Presentation on theme: "Machine Guarding for Plastic Sheet and Roll Stock Extrusion OSHA 10-Hour Outreach Training Program for the Plastics Processing Industry A Presentation."— Presentation transcript:
Machine Guarding for Plastic Sheet and Roll Stock Extrusion OSHA 10-Hour Outreach Training Program for the Plastics Processing Industry A Presentation of the SPI-OSHA Alliance
Course Objectives Identify the types of injuries that can occur while operating plastics sheet and roll stock extrusion equipment Describe the possible causes of these injuries Identify ways to safely operate plastic extrusion equipment Recognize the importance of a total safety and health approach
Reasons to Focus on Injuries in the Extrusion Process High injury/illness rates OSHA citations National Emphasis Program on Amputations Site-Specific Targeting High workers compensation costs
Types of Injuries Fatalities Amputations Avulsions Fractures Burns Cuts and bruises Sprains and strains Electric shock
Some Causes of Injuries Reaching around, under, over or through guards into hazardous areas Removing or bypassing guards Inadequate temperature monitoring during cleanup Not using LOTO procedures Machine/equipment malfunctions
Causes of Injuries (cont’d) Lack of recognition of hazards of the job Lack of familiarity with the equipment Inadequate training, comprehension, or both Operating machines with missing or inoperable guards and improper or inadequate machine maintenance Lack of proper PPE Loose clothing around winding equipment
Accident #1 Third-Degree Skin Burns Two employees were cleaning the feed pipe for a line extruder Resin in the feed pipe hardened during shutdown Employee heated the feed pipe to soften the plastic for 30 minutes The employee pulled plastic plug at bottom of feed pipe Hot plastic sprayed out causing 2 nd & 3 rd degree burns
Accident # 2 Fatality Machine operator was threading plastic film through rolls of film extruder line when he got caught between top and bottom rolls Skull fracture and head trauma resulted in his death
Accident #3 Fatality Employee was splicing plastic on new extruder winder rolls to get it started –drawstring on hooded sweatshirt got caught in roll –employee died by asphyxia
Grinder Guarding Guarding by: Enclosure over moving components Anti-kickback flaps in feed throat Proximity guarding – distance from feed chute to rotating knives Proximity Guarding
Abrasive Wheel Machinery Work rests on offhand grinding machines must be kept adjusted closely to the wheel with a maximum opening of 1/8-inch to prevent the work piece or tool from being jammed between the wheel and the rest, which may result in wheel breakage or wheel explosion.
Abrasive Wheel Machinery The distance between the wheel periphery and the adjustable tongue must never exceed 1/4-inch.
Power-Transmission Apparatus Power-transmission apparatus (shafting, flywheels, pulleys, belts, chain drives, etc.) less than 7 feet from the floor or working platform must be guarded. Unguarded belt and pulley
Safety Guards and Devices Types of guards and devices –Movable guards with interlocks –Fixed barrier or proximity guards –Presence-sensing device Locations of guards – Over/around moving equipment – Around electrical hazards – Around thermal hazards – Around cut hazards
Movable Guards with Interlocks Allows the electrical system to operate Actuated when the interlocked guard is closed or opened Prevents machine from operating when the guard is open Electrical Interlock Switch
References for Extrusion Safety ANSI B11.TR3-2000 Risk Assessment and Risk Reduction - A Guide to Estimate, Evaluate and Reduce Risks Associated with Machine Tools ANSI B11.19-2003 Performance Criteria for Safeguarding ANSI/SPI B151.7-1996 Plastics Machinery - Plastics Extrusion Machines - Requirements for the Manufacture, Care and Use ANSI/SPI B151.5-2000 Plastic Film and Sheet Winding Machinery - Manufacture, Care, and Use ANSI/SPI B151.20-1999 Plastic Sheet Production Machinery - Manufacture, Care and Use ANSI Standards are available at the following web site: www.ansi.org SPI Guide to Extruded Plastic Sheet Products, www.plasticsheet.org/Guide/index.htm
OSHA's Site-Specific Targeting (SST) Program OSHA's Site-Specific Targeting (SST) program selects for inspection individual worksites with the nation's highest Days Away from Work Injury and Illness (DAFWII) Case Rate and Days Away, Restricted, or Transferred (DART) Rates. It is based on data reported by more than 80,000 employers surveyed by the agency. See the OSHA Web site for the most current directive and the rates used to target inspections.OSHA Web site In order to verify the reliability of claims by establishments that they have achieved low DART rates, OSHA inspects a certain percentage of employers with low rates.
OSHA National Emphasis Program on Amputations On October 27, 2006, the Occupational Safety and Health Administration (OSHA) revised its national emphasis program aimed at reducing amputations in general industry workplaces. The National Emphasis Program on Amputations targets all types of machinery and equipment that are considered a high risk for causing amputations. The plastics processing industry is among the industries under scrutiny for workplace amputations. The twenty-four states and two territories which operate their own OSHA programs are encouraged, but not required, to adopt a similar emphasis program. State Plan State information is available on OSHA’s Web site. The OSHA directive on this emphasis program is available on OSHA's Web site under Regulations and Compliance, subcategory Compliance Directives, No. CPL 03-00-003.National Emphasis Program on AmputationsState Plan State information Under this initiative, regional and area OSHA offices will continue to conduct outreach; targeting and selection; and inspections. Area offices will obtain and use additional data to identify and add establishments where serious injuries or fatalities related to these machines have occurred.
The Job Safety Analysis Process The Job Safety Analysis (JSA) process is a very effective means of helping reduce incidents, accidents, and injuries in the workplace. It is a multi-step process. Basic Job Steps Potential Hazards Recommended Safe Job Procedures
Summary Injuries can occur while operating plastics sheet and roll stock extrusion equipment Risk areas can be protected by safety guards and devices Protect yourself and operate plastic extrusion equipment safely Recognize the importance of a total safety and health approach