Machine Safety Instructions for an Compliance Factory

Machine Safety

Machine Safety – To protect person(s) working is isolated mechanical, hydraulic, electronic, electrical and or steam / pneumatic operated machinery or equipment or pipelines / fittings…

  • Machine Safety– machines without protective safety device (e.g. eye shields, pulley covers, safety cover, paddle guards on bartack machines, auto placket knitting machines, sewing machines etc.) pulley guards found loose
  • sewing machines without needle guards
  • compressor machines not fenced in and don’t have relevant safety guards (to include any temporary placement of machinery)
  • compressor rooms not closed on all sides and not marked properly
  • pressing machines/pressing wires do not have adequate heat protective covers
  • ironing pipes without heat protection cover
  • steam pipe found wrapped with asbestos cover
  • no records kept for all maintenance checks incl. electrical installations
  • air pressure checked reports not up to date
  • relevant certificates not available and not up to date for all machinery as required by law, such as generators
  • pressure vessel certificates missing for boiler and compressor
  • boiler certificate not up to date
  • temperature higher than normal in some areas e.g. fusing, dining room etc.
  • no fans or other means of cooling provided in dining area, fusing etc.
  • no dining facility/canteen provided (as per law there should be a canteen either with cooked food or snack items for sale)
  • seating facility missing at canteen/dining area
  • sitting capacity of dining area does not offer seating for at least 30% of workforce at any given time (Bangladesh)
  • no hygiene certificate for canteen
  • factory does not have canteen committee with worker’s representatives, with tasks clearly laid out, regular meetings (once a month) and workers not aware of committee and the outcome of their meetings
  • no wash facilities or drinking water provided in dining area
  • drinking water not clean and not sufficient for all areas
  • drinking water not marked as such
  • drinking water test report not available or expired
  • drinking water test report incomplete (needs to include bacteriological, physical and chemical tests)
  • workers collecting drinking water from the toilet area rather than using provided drinking water on the production floor due to insufficient water supply
  • excessive noise from generator affecting workers/security guards
  • no pest control programme established
  • no mats or slippers provided to workers who have to stand on the production floor during winter season
  • boiler operators do not have official competency certificate
  • competency certificate of electrician & generator operator not available
  • electric switchboards open and loose wiring found – No Objection Certificate (NOC) for installation of diesel power generator missing

Lockout purpose:

When working on any machinery or equipment it is essential that all sources of enery are isolated to prevent inadvertent operation of that machinery or equipment which could result in injury to any p0erson working thereon.

In order to ensure the above isolation must b e available on:

  • transformer room
  • substations
  • electrical / distribution panels
  • starting switches of electrically operated machinery
  • staring device of hydraulically operated machinery
  • up stream valves on pipeline of air, water, natural gas, oxygen nitrogen, nitrous oxide, etc.

Main switches should always be accessible.

Procedure:

  • identify the hazard(s) associated with work to be undertaken
  • obtain a permit to work in accordance with element 5.22
  • notify personnel within the area that work is to be carried out on the equipment
  • lockout the equipment
  • place warning  sign (s) on the equipment
  • carry out zero potential test (s)-operate start stop switch at least twice

carry out the work

when work is complete

  • replace guards, tools and parts
  • move tools
  • clean area
  • notify personnel in that area
  • notify supervisor
  • sign off work permit
  • ensure equipment is switched off

Open the lock.

Preparation for installing, this element to sites:

  • carry out lockout survey on all site moving machinery/equipment, use form attached
  • make out an isolation plan to isolate:
  • transformer room
  • substations
  • electrical distribution panels
  • starting switches of electrically operated machinery
  • starting device of hydraulically operated machinery.
  • up stream valves on pipelines of air, water, natural gas, oxygen, nitrogen, nitrous oxide, etc.
  • provide locking system for each identified machinery/equipment.
  • provide a place to keep locks with one key only, the duplicate key to be sealed and kept with the site manager
  • provide a register as per enclosed format to keep record of issues of locks.
  • identify by name the users of the lockout system for each site.
  • train the users of the lockout system

issue the procedure to each user of lockout system on site & keep record of such issue

Notes:

  • Where more than one person is working on the equipment a gang lock must be used
  • in such cases each person will lockout individually and retain the key on person-only that person will remove the lockout, no delegation is allowed.
  • no person who has not been formally trained or issued with a lock is to lockout machinery
  • as an additional safety checks it is recommended where possible to physically disconnect the energy source
  • new equipment must include a lockout facility in the design
  • Safety representatives to include if switches are lockable, checks the locks & register and the procedures if available during their monthly checks and report to the site coordinator.

About Engr. Kh. Mashiur Rahman

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