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Machine Guarding for Plastic Sheet and Roll Stock Extrusion OSHA 10-Hour Outreach Training Program for the Plastics Processing Industry A Presentation.

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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:

1 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

2 (Screen Capture of Website)

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4 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

5 (Screen Capture of Website)

6 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

7 Types of Injuries Fatalities Amputations Avulsions Fractures Burns Cuts and bruises Sprains and strains Electric shock

8 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

9 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

10 Schematic of Extruder

11 Schematic of Extrusion Process

12 Risk Areas Feed Tubes Roll Stack Trim Knives Pull/Nip Rolls Shear Winder Grinder

13 Feed Tubes

14 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

15 Roll Stack

16 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

17 Trim Knives trim knife pivoting blade guard

18 Trim Knives

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20 Trim Knife Guarding

21 Trim Knife Blade Disposal

22 Pull-Roll Nips Emergency stop pull cord Sturdy metal mesh in guard

23 Shear

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25 Winder

26 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

27 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

28 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.

29 Abrasive Wheel Machinery The distance between the wheel periphery and the adjustable tongue must never exceed 1/4-inch.

30 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

31 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

32 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

33 Interlocked Guard Electrical interlock switch Emergency stop pull cable

34 Electrical Interlock Operation

35 Fixed Barrier Guards Prevent contact with the hazard Yellow fixed guard

36 Fixed Barrier Guards Guard over moving machine components Wing guards

37 Fixed Barrier Guards

38 Presence Sensing Devices Safety mat Light curtain

39 Presence Sensing Devices Safety Mat

40 Safety Guards and Devices Light Curtain

41 How to Protect Yourself Recognize the hazards in the job you are doing Understand the requirements for guarding machines Implement guarding solutions

42 Emergency Stop Button Know: Where they are located What they control When to use them

43 Emergency Stop Cable Know: –Where they are located –What they control –When to use them

44 Signs and Warnings

45 Colors used with Safety Signs have meaning! DANGER White Lettering/Red Background WARNING Black Lettering/Orange Background CAUTION Black Lettering/Yellow Background

46 High Voltage

47 Rotating Screw

48 High Temperature

49 High Pressure

50 Crushing Fingers

51 Amputated Fingers

52 References for Extrusion Safety ANSI B11.TR Risk Assessment and Risk Reduction - A Guide to Estimate, Evaluate and Reduce Risks Associated with Machine Tools ANSI B Performance Criteria for Safeguarding ANSI/SPI B Plastics Machinery - Plastics Extrusion Machines - Requirements for the Manufacture, Care and Use ANSI/SPI B Plastic Film and Sheet Winding Machinery - Manufacture, Care, and Use ANSI/SPI B Plastic Sheet Production Machinery - Manufacture, Care and Use ANSI Standards are available at the following web site: SPI Guide to Extruded Plastic Sheet Products,

53 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.

54 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 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.

55 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

56 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

57 Do you have any Questions?


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