Summer Intern Project Report

GAP Analysis of various hazardous Machinery in a plant &

Safegaurding these machinery in a way to Protect workers
from Injuries/Amputations.

Submitted by:
Kritarth Srivastav
B.Tech (FSE)
University Of Petroleum & Energy Studies
(Dehradun)
 “ Safety is a Common Sense
But…………………..
Its Not Common to All”

Note: This Report is made with full dedication & by thorough study regarding the current safety issues in
industries with major concern on complex machine related hazards and injuries/accident associated with it. The
objective of this report is to spread awareness among the workers of the industries which is possible through
training and by the knowledge of safety and safe working environment to the workers.
 ACKNOWLEDGEMENT

With the will to attain more practical knowledge in manufacturing Industry, I have
taken efforts in this intern to correlate the theoritical knowledge to Practical.
My Project on GAP analysis of various hazardous machinery in a plant &
Safegaurding these machinery in a way to protect workers from injuries at
Escorts Limited(Farmtrac Division) Faridabad exposed me to the vast field of
industrial safety and gave the me the immense knowledge about various safety
aspects and related techniques but all this would not have been possible without
the help and guidance of Department of Environment,Health & Safety at Escorts
limited.
I am immensely grateful to my guide Mr. Vinod Kumar(Safety Officer) who has
guided me to complete the project and also arranged the industrial visit at the
premisis.
I also indebted to my guide for his generous help in viewing the whole project and
providing constructive guidance and encouragement during the term of this
project.
I would also like to express gratitude towards other members of EHS Deparment
of Escorts limited (FARMTRAC Manufacturing Division) Faridabad for their kind
cooperation & encouragement which helped me in completion of the project.
 DECLARATION

We hereby declare that the work being presented for Summer Internship project
entitled “GAP analysis of various hazardous machinery in a plant & safeguarding
in a way to protect workers from injuries/Amputations” is an authentic record of
work that has been carried out at Escorts Limited (Farmtrac Manufacturing
Division) Faridabad, under the guidance of Mr. Vinod Kumar (Safety Officer), EHS
Department.
The data mentioned in this project was obtained during the genuine work done
and was collected by us. Any other data or information in this report, if collected
or borrowed from outside agency has been duly acknowledged.

Mr. Vinod Kumar

Mentor

Kritarth Srivastav
B.Tech (Fire & Safety Engineering)
3rd Year
Roll no: R260214016
 EXECUTIVE SUMMARY

Today, the growth of an industry depends on its technological advancement.

A large number of machines are used in every industry. Since more and more
machines are being used in industries, hazards of accident have also increased
considerably.
The number of accident due to machinery is nearly one-third of the total
reportable accidents in factories each year.
My Summer Internship project topic is “GAP analysis of various hazardous
machines and safeguarding these machinery in a way to protect workers from
injuries which has a major concern towards the Amputation (Permanent Loss of
body parts such as limb). Amputations are among the most severe and disabling
workplace injuries that often result in permanent disability. It results from the use
and improper care of machines such as saws, presses, conveyors and bending,
rolling & shaping machines as well as from powered and non-powered hand tools,
forklifts & during material handling.
Therefore it becomes necessary that dangerous parts of machinery & work in
process must be guarded so that the workers who operate and maintains the
machines do not get involved in the accidents.
 GLOSSARY

Machinery: Any arrangement of elements having mechanical movements

including complete assemblies such as prime movers, transmission drives,
machines, electric generators, electric motors, rotary convertors and hydraulic
accumulators.

Exposed to Contact: Means that the location of an object is such that a person is
likely to come in contact with it and get injured.

Point of Operation : That part of a working machine at which cutting, shaping,

and forming or any other necessary operation is accomplished, including such
other parts as may offer a hazard to the operator in inserting or manipulating
stock or material.

Machinery Guard - Any barrier or device constructed to prevent a person or his

clothing coming into contact with dangerous parts of machinery. The term guard
is not intended to specify a particular type of safeguard, but implies a prohibition
of access to dangerous part; thus for all practical purposes enclosure, fencing and
guarding may be taken to have the same meaning.

Fixed Guard - A barrier which by the nature of its design and construction
prohibits access to dangerous moving parts of machinery and remains in its
position after installation.

Interlocking Guard - A barrier to prevent access to the dangerous parts except

when those parts are at rest and prevents the machinery from being operated
until the barrier is in enclosed position.
Automatic Guard - A device which operates to remove any part of a person
exposed to danger to a position of safety and functions independently of the
operator.
Trip Guard - A barrier or device arranged so that approach beyond a safe limit
causes machinery to stop before a person can come in contact with the
dangerous parts.
Securely Fastened - Means that the safety device or object referred to shall be so
secured in place that it cannot be moved under normal or reasonably foreseen
conditions or circumstances.
Belt - Includes all power transmission belts, such as flat belts, round belts, V-belts,
etc.
Flywheels - Includes flywheels, balance wheels and flywheel pulleys mounted and
rotating on crankshaft of engine or other shafting.
Gear - A set or train of gears comprising two or more inter-meshing gears
 Tractor

A tractor is an engineering vehicle specially designed to deliver a high tractive

effort (or torque) at slow speeds, for the purposes of hauling a trailer or
machinery used in agriculture or construction.
 CONTENTS

INTRODUCTIOn

 General Information on Industrial Safety

 Machine Safeguarding
 Types of Hazards Associated with machinery

COMPANY PROFILE

 Farmtrac Manufacturing Division

 Plant Overview
 Overview of Tractor Assemblies

Machinery guards & Its types

 Types of Machine Guards & Other Safety Devices

 Primary Safeguarding Methods
 Secondary Safeguarding Methods
 Risk Matrix for Machine Safeguarding

OBJECTIVE

 To identify the dangerous parts of machinery

 To Identify the Method of Safeguarding
 METHODOLOGY

 Through identification of hazardous mechanical motion various

safeguarding methods and other safety devices are suggested for various
machinery used in a plant.

CONCLUSION

REFERENCE
 INTRODUCTION

Industrial Safety
Industrial Safety is primarily a management activity which is concerned with

Reducing
Controlling &
Eliminating hazards from the industries or the industrial units.

Accident: An “Accident” is defined as an unplanned event that results in personal

injury or property damage. A major concern of safety at work is preventing
accidents at work.
Prevention of accidents at work focuses on the causes of accidents
Measurement & Record of Accident
The two main ratios used to measure accident are:

Accident Accident
Frequency Rate Severity Rate

AFR= Number of Injuries x 106

Total Number of Man Hours Worked

ASR= Number of man day lost x 106

Total Number of Man Hours Worked
Causes of Industrial Accident 12

Unsafe Conditions
 a) The Job itself
b) Work schedule
c) Psychological Conditions
d) Machinery & Equipment
(The Project Mainly Focuses on this Subject)

Unsafe Acts
Miscellaneous Causes
Measures to ensure Industrial Safety
1) Safety Policy
2) Safety Committee
3) Safety Engineering
 Guarding of Machinery
 Material Handling Equipment
Forklifts
Hoist
Lifts
Conveyors
 Safety Devices
 Ergonomics
 Plan Maintenance
 General house keeping
4) Safety Education & Training
5) Role of Government

Four E’s of Safety

Engineering: i.e. safety at the design, equipment installation stage
Education: i.e. education of employees in safe practices
Enlistment: i.e. It concerns the attitude of the employees and
management towards the program and its purpose. This necessary arose
the interest of employees in accident prevention and safety consciousness.
Encouragement: i.e. to enforce adherence to safe rules & practices.
Safety Inspection Procedures
Safety Audit: A safety audit subjects each area of a company’s activity to a
systematic critical examination with the objective to minimize loss.
Safety survey: A safety survey is a detailed examination in depth of a
narrower field of activity
Safety Inspection: A routine scheduled inspection of a unit or a department,
which may be carried out by someone (may be a safety representative)
from within the unit, possibly accompanied by the safety advisor. The
inspection would check the maintenance standard.
PPE’S (Personnel Protective Equipment’s)
Some Statistical Data of Industrial Accident Rate Mainly Due to Machinery

Source: Health & Safety Authority

FACTORIES ACT, 1948

Chapter IV Safety under Section 21 (Fencing of Machinery)

According to this Act,
a) Every part of an electric generator, a motor or rotary convertor;
(b) Every part of transmission machinery; And
(c) Every dangerous part of any other machinery; Shall be securely fenced by
Safeguards of a substantial construction which shall be constantly maintained
And kept in position while the parts of machinery they are fencing, are in motion
or in use.
Machine Guarding
Machine safeguarding is the application of safety, engineering, work practices and
administrative controls to prevent the injuries of the employees who operate
machines or who are in the vicinity of the machine operation

Why Machine guarding is Important?

Crushed hands and arms, severed fingers and blindness are some machinery
related injuries that can result from the hazards created by moving machine parts
and the proper use of the safeguard can avoid them.
According to US Bureau of labor Statistics, the injury and illness rate is the
greatest among the full time workers due to the hazards associated with the
moving parts of the machinery than any other hazards associated with the
manufacturing units. Approximately forty-four percent (44%) of all workplace
amputations occurred in the manufacturing sector and the rest occurred across
the construction, agriculture, wholesale and retail trade, and service industries.)
Hazards Associated with the moving parts of Machinery.

Drawing in or Trapping Hazard

Entanglement Hazard

Shearing Hazard

Cutting Hazard

Impact Hazard

Crushing hazard

Stabbing or Puncturing Hazard

Friction & Abrassion Hazard

Drawing in or Trapping Hazard

Injuries can be caused when a part of the body is drawn into a ‘nip-point’, formed
by:
1) In-running nips between two counter-rotating parts, for example meshing
gears, rolling mills, mixing rolls etc.
2) In-running nips between a rotating surface and a tangentially moving surface,
for example a power transmission belt and its pulley, a chain and its chain wheel
etc.
3) running nips between a rotating surface and a tangentially moving surface
where material, for example metal, paper, cable or rope, runs on to a reel, drum
or shaft; and
4) Nips between rotating and fixed parts, which create a shearing, crushing or
abrading action, as in spoked hand-wheels, flywheels and screw conveyors

Illustration: Drawing-in hazards between counter-rotating parts: Solid red arrows: where a part of
body could be drawn into a ‘nip point’. White arrows: movement of machine parts.
Entanglement Hazard
Entanglement involves being caught in a machine by loose items such as clothing,
gloves, ties, jewelry, long hair, cleaning rags, bandages or rough material being
fed into the machine. The types of body contact that may lead to entanglement
include:
Contact with a single rotating surface:

Being caught on projections or in gaps:

Shearing Hazard

Shearing action involves applying power to a slide or knife in order to trim or

shear metal or other materials. Shear points occur where stock is actually
inserted, held and withdrawn.

Parts of the human body can be sheared:

1) Between two machine parts, for example the table of a metal planing machine
(shaper) and its bed, the table and blade of a guillotine or power press, nip points
between connecting rods or links and rotating wheels or between parts that
oscillate; and

2) Between a machine part and a work piece, for example the tool of a broaching
machine and the part
Cutting Hazard
Cutting hazards are present at the point of operation in cutting wood, metal, or
other materials. Examples of mechanisms involving cutting hazards are all kinds of
cutting tools, band and circular saws, boring or drilling machines, planing , milling
machines, water jet cutting, high energy lasers or moving sheet material in a
machine.
Cutting hazards may involve rotating, reciprocating, or transverse motion. The
danger of cutting action exists at the point of operation where finger, arm and
body injuries can occur and where flying chips or scrap material can strike the
head, particularly in the area of the eyes or face. The cutting effect may be
aggravated by the body being unable to move away from the cutter.

Impact hazards
Impact hazards relate to objects that strike the human body, but do not penetrate
it. Examples include the rotating arm of a robot, the reciprocating bed of a metal
planing machine and the pendulum movement of the arms of a wool scouring
machine.
Impact hazards are different to crush hazards although the machines involved
may be the same.
Impact hazards operate against the inertia of the body whereas crush hazards
involve the trapping of the body between two machine parts or between a
machine part and a fixed structure.
Crushing Hazard
Crushing occurs when a part of the body is caught:
1) Between a fixed and moving part of a machine such as the bed and tool of a
power press;
2) Between two moving parts of a machine such as the support arms of a scissor
lift platform; and
3) Between a moving part of a machine and a fixed structure such as a
counterweight and the floor.
Stabbing and puncturing hazards
The human body can be penetrated by:
Flying objects such as:
Parts of a machine, for example a loose tool in a lathe, broken tooling on a press
or the breaking up of an abrasive wheel; and
Material ejected from a machine, for example swarf (fine chips) timber from a
bench saw, a work piece,
Molten metal from a die-casting machine sparks from a welding process, a bolt
from an explosive powered tool or debris thrown by rotary mowers and hedge
cutters. Injection of fluids through the skin can cause tissue damage similar to
crushing; and
Rapidly moving parts of machinery or pieces of material, for example the needle
of a sewing machine, the drill of a drilling machine or the arm of a robot.
Friction and abrasion hazards
Friction burns can be caused by smooth parts operating at high speed. Other
examples of friction or abrasion hazards include the sides of a grinding wheel, the
belt of a belt sanding machine, material running onto a reel or shaft, a conveyor
belt and its drums, and pulleys and fast-moving ropes or belts.
 COMPANY PROFILE

The Escorts group is among India’s leading engineering combination operating in

the high growth sectors of agro-machinery, construction & material handling
equipment, railway equipment and auto components.
Escorts offers a comprehensive range of tractors more than 45 variant starting
from 25 HP to 80 HP. Escorts, Farmtrac & Powertrac are the widely accepted and
preferred brands of tractors from the house of escorts.
Escorts is a leading material handling and construction equipment manufacturer
which includes equipment’s like cranes, loaders, vibratory rollers and forklifts.
Escorts today is the world’s largest pick ‘n’ carry hydraulic mobile crane
Manufacturer.
It has been a major role player in railway equipment’s business in India for nearly
five decades which includes brakes, couplers, shock absorbers, rail fastening
systems, composite brake blocks and vulcanized rubber parts.
In the auto component segment, Escorts is a leading manufacturer of auto
suspension products including shock absorber & telescopic front forks. Over the
years, with continuous development and improvement in manufacturing
technology & design, new reliable products have been introduced.
About Farmtrac Manufacturing Division (Plant 2) Faridabad.
Escorts have played a vital role in the agricultural growth of the India for over six
decades. Having introduced the farm mechanization in the country, Escorts have
been developing solutions to enhance the agricultural productivity and improve
the quality of life in the rural India.
It has launched tractors fitted with 4-cylinder engines that are around 15% more
fuel efficient than most other tractors in the market.
The company has launched the ‘Jai Kisan’ initiative, a unifying platform to
empower the Indian farmer and to make him self- reliant.
The escorts ‘Jai Kisan Series’ focuses on maximizing farmers productivity through
varied needs of the Indian farmers and changing the tractor usage for specialized
applications & usage of modern and heavy duty implements & attachments,
thereby offering wider options for agricultural, infrastructure as well as
specialized applications for land development activities.
Basic Plant Layout.
Tractor over view & Its Power Transmission System

The above figure shows the basic parts of tractor and Its Power Transmission
system consisting of sequence of gears and shaft through which the engine power
is transmitted to the tractor wheels. The system consists of various devices that
cause forward and backward movement of tractor to suit different field condition.
The complete path of power from the engine to the wheels is called power train.
Function of power transmission system:
(i) To transmit power from the engine to the rear wheels of the tractor,
(ii) To make reduced speed available, to rear wheels of the tractor,
(iii) To alter the ratio of wheel speed and engine speed in order to suit the field
conditions

The power transmission system consists of:

(a) Clutch (b) Transmission gears (c) Differential
(d) Final drive (e) Rear axle (f) Rear wheels. Combination of all these components
is responsible for transmission of power.
Types of Guards & Other Safety Devices
Primary Safeguarding Method
There are two ways in which machines can be safeguarded primarily:
 By use of Guards
 By use of some types of safeguarding devices.
Guards provide physical barriers that prevent access to danger areas.
Safeguarding devices either prevent or detect operator contact with the point of
operation or stop potentially hazardous machine motion if any part of an
individual’s body is within the hazardous portion of the machine. Both types of
safeguards need to be properly designed, constructed, installed, used and
maintained in good operating condition to ensure employee protection.
Criteria for Machine Safeguarding
• Prevents employee contact with the hazard area during machine operation.
• Avoids creating additional hazards.
• Is secure, tamper-resistant, and durable.
• Avoids interfering with normal operation of the machine.
• Allows for safe lubrication and maintenance.

Guards
Guards are physical barriers that enclose dangerous machine parts and prevent
employee contact with them. To be effective, guards must be strong and fastened
by any secure method that prevents the guard from being inadvertently dislodged
or removed. Guards typically are designed with screws, bolts and lock fasteners
and usually a tool is necessary to unfasten and remove them. Generally, guards
are designed not to obstruct the operator’s view or to prevent employees from
doing a job.
In some cases, guarding may be used as an alternative to lockout/tagout because
employees can safely service or maintain machines with a guard in place. For
example, polycarbonate and wire-mesh guards provide greater visibility and can
be used to allow maintenance employees to safely observe system components.
In other instances, employees may safely access machine areas, without locking
or tagging out, to perform maintenance work (such as machine cleaning or oiling
tasks) because the hazardous machine components remain effectively guarded.
Guards must not create additional hazards such as pinch points or shear points
between guards and other machine parts. Guard openings should be small
enough to prevent employees from accessing danger areas.
Horizontal Shafting
Safeguarding Devices
Safeguarding devices are controls or attachments that, when properly designed,
applied and used, usually prevent inadvertent access by employees to hazardous
machine areas by:
Preventing hazardous machine component operation if your hand or body part is
inadvertently placed in the danger area;
Restraining or withdrawing your hands from the danger area during machine
operation;
Requiring the use of both of your hands on machine controls (or the use of one
hand if the control is mounted at a safe distance from the danger area) that are
mounted at a predetermined safety distance; or
• Providing a barrier which is synchronized with the operating cycle in order to
prevent entry to the danger area during the hazardous part of the cycle.
These types of engineering controls, which either prevent the start of or stop
hazardous motion, may be used in place of guards or as supplemental control
measures when guards alone do not adequately enclose the hazard.
In order for these safeguarding devices to accomplish this requirement, they must
be properly designed and installed at a predetermined safe distance from the
machine’s danger area.
Secondary Safeguarding Methods
These methods provide a lesser degree of employee protection than the primary
Safeguarding methods and they are considered secondary control measures as
they do not prevent employees from placing or having any part of their bodies in
the hazardous machine areas.
Secondary safeguarding methods are acceptable only when guards or
safeguarding devices (that prevent you from being exposed to machine hazards)
cannot be installed due to reasons of infeasibility. Where it is feasible to use
primary safeguarding methods, secondary safeguarding methods may
supplement these primary control measures; however, these secondary
safeguarding methods must not be used in place of primary safeguarding
methods.
Probe Detection and Safety Edge Devices
A probe detection device (sometimes referred to as a ring guard) detects the
presence or absence of a person’s hand or finger by encircling all or part of the
machine hazard area. The ring guard makes you aware of your hand’s entry into a
hazardous area and usually stops or prevents a hazardous machine cycle or
stroke, thereby reducing the likelihood of injuring yourself in the point of
operation. These types of detection devices are commonly used on spot welders,
riveters, staplers and stackers because primary safeguarding methods are not
possible. However, probe detection devices do not prevent inadvertent access to
the point-of-operation danger area; rather, they serve as a warning mechanism
and may prevent the initiation of or stop the machine cycle if an employee’s hand
or finger(s) is too close to the hazard area.
A safety edge device (sometimes called a bump switch) is another type of
safeguard that detects the presence of an employee when they are in contact
with the device’s sensing edge. A safety edge device protects employees by
initiating a stop command when the sensing surface detects the presence of a
person; however, they do not usually, when used by themselves, prevent
inadvertent access to machine danger areas. Therefore, additional guarding or
safeguarding devices must be provided to prevent employee exposure to a
machine hazard
Awareness Devices
Awareness devices warn employees of an impending, approaching or present
hazard. The first type is an awareness barrier which allows access to machine
danger areas, but it is designed to contact the employee, creating an awareness
that he or she is close to the danger point. Awareness signals, through the use of
recognizable audible or visual signals, are other devices that alert employees to
an approaching or present hazard. Lastly, awareness signs are used to notify
employees of the nature of the hazard and to provide instructions
Risk Matrix for Safeguarding Machinery

The above mentioned risk matrix categorizes risk into 5 levels ranging from B to 4
At level B severity of any particular potential injury is slight and the consequence
is relatively very small. Level 4 the highest level of assessed risk is characterized
by frequent exposure to situation where the possibility of avoiding severe injury is
difficult.

The best time to carry out risk assessment is during the design stage, In this way
Engineers can eliminate potential hazard before they occur as well as determine
which risks cannot be eliminated through design consideration.

Most often serious manufacturing hazards which cannot be eliminated during the
design phase are categorized as level 3 risk.
This can be generally adequately addressed with controlled reliable safety
system.

OBJECTIVE
To identify the dangerous parts of machinery
To Identify the Method of Safeguarding

METHODOLOGY
Through identification of hazardous mechanical motion various
safeguarding methods and other safety devices are suggested for various
machinery used in a plant.
Based on the plant visited below are the collected data for the actual
conditions of various machinery in the production units and status of machine
safeguarding

1) SFB-04 (Special Rough Boring Machine)

Unit: Transmission PU
Status of guard: No Guard
Requirement: Interlock Guard Required

Not Appropriate Apropriate & Recommended

SFB-04 (Not Guarded)

2) BBM-02 (Bush Burnishing Machine)

Unit: Transmission PU
Status of guard: No guards are used
Requirement: Requirement of Fixed/Interlocked guard as well as maintenance
Of machine is to be done.

3) BMM 01
 Unit: Transmission Production Unit
Status of the Guard: No Guard
Requirement: Interlock guard

4) DMM 04 (Duplex Milling Machine)

Unit: Transmission Production Unit
Status of the guard: Fixed guard are being used but are not in good condition
Requirement: Guards must be replaced with new ones
5) DBM 03 (Multi-Drilling Boring Machine)
Unit: Transmission PU
Status: No Guards Present
Requirement: Fixed/Inter-locking Guards must be used to prevent accident.

DBM 03 (Multi-Drilling Boring Machine)

6) SRB 08 (Special Rough Boring Machine)

Unit: Transmission PU
Status: Fixed Guards are Present
Requirement: Inter-lock Guard can be used in place of fixed guards.
7) Wall deletion Drilling Unit
Unit: Transmission PU
Status: No Guards are used
Requirement: Guards must be used and along with that a safety device such as
Presence Sensing Device must be installed.
8) HDP 04 (Cone Pressing Machine)
Unit: Tractor Assembly Unit
Status: No Guard
Requirement: Fixed Guard is required
9) HDP 05 (STUD Pressing Machine)
Unit: Tractor Assembly Unit
Status: Not Guarded
Requirement: Must be guarded

10) HMC -16 (Horizontal Machining Centre)

Unit: Transmission PU
Status: The Electrical Panel of the Machine has fixed guarding with appropriate
Warning Signs but the rotating shaft of the machine requires some kind of
Photoelectric safety device.
11) VMD 05 (Vertical Multiple Drilling Machine)
Unit: Transmission PU
Status: Not Guarded
Requirement: Must be Guarded and Maintained

12) SRB 08 (Special Rough Boring Machine)

Unit: Transmission Unit
Status: Guarding is there but proper guarding is required and should be
Maintained.
13) Duplex Milling Machine (DMM 05)
Unit: Transmission Unit
Status: Fixed Guard Present
Requirement: Sensing device or Interlock guard can be used.
14) HMC -20(Horizontal Machining Centre)
Unit: Engine PU
Status: Guards are Present
Requirement: N.A

15) RDL -17 (Radial Drilling Machine)

Unit: Engine PU
Status: Guards not present
Requirement: Fixed and interlocking guards are required
This type of fixed guard is recommended for the Radial Drilling Machine
16) VBM-02 (Vertical Boring Machine)
Unit: Engine PU
Status: No guard Present, although Chip Guard was Present
Requirement: Proper maintenance and guard must be installed.
17) VMD-08
Unit: Engine Production Unit
Status: No Guard Present
Requirement: There must be a proper guarding either through use of fixed
guard or interlock guard or through sensing device.
18) VHM 03
Unit: Engine PU
Status: No guards are present
Requirement: Fixed guards must be used.
Results & Findings
 In order to achieve minimum or zero accidents which occurs due to
machine related hazards to the workers/employees of the company or
plant, the types of guards and other safety devices have been studies
thoroughly.
 During the visit and visual inspection of the plant it was found that most of
the machinery requires proper maintenance.
 There were many machinery as reported above in this report which are not
guarded or guarded were not at all maintained, therefore there is a need of
appropriate and suggested guarding systems which should be installed at
the machinery at a safe distance as discussed in this report.
 During the visit to the plant it was also observed that there is improper
housekeeping of the assembly parts of the tractor, also the use of safety
hat or safety helmet is also not in practice where it is required.
 During the visit / Inspection to the paint shop it was found that worker
works continuously inside the painting section which is quite dangerous for
their health. Hence the manual painting must be replaced with the use of
robot.

Manual Painting In Paint Shop Robot Based Painting (Recommended)

 No Safety hat/helmet

Use of Safety hat is recommended

 Conclusion

Using a machine without proper safeguard can lead to injuries that range from
minor to life altering. The consequences could be even fatal. Hazard presented by
unguarded machines includes moving parts such as belts, gears, rollers and
chains, electrically charged parts, entanglement areas & pinch points, debris or
material ejected from/fed into machine, Items falling into machines.
With so many different types of machines it’s no surprise that there are many
different kinds of guards. The hierarchy of controls lists five types of safeguards
that can be used alone or together to help protect workers. It’s the employers
responsibility to do a risk assessment on each machine in a workplace & to put
the proper safeguards in place to eliminate or control the hazard.
The best way to safeguard against the hazard is to eliminate it or substitute a
safer process, for machines this means eliminating pinch points, entanglement
areas and automatic task like material handling. If the hazard cannot be
eliminated, the next step to consider is Engineering Controls, for machines this
includes fixed barrier guards (They are designed so that workers can go over,
under, around or through to reach moving parts , harmful liquids or possible
projectiles) If there are gaps in the guards the machine may also be equipped with
laser light curtain system. A fixed barrier guard is firmly attached & can’t be
removed without a tool. Before removing a guard, “lock out” safe work
procedures, removing energy sources from the machines should be followed.
There are other types of safe guarding devices that are not fixed, a worker can
handle/ access a potentially hazardous area with their hands or entire body,
however these types of proper safe guarding devices will let the machine start
until the worker is clear of the danger area. Many machines are equipped with
interlocked device which stops the machine if the safeguard is lifted. Some safe
guarding devices may also limit the movement of the machine or require the
worker to control the power with two hands, so if they the worker let go to the
control with one hand, the machine stops. In addition to barrier guards,
emergency and lockout devices and other safeguarding devices must be used.
Other safeguarding Methods include safe work procedures, training and PPE used
in combination with other safeguards, these strengthen worker protection.
Awareness method can be a part of machine safeguarding, splash shields flashing
lights audible warning devices, warning signs, barrier that restrict access. They all
exist to make the worker aware of the potential hazards.
Proper Training and following safe work procedures are also part of machine
safeguarding because “safety start with knowing how to use machine safely”
(including any safeguard required). One should be trained on why and how guards
protects us and how to do a preuse inspection check on the machine & its guard
to ensure safe and appropriate working of machinery.
Finally Personal Protective Equipment’s or PPE may be the part of this safeguard
required to help prevent injuries from certain machines. Also long hairs should be
tied back and no loose clothing or jewelry should be worn. But one should
not/never relay solely on PPE as it’s the last line of defense.
The need of proper training, learning safe work procedures and the aware of the
potential hazard involved with each machinery is must to ensure safety of
workers and zero chance of accident, know matter what kind of machine a worker
use, there are some simple thinks to remember before the work is started i.e
make sure that the guards are in proper position, in good condition & provide
adequate protection for moving & hazardous machinery parts.
 REFERENCES

 IS 9474:1980 Specification for Principles of Mechanical Guarding of

Machinery.
 Indian Factories Act 1948
 OSHA Guidelines for Safeguarding Equipment and Protecting Employees
from Amputations
 Code of Practice: Safe Guarding of Machinery & Plant 2009 (Commission for
occupational safety and health)
 Power Transmission system of a tractor (AG ENGG 243 Lecture 8)