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Machine Guarding for Injection Molding Machines The Society of the Plastics Industry, Inc. A Presentation of the SPI-OSHA Alliance.

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Presentation on theme: "Machine Guarding for Injection Molding Machines The Society of the Plastics Industry, Inc. A Presentation of the SPI-OSHA Alliance."— Presentation transcript:

1 Machine Guarding for Injection Molding Machines The Society of the Plastics Industry, Inc. A Presentation of the SPI-OSHA Alliance

2 The Society of the Plastics Industry, Inc. (Screen Capture of Website)

3 The Society of the Plastics Industry, Inc. (Screen Capture of Website)

4 The Society of the Plastics Industry, Inc. Course Objectives Identify the types of injuries that can occur while operating injection molding machines Describe the possible causes of these injuries Identify ways to safely operate injection molding machines Recognize the importance of a total safety and health approach

5 The Society of the Plastics Industry, Inc. (Screen Capture of Website)

6 The Society of the Plastics Industry, Inc. Reasons to Focus on Injuries in the Injection Molding Process High injury/illness rates OSHA citations National Emphasis Program Site-Specific Targeting High workers' compensation costs

7 The Society of the Plastics Industry, Inc. Types of Injuries Fatalities Amputations Avulsions Fractures Cuts and bruises Sprains and strains Burns Electric shock

8 The Society of the Plastics Industry, Inc. Some Causes of Injuries Reaching around, under, over or through guards into hazardous areas Removing or bypassing guards Reaching into equipment to remove stuck or jammed material Not using LOTO procedures Machine/equipment malfunctions

9 The Society of the Plastics Industry, Inc. Causes of Injuries (cont’d) Lack of recognition of job hazards Lack of familiarity with the equipment Inadequate training, comprehension, or both Operating machines with missing or inoperable guards and improper or inadequate machine maintenance

10 The Society of the Plastics Industry, Inc. Injection Molding Machinery Horizontal injection molding machine (HIMM) Vertical injection molding machine (VIMM)

11 The Society of the Plastics Industry, Inc. Vertical Injection Molding Machines VIMMs

12 The Society of the Plastics Industry, Inc. VIMMs Combinations of vertical and horizontal clamp and injection configurations of machines Regardless of the configuration of the machine, basic machine guarding and good safe work practices must be applied –Point of operation –Other moving machine parts

13 The Society of the Plastics Industry, Inc. VIMMs: Unique Hazards and Issues Gravity Plastic splatter/missing insert Flying inserts Unexpected bystander interventions

14 The Society of the Plastics Industry, Inc. Horizontal Injection Molding Machines - HIMMs

15 The Society of the Plastics Industry, Inc. HIMMs: Mechanical Hazards Point of operation Pinch points Nip points Rotating parts

16 The Society of the Plastics Industry, Inc. Potential Injuries from Mechanical Hazards Fatalities Amputations Avulsions Crushing injuries Fractures

17 The Society of the Plastics Industry, Inc. Safety Guards and Devices Types of guards and devices –Movable guards with interlocks –Fixed barrier guards –Presence-sensing devices –Mechanical safety bars Locations of guards –Over/around moving equipment –Around electrical hazards –Around thermal hazards

18 The Society of the Plastics Industry, Inc. Operator’s Gate Equipped with redundant interlocks –Electrical –Hydraulic –Mechanical safety bar Allows the machine to operate only when the gate is closed

19 The Society of the Plastics Industry, Inc. Electrical Interlock Allows the electrical system to operate and close the clamp Actuated when the operator’s gate is opened or closed Prevents clamp from closing when the operator’s gate is open

20 The Society of the Plastics Industry, Inc. Electrical Interlock Operation

21 The Society of the Plastics Industry, Inc. Hydraulic Interlock Actuated by opening or closing the operator’s gate Each hydraulic IMM requires at least one Prevents clamp from closing when the operator’s gate is open

22 The Society of the Plastics Industry, Inc. Hydraulic Interlock Operation

23 The Society of the Plastics Industry, Inc. Before Activation After Activation Hydraulic Interlock Operation

24 The Society of the Plastics Industry, Inc. Prevents clamp from closing when the operator’s gate is open Must have at least one mechanical device on all IMMs Mechanical Safety Device

25 The Society of the Plastics Industry, Inc. Mechanical Safety Device Operation

26 The Society of the Plastics Industry, Inc. Other Guarding Rear guard Top guard Parts discharge guard Feed opening guard Electrical system guards Purge guard Injection barrel cover

27 The Society of the Plastics Industry, Inc. Rear Guard Prevents clamp from closing when interlocked rear guard is opened Should have at least two interlocks Prevents access to mold areas

28 The Society of the Plastics Industry, Inc. Top Guard Required if employees can reach over the top of the machine and into hazardous areas Should be interlocked if movable

29 The Society of the Plastics Industry, Inc. Top Guards (cont’d)

30 The Society of the Plastics Industry, Inc. Parts Discharge Guard Keeps employees from reaching under the operator’s gate and into hazardous areas

31 The Society of the Plastics Industry, Inc. Purge Protection Covers the nozzle and purging area In combination with PPE, minimizes exposure to molten plastic during purging Window allows observation through purge guard, if equipped Should be equipped with an interlock Purge guard Safety window Barrel cover

32 The Society of the Plastics Industry, Inc. Injection Barrel Cover Protects from exposure to high voltage and high temperatures

33 The Society of the Plastics Industry, Inc. 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

34 The Society of the Plastics Industry, Inc. Presence Sensing Devices Safety mat Light curtain

35 The Society of the Plastics Industry, Inc. Safety Guards and Devices Light Curtain

36 The Society of the Plastics Industry, Inc. Presence Sensing Devices Safety Mat

37 The Society of the Plastics Industry, Inc. How to Protect Yourself Recognize the hazards in the job you are doing Understand the requirements for guarding machines Implement guarding solutions

38 The Society of the Plastics Industry, Inc. Emergency Stop Know: Where it is located What it controls When to use it

39 The Society of the Plastics Industry, Inc. Signs and Warnings

40 The Society of the Plastics Industry, Inc. Colors used with Safety Signs have meaning! DANGER White Lettering/Red Background WARNING Black Lettering/Orange Background CAUTION Black Lettering/Yellow Background

41 The Society of the Plastics Industry, Inc. High Voltage

42 The Society of the Plastics Industry, Inc. Rotating Screw

43 The Society of the Plastics Industry, Inc. High Temperature

44 The Society of the Plastics Industry, Inc. High Pressure

45 The Society of the Plastics Industry, Inc. Robots Used to automate repetitive or hazardous tasks Must be guarded to prevent workers from entering or reaching into hazardous areas

46 The Society of the Plastics Industry, Inc. The Robot

47 The Society of the Plastics Industry, Inc. References for Injection Molding Safety ANSI/SPI B Horizontal Injection Molding Machines - Safety Requirements for Manufacture, Care and Use ANSI B Performance Criteria for Safeguarding ANSI Standards are available at the following web site:

48 The Society of the Plastics Industry, Inc. OSHA's Site-Specific Targeting (SST) Program OSHA's Site-Specific Targeting (SST) program selects for inspection individual worksites with the nation's highest lost workday injury and illness rates based on data reported by more than 80,000 employers surveyed by the agency. In April of this year, OSHA announced that its site-specific targeting plan for 2006 would focus on approximately 14,000 worksites with higher than average injury and illness rates for unannounced comprehensive safety and health inspections over the coming year. The 14,000 identified sites are establishments located in stated covered by Federal OSHA. This year's SST program will initially cover worksites that reported 6 or more injuries or illnesses resulting in days away from work, restricted work activity, or job transfer for every 100 full-time workers (known as the DART rate). The average national DART rate in 2004 for private industry was 2.5. Over the past eight years, OSHA has used a site-specific targeting inspection program based on injury and illness data. This year's program stems from the agency's Data Initiative for 2005, which surveyed approximately 80,000 employers to attain their injury and illness numbers for 2004.

49 The Society of the Plastics Industry, Inc. OSHA National Emphasis Program on Amputations On March 26, 2002, the Occupational Safety and Health Administration (OSHA) announced a special national emphasis program aimed at reducing amputations in general industry workplaces. The National Emphasis Program on Amputations targets all types of power presses, including press brakes, saws, shears and slicers. This program is targeted to industries that are considered a high risk for operating equipment that can be very dangerous, as injuries involving these machines are often fatal or result in permanent disability. The plastics processing industry is among the industries under scrutiny for workplace amputations. In keeping with OSHA's mission to identify and reduce or eliminate the workplace incidence of hazards which are causing or are likely to cause amputations, OSHA initiated targeted inspections of workplaces under SIC 3089, Plastics Products, Not Elsewhere Classified. These amputation hazard inspections began in April This is a Federal Emphasis Program. The twenty-four states and two territories which operate their own OSHA programs are encouraged, but not required, to adopt a similar emphasis program. The OSHA directive on this emphasis program is available on OSHA's web site under Regulations and Compliance, subcategory Compliance Directives, No. CPL Under this new initiative, regional and area OSHA offices will conduct outreach programs to identify, reduce and eliminate workplace hazards associated with these machines. Their programs will be conducted in three parts: outreach; targeting and selection; and inspection. Area offices will obtain and use additional data to identify and add establishments where serious injuries or fatalities related to these machines have occurred.

50 The Society of the Plastics Industry, Inc. 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

51 The Society of the Plastics Industry, Inc. Our sincere thanks to: United Southern Industries, Inc. OSHA Regions V & VIII OSHA's Office of Education and Training OSHA’s Salt Lake Technical Center Michigan OSHA The Society of the Plastics Industry, Inc.

52 The Society of the Plastics Industry, Inc. Do you have any Questions?


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