workshop safety

Workshop SafetyYusron Sugiarto, STP, MP, 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

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 minimumIt is needed to reduce workman’s

compensation, insurance rate and all the cost of accidents.

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 required to educate all members regarding the safety principles to avoid accidentsin industry.

OBJECTIVE OF WORKSHOP SAFETY

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 AccidentAn accident with no damage or injury is called near accident.2. TrivialAn accident with very less damage is called trivial.3. Minor AccidentIt is an accident with damage and injury more than trivial.4. Serious AccidentAn accident with heavy damage and lot of injury is called serious accident.5. FatalIt 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


Direct cost of an accident1. 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


Indirect cost of an accident1. 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 society1. 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

Mechanical Causes

Environmental Causes


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.


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.


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.


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 beensured that all their dangerous parts are either enclosed in suitable housings or providedwith suitably designed safety guards in order to eliminate any chances of danger that couldoccur due to exposure of the dangerous parts.All control handles of machines should be carefully located to ensure adequate safety in their operation.

Safety by Construction



Safety by position.







The main principle involved in the method for safety by position is to design the machine insuch a way that the dangerous parts are so located or placed that they are always beyondreach of the operator. It is therefore always advisable that all the dangerous parts of themachine 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

Safety by Position



Safety by position.







Such fixed guards either form an integral part of the machine or are so tightly secured tothem that they are not easily removable.

In all cases, fixed guards are developed to have arobust and rigid construction and they should be so placed that any access to the dangerousparts of the machine is totally prevented from all directions particularly in the runningcondition 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.

Safety by Using Fixed Guards



Safety by position.







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.



Safety by position.







Safety by Using Distance Guards

Distance guard helps to fence the dangerous components of machine such as bars or rails andposition 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 thearea 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.



Safety by position.







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.

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.

Safety by Workplace Layout

The following general types of safety are considered in the workshop1. Safety of self.2. Safety of job.3. Safety of machines tools.

TYPES OF SAFETY

However there are general safety precautions to be adopted while working in any workshop

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

Personal Protective Equipment at WorkHead protection: Includes industrial safety helmets to protect against falling objects or impact with fixed objects; industrial scalp protectors to protect against strikingfixed 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.


Hand protection: Gloves of various design provide protection against a range ofhazards 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.


Protective clothing: Types of clothing used for body protection include coveralls,overalls and aprons to protect against chemicals and other hazardous substances; outfitsto protect against cold, heat and bad weather; and clothing to protect against machinerysuch as chain saws. Types of clothing worn on the body to protect the person includehigh-visibility clothing; life-jackets 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

workshop safety

Documents

cost of accidents

near accident

production loss

trivialan accident

safety principles

safety prec

safety engineers

serious accidentan accident