the causes of incidents and accidents at the workplace

Carry our inspections of the workplace within scope of authority including inspections of the plant, machinery, health and safety equipment, any article or any substance at the workplace with a view to protecting the health and safety of employees

Identify hazards and deviations that may cause incidents at the workplace

Investigate complaints by employees relating to the employees health and safety at work

Make representations to the Health and Safety Committee or the employer on matters affecting the health and safety of employees at the workplace as well as matters causing incidents and accidents

Review the effectiveness of health and safety measures at the workplace

Participate in consultations with inspectors at the workplace to accompany Inspectors on inspections of the workplace (Remember that Health and Safety Representatives have been informed of visits by Inspectors to the are for which they have been appointed)

In his capacity as a Health and Safety Representative attend meetings of the Health and Safety Committee of which he is a member

Further to the above, a Health and Safety Representative may, in respect of the workplace or section of a workplace for which he has been appointed, perform the following functions:

Visit the site of an incident/accident and attend any inspections

Attend any investigation of formal inquiry

In so far as is reasonably necessary to perform his function, inspect any documents which the employer is required to keep, concerning the health and safety of employees in terms of legislation

With the approval of the employer be accompanied by a technical advisor on any inspection

Participate in any internal health and safety audit

We are going to have a more detailed look at two of the major functions of a Health and Safety Representative:

Accident/incident investigation

Inspections of the workplace or section of the workplace for which the Health and Safety Representative is designated

SECTION 19

FUNCTIONS OF THE SAFET, HEALTH AND ENVIRONMENTAL COMMITTEE

What is the function of a Health and Safety Committee?

A Health and Safety Committee has the task of noting the remedial action required by the employer arising out of reports received from the Health and Safety Representative. The Committee may make further recommendations to the employer regarding any health and safety hazards at the workplace. The Health and Safety Committee also has the task of noting the action taken by the employer to prevent a recurrence of accidents and incidents and may report any incident that occurred at the workplace to an Inspector. Furthermore, a Health and Safety Committee must keep a record of all recommendations made to employers or Inspectors on Health and Safety matters.

Does a Health and Safety Committee have to keep a record of proceedings?

It is legislated that the Health and Safety Committee keep the minutes of the proceedings of all meetings. These minutes should be signed by the employer indicating the steps that are to be taken to implement recommendations made by the Committee on health and safety matters at the workplace or a section of the workplace.

What procedures are followed at a Health and Safety Committee meeting?

The committee determines the procedures followed, but the steps indicated on the minutes serve as an example of procedures, which could be followed.

4. BASIC CRITERIA OF THE HEALTH AND SAFETY SYSTEM

What is an accident?

An accident is an unplanned and undesired event, mainly caused by human error / inefficiencies and/or high risk conditions that result in or have the potential for physical harm to persons and/or damage to property and/or business interruption.

Why should accidents/incidents be investigated?

Because it is important to arrive at some definite conclusion on how to prevent similar accidents/incidents in the future. Accidents/incidents investigation is thus about fact finding and not fault finding and the ultimate objective of accident investigations is to prevent similar occurrences in future.

What is an injury?

Any damaging physical force which applied to the body which leaves the person harmed or weakened in some way.

What is occupational illness?

A state where the systems or organs (liver, lungs, etc.) of the body are affected by substances, so that they do not function in a balanced and normal way.

What is occupational disease?

A physical condition which has specific signs and symptoms caused by exposure to substances in the workplace, and which is limited to and effects a certain part of the body.

What are the basic caused of incidents?

Personal factors

lack of knowledge, skill or both

physical or mental incompatibility

improper attitude or lack of motivation

Job factors

unsafe physical environment

inadequate work standards

What are unsafe acts?

Unsafe acts may motivate an action, which could result in injury, illness, disease or damage.

What are human errors / inefficiencies? (These cause 88% of all accidents)

Working at unsafe speeds

A forklift driver, in a hurry to deliver a pallet load of tin plates to the production area before lunch time, ignored the prescribed speed limit of walking pace when transporting a load. Whilst negotiating a right-angled turn, the load of plates slid from the pallet and skidded across the floor. The resulting scratch marks on the tin plated made them unsuitable for the intended product.

Working without authority

A machine operator at a printing works arrived early for work one morning. Without following the correct procedures he decided to clean the print rolls on one of the machines. Running the machine at high speed he commenced cleaning the rolls with a rag. The rag became between the rolls, pulling the mans hand and arm into the machine, resulting in his arm being torn off at the shoulder.

Failure to secure machinery and material

A worker cleaning an empty mixing drum of a concrete batching plat failed to follow WSWPs and isolate and lock-out. An operator inadvertently activated the mixing drum when commencing the next batch. The worker in the empty drum lost his life.

Rendering safety devices inoperative

A worker operating a two-hand controlled punch-press found that he could speed up the production rate by securing the one lever with a piece of string, feeding the press with his left hand whilst activating the press with the right hand lever only. Establishing a rhythm, he activated the press too soon, which did not allow sufficient time for his left hand to clear the point of operation. Four fingers were amputated.

Arranging or placing objects unsafely

To avoid the time consumed in building and breaking down stacks of bags of mealies at an animal feed mill, the bags were stacked without making use of the bonding method. Whilst breaking down a stack, the entire side of the stack collapsed onto several workers who suffered broken arms and legs.

Fooling, teasing, abusing workmates

A group of workers, fooling with a compressed air hose, blew compressed air into a colleagues rectum. This resulted in the rapture of his intestines. He subsequently died.

Using equipment unsafely or limbs instead of equipment supplied

In spiting a board on a circular saw the operator suffered the loss of his thumb. Instead of using the push-stick that had been provided he pushed the board past the saw with his hand. He had been performing similar operations at an average of twenty times a day for three months during which time he sustained many minor cuts and hundreds of close shaves.

Adjusting or working on moving machinery

A fitter decided to adjust the tension on a portable conveyer belt whilst the belt was in motion. His arm became trapped between the belt and the head pulley. This resulted in his arm being amputated at the shoulder.

Taking chances

Instead of walking around the factory premises to enter via the authorised entrance, a worker took the chance of illegally crossing a railway line to use an unauthorised entrance. He was struck by an oncoming train and killed.

Taking up unsafe positions

A lift serviceman sat on the edge of the landing with his legs dangling into the lift well. The lift, operated by his assistant without him being aware of its descent. Both his legs were severed.

Failure to use safety equipment or to wear protective apparel

A worker, not wearing the breathing apparatus provided, entered a wine maturation vat to clean out the dregs. He was overcome by fumes and lost his life.

What are unsafe conditions? (Engineering factors)

Any variation from accepted safety standards, which may be the cause of incidents. Some examples are listed below:

What are high risk conditions? (These cause 10% of all accidents)

Any physical condition which is a departure from accepted safety standards which, if left uncorrected, may be the cause of an accident/incident resulting in damage and/or injury.

Unsafe construction

A wooden ladder with knots in the rungs was used. The rungs broke when a builders assistant was climbing the ladder carrying a bucket filled with bricks.

Disorder and hazard planning (inadequate planning)

A conveyer belt was installed in the centre of the work area, without giving consideration as to how workers would cross from one side of the work area to the other. A worker lost his balance, fell and broke an arm.

Lack of machine or other guards

Many production machines are not provided with suitable guarding. Serious accidents could result.

Defective working conditions, such as rough, sharp or slippery surfaces

One of the major causes of falls in hotels for instance, is that floors are not constructed to the same level. Small differences in floor levels are not readily noticed and are tripping hazards.

Inadequate guarding

Large openings in the metal used for a machine guard, allowed an operators finger to extend through the guard. It was amputated by a V-belt running over a pulley.

Poor factory layout with inadequate or poorly marked walkways and exists

In a workshop where walkways had not been marked out on the floor, workers stacked material and equipment in any open space they could find, thereby forcing workers to either climb over the material or brush past dangerous machines in operation. This unsafe condition was the cause of a worker passing to close to a milling machine and being struck in the eye by a piece of swarf.

Overcrowding in workshops

Too many machines in a workshop limit the free space required around machinery. These conditions often lead to accidents/incidents which result in damage and/or injuries.

No personal protective equipment

People who do not wear suitable PPE may suffer injury, illness of disease

Unsafe ventilation

In areas where volatile flammable liquids are used, ventilation should be sufficient to either remove or dilute the air/vapour mixture to avoid ignition. This will help to prevent fires and explosions.

Unsafe lighting

Lighting in passageways and on stairway needs to be of correct intensity so that protrusions and tripping hazards are illuminated adequately. This is very important in emergencies. All lighting must comply with legal standards.

Storing of hazardous substances

A woman farm worker sent her small son to fetch some mealie meal in the farmers barn. A bag of insecticide was stored with the mealie meal and the youngster took some of the insecticide instead of the mealie meal. Members of the family died because of poisoning.

NOTICES AND SIGNS

Uniform SABS approved signs should be used. They consist of a specific shape, associated colour and a pictogram.

GREEN

Information (background used with white lettering)

Equipment start buttons

General locations

first aid

exit routes

rest areas

emergency showers

safety information

ORANGE

Indicates electrical utilities

electric service supply lines

electrical switchgear and fittings

Draws attention to dangerous moving machine parts

inside machine guards

parts capable of cutting, crushing or shearing shaft ends

exposed rotating machine parts

faces of gears

BLUE

Basic background colour used with white lettering or pictograms for mandatory purposes (PPE, etc.) e.g. noise area wear ear protection

FIRE FIGHTING INFO SIGNS

Location of fire Fire extinguisher Fire hose

fighting equipment

Fire hydrant Fire alarm Sprinkler stop

valve

Fire telephone Fire pump Location of

connection fire blanket

WARNING SIGNS

General warning Warning of Warning of

of danger fire hazard corrosion hazard

Warning of poisonous Warning of ionizing Warning of electrical

substance hazard radiation hazard shock hazard

Warning of suspended Warning of Warning of

loads hazard fragile roof workers overhead

Warning of slippery Warning of hazard of Warning of hazard

walking surface moving machinery of cold burns

Beware of forklifts Warning of hazard Warning of hazard of

of slippery stairs exposed high-voltage

equipment

PROHIBITORY SIGNS (DO NOT)

Smoking prohibited Fire and open flames

prohibited

Thoroughfare for Water as an

pedestrians prohibited extinguishing agent

prohibited

Drinking of this Use of compressed

water prohibited air to dust body

prohibited

Carrying of firearms Loose clothing, ties and

prohibited unconfined long hair

prohibited

Cameras prohibited Alcohol prohibited

MANDATORY SIGNS (MUST DO)

Eye protection Respiratory protection Hearing protection

shall be worn shall be worn shall be worn

Hand protection Foot and leg protection Foot protection against

against liquids shall be worn crushing shall be worn

Safety harness and Apron shall be worn Face protection

lifeline shall be worn shall be worn

Dust mask Keep area clean Screening to be used

shall be worn

GENERAL INFO SIGNS

First aid equipment General direction Direction to

escape route

Direction to Manned first aid Drinking water

escape route station

Traveling away Ladies toilets Gents toulets

Telephone Stairs going down Stairs going up

Eye wash Safety shower

COLOUR CODING, PLANT AND MACHINERY

For many years, in the absence of a standard colour code, many firms resorted to their own standards for colours for machinery, hazards, electrical equipment, pipe content, etc. This, at least provided a standard within an individual firm, but the time has arrived when it is highly desirable for the standardisation of colour coding throughout industry.

There is no doubt that uniformity of colour identification promotes greater safety, lessens the chance of error and warns against hazards caused by the mishandling of materials. The SABS, in conjunction with NOSA and other representatives from industry, have set out standards for colour identification. This NOSADATA has been prepared for the benefit of our members and is applicable to plant and machinery. Further NOSADATA setting colour standards for pipeline content, fire extinguishers, etc. will be issued as soon as these standards have been finalised.

The use of identification of hazardous machine parts, obstructions, pipes and services enables speedy recognition and, where intended, immediate warning of danger. Its value is obvious as a major contributing factor in the reduction of accidents and this value becomes of even greater importance where there is uniformity of colour marking among plants and organizations as it serves to eliminate confusion where workers transfer from one location or organization to another. Obvious too is its importance where the work force lacks a common language, as a standardized system has little or no need for words.

Education is an essential part of any system for giving information. On premises where colour identification is adopted, whether it be for safety, informatory or identification purposes, it is essential that a program of education be implemented. Such a program requires competent administration and should be of such a nature that no personnel are allowed to work in any area of a factory or plant until proved to be fully conversant with all relevant colour codes.

The marking of a physical hazard by a standard colour warning should never be accepted as a substitute for complete elimination of the hazard, wherever possible. It should supplement the proper guarding of machinery and other methods of eliminating hazardous conditions. Standard colour coding triggers off spontaneous action in an emergency.

COLOURS

All colours are based on, and should match SABS Code 1091. If improvement of conspicuity or emphasis of a specific colour is required, black or white may be used to provide contrast.

TABLE OF COLOURS

SABS 1091

Colour

Colour no.

Colour name

Blue

Green

Orange

Red

Yellow

F29

E14

B26

A11

B49

Cornflower blue

Emerald green

Light orange

Signal red

Golden yellow

Applicability of colours

Blue

Blue is a colour which should not be used on machinery. It is used as a colour code indicator on pipelines carrying drinkable water.

Green

Restrict the use of emerald green (when relevant, in conjunction with white lettering, stripes or edging, whichever provides the most effective contrast to the surroundings) to the identifications of:

the location of safety and first aid equipment

emergency exits and safety areas

informatory signs

starting devices on electrical equipment

miscellaneous safe conditions

AGRI-13-13000-FOU-13-00

Typical examples: (see also Fig. 1)

Location of safety and first aid equipment

location of first aid facilities, including stretchers

location of gas masks and rescue equipment

safety deluge showers or their location

Emergency exits and safety areas

emergency and other exits

areas of freedom from danger, e.g. safety refuges in quarries and steelworks (preferably shown by the block form of a shelter or shed)

Informatory signs

safety instruction signs

information signs

directional signs

Starting devices on electrical equipment

Starting devices on electrical equipment that is used for the control of machinery

Miscellaneous safe conditions

entrances

equipment stores and storage areas

locker rooms

offices

Parking areas

toilets

Orange

Restrict the use of light orange to the identification of:

electrical switchgear

electrical services

exposed and rotating machine parts

Typical examples: (see also Fig. 2)

Electrical switchgear

All electrical switchgear other than starting and stopping devices and emergency stop controls

Electrical services

All conduit and allied fittings

Exposed and rotating machine parts

the inside surfaces of chasings and guards of equipment and machinery that constitute a hazard (marked in such a way as to indicate when the casing or guard is not completely closed)

Note: the outside of such surfaces should be of a colour that provides an

effective contrast to light orange

the surfaces or protruding shafts, faces of exposed gear-wheels and any exposed rotating part of a machine

Red

Restrict the use of signal red (when relevant, in conjunction with white lettering, stripes or edging, whichever provides the most effective contrast to the surroundings) to the identification of:

danger

fire protection equipment and apparatus other than fire extinguishers. Fire extinguishers should be marked in accordance with the relevant part of this code (which will be added later)

stopping devices on electrical equipment that are used for the control of machinery

emergency devices for stopping machinery

Typical examples: (See also Fig. 3)

Danger

flashing red lights at rail crossings

danger signs

stores for explosives and other dangerous substances

barricades and obstructions prohibiting the passage of persons, vehicles or materials

Yellow

Restrict the use of golden yellow (when relevant, in conjunction with black) to the identification of:

objects and places where caution should be exercised

places where radiation hazards from radio-active materials exist

housekeeping markings

Typical examples: (See also Fig. 4)

Objects and places where caution should be exercised

industrial locomotives and other forms of mobile equipment that may constitute a hazard

barricades and temporary constructions that define the limits of an area in which caution should be exercised

low head room caused by the presence of structures, pipes, etc.

crane lifting hooks

changes in floor level and other similar tripping hazards

demarcation of No Parking areas on the floor below fire equipment and electrical switchgear panels

locations of explosive substances

Places where radiation hazards from radio-active materials exist

rooms and areas (outside or inside buildings) where radio-active materials are stored or handled or that have been contaminated with a radio-active material

burial grounds and storage areas for contaminated materials and equipment

disposal cans for contaminated materials

contaminated equipment that is not placed in special storage

Housekeeping markings

definition of walkways, etc.

demarcation of clear areas

If PPE is not the first choice or ideal method, is it then of any value in employee exposure protection?

PPE is very valuable as an interim measure i.e. where an exposure hazard has been identified, and engineering controls are not yet in place, or perhaps cannot ensure adequate protection due to circumstances beyond fixed reasonably practicable control.

What action is necessary when work needs to be carried out and is it not possible to engineer out personal exposure hazards?

The employer must identify the nature and extent of the problem. He then needs to obtain suitable protective equipment and ensure that it is issued to all staff after they have received education and training in its correct use, maintenance, cleaning and storage requirements.

What must employees do regarding PPE?

Every employee must use appropriate PPE correctly. Failure to do so may result in the employer being forced to take disciplinary steps. The Inspector may also decide to prosecute the employee and is he is found guilty of negligence of wilful misconduct he may be fined. Employees should be motivated to take responsibility for their own health and safety. This will be achieved through creating awareness and understanding of the principles, purpose and benefits of using all given PPE correctly at all times.

How do we know which type of equipment to use?

There is a large variety of equipment available. Once the hazard type and risk is known, someone should be appointed to be responsible for making sure that the correct equipment is in stock and used correctly.

SAPEMA (South African Protective Equipment Manufacturers Association) may be contacted for advice.

Who is responsible for training employees on PPE use?

The employer must see that employees receive appropriate training. Many suppliers of PPE run excellent programs on their own products. If this service is not available, training may be done by suitable in-house staff.

Does using PPE guarantee that there is no exposure to hazards?

Each type of PPE is designated with a specific purpose in mind. However, there are many factors which have an effect on its efficiency. These could include cleaning and storage practices; humidity levels, solvent exposure causing degeneration of certain materials, etc. The individual susceptibility of the person also needs to be taken into account.

Also, the way we wear PPE will have a bearing on how effective it is.

For example:

a hard hat is worn at the back of the head instead of centred over the crown, will not offer much protection if an object falls from above

ear plugs which are not correctly placed in the ear, will not reduce noise by the stated amount claimed by the manufacturer

respirators must have the right cartridge for the hazard. Users must also be trained to know when the cartridge is no longer effective and how to replace it

safety harnesses selection of correct type

What types of protective equipment are available?

Head

Hard hats, caps, crash helmets, hair nets

Eyes

Glasses, goggles, face shields, visors and strengthened prescription lenses

Ears

Earplugs (various types) and ear muffs

Lungs

Face masks, (application varies from nuisance dust to protection against certain substances. Selection is dependent on toxicity and type of substance)

respirators, the cartridges of which must be substance specific and compatible

air-lines which may include full air-line suits

self contained breathing apparatus sets for fire, rescue, or work in areas indicated by TLV-STEL or TLV-C measurements (Threshold Limited Value TLV)

Body

Aprons, suits, jackets, overalls

Legs

Spats and leggings, aprons

Hands

Gloves, mittens and gauntlets

Feet

Boots and shoes and foot protectors

EMERGENC ROUTES AND EQUIPMENT

Employees should be walked along the route, assembly points should be identified, and alarms demonstrated and understood.

POSTERS, BULLETINS, COMPETITIONS, VIDEOS, ETC.

Should be used on an continuing basis by the supervisor and Health and Safety Representative to explain or re-enforce programme requirements. All material should be discussed and explained. Posters should be rotated regularly.

INCIDENT RECALL

Recall and toolbox talks should be planned and carried out on a regular departmental basis.

5. COMPLIANCE WITH THE STANDARD AND PERSONAL PARTICIPATION

WORKPLACE RISK ASSESSMENT

The objective of this technique is:

To help employers and employees to assess risks in the workplace. It is aimed at practical workplace risk assessment

An assessment of risk is nothing more than a careful examination of what, in your work, could cause harm to people, so that you can weigh up whether you have taken enough precautions or should do more to prevent harm. The aim is make sure that no one gets hurt or becomes ill. Accidents and ill health can ruin lives, and affect your production too if output is lost, machinery is damaged, insurance costs increase, or you have to go to court.

Dont be put off by some of the words used in this guide:

i. Hazard means anything that can cause harm (e.g. chemicals, electricity, noise, etc.)

ii. Risk is the chance, great or small, that someone will be harmed by the hazard

The important things you need to decide are whether a hazard is significant, and whether you have it covered by satisfactory precautions so that the risk is small. You need to check this when you asses the risks. For instance, electricity can kill but the risk of doing so is an office environment is remote, provided live components are insulated and metal casings properly earthed.

HOW TO ASSESS THE RISK IN THE WORKPLACE?

Dont be overcomplicated in every department, the hazards are well known to supervisors but you will have to review the effectiveness of existing health and safety controls with all your workers. You may have already assessed some of them for example, if you use toxic or dangerous chemicals, you should already have made an assessment of the risks to health and precautions you need to take under the Regulations for Hazardous Chemical Substances, 25 August 1995. If so, you can consider them checked and write down if you are making a written assessment. For other hazards, you probably already know whether you have machinery that could cause harm or if there is an awkward entrance of travelling way where someone could be hurt. If so, check that you have taken what reasonable precautions you can to avoid injury.

If you are confident you understand the work, you can facilitate the assessment yourself. You could ask a responsible employee, safety representative or safety officer to help you. If you are not confident, get help from a competent source. But remember you are responsible for seeing it is adequately done.

STEP 1

LOOK FOR THE HAZARDS

If you are doing the assessment yourself, walk around your workplace and look afresh at what could reasonably be expected to cause harm. Ignore the trivial and concentrate only on significant hazards which could result in serious harm or affect several people. Ask your employees or their representatives what they think. They may have noticed things which are not immediately obvious. Manufacturers instructions or datasheets can also help you spot hazards and put risks in their true perspective. So can accidents and ill-health records.

STEP 2

DECIDE WHO MIGHT BE HARMED, AND HOW

Think about people who may not be in the workplace all the time, e.g. surveyors, visitors, contractors, maintenance personnel, etc. Include members of the public, or people you share your workplace with, if there is a chance they could be hurt by your activities.

STEP 3

EVALUATE THE RISKS ARISING FROM THE HAZARDS AND DECIDE WHETHER EXISTING PRECAUTIONS AND ADEQUATE OR MORE SHOULD BE DONE

Even after all precautions have been taken, usually some risk remains. What you have to decide for each significant hazard is whether this remaining risk is high, medium or low. First, ask yourself whether you have done all things that the law says you have got to do. For example, there are legal requirements on prevention of access to dangerous parts of machinery. Then ask yourself whether generally accepted industry standards are in place. But dont stop there think for yourself, because the law also says that you must do what is reasonably practicable to keep your workplace safe. Your real aim is to make all risks small by adding to your precautions if necessary.

If you find that something needs to be done, ask yourself:

(a) Can I get rid of the hazard altogether?

(b) If not, how can I control the risks so that harm is unlikely?

Only use personal protective equipment when there is nothing else that you can reasonably do.

If the work you do tends to vary a lot, or if you or your employees move from one site to another, select those hazards which you can reasonably foresee and assess the risks from them. After that, if you spot any unusual hazard when you get to a site, get information from others on site, and take what action seems necessary.

If you share a workplace, tell the other employers and self-employed people there about any risks your work could cause them, and what precautions you are taking. Also, think about the risks to your workforce from those who share your workplace.

STEP 4

RECORD YOUR FINDINGS

You should record the significant findings of your assessment. This means:

(1) writing down the more significant hazards and

(2) recording your most important conclusions for example, Electrical cable installation: insulation and suspension checked and found sound or Fumes from blasting: local exhaust ventilation provided and regularly checked. You should also inform your employees and their representatives about your findings.

There is no need to show how you did your assessment, provided you can show that:

A proper check was made by the team

You asked who might be affected

You dealt with all the obvious significant hazards, taking into account the number of people who could be involved

The precautions are reasonable and the remaining risk is low

Assessments need to be suitable and sufficient, not perfect. The real points are:

Are the precautions reasonable, and

Is there something to show that a proper check was made?

Keep the written document for future reference or use; it can help you if an inspector questions your precautions, or if you became involved in any action for civil liability. It can also remind you to keep an eye on particular matters. And it helps to show that you have done what the law requires. There is a form with this guide which you may find helpful but, by all means, produce your own form if it suits you better.

To make things simpler, you can refer to other documents, such as manuals, the arrangements in your health and safety policy statement, company rules, manufacturers instructions and your health and safety procedures. These may already list hazards and precautions. You dont need to repeat all that, and it is up to you whether you combine all the documents, or keep them separately.

STEP 5

REVIEW YOUR ASSESSMENT FROM TIME TO TIME AND REVISE IT IF NECESSARY

Sooner or later you will bring in new machines, substances and procedures, which could lead to new hazards. If there is any significant change, you should add to the assessment to take account from time to time. Dont amend your assessment for every trivial change, or still more, for each new job, but if a new job introduces significant new hazards of its own, you will want to consider them in their own right and do whether you need to keep the risks down.

WRITTEN SAFE WORK PROCEDURE

This is a systematic approach which enables us to identify all hazardous tasks and establish the likelihood of harm or loss arising out of or during the task. It means we can prioritise the action we need to take on an ongoing basis, until all tasks have been analyzed.

Once this analysis is completed, a second procedure is followed. This involves writing safe work procedures to be followed by anyone carrying out this job.

For companies who follow the ISO 9000 system, this means only having to review and add safety steps for all jobs which have already been analysed and documented. For other companies, who want to export to other countries, and intend going on to the ISO 9000 system, this is a major preliminary step in that direction, With or without incorporating the formal ISO 9000 system, this procedure will automatically improve quality control and maintain them on an ongoing basis health, safety and quality are inseparable.

An added benefit of Job Safety Analysis and written safe work procedures is that it gives us a ready tool which can be used for training new staff, checking on performance, investigation incidents and deviations, and giving recognition for good performance according to set standards as trained.

It also assists the operator to refresh his memory, when carrying out tasks which are not routine or are only required at intervals which may be far apart e.g. at shut-down.

What general precautionary measures would you take to protect employees and especially maintenance crews when working on mechanical and electrical equipment:

Never work on any live or moving equipment

All adjustments should only be undertaken by trained staff

Any hazardous tasks should be identified and covered by a work permit or written safe work procedure

Supervision / job observation should be on-going

Education and training should be given appropriate to tasks

Awareness and compliance of legislative requirements

Purchase specifications should ensure safety is incorporated at the design / manufacture stage

Inspect / check before commissioning

Formal hand-over should be completed after re-design, major repairs or new installations

Use of pirate parts must be checked to ensure load design capacities are appropriate and compatible

Safety devices should be part of regular scheduled checks

Never leave machines running while unattended

Wear appropriate PPE

No bypassing of safety devices

Use correct tools and procedures

Do not use hand to remove jammed particles

Isolation requirements must always be followed

All machinery and equipment should be on a preventative maintenance programme

INCIDENT / ACCIDENT REPORTING

There are two government departments which must be informed of certain incidents. There are specific forms and procedures which management must ensure are forwarded to the appropriate Regional Director: Occupational Health and Safety and the Compensation Commissioner of the Department of Labour. Someone should be appointed to ensure that this documentation is correctly completed at the Department of Labour.

The Regional Director at the Department of Labour must be told of any of the following by phone or fax, and this must be followed by the correct documentation being forwarded to him as soon as possible thereafter.

Unconsciousness

Any loss of a limb or part thereof

Death or likelihood of death

If a person is expected to be away from work, or on light duties for more that 14 days

Any broken bone

Any uncontrolled substance release

Any machine which runs out of control

Any parts of machinery which flies through the air

Any major hazard or major hazard installation risk

Any collapse of a building or structure

Does the company need to keep any other records of incidents?

Apart from copies of the above documents, the employer must carry out an investigation and keep record of findings and recommendations. The investigator should be trained in investigations. Management and the Health and Safety Representatives for the area should be involved, as well as the supervisor or manager. These reports must be discussed at the next committee meeting.

INTERNAL INCIDENT REPORTING

Should all incidents be investigated even if there is no loss or damage?

Incidents occur when something is wrong with the procedure, the system or the process otherwise the incident would not have happened. Therefore, even if there is no loss or damage this should be taken as a warning.

Investigations provide very important information so that the same or s similar situation does not happen again, where the outcome could be more serious.

The purpose of internal investigations is therefore to find the basic cause of the incident. Thereafter, steps can be taken to make sure that it does not happen again.

The steps in incident investigation are:

Train staff to carry out investigations

Appoint an investigator if appropriate

Inspect the scene and interview everyone involved or who witnessed it

Make notes and sketches and check systems

Identify the direct cause as well as the basic cause

Check the existing steps in the procedure

Evaluate and correct the standards

Review all other similar situations

Notify all necessary persons of recommendations

Record findings and report to Health and Safety Committee

Re-assess on a planned basis

Are statistics a valuable tool to prevent and anticipate future incidents?

Accurate records and an analysis of what type of incidents happen, at what time of the day or week, and how they happened are a most valuable source of information.

From these statistics we can identify exactly what training, education or procedures need to be changes. For example is the person new on that job; would an assistant be needed; is the pre-start check adequate, is the lighting adequate on night shift, etc.

Statistics, if correctly compiled and analysed, serve as a pro-active tool to identify areas which need attention and that should be included or provided for in the next financial years budget. (In critical instances immediate steps should be taken)

How can injury statistics be analyzed to pin-point problem areas?

Problem areas can be more easily pin-pointed if statistical information can be categorised to show trends or areas which need urgent or special attention.

The number of injuries to different body parts can be analyzed to show the prevalence of injuries to feet, hands, head, eyes, neck, backs, etc.

Information analyzed in this way can be presented in chart form at monthly Health and Safety Committee meetings.

6. OCCUPATIONAL HEALTH

Must every company employ Occupational Health Practitioners?

Management must identify the risks associated with the production process and then decide what systems and people they need to ensure that their workers occupational health and safety needs are catered for.

Is it a recommendation that all firms use the services of medically trained staff?

Again, this decision will need to be taken by each company according to the hazards associated with the nature of the tasks. Some points of consideration would include the following:

(a) Selection and Placement

It makes good sense for both the employee and the employer to ensure that the right person is employed for the job. One of the criteria is not to just to check on qualifications and experience, but also on physical and mental abilities to meet the demands of the job. Failure to do this, could result in the introduction of unsafe conditions.

(b) Medical Examinations

Man-job specifications and medical examinations form part of a thorough screenings process. These examinations can be done on site if facilities are available, or on a contractual basis by practitioners in private practice.

By choice, operations with high risks substances would benefit greatly by having suitable staff available on call, or on site. They should where practical, be appropriately trained in the specifics of occupational health and medicine. This training / experience should be appropriate to the risks associated with the many pertinent differences in approach to occupationally related health issues as opposed to general medicine. In the area of occupational health, the practitioner is dealing with a well person. The emphasis being on anticipation, identification and assessment of inherent risks i.e. preventative medicine.

Should all premises have trained First Aiders on site?

First aid facilities must be provided. Legislation lays down the requirements. Suitable supplies specific to the risks of the particular hazards staff may be exposed to must be available. Trained staff should be available to or stationed in areas so that in an emergency they can cope with any anticipated problems until outside help can take over.

Are Occupational Hygienists part of the health team?

Their knowledge of specific chemical and other health hazards, and the means of surveying and monitoring these are integral to accurately assessing hazards and their effects on the workforce.

This is a specialized field and abilities, qualifications and expertise should be verified in relation to each organizations hazards before appointing such a person.

7. ERGONOMICS

This is also an important health factor and someone should be appointed to look at the different areas, which can effect an employees well-being and productivity in the long term.

Ergonomics incorporates many areas which are best addressed in more detail than there is time for during this course. A separate course is available to cater for its many facets.

What is Ergonomics?

This field is also known as Human Factors Engineering.

Areas include:

Ventilation, temperatures, air movement, extraction of substances

Lighting

Noise

Work station design

Instrumentation controls and design

Muscular strains and stresses

Manual handling

Vibration

What is the purpose of practising ergonomics?

The implementation of a sound ergonomic program results in:

Better utilization of worker skills

Reduction of fatigue

Reduction of injuries and associated claims

Reduction of absenteeism

Increased output

Increased worker morale

Increased job satisfaction

Increased productivity

Must ergonomics be carries out by specialists?

With a little training, persons with appropriate backgrounds (e.g. engineers, or persons with a physiological background) can be trained to carry out many cost effective productive programs, for initial identification and improvements of conditions.

Thereafter, more specialized persons (e.g. design engineers and occupational hygienists) can be called in to further assist and refine programs.

Are ergonomic studies and programmes costly to implement?

In many instances they cost little or next to nothing. All that is required is a change of position, screening off glare from lights, or raising or lowering a work surface, to achieve very quick and measurable effects.

MANUAL HANDLING

Back injuries account for the highest number of employee injuries annually.

Employees should be taught correct techniques. They must also be aware that any back pain should be reported immediately, even if not severe, to avoid long term, or permanent damage

Load size and shape should be assessed and the method determined to handle it appropriately i.e. by hand or mechanically

Work station design should be assessed and wide range lifting be engineered out of the process

Large load, or high volume manual lifting per shift should be avoided.

Lifting and twisting must be avoided. Lift, move feet, face drop area and lower

Objects required to be lifted repetitively should be located in the reach area between shoulder and knee height

Man-job specifications must be utilized for employees doing manual lifting tasks

Appropriate PPE (e.g. gloves, hard hats) should be provided where indicated

Pushing and pulling loads can also place excessive strain on the back, and correct techniques and equipment should be used after training has been given

Drop and pick-up areas should be designed to accommodate unrestricted work flow without excessive handling

8. MACHINE GUARDS

Why is machine guarding important?

Injuries caused by machines, are usually severe and permanent

Machine guarding can help prevent incidents and injuries

Dangers can often be reduced or removed altogether by mechanical safeguards and better machine design or construction. On the other hand, safe human habits and practices are difficult to cultivate and maintain. Furthermore, mechanical improvements are usually permanent.

What are the three basic types of guards?

Fixed guards

These are usually used on transmission machinery. They do not move with each operation. They are also used on power presses and are adjusted to accommodate various different sizes of work and are fixed into place after adjustment.

Interlocking guards

This type of operation prevents the operation of the controls which set the machine in operation until the guard is moved into place. This means that operators cannot place their hands in the machine when it is in motion. These guards may be operated electronically, mechanically, pneumatically, or by a combination of all three.

Automatic guards

This type prevents the operator from coming into contact with dangerous parts of the machine while it is moving. Other automatic guards stop machines when there is danger, for example an electronic beam system which stops the machine as soon as the beam is broken by any part of the body or by an object.

What characteristics should a good guard have?

Provide maximum positive protection

Block access to the danger zone during operation

Corrosion and fire resistant and easily repairable

Hazards such as splinters and nip points should not be created by the guard

It should be a permanent part of the machinery without weakening its structure

Efficient operation of the machine should not be affected by the guard

It should be strong enough to withstand normal wear and tear

Where the guard is bulky, hinging should be considered to facilitate the servicing and repair of belts or gears, etc.

Why are treadle or stirrup guards essential for foot operated machines?

Foot treadle or stirrup guards prevent the accidental operation of punch presses and other foot-operated equipment from objects falling on the treadle or by the operator unintentionally stepping on it.

How does a phote-electric device operate?

It is an automatic stop device which makes use of light beams or light curtains. As soon as the light beam is broken it stops the machine at whatever stage of the operation is it in at the time.

9. LOCK-OUTS

Unexpected or uncontrolled operation may result in death or serious injury.

Policy and procedures should be established and training given

Principles include:

Each appropriate individual has a copy and signs for receipt and training regarding this procedure

All areas / tasks should be identified in writing

- Electrical energy sources

- Mechanical energy sources (e.g. steam, hydraulics, air)

- Chemical lines and piping

- Confined spaces

- Shut down procedures

- Unplanned downtime procedures

- Identify all energy sources to any one piece of equipment or plane

One lock issued per person

Locks should be numbered and their issue documented

Duplicate key to be locked away in responsible persons care. Only he may unlock in an emergency / key loss and signs for doing this

Issue Work permits where appropriate

Lock-out may not be substituted by tag-out

All equipment must be able to accommodate locks

No exchanging of locks allowed

Gang locks to be used when more than one person is assigned to one piece of equipment, with each worker locking out individually

Test electrical supply to zero potential before starting repairs / adjustments

Release stores / residual energy in supply lines

Notify affected persons / departments that line is going down

On completion, test safe, remove locks and notify operator(s) and supervisor that energy and lines are restored

10. LADDERS AND SCAFFOLD

What are the basic rules for the safe use of ladders?

Always avoid bringing metal or alloy ladders into contact with electrical supply sources

Place the ladder so that its feet are a quarter of its length to the top support from the surface which it is resting against

Unless the ladder is secured at the top, it should always be held in position by another person as long as someone is standing on it

Wherever possible it should extend 1 meter of at least three rungs above its top support

Ladders should be inspected at frequent intervals. Defects should be repaired immediately or the ladder replaced

Keep ladders clean and do not paint them, as this hides any defects

Do not leave ladders on wet ground or exposed to the weather

Ladders lying on floors may cause employees to trip or fall, or they may be run over by vehicles and damaged

Do not use ladders horizontally as walkways or scaffolds

Tools and equipment should be hauled up by rope

Never leave a ladder standing where it may fall over

Never place a ladder in front of an unlocked doorway

Ladders should be fitted with non-slip feet

Store ladders in a cool dry place, either lying on their side, or supported on hooks against a wall, this will help to avoid warping of wooden ladders and makes it easier to check its length

All ladders should be identified and entered on a register. Checks should be regular and any defects recorded and reported

Only one person should be on a ladder at any one time, and both hands should be used for climbing

Do not leave any tools on the ladder

Use the correct ladder for the job

What are the most important safety requirements to be considered with regard to scaffold platforms and supports?

Legislation in regard to scaffolding regulations is extensive and should be referred to for detailed information. The following indicate some general principles in regard to erecting and using scaffolding.

Scaffold must be erected, changed, broken down and stored only under the supervision of a competent person

Inspection by a competent person must be carried out after erection and thereafter once a week, as well as after any bad weather

Working platforms must be kept clean and all boards are to be secured and flush

Asbestos

Dusts

Lead laden combustion fumes or leachate from dumps

Carbon monoxide generated from fuel consumption

Acid or alkali dumps into water drainage systems as well as any toxic chemicals or carcinogenic substances which may not, in themselves be toxic, but pose a threat to the ecological balance and systems (e.g. insecticides, pesticides, organic phosphates, etc,)

Carbon products from various combustion processes, (power stations, boilers, etc.)

Benzene, petroleum products leaching through ground soils or into water supplies (often from poorly controlled run-off)

Formaldehydes (especially when they are incinerated)

Packaging products which contain PVCs etc. or other materials which are not biodegradable

What are the major concerns we are faced with in South Africa in regard to pollution?

Of major importance and concern is the amount of overall general waste in generated in this country where our specialised disposal and treatment facilities are minimal, and our infrastructure makes effective handling difficult and costly.

South Africa generates an average of 20kg of waste per person per day. Our geographic distance are vast and our comparatively small population cannot financially support the type of high-tech waste disposal and/or treatment operations which are viable in overseas industrialized countries.

How can industry have a positive impact on pollution control measurements?

We need to follow a systematic approach in regard to containment, reduction and disposal approaches.

Identify the risk substances and/or processes

Formulate an Environmental Engineering Pollution Control Policy

Establish a programme

Appoint a co-ordinator and provide adequate education, training and other necessary facilities as indicated by demands

Prioritize critical issues and establish an action plan

Educate and train:

- employees

- users

- intermediate agents (e.g. transportation agents)

- appropriate support services (Fire, Municipal, Civil Defence, Air Traffic stations, etc)

What type of issues should an APC Policy address?

Any areas where there is a responsibility for generating or using any substances which give rise to emissions, and eliminate them or handle them at the source

Develop products which have minimal environmental affects

Conserve natural resources (re-design, re-cycle, re-use)

Comply with local legislation and work towards international standards

Share knowledge and if appropriate resources with other companies who generate like waste

Educate employees and the community

11. OFFENCES AND PENALTIES

Any person who:

tampers with or misuses any safety equipment installed or provided to any person by an employer or used;

fails to use any safety equipment at a workplace or in the course of his employment or in connection with the use of plant or machinery, which was provided to him by an employer or such a user;

wilfully or recklessly does anything at a workplace or in connection with the use of plant or machinery which threatens the health or safety of any person

shall be guilty of an offence and on conviction be liable to a fine up to R50 000 or to imprisonment for up to one year or both.

Any employer who does or omits to do an act, thereby causing any person to be injured at a workplace, or, in the case of a person employed by him, to be injured at any place in the course of his employment, or any user who does or omits to do an act in connection with the use of plant or machinery, thereby causing any person to be injured, shall be guilty of an offence if that employer or user would in respect of that act or omission caused the death of the person, irrespective of whether or not the injury could have led to the death of the person, and on conviction be liable to a fine up to R100 000 or to imprisonment for up to two years, or both.

PROCEDURE WHEN HEALTH AND SAFETY IS ENDANGERED

WORKER HAS REASON TO BELIEVE WORK IS LIKELY TO ENDANGER HIMSELF OR ANOTHER PERSON

SUPERVISOR

Investigates forthwith in presence of the worker and an H & S Committee member

WORKER

Promptly reports circumstance to supervisor, remains in safe place

Agreement and/or resolution

DISAGREEMENT:

Worker continues to refuse:

Worker has reasonable grounds to believe work still likely to endanger himself or another worker

RETURN TO WORK

SUPERVISOR:

Notifies plant risk control manager

Disputed equipment or workplace not to be used pending investigation and decision

WORKER

Remains in safe place unless assigned to reasonable alternative work or given other directions pending investigation and decision

PLANT RISK CONTROL MANAGER:

Investigates in presence of employee, supervisor and employee representative

RISK CONTROL

MANAGER

Gives decision to employee and supervisor as soon as practicable

CORRECT PROBLEM

RETURN TO WORK

SAFETY, HEALTH AND ENVIRONMENTAL ATTENDANCE REGISTER

Employee Name:___________________________Company Number:______________________________

Occupation:_______________________________Business Unit:__________________________________

ITEMS COVERED DURING INDUCTION

EMPLOYEE INITIAL

ITEMS COVERED DURING INDUCTION

EMPLOYEE INITIAL

Introduction to the Occupational Health and Safety Act

Know your QFC (Quality Focus Centre)

Know the duties of the Employers to the employees

Know your fire equipment

Know the duties of the employees at work

How to report a fire

Know your Health and Safety Representatives

Environmental policy

Know the functions of the Health and Safety Representatives

Clock in/out procedure

Know your Health and Safety Committee

Know the danger areas (noise zones, etc.)

Know the functions of the Health and Safety Committee

Know the area of smoking / fire requirements

Know the five practical steps to workplace risk assessment

Understand all signs and notices

Know your written Health and Safety work procedures

Know your information boards

Know the definition of an incident / accident

Understand your colour coding

Understand the eleven points of unsafe practices

Understand good housekeeping

Understand the eleven points of unsafe conditions

How to obtain Personal Protective Equipment

Know your first aider

How to use and maintain Personal Protective Equipment

How to report an incident / accident (Ref to duties of employee)

Understand the offences and penalties

Compensation for injuries

Understand T.Q.M. grading board

Know your fire team members

Use of refuse bins

Know your fire prevention programme

Understand equipment inspection

Know your emergency evacuation procedure

Lock-outs and machine guarding

PLANNED JOB OBSERVATION

MONDI CARTONBOARD

Department: ______________________Date: ________________________

Task: _______________________________________________________________

Observer: ___________________________________________________________

Employee Name: _____________________________________________________

REASON FOR JOB OBSERVATION

New worker

Accident repeater

Ergonomic factor

Risk taker

Unusual job

Environmental

Poor performer

High risk job

TYPE OF DEVIATION

FULL DESCRIPTION

ACTION TAKEN

RECOMMENDATIONS

Transfer employee

Induction training

Discipline

Health and Safety Training

Provide Protection

Environmental Impairment Programme

Training on safe work procedures

SIGNATURE OF SUPERVISOR________________________DATE:_________________

SIGNATURE OF EMPLOYEE:_________________________DATE:_________________

INDUCTION QUESTIONNAIRE

Name: _____________________________________________________ Coy no: ________

1. What is the law that governs the health and safety of the workplace?

__________________________________________________________________________

2. What are the law regarding health and safety in connection with machinery

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

3. How are you responsible for the safety of others at the workplace?

____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

4. What are the consequences of any person if injured while ignoring or deviated from the set health and safety standard?

____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

5. What is the definition of the word safety?

____________________________________________________________________________________________________________________________________________________

6. Whose responsibility is safety?

____________________________________________________________________________________________________________________________________________________

7. What is every employees responsibility with regard to unsafe practices or conditions?

______________________________________________________________________________________________________________________________________________________________________________________________________________________________

8. When should an incident / accident be reported?

____________________________________________________________________________________________________________________________________________________

9. Who are the Safety, Health and Environmental Representative of your department?

__________________________________________________________________________

10. What is the function of the Safety, Health and Environmental Representative?

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

11. What is the lock out procedure?

____________________________________________________________________________________________________________________________________________________

12. What is the purpose of the lock out procedure?

____________________________________________________________________________________________________________________________________________________

13. Who is authorised to isolate / de-isolate electrical driven machinery?

____________________________________________________________________________________________________________________________________________________

14. What is the equipment in the plant of which an operating license is required?

__________________________________________________________________________

15. What should you do when observing fire or bomb threat?

____________________________________________________________________________________________________________________________________________________

16. What should you do on hearing a fire alarm?

______________________________________________________________________________________________________________________________________________________________________________________________________________________________

17. What type of fire extinguisher should be used to extinguish fire when electrical equipment is involved?

____________________________________________________________________________________________________________________________________________________

18. Briefly explain the term Multi-skilled

____________________________________________________________________________________________________________________________________________________

19. Name at least four places where smoking is strictly prohibited

(a) _______________________________________________________________________

(b) _______________________________________________________________________

(c) _______________________________________________________________________

(d) _______________________________________________________________________

20. Briefly explain the term Housekeeping

________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

21. What do the following signs signify?

_______________________ _________________________

________________________________________________

_________________________________________________

Signature: __________________________________Date: ____/____/________

WORKSHOP 1

We have seen what the general duties of employers, the general duties of employees and the duties of employers towards their Health and Safety Representative are. List five general duties of employers and five general duties of employees and then discuss briefly how the health and safety standard in the workplace will improve if both parties conform to these duties laid upon them.

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

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__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

__________________________________________________________________________

Environmental care and Waste disposal

Use of tools and Tool Care

Hand Tools - Pliers and Wrenches

General

Use tools for their intended purpose. Don't use pliers as wrenches. Don't use wrenches as hammers.

Wherever possible, don't expose tools to extremes of heat and cold. Metal will lose its temper and get brittle.

Don't extend the handles of tools with sleeves or cheater bars for more leverage and power.

Don't mistake cushion grips with insulated handles. Cushion grips are for comfort only. Insulated handles are for electrical shock protection.

Don't hammer on the handles of wrenches or pliers to gain more force. The tool could bend, break, or fly off and hit you or someone else.

Pliers

Use pliers with enough space between the handles to keep palm and fingers from being pinched.

Pull on pliers - don't push.

Oil regularly. All it takes is a drop of oil on the hinge.

Cut at right angles. Don't rock cutting edges from side to side or bend wire back and forth. That means your pliers are too small or too dull for the job.

Don't use pliers to turn nuts and bolts. The jaws will slip and damage corners and edges of nuts and bolt heads.

Wrenches

Replace damaged wrenches. Straightening a bent wrench only weakens it.

Pull on a wrench - don't push.

Be prepared in case the wrench slips. Make sure your footing is solid, your stance balanced and your hands clear.

With adjustable wrenches, put pressure on the permanent jaw, not the movable jaw.

Use the right wrench for the job. Don't use pipe wrenches on nuts or bolts. Don't use adjustable wrenches on pipe.

On adjustable wrenches, inspect knurl, jaw and pin for wear.

Safe Work Practices

Safe work practices are ways of controlling hazards and doing jobs with a minimum of risk to people and property. To reduce risks, an organization must have a set of safe work practices. These must be developed to fit the particular company.

Management must understand and fully endorse these safe work practices, and ensure that:

safe work practices are in writing

all employees understand the safe work practices that apply to them

all equipment and management support to permit compliance are available

supervisors ensure that all safe work practices are followed

safe work practices are reviewed annually and recorded

Use of Portable Grinders

Abrasive wheels can cause severe injury. Proper storage, use and maintenance of wheels must be observed.

Familiarize yourself with the grinder operation before starting work.

Ensure proper guards are in place and that safety glasses, face shields, gloves