QPR- RHT- 018

MACHINERY SAFETY
Rev. A0
Date 02.03.2006

DOCUMENT CHANGE HISTORY

Issue Issue Page Approved

Doc. No. Revision Description
No. Date No. by

QPR RHT - 018 A0 02.03.2006 New Document All

Remarks :
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CONTENTS

Page No.
1.0 Objectives ----------------------------- 2
2.0 Scope ----------------------------- 2
3.0 Policy/Management Intent ----------------------------- 2
4.0 Related Documents ----------------------------- 2
5.0 Definitions ----------------------------- 2

6.0 Machinery Hazards and Safeguarding ----------------------------- 3

6.1 Identification of Hazards 5
6.2 Elimination or Reduction of Hazards 5
6.3 Use of Safeguards 6
6.4 Safe Working Practices and Training 8
6.5 Machinery Maintenance and Repair 9
6.6 Personal Protective Equipments 10
6.7 General Requirements 11
7.0 Responsibilities -----------------------------
7.1 Operator 16
7.2 Work Supervisor 17
7.3 Sectional Head / Manager 17
7.4 Safety Section 18
8.0 Attachments -----------------------------
8.1 Machinery Safety Checklist 19
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1.0 OBJECTIVES

To ensure that all the machineries are used and maintained correctly to reduce the
risk of accident or damage to health and to meet the RLC HSE requirements.

2.0 SCOPE

This procedure shall apply to all the machineries and equipments used and
installed within Ras Laffan Industrial City common areas and RLC Contractors
work sites.

3.0 POLICY/ MANAGEMENT INTENT

Ras Laffan Industrial City shall develop an effective machinery safety program in
order to reduce the potential for serious injuries and to improve efficiency,
productivity and moral. A comprehensive machinery safety effort is an essential
part of RLC HSE Management System.

All machinery must be securely guarded to prevent access to dangerous parts to

protect the employees from potential injuries.

4.0 RELATED DOCUMENTS

QPR-RHT- 001 RLC Health, Safety and Environmental Requirements

PD 5304: 2000 Safety of Machinery

QPR- RHT- 008 Job Safety Analysis Procedure

QP-REG-S-001 Safety Regulations for Contractors

Health and Safety At Work Act 1974

Provision and use of work equipment Regulations 1998

Management of Health and Safety at Work Regulations 1999

OHSAS 18001

5.0 DEFINITIONS

Machinery An assembly of linked parts or components, at least one

of which moves, with the appropriate machine actuators,
control and power circuits, etc., joined together for a
specific application, in particular for the processing,
treatment, moving or packaging of a material.

Hazard A source of possible injury or damage to health.

Hazardous Situation A situation in which a worker is exposed to hazard

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Risk A combination of the probability and the degree of the

possible injury or damage to health in a hazardous
situation.

Danger Zone Any zone within and/or around machinery in which a

person is exposed to risk of injury or damage to health.

Guard A part of machinery specially used to provide protection

by means of a physical barrier that prevents entry of any
body part of the operator into the operating machine.

Safeguarding safety measures consisting of the use of specific

technical means called safeguards (guards, safety
devices), to protect persons from hazards which cannot
be reasonably removed or sufficiently limited by design

In Running Nip Points Formed whenever two or more parallel shafts, whether in
contact or apart, rotate in opposite directions

Interlock A safety device that interconnects a guard with the

control system or the power system of the machinery.

Point of Operation That part of the machine at which blanking, boring,

cutting, shaping, etc., is accomplished on the stock.

Prime Mover Means an engine, motor or other appliance that

provides mechanical energy derived from steam, water,
wind, electricity, gas, gaseous products or any other
source and includes any device which converts stored or
potential energy into movement or mechanical energy.

Safety Device A device other than a guard that eliminates or reduces

risk, alone or associated with a guard.

Safe Work Practice A safe system of work, i.e. a method of working that
eliminates or reduces the risk of injury.

Shall Signifies the mandatory requirement

Should Signifies the recommended or optional requirement

6.0 MACHINERY HAZARDS AND SAFEGUARDING

Moving machine parts have the potential for causing severe workplace injuries,
such as crushed hands and arms, severed fingers, amputations, burns and
blindness etc. The absence of proper safeguarding of machinery, poor design or
poor maintenance of machinery, inadequate or inappropriate work processes and
lack of training are some key causes of such injuries to employees. Safeguards

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are essential for protecting employees from these needless and preventable
injuries.

Any machine part, function or process that may cause injury must be safeguarded.
Where the operation of a machine or accidental contact with it can injure the
operator or others in the vicinity, the hazard must be either eliminated or
controlled.

Machines are potentially hazardous for a number of reasons. They almost always
include moving parts that may accidentally come into contact with a worker's body.
Many incorporate other hazards, such as hydraulic and pneumatic systems,
electrical circuits, hot exhausts or surfaces and toxic chemicals.

The hazards posed by most types of moving machinery are located at two key
hazard points:

The point of operation: that point where work is performed on the material,
such as cutting, shaping, boring or forming of stock.

Power transmission apparatus: all components of the mechanical system

which transmit energy to the part of the machine performing the work. These
components include flywheels, pulleys, belts, connecting rods, couplings,
cams, spindles, chains, cranks, and gears.

A wide variety of mechanical motions and actions may present hazards to the
worker. These can include the movement of rotating members, reciprocating arms,
moving belts, meshing gears, cutting teeth, and any parts that impact or shear.
Whether they occur at the point of operation or during power transmission, these
machine hazards involve three kinds of motion:
- rotating,
- reciprocating and
- transverse motion.

Besides the mechanical hazards, machinery may present variety of other hazards.
All power sources for machinery are potential sources of danger. When using
electrically powered or controlled machines, for instance, the equipment as well as
the electrical system itself must be properly grounded. Replacing frayed, exposed
or old wiring will also help to protect the operator and others from electrical shocks
or electrocution. High pressure systems need careful inspection and maintenance
to prevent possible failure from pulsation, vibration or leaks. Such a failure could
cause explosions or flying objects.

Machines often produce noise (unwanted sound), and this can result in a number
of hazards to workers. Not only can it startle and disrupt concentration, but it can
interfere with communications, thus hindering the workers safe job performance.
Excessive noise may result into a range of harmful health effects, from hearing
loss and aural pain to nausea, fatigue, reduced muscle control and emotional
disturbances. Engineering controls, such as the use of sound-dampening
materials, as well as less sophisticated hearing protection, such as ear plugs and

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muffs, must be exercised in controlling the harmful effects of noise. Vibration, a

related hazard that can cause noise and thus result in fatigue and illness for the
worker, may be avoided if machines are properly aligned, supported and, if
necessary, anchored.

Because some machines require the use of cutting fluids, coolants and other
potentially harmful substances, operators, maintenance workers and others in the
vicinity may need protection. These substances can cause ailments ranging from
dermatitis to serious illnesses and disease. Specially constructed safeguards,
ventilation, and protective equipment and clothing are possible temporary solutions
to the problem of machinery-related chemical hazards until those hazards can be
better controlled or eliminated from the workplace.

6.1 IDENTIFICATION OF HAZARD(S)

The techniques used to assess machine hazards are similar to those used for
other workplace hazards. The first line of defense is the visual inspection of the
machine before it is started and every time it is operated. The workplace
inspection, conducted regularly, is another important assessment tool. Every
machine in the workplace must be inspected periodically so that its hazards can be
evaluated and controlled.

Workplace inspections must be performed regularly and must not be rushed. An

inspection plan ensures that every part of the workplace is inspected periodically.
Machine guarding should be treated as a separate inspection item. Referring to a
list of machines and their controls, each machine should be observed and its
hazards analyzed. The focus should be on identifying unguarded areas as well as
assessing the effectiveness of existing guards and safety devices.

Discussions with operators are an important and effective way of assessing

machine hazards. Their experience reflects safety factors, as well as flexibility and
convenience of operation. Hazard controls work best when everyone affected has
a voice in making improvements and believes that the systems used are the most
appropriate and effective possible.

A checklist (as per attachment 8.1) can be a useful tool to ensure that every
aspect of each machine is considered. Checklists are only effective, though, when
they are customized to account for the unique conditions of each workplace. Each
component of an operation can be separately evaluated, as well as the entire work
cycle.

Once the hazards are identified, an assessment of risks associated with the
hazards must be made. A separate risk assessment must be conducted for each
machine and any associated system of work used with that machine.

Risk assessment seeks to prioritize identified hazards so that effort can be

directed to eliminate or control risks that have a high potential to cause harm.
Identified hazards must be assessed to determine their real potential to cause
injury. Consider the likelihood of the hazard causing an injury (probability), and
how severe the injury could be (consequence).

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6.2 ELIMINATION OR REDUCTION OF HAZARD (S)

Where an assessment identifies a requirement to control a risk to health and

safety, that risk must be eliminated or, where it cannot be eliminated, minimised.

Appropriate control measures must be put in place to eliminate the risk or where it
is not practical to do so, the identified risk must be minimised. Control measures
must be chosen from the highest possible level in the following hierarchy:
LEVEL 1: Eliminate the risk
LEVEL 2: Minimise the risk by one or a combination of:
- substitution of a less hazardous machine
- modify the design of the machine
- isolation of the machinery
LEVEL 3: Where risk not minimised:
- introduction of administrative controls
- appropriate personal protective equipment

Many standard devices for controlling machine hazards as well as a variety of

barriers, enclosures and tools are intended to control worker exposure to machine
hazards. Machine guards and other safety devices prevent human contact with
hazard points during the normal operation of the machine. Control devices may be
used to prevent the operation of the machine while a worker is exposed. In
general, these devices are forms of control along the path from the hazard to the
worker.

Specific control devices are intended to prevent access to moving parts while they
are in motion, prevent parts from moving while the worker is in a danger zone, or
contain fragments of particles thrown off by the process or pieces of broken
machinery should the machine itself break.

Control measures adopted should be monitored, on a regular basis, to ensure their

effectiveness.

6.3 USE OF SAFEGUARDS

There are many ways to safeguard machinery. The type of operation, the size
or shape of stock, the method of handling, the physical layout of the work
area, the type of material, and production requirements or limitations will help
to determine the appropriate safeguarding for the individual machine.

All the safeguards must meet the following minimum requirements:

Prevent Contact

The safeguard must prevent hands, arms or any other part of a workers body
from making contact with dangerous moving parts. A good safeguard system

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eliminates the possibility of the operator or another worker placing his or her
hands near hazardous moving parts.

Be Secured to the Machine

Workers should not be able to remove or tamper easily with the safeguard,
because a safeguard that can easily be made ineffective is no safeguard at
all. Guards and safety devices should be made of durable material that will
withstand the conditions of normal use. They must be firmly secured to the
machine.

Protect From Falling Objects

The safeguard should ensure that no objects can fall into moving parts. A
small tool that is dropped into a cycling machine could easily become a
projectile that could strike and injure someone.

Not Create New Hazards

A safeguard defeats its own purpose if it creates a hazard of its own, such as
a shear point, a jagged edge or an unfinished surface that can cause a
laceration. The edges of guards, for instance, should be rolled or bolted in
such a way that they eliminate sharp edges.

Not Interfere With Job Performance

Any safeguard that impedes a worker from performing the job quickly and
comfortably might soon be overridden or disregarded. Proper safeguarding
can actually enhance efficiency since it can relieve the workers
apprehensions about injury.

Allow for Safe Lubrication of the Machine

If possible, one should be able to lubricate the machine without removing the
safeguards. Locating oil reservoirs outside the guard, with a line leading to
the lubrication point, will reduce the need for the operator or maintenance
worker to enter the hazardous area.

Despite all the machines having the same basic components, their safeguarding
needs widely differ due to varying physical characteristics and operator
involvement. The following appropriate machine safeguarding method, equipment
or devices must be used to protect the worker who operate and maintain
machinery:

1. Guards
Fixed
Interlocked
Adjustable
Self Adjusting

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2. Devices
Presence Sensing Devices
- Photoelectric (optical)
- Radiofrequency
- Electromechanical
Pullback Devices
Restraint (holdout) Devices
Safety Control Devices
- Safety Trip Controls
- Two hand Controls
- Two hand Trips
Gates

3. Safe by location or position or distance.

4. Potential Feeding and Ejection Methods

- Automatic Feed
- Semi-automatic Feed
- Automatic Ejection
- Semi-automatic Ejection
- Robots

5. Miscellaneous Aids
Awareness Barriers
Protective Shields
Holding fixtures and hand held tools

6.4 SAFE WORKING PRACTICES AND TRAINING

As a part of any comprehensive Machinery Safety Programme, effective and

efficient Safety Practices and Procedures must be established to verify that the
work is being carried out according to the predetermined safe standard operating
procedures to prevent the workers from the hazards of machinery. Regular
inspections verify the state of appropriate, safe physical conditions with effectively
controlled components, process equipment and materials.

Standard Operating Procedures must be developed through the use of Job/Task

Analysis. Owners/Manufacturers manuals recommended procedures are helpful,
especially for high priority processes and critical tasks.

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Besides the provision of efficient and effective guarding, the Safe Working
practices shall include:
Ensuring safe access
A good standard of housekeeping
Provision/display of suitable warning notices
Procedures for emergency isolation and dissipation
Adequate degree of supervision (which generally increases with risk, up to
written procedures and permit to work systems)
Adequate information, instruction and training for operators and supervisors
Effective maintenance (& keeping of records) by competent persons. (NB Safe
working procedures for maintenance and cleaning are required. This will
include effective isolation or locking off, not just switching off).
Machine operators shall receive instructions from nominated trainers (Safety
Officers / Supervisors) in the following:
The hazards associated with particular machines.
How specific guards are fitted, their design purpose and their role in any power
interlock system.
How to use the guards and any specialized tools associated with the
machinery.
Actions to be taken in the event of defective, damaged or missing guards.
Retraining shall be provided whenever there is a change in job assignments, a
change in machines, equipment or processes that a present a new hazard, a
change in the type of guard installed on a given machine or when the Safety
Officer / Supervisor feels that the personnels proficiency in the use of guards is
inadequate.

6.5 MACHINERY MAINTENANCE AND REPAIR

Good maintenance and repair procedures contribute significantly to the safety of

the maintenance crew as well as to that of machine operators. But the variety and
complexity of machines to be serviced, the hazards associated with their power
sources, the special dangers that may be present during machine breakdown, and
the severe time constraints often placed on maintenance personnel all make safe
maintenance and repair work difficult.

Training and aptitude of people assigned to these jobs should make them alert for
the intermittent electrical failure, the worn part, the inappropriate noise, the cracks
or other signs that warn of impending breakage or that a safeguard has been
damaged, altered or removed. Any damage observed or suspected should be
immediately reported to the supervisor; if the condition impairs safe operation, the
machine should be taken out of service for repair. Safeguards that are missing,
altered or damaged should also be reported so that appropriate action can be
taken to ensure against worker injury.

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If possible, machine design should permit routine lubrication and adjustment

without removal of safeguards. But when safeguards must be removed and
machine serviced, the prevailing lockout procedure must be adhered to. The
maintenance and repair crew must never fail to replace the guards before the job
is considered finished and the machine released from lockout.

In situations where the maintenance or repair worker would necessarily be

exposed to electrical elements or hazardous moving machine parts in the
performance of the job, all power sources must be shut off and locked out before
work begins. Warning signs or tags are inadequate insurance against the untimely
energizing of mechanical equipment. Thus, one of the first procedures for the
maintenance person is to disconnect and lock out the machine from its power
sources, whether the source is electrical, mechanical, pneumatic, and hydraulic or
a combination of these. Energy accumulation devices must be bled down.

The following practices shall be observed by personnel performing machinery

maintenance:
a) Appropriate permit to work shall be obtained.
b) Adjustments, repair or cleaning operations, which may be a possible source
of danger, must not be performed until the equipment is isolated from all
sources of power as per prevailing Energy Isolation procedure.
c) Electrical power must be locked off at the switch-gear of any items of
machinery by an authorised person. Machinery electrical isolation shall be
performed in accordance with the work permit systems.
d) Prior to restarting machinery after maintenance, care shall be taken that no
apparatus, tools, rags etc are in position to foul a moving part and that no
person is in a position of danger.

6.6 PERSONAL PROTECTIVE EQUIPMENTS (PPE)

Engineering controls, which control the hazard at the source and do not rely on the
workers behaviour for their effectiveness, offer the best and most reliable means
of safeguarding. Therefore, engineering controls must be the employers first
choice for controlling machinery hazards. But whenever an extra measure of
protection is necessary, operators must wear protective clothing or personal
protective equipment.

Supervisors shall ensure that PPE, as specified in QPR- RHT- 015 , shall be worn
by operators and that such equipment selected shall always be:
appropriate for the particular hazard.
maintained in good condition.
properly stored when not in use to prevent damage or loss.
kept clean, fully functional and sanitary.

Protective clothing is, of course, available for different parts of the body. Hard hats
can protect the head from the impact of bumps and falling objects when the worker
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is handling stock; caps and hair nets can help keep the workers hair from being
caught in machinery. If machinery coolants could splash or if particles could fly into
the operators eyes or face, then face shields, safety goggles, glasses or similar
kinds of protection might be necessary. Hearing protection may be needed when
workers operate noisy machinery. To guard the trunk of the body from cuts or
impacts from heavy or rough-edged stock, there are certain protective coveralls,
jackets, vests, aprons and full-body suits. Workers can protect their hands and
arms from the same kinds of injury with special sleeves and gloves. And safety
shoes and boots, or other acceptable foot guards, can shield the feet against injury
in case the worker needs to handle heavy stock that might drop.

In addition, Supervisor shall advise on the hazards associated with the wearing of
inappropriate personal clothing, jewellery etc. which in themselves, create
additional hazards.

6.7 GENERAL REQUIREMENTS

Appropriate guards within one meter shall be installed on the conveyors and
machines that have moving parts. The guard shall be provided in a space
from the floor or platform to a height of 2.1 meters.

Moving equipment located less than 2.1 meters from the floor or working
platform shall be properly guarded. If the moving part is more than 2.1 meters
above ground level or from the nearest point of access, it may be considered
safe by position and no localized guarding is required. Care shall be taken in
the event that temporary access for maintenance is required.

Machine guards shall be designed so as to eliminate the hazard. They shall

not create hazard of their own and shall be sturdy enough to withstand normal
wear and impact of flying broken parts.

Installation of fixed enclosure guards is preferred. However, if fixed enclosure

cannot be installed then any of the following method may be used as a
guarding protection:
o Presence Sensing Devices.
o Interlocking guards.
o Automatic guards.
o Remote control, placement, feeding, and ejecting.

An interlocking barrier shall be considered when an enclosure guard is not

practicable. The interlocking barrier shall:
o Shut off or disengage the power to prevent the starting of the machine
when the guard is open.
o Guard the danger point before the machine can be operated.
o Keep the guard closed until the dangerous part is at rest, or stop the
machine when the guard is opened.

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Guards shall be affixed to the machine where possible and secured

elsewhere when attachment to the machine is not possible.

Appropriate lockout procedures and devices to prevent movement or rotation

of machines shall be used when guards are removed for repairs or to adjust
the machine.

Whenever possible, use guards provided by the manufacturer and specify

guards when buying new equipment. Make shift guards may give a false
sense of security and make the machine more hazardous.

When access is required for maintenance, repair, etc., the equipment shall be
switched off and, where applicable, isolated from its power source by
disconnection, lock-out, etc., prior to removal of the guards.

All drive belts, chain and sprocket drives, V-belts, shafts, guillotine cutters,
shears, power press, milling machines, power saws, jointers, power tools,
flywheels, cooling fans and any other rotating equipment shall be so guarded
as to prevent a person from making accidental contact with the moving parts.

All guards shall be re-installed prior to the machine being re-energized.

Rings on fingers, bracelets or gloves shall not be worn when operating lathes,
drill, presses or machinery with rotating shafts.

Personnel with long shoulder length hair shall wear a suitable cap or hair
net when operating lathes, drill, conveyors, presses or machinery with rotating
shafts.

Loose clothing and scarves shall not be worn while operating or working near
conveyors and rotary machine that are in operation.

Unless they are of such a size and weight as to render it unnecessary, all
work pieces shall be secured by a vise or clamp before drilling, grinding, etc.

All powered rotating equipment shall be provided with an emergency stop

mechanism. The actuating button, bar or lever shall be easily accessible from
the normal work position. In certain conditions, dual activation by hand or foot
may be necessary.

Additional requirements for Lathe machines

o All chucks and stocks shall be guarded when the lathe is in motion.
o If the work piece protrudes beyond the headstock, it should be surrounded
by barriers to prevent accidental contact.
o Cutting chips shall be removed with a brush or a hook. Do not use hand or
compressed air.
o The shaft of the Lathe machines shall not be stopped by hand.
o Emergency stop button shall be free from obstruction and operating
correctly.
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o Machine shall be stopped before oiling or adjusting.

o Lathe cutting head, rotating or not, shall be covered except at contact
points while stock is being cut.
o Lathes used for turning long pieces of wood held only between the two
centers shall have long curved guards extending over the tops of the
lathes in order to prevent the work pieces from being thrown out if they
become loose.

Additional requirements for Wood Working Machinery

o Hoods that enclose the portion of saw above the table and above the
material being cut shall be provided for Circular saws. The hood shall be
protecting the operator from flying chips and broken saw teeth. The hood
shall be designed so that it automatically adjusts itself to the thickness of
the material being cut and remains in contact with the materials.
o Non-kickback fingers or dogs shall be required on both sides of rip saws to
oppose the thrust or the tendency of the saw to throw material back toward
the operator.
o All portions of a band saw blade shall be guarded except the working
portion of the blade between the bottom of the guide rolls and the table.
Guards shall be required to prevent the operators hands from contacting
in-running rolls at any point.
o Jointers, shapers, and milling machines that are hand fed shall have
guards that prevent the operators hands from coming in contact with the
rotating heads or in-running feed rolls and cover the unused portion of the
head.
o Special hand tools (push sticks, etc.) for placing or removing material shall
be such as to permit easy handling of material without the operator placing
a hand in the danger zone. These tools cannot be used in lieu of required
guarding.
o Drum or disk sanders shall have an exhaust hood or guard enclosing the
entire rotating part except that portion above the table.
o Belt sanders shall have guards which prevent the operators fingers and
hands from contacting the nip points or the unused run of the sanding belt.

Additional requirements for Power Press

o Point of operation guards or devices shall be used on every operation
performed on a mechanical power press.
o A press barrier guard shall be attached to the press frame and interlock
with the press clutch so that the clutch cannot be activated unless the
guard is in place.

Additional requirements for Abrasive Wheels

o Abrasive wheels shall be used only on machines with safety guards except
for the following:

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- Wheels used for internal work is within the work being ground.
- Mounted wheels used in portable operations 5.08 cm. and smaller in
diameter.
o Abrasive wheel safety guards shall cover spindle end nut and flange
projections except:
- Where the work covers the entire side of wheel.
- Machines designed as portable saws.
o Work rests should be provided to support work on machines used for
offhand grinding.
o Grinding wheels, grinding discs, disc cutters and similar devices are only
mounted on the driving unit by properly trained personnel. All personnel
whose duties require them to use such tools should attend training on their
use.
o All such grinding and cutting tools shall be so guarded as to expose only
the minimum surface of the disc or wheel necessary to carry out the work.

Additional requirements for Portable Power Tools

o All portable power driven circular saws with blade diameter of greater than
5.08 cm. shall have guards above and below the base plate. Guards shall
cover the blade to the depth of the teeth. The lower guard shall remain in
contact with the work and when the saw is withdrawn from the work return
automatically and instantly to covering position.
o Portable belt sanders shall have guards that effectively prevent the hands
and fingers of operator from coming in contact with in-running nip points.
o Portable abrasive wheels, buffers, and brushes shall be guarded except
when used for internal work. Maximum guard opening is 180 degrees. The
guard should be positioned so it is between the operator and the wheel so
that pieces of an accidentally broken wheel will be deflected away from the
operator.

Additional requirements for Conveyors

o Conveyors within 2.1 meters of the floor or walkways shall have
crossovers at aisles or passageways.
o Conveyors 2.1 meters or more above the floor that pass over work areas,
aisles, or thoroughfares shall have guards to protect personnel from falling
materials.
o Open hoppers and chutes shall be guarded by standard railings and toe
boards or by some other comparable safety device.
o Emergency stop switches connected by a pull-rope shall be provided on
the sides of the conveyor belts so that the conveyor can be stopped by the
person whose clothes or any part of the body gets entangled in the moving
conveyor.

The chucks and bits of Bench Drills shall be protected by a telescopic guard.
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Personnel using machines shall be made aware of any personal protective

equipment required while using the machine.

Personnel should be trained in lockout and deactivation procedures to be

used when guards are removed from machines.

Personnel shall be trained to replace and secure all guards before returning a
machine to service.

Special training is required for personnel who use or service abrasive wheel
devices.

The following general safety precautions must be taken when operating any
machinery:
o All guards, whether fixed or automatic, must be constantly maintained and
kept in position while machinery is in use.
o Guards must be maintained systematically by competent persons and
defects must be repaired immediately.
o Fixed guards must be checked to ensure that they are securely fastened in
place that no access is possible from any point into the trapping area and
no secondary trap has been formed between the guard itself and any
moving part of the machinery.
o The motor safety switch must be OFF before operator work on a machine.
The safety switch should be locked and tagged off, if the machine should
not be started. This is the only way to prevent an accident if someone
should accidentally brush or press against the starting button or lever.
o No machine should be oiled, cleaned or adjusted while it is in operation
unless specific provisions have been made for this purpose.
o Safety devices should not be by-passed, blocked or tied down.
o The safety interlock should never be used as a starting device.
o Guards are placed at all hazardous points on the machine. They must be
in place when the machinery is in operation.
o If, of necessity, a guard must be removed and the machine power
operated, keep a safe distance. Never attempt a repair or adjustment in an
area that cannot be reached safely.
o Dont make any alterations on your own. Tell your supervisor if you feel a
guard needs changing.
o Only those operating adjustments stated in the machine operation
instructions shall be permitted.
o No machine should be left running unattended unless specifically designed
for that purpose. If the machine should not be operated, be sure to tag and
lock the safety switch OFF.

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o Wait for the machine to stop! Do not try to slow down or brake a moving
machine by hand or with a makeshift device. If there is a problem,
immediately notify your supervisor.
o Before clearing a jam, be sure to turn the safety switch OFF unless there
are other written procedures.
o Always ensure that everyone is clear of the machine before starting.
o Adjusting tools or keys should not be left in places where they can fall,
slide or be thrown into the machine when it is started.
o Only use those machines and equipment for which you have been trained
and authorized.
o Do not wear jewelry, gloves, neckties, long sleeves or loose clothing
around machines. Hair should not be loose or straggly. Revolving shafts
can catch onto these. Extreme caution is always necessary around
running machinery.
o Machines should always be clean and free of rags, tools or other devices.
The floor around the machine must be clean and dry to avoid stumbling,
slipping or bumping.
o Use the proper brush, hook or tool to remove residue such as chips or
shavings. Never use your hands or an air hose.
o Transparent guards must be clean at all times.
o Do not use pins, projecting set screws, etc. on rotating parts unless
properly guarded.
o Use special tools such as pliers, push sticks, hooks, etc. Keep fingers and
hands clear of operating surfaces.
o Immediately report all hazards to your supervisor.

7.0 RESPONSIBILITIES

7.1 OPERATOR

Machine Operator shall:

Operate or work on only those machinery for which he is trained and/or

authorised.

Check the machinery they use to ensure that it is in perfect working order.

Report immediately any defects noted to Supervisor

Use any safety devices, guards, appliances, protective devices and any other
methods used to make the machinery safe.

Never do anything likely to endanger themselves or others.

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Never remove any guards and / or bypass the safety devices of the
machinery while working on it.

Always follow the standard operating procedures

Use appropriate personal protective equipments.

Immediately stop the machinery or job when there is a possibility of any

hazardous condition and inform supervisor.

7.2 WORK SUPERVISOR

The Work Supervisor shall:

take all practical steps to ensure that people in the place of work and the
vicinity are not harmed by any hazards that are or arises in the place of work.

ensure that all the workers are suitably trained and work instructions properly
given prior to the operation of any machinery.

conduct the inspection of work areas and machinery therein to identify any
hazards associated with the machinery.

ensure that procedure is established for carrying out the cleaning,

maintenance or repair of all the machinery in a safe manner.

ensure that only employee who has been adequately trained in the purpose,
carry out the cleaning, maintenance or repair.

ensure that while at work employees are not exposed to hazards arising out
of the arrangement, disposal, manipulation, processing or use of machinery in
their work place.

ensure that all the machinery installed, adjusted, used, cleaned, maintained,
repaired in accordance with the manufactures instructions and as per the
prevailing work procedures.

ensure the use of proper PPE by the workers.

Immediately stop the machinery or job when there is a possibility of any

hazardous condition.

7.3 SECTIONAL HEAD / MANAGER

The Sectional Head / Manager shall be responsible for:

Safety of all the workers

Identifying all the hazards associated with the use and/or operation of
machinery.

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Implementation of all the necessary required controls measures for the safe
operation of machinery.

Training of the employees

Development of appropriate Safe Operating Procedures for the machinery or

processes.

7.4 SAFETY SECTION

RLC Safety Section Representative shall:

Conduct regular inspection of machinery.

Ensure that hazards associated with the use and/or operation of the
machinery identified and adequate control measures taken.

Ensure that only trained, experienced and qualified operators are working with
machinery.

Ensure that Safe Working practices are strictly adhered to.

Ensure the use of appropriate PPEs by the workers.

8.0 ATTACHMENTS

8.1 CHECKLIST MACHINERY SAFETY

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Date 02.03.2006
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Attachment 8.1

MACHINERY SAFETY CHECKLIST

Area : __ __ __ __ __ __ __ __ __ __ __ Date of Inspection: __ __ __ __ __ __ _ _

Location : __ __ __ __ __ __ __ __ __ _ Inspected By : __ __ __ __ __ __ __ __ __

CRITERIA YES NO COMMENTS

ALL SAFEGUARDS
Do the safeguards provided meet the standard
requirements?
Do the safeguards prevent workers hands, arms and
other body parts from making contact with dangerous
moving parts?
Are the safeguards firmly secured and not easily
removable?
Do the safeguards ensure that no objects will fall into
the moving parts?
Do the safeguards permit safe, comfortable and
relatively easy operation of the machine?
Can the machine be oiled without removing the
safeguard?
Is there a system for shutting down the machinery
before safeguards are removed?
Can the existing safeguards be improved?
MECHANICAL HAZARDS
Is there a point-of-operation safeguard provided for the
machine?
Does it keep the operators hands, fingers and body
out of the danger area?
Is there evidence that the safeguards have been
tampered with or removed?
Could you suggest a more practical, effective
safeguard?
Could changes be made on the machine to eliminate
the point-of-operation hazard entirely?
Are there any unguarded gears, sprockets, pulleys or
fly-wheels on the apparatus?
Are there any exposed belts or chain drives?
Are there any exposed set screws, key ways or
collars?
Are starting and stopping controls within easy reach of
the operator?

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Date 02.03.2006
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If there is more than one operator, are separate

controls provided?
Are safeguards provided for all hazardous moving
parts of the machine, including auxiliary parts?

NON-MECHANICAL HAZARDS
Have appropriate measures been taken to safeguard
workers against noise hazards?
Have special guards, enclosures or personal protective
equipment been provided, where necessary, to protect
workers from exposure to harmful substances used in
machine operation?

ELECTRICAL HAZARDS
Is the machine installed in accordance National
Electrical Code requirements?
Are there loose conduit fittings?
Is the machine properly grounded?
Is the power supply correctly fused and protected?
Do workers occasionally receive minor shocks while
operating any of the machines?

TRAINING
Do operators and maintenance workers have the
necessary training in how to use the safeguards and
why?
Have operators and maintenance workers been
trained in where the safeguards are located, how they
provide protection, and what hazards they protect
against?
Have operators and maintenance workers been
trained in how and under what circumstances guards
can be removed?
Have workers been trained in the procedures to follow
if they notice guards that are damaged, missing or
inadequate?

PROTECTIVE EQUIPMENTS AND PROPER CLOTHING

Is protective equipment required?

If protective equipment is required, is it appropriate for
the job, in good condition, kept clean and sanitary, and
stored carefully when not in use?
Is the operator dressed safely for the job (that is, no
loose-fitting clothing or jewelry)?

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Date 02.03.2006
Page No. 21

MACHINERY MAINTENANCE AND REPAIR

Have maintenance workers received up-to-date
instruction on the machinery they service?
Do maintenance workers lock out the machine from its
power sources before beginning repairs?
Where several maintenance persons work on the
same machine, are multiple lockout devices used?
Do maintenance persons use appropriate and safe
equipment in their repair work?
Is the maintenance equipment itself properly guarded?
MISCELLANEOUS ITEMS

Are emergency stop buttons, wires or bars provided?

Are the emergency stops clearly marked and painted
red?
Are there warning labels or markings to show
hazardous areas?
Are the warning labels or markings appropriately
identified by yellow, yellow and black, or orange
colors?

ADDITIONAL COMMENTS / REMARKS:

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QFM- RHT- 018 - 001 Rev A0 Jan 06

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