Safety Mechanism in Mechanical Press Machine

A PROJECT REPORT

Submitted by

Lalpurwala Apurv D. (090370119012)

Vaghasiya Mayur R. (090370119013)

Desai Raviraj H. (090370119017)

Rambhapurwala Prarthan H. (090370119090)

In fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

in

Mechanical Engineering

Parul Institute of Engineering and Technology

Limda,Waghodia, Vadodara.

Gujarat Technological University, Ahmedabad

November, 2012

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 Parul Institute of Engineering and Technology

Mechanical Engineering

2012

CERTIFICATE

Date: 24/11/2012

This is to certify that the dissertation entitled “SAFETY MECHANISM IN

MECHANICAL PRESS MACHINE” has been carried out by

LALPURWALA APURV D. 090370119012

VAGHASIYA MAYUR R. 090370119013

DESAI RAVIRAJ H. 090370119017

RAMBHAPURWALA PRARTHAN H. 090370119090

under my guidance in fulfillment of the degree of Bachelor of Engineering in

Mechanical Engineering 7th Semester of Gujarat Technological University,
Ahmedabad during the academic year 2012-13.

Guide:

ASST. PROF. NIRAV GANDHI,

MECHANICAL ENGG. DEPARTMENT,

P.I.E.T. LIMDA.

Head of the Department

PROF. K.B.K. LAMBA,

P.I.E.T. LIMDA.

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 ACKNOWLEDGEMENT

First of all, we are indebted to Parul Institute of Engineering and Technology, Limda and LK
Industries Pvt. Ltd., Vadodara for giving us all the utility that we needs towards the completion
of this project and report. With great pleasure we wish to express our deep gratitude to Prof.
K.B.K. Lamba, (Head of Mechanical Engineering Department, PIET, Limda) for his keen
interest, constant encouragement and valuable guidance for this work.

We would like to express our deepest appreciation and gratitude to our project guide, Asst. Prof.
Nirav Gandhi, Mechanical Engineering Department, PIET for his guidance, patience for giving
advices and support throughout the progress of this project.

Since this project is a result of a class assignment, it has been graded and accepted as fulfillment
of the course requirements. Any use of information in this report is done at the risk of the user.
These risks may include catastrophic failure of the device or infringement of patent or copyright
laws.

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 ABSTRACT

In our industrial training period, we found that at the time of mass production,
workers cannot concentrate on their safety. Due to continue production process in
mechanical press machine, many accidents created during press operation, e.g.
hands injured.

So we proposed mechanism to an industry which attach to

mechanical press machine and this mechanism functioning fulfill when worker
hand operate this mechanism with press machine, so insure worker hands are
outside the accident zone. Due to this proposes safety mechanism worker hands
are safe and protected from any accidental injury. This project proposes safety
mechanism with improved response time on industrial machineries than existing
machine guards.

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 LIST OF FIGURES
Figure No. Figure Description Page No.

Fig.1 (a) Typical Mechanical presses 06

Fig.1 (b) Foot control 07

Fig.1 (c) Dual palm-button control 08

Fig.1 (d) Punching Action 10

Fig.1 (e) Bending Action 10

Fig.4.1 (a) Fixed Guard on a Power Press 25

Fig.4.1 (b) Power Press with an Adjustable Barrier Guard 26

Fig.4.1 (c) Pullback Device on a Power Press 29

Fig.4.1 (d) Restraint Device on a Power Press 30

Fig.4.1 (e) Presence- Sensing Devices 31

Fig.4.1 (f) Two-hand Trip Device 33

Fig.4.1 (g) Two-hand Trip Device 33

Fig.4.1 (h) Movable gate mounted on a punch press. 35

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 TABLE OF CONTENTS

Acknowledgement i
Abstract ii
List of Figures iii
Table of Contents iv

CHAPTER: 1 INTRODUCTION 1

1.1 Basic information of industry 1

1.2 Introduction to project 2

1.2.1 Safety risks associated 2
1.2.2 Hazardous mechanical components 3
1.2.3 Press machine 5
1.2.4 Types of power presses 5
1.2.5 Existing standard for dual palm-button controlled
Power presses and problem associated with safety 8
1.2.6 Safety problem associate with press machine -
Operation 9
1.2.7 Introduction to problem 11

1.2.7(A) Worker’s safety problem in press machine 11

1.2.7(B) Lack of selection of proper safety -

Mechanism (safety guard) in industry 11

1.2.8 Project objectives 11

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CHAPTER: 2 BRIEF HISTORY OF THE WORK 12

2.1 The nature and problems of press machine 12

2.2 Emphasized measures 14

2.3 Specific implementation items 15

2.4 Promoting press machine safety 17

2.5 Safety educations 20

2.6 Action plan on time scale 21

CHAPTER: 3 LITERATURE REVIEW 22

CHAPTER: 4 IMPLEMENTATION OF PROJECT WORK 24

4.1 Proposed varies system for safety in Mechanical Press -

Machine 24
4.1.1 Machine Guarding 24
4.1.2 Safeguarding Devices 28

CHAPTER: 5 EXPECTED RESULT 36

 REFERENCES 37

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 CHAPTER: 1. INTRODUCTION

1.1 BASIC INFORMATION OF INDUSTRY

NAME: LK Automotive Pvt. Ltd.

LK Industries is the manufacturer of various Chassis Parts, Clutch & lever, Door Part,
Exhaust Systems and Accessories and also manufacture automotive components Stampings
& Pipe Assembly.
In 1982, LK was established in vadodara to manufacture heavy sheet metal parts/fabrication.
Since then, the company has evolved into one of the most respected & trusted automotive
engineering group to meet the growing needs of automobile industries. Company is
recognized by reputed customers and Inspection Agencies for its quality products.

Sheet Metal: - LK has accorded the highest priority to make customer expectation,
empowering its plant with wide range of presses-50T to 500T, both in mechanical and
hydraulic versions.
Pipe Assy.:- Pipe auto bending – OD 38mm.Thk4.5mm.welding gadgets like stationary and
portable spot welding, seam welding, MIG/TIG welding, submerged arc welding and SPMs,
have propelled LK to emerge as a single source supplier in this segment.

RANGE OF PRODUCT:
CHASSIS PARTS: -
CLUTCH & LEVER: -
EXHAUST SYSTEMS: -
1. SHOCK ABSORBER BRACKET L/R
2. 2ND CROSS MEMBER BRACKET
3. 3RD CROSS BRACKET L/R
1. BRAKE PEDAL & LEVER
2. CLUTCH - DRIVER PLATE
1. RICKSHAW MUFFLER

2. TRACTOR MUFFLER
ACCESSORIES: - 1. FENDER SEAT
2. SPARE WHEEL BRACKET

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TYPE OF INDUSTRY: MEDIUM SCALE

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1.2 INTRODUCTION TO PROJECT

Nowadays, all responsible industries recognize the duty of care they owe their employees.
Taking all possible measures to avoid accidents in the workplace is not only a moral
obligation; it also makes sound financial sense. Accidents are expensive – not only in lost
working days, compensation for injury and higher insurance premiums, but also in other
costs less easy to quantify like disrupted production, and the costs of accident
investigations and of training new personnel to replace those injured in industrial
accidents. In every way, therefore, creating a safe industrial environment is a wise
investment.

Main content of our industry defined problem is an introduction to manage the risks
associated with the use of press machine in the workplace. There are different types of
problem occurs in any small and medium scale industries which are having mechanical
press machine, out of all main problem occurring is the safety problem and hence safety has
main point to concern. Worker’s physical safety is as important as other safety which
concern with mechanical hazard.

1.2.1 Safety Risks associated with:

1.2.1(A) Mechanical hazards: Machines have moving parts. The action of moving parts
may have sufficient force in motion to cause injury to people.

1.2.1(B) Non-mechanical hazards: Non-mechanical hazards associated with machinery

and equipment can include harmful emissions, contained fluids or gas under pressure,
chemicals and chemical by-products, electricity and noise, all of which can cause serious
injury if not adequately controlled. In some cases, people exposed to these hazards may not
show signs of injury or illness for years. Where people are at risk of injury due to harmful
emissions from machinery and equipment, the emissions should be controlled at their
source.

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1.2.1(C) Access hazards: People must be provided with safe access that is suitable for the
work they perform in, on and around machinery and equipment. A stable work platform
suited to the nature of the work that allows for good posture relative to the work performed,
sure footing, safe environment and fall prevention (if a fall may occur) is a basic
requirement.

To prevent worker amputations, we must first be able to recognize the contributing factors,
such as the hazardous energy associated with your machinery and the specific employee
activities performed with the mechanical operation.
Understanding the mechanical components of machinery, the hazardous mechanical motion
that occurs at or near these components and specific employee activities performed in
conjunction with machinery operation will help workers avoid injury.

1.2.2 Hazardous Mechanical Components

Three types of mechanical components present amputation hazards:

Point of Operation is the area of the machine where the machine performs work – i.e.,
mechanical actions that occur at the point of operation, such as cutting, shaping, boring, and
forming.

Power-Transmission Apparatus is all components of the mechanical system that transmit

energy, such as flywheels, pulleys, belts, chains, couplings, connecting rods, spindles, cams,
and gears.

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Other Moving Parts are the parts of the machine that move while the machine is operating,
such as reciprocating, rotating, and transverse moving parts as well as lead mechanisms and
auxiliary parts of the machine.

Mechanical hazard prevented by guarding. The types of guarding to be provided for

different cases and other requirements are contained in industries.

Guarding
A guard can perform several functions: it can deny bodily access, contain ejected parts,
tools, off-cuts or swath, prevent emissions escaping or form part of a safe working platform.

Guarding is commonly used with machinery and equipment to prevent access to:
• rotating end drums of belt conveyors
• moving augers of auger conveyors
• rotating shafts
• moving parts that do not require regular adjustment
• Machine transmissions, such as pulley and belt drives, chain drives, exposed drive gears
• Any dangerous moving parts, machines or equipment.

Where access is not anticipated, a fixed guard can be permanently applied by bonding
agent, welding or secured with one-way screws. If access is generally not required, a
permanently fixed barrier is the preferred option. Where access to the hazard is infrequent,
the installation of a fitted guard that can be removed by use of a tool may be an acceptable
control, where the tool to remove the barrier or guard is not normally available to the
operator. Adjustable guarding incorporates movable sections or panels of the guard and
allows for material or parts to be fed into the guarded area while still preventing bodily
contact.

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1.2.3 Press Machine

Press working is one of the extensively employed methods of fabricating parts of intricate
Shape with thin walls. Many of the consumer goods enjoyed by the modern man owe.
Their low cost to the press working. Press working processes make use of large forces by
press tool on die set for a short time interval which results in cutting or shaping the sheet
metal.

Press: A machine where, Press working forces are setup, guided and controlled. In spite
of the great variety of press tools, most of them have certain components similar in
purpose and design. To facilitate design, manufacture, maintenance and repair of press
tools, similar unit sand components have been standardize.

1.2.4 Types of power presses:

There are three types of power presses: mechanical, hydraulic, and pneumatic. Their
control systems may be mechanical or electro-mechanical. Though these three major types
of power presses share some common features, the mechanical power press is the most
commonly used and researched.

The two major components of a mechanical power press are a stationary bed and a moving
ram. The press shears, punches, forms, or assembles metal or other material by cutting or
shaping; using combination dies attached to the ram and bed. The mechanical power press
operates on a reciprocating motion principle. The main components for power
transmission are the clutch, flywheel, and crankshaft. A motor powers the rotation of the
flywheel. A clutch is used to couple the spinning flywheel to the crankshaft.

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The crankshaft converts the rotary motion of the flywheel to the downward and upward
motions of the press ram. A workpiece is fed into the lower die, either automatically or
manually, and the machine cycle is initiated. On the downstroke, the ram (with an upper
die) moves toward the work area, or point of operation (see Fig.1 (a)). When the upper and
lower dies press together on the stock material, a re-formed piece is produced. Once the
down stroke is completed, the newly formed workpiece is removed, a new workpiece fed
into the die and the process repeated.

Fig.1 (a) Typical Mechanical presses

Clutches
There are two types of clutches used on mechanical power presses: full-revolution
clutches and part-revolution clutches. There are important differences between the two
clutches with respect to operator safety. When the clutch is engaged, on presses with a

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full-revolution clutch, it remains engaged until the crankshaft has completed a full cycle.
The part-revolution clutch differs in that it can be disengaged at any point in the
downward cycle; thus stopping for safety reasons before the crankshaft completes the
downstroke is possible. Since the full-revolution clutch makes a complete revolution
before it disengages, presses equipped with this type of clutch generally pose a greater
hazard after a stroke is initiated than presses equipped with a part-revolution clutch.

Foot and Hand Controls

Initiation of the power press stroke can be either automatic or manual. On manually
operated presses there are two popular modes for initiating machine motion: foot or dual
palm-button (two-hand) controls (see Figures 1(b) and (c)). When foot controls are used,
the press is activated by pressing down on a foot switch or pedal which allows the hands
to be free during the cycling of the press. Foot controls do not intrinsically separate the
operator s hands from the machine’s point of operation during the operating cycle.
Person’s operating power presses with foot controls must be protected by safeguarding
devices not always directly linked to machine operation. These safeguarding devices (i.e.,
barriers, gates, pullouts) may have interlocks capable of controlling initiation of the stroke.
However, it also may be possible to operate the press with safeguards removed or
modified so that they do not function as intended.

Fig.1 (b) Foot control

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 Fig.1 (c) Dual palm-button control

With dual palm-button controls, once a workpiece is manually positioned in the press,
both hands must be removed from the point of operation to depress the palm-buttons. Dual
palm-buttons require both hands to be away from the point of operation when the press
cycle is initiated. Operator productivity may be greater with foot switch operation than
with dual palm button operation since the hands are free during the entire period of the
press cycle. However, this freedom of hand movement also places operators using foot
switches at greater potential risk of sustaining a point-of-operation injury.

1.2.5 Existing Standard for Dual Palm-Button Controlled Power Presses

and Problem associated with safety:

Mechanical power presses shall incorporate a single-stroke (or anti-repeat) feature that
allows the clutch to engage and the press to cycle only once each time the dual palm-
buttons are depressed.

Dual palm-buttons shall incorporate an antitie- down feature. This feature allows the
buttons to be wired so that they must both be depressed and released for each cycle of the
press. This eliminates the possibility that operators will “tie-down” one of the palm-
buttons, permitting the use of only one button to cycle the press.

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Both palm-buttons shall have guards to prevent unintended operation and separation
between buttons to prevent “bridging” of the palm-buttons by operators --i.e., activating
the press without using both hands.

Even though there is an existing standard that addresses construction and operation of
mechanical power presses, injuries and amputations among press operator are still
occurring with alarming frequency. In many cases, these injuries occur when the press is
inadvertently activated while the operator’s hands are in the operating zone of the press.
The results of a recent experiment indicate that the chance for inadvertent press activation
(possibly involving injury) may increase as the cycling rate increases. Hence because of
this varies injury , Employers are paying anywhere from Rs1,50,500 to Rs 4,70,000 in
workers’ compensation costs and indirect costs for each of the injuries.

Injuries occur as a result of “after-reach” among operators who initiate power presses
using dual palm-buttons. Therefore, attention should be given to the individual operator’s
hand speed, keeping in mind that, in general, hand speed may be a function of age and
gender. The recommendations contained are intended to address these problems and
thereby reduce injuries among mechanical power press operators.

1.2.6 Safety Problem Associate with Press Machine operation

Punching Action (Fig.1 (d)) begins when power causes the machine to hit a slide (ram) to
stamp or blank metal or other material. The hazard occurs at the point of operation where
the employee typically inserts, holds, or withdraws the stock by hand.

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 Fig.1 (d) Punching Action

Bending Action (Fig.1 (e)) is power applied to a slide to draw or stamp metal or other
materials in a bending motion. The hazard occurs at the point of operation where the
employee typically inserts, holds, or withdraws the stock by hand.

Fig.1 (e) Bending Action

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1.2.7 Introduction to Problem:

1.2.7(A) Worker’s Safety Problem in Press Machine:

An appraisal of the state of safety measures with respect to press machine

involved in accidents reveals that those lacking hands safety devices. An
examination of the behavior of workers at the time of accidents indicates that
many accidents involved unsafe activities, such as using one's hands instead of
hand tools and/or removing safety device. Such accidents show a slow declining
trend while the total number of press machine accidents has been decreasing.

1.2.7(B) Lack of Selection of Proper Safety Mechanism (Safety Guard) in

Industry:

There are many safety mechanism available in market, but problem arise for small
and medium scale industries to select safety mechanism which depends on
worker’s interest, efficiency, productivity, cost effectiveness and easy to use for a
longer time.

1.2.8 PROJECT OBJECTIVES

 Select optimum safety mechanism (Safety guard) out of available safety

mechanisms.

 It reduces the problem of hand safety for workers.

 Safety mechanism should be cost effective for small and medium scale
industries (our industry).

 Safety mechanism should be easy to use for longer time.

 Maintenance of safety mechanism should be lower.

 It is also proven to less affect productivity when it is practically installed on

the machine.

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 CHAPTER: 2. BRIEF HISTORY OF THE WORK

It is in the public interest to reduce or eliminate the unreasonable number of mechanical power
press operator injuries. A disabled worker is not cost-effective in our society. Moreover, these
injuries are unacceptable from a human factor perspective, especially when there are reasonable
methods to prevent these injuries.
The results of our project indicate the critical importance of human factors engineering principles
in press operator accident causation. Human factors are the primary causation factor, and press
safeguarding is the second causation factor. Human factors engineers can contribute to operator
safety by applying these principles to overcome the decrement in operator performance caused
by human error, environment, and press malfunction.

Types of problem occurring in press machine are

2.1 The nature and problems of press machine:

(1) The incidence of accidents

Based on a review of recent press machine accidents, the major problems concerning press
machine accident prevention are as follows.

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A. While press machine accidents have shown a declining trend, the pace of this downturn
has slowed down in recent years, with a reported 2,400 accidents involving fatalities and
injuries in 1997, 40 percent of which resulting in physical impairments.

B. By operational method, accidents involving foot-pedal press machine, which constitute

some 20 percent of the total in terms of the number of press machine installed, constitute the
bulk of these accidents.

C. In terms of the types of clutches, the ratio of accidents caused by positive clutch press
machine, which occupied the highest share in the past, has substantially decreased. In turn,
the ratio of accidents caused by friction-clutch press machine has now become the highest.

D. An appraisal of the state of safety measures with respect to press machine involved in
accidents reveals that those lacking safety devices, constitute some 40 percent among total
accident cases, and those which had safety device, etc., but the functions and/or installation
methods were defective or improper represent approximately 25 percent. This means that
accidents involving press machine whose safety device, etc., were inadequate make up some
65 percent of the total.

E. An examination of the behavior of workers at the time of accidents indicates that many
accidents involved unsafe activities, such as using one's hands instead of hand tools and/or
removing safety device. Such accidents show a slow declining trend while the total number
of press machine accidents has been decreasing.

F. By type of business, many accidents occur in metal product manufacturing, general

machinery and tool manufacturing, transportation machinery and tool manufacturing, etc.

(2) Overview of safety steps for press machine

With respect to the general implementation of safety steps for press machine, there are still
many workplaces that have press machine for which the steps for safety are not taken.

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 At the same time, the ongoing progress in the introduction of presence sensing device
initiation equipment is creating the need for disseminating knowledge on safety
management that remains abreast of the functions and characteristics of such equipment.

(3) Situation regarding the appointment of press machine operation chief, etc.

There are still many workplaces with five or more units of power-driven press machine
involved in press machine work where no press machine operation chief has been appointed,
or where such an appointment is made but the actual duties are neglected.

(4) Situation regarding the implementation of special voluntary inspections

There are still many workplaces where special voluntary inspection is not conducted.
Moreover, as there are many cases in which such inspections do indicate abnormalities in
positive clutch press machine, it is necessary to thoroughly undertake appropriate steps such
as proper repairs in such cases.

2.2 Emphasized measures:

(1) Promoting the safety of press machinery

In order to prevent press machine accidents, the safest measure is to take the "no hand in
dies" approach, which prevents any part of the body from entering the danger limit by using
such means as installing safety enclosures. While this is the basic step among measures that
should be promoted, accident prevention steps that use the safety presses shall be taken in
cases where the "no hand in dies" approach is difficult to apply due to the nature of the
work. It is necessary to take accident prevention steps by installing the safety device in cases
where the use of safety presses is also difficult.

A specific safety promotion measure that is effective for many types of press machine is to
switch from foot-pedal operation to the use of push buttons that require both hands to
operate. In all cases, however, it is necessary to give particular attention to improvements
that adopt the "no hand in dies" method as a fundamental accident prevention measure.

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 (2) Full implementation of press machine safety device, etc.

With respect to safety device and the safety mechanisms of safe presses (hereinafter called
"safety device, etc."), it is important to fully implement the appropriate selection, use, etc.,
of press machine safety device, etc., in order to prevent accidents stemming from the failure
of safety device, etc., to function effectively. Such reasons are often related to the fact that
the type of safety device, etc., are not appropriate for the type of press machine or the work
contents, and/or the usage method is not appropriate due to such reasons as an insufficient
safety distance.

This requires that careful attention and consideration be given to appointing a press machine
operation chief, etc., and that the duties of this appointee be thoroughly carried out. In
addition, it is necessary that positive safety management activities centered around the press
machine operation chief be implemented through safety education, etc., for employers, press
machine operation chiefs and press workers.

(3) Effective measures in accordance with the situation at workplaces where press machine
is installed

In large-scale workplace and his affiliate company group, it is important to make efforts to
establish an organization to discuss safety related to press machine and to carry out
voluntary safety activities through this organization, and that multiple subcontractor be
included in these activities.

In industrial accident prevention organization, press-related industrial association, etc., it is

necessary to make efforts to enhance voluntary safety activities including the promotion of
new membership by non-member workplace that have press machine installed. Moreover, in
small and medium-sized workplace where it is difficult to fully take press machine accident
prevention steps due to technical and financial reasons, it is important to carry out
continuous voluntary safety activities by receiving external technical guidance, etc., as well
as by utilizing various assistance systems such as the safety loan system.

2.3 Specific implementation items:

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Implementing safety activities such as establishing an organization for safety management

(1) Establishing an organization for management

Safety supervisors, safety and health promoters, press machine operation chief, etc., shall be
appointed in accordance with the scale of the workplace, the situation of press machine
work, etc., and the respective scope of his responsibilities and work assignments shall be
clarified.

(2) Deliberations at the safety committee

The safety committee shall discuss and deliberate such matters as the preparation of rules on
press machine work safety and the prevention of dangers concerning press machine to be
newly introduced.

(3) Scrupulous management by operation chief, etc.

In order to firmly establish the maintenance and inspections of press machine and
appropriate work in the workplace, the necessary number of press machine operation chief
shall be appointed to fully carry out the assigned duties in consideration of the number of
press machine units installed, the situation of press machine work, etc., and the management
responsibilities and authority for each press machine unit shall be clarified to promote the
establishment of safety management activities. For this purpose, the appointment of press
machine operation chief shall be implemented without fail where required. In addition,
workplace not required to make such appointment shall designate personnel in charge, and
shall instruct such personnel to take charge of the practical application of the following
matters.

In addition, the name of the press machine operation chief, etc., in charge of the
management, as well as the names of personnel in charge of installing and adjusting metal
dies and safety device for each press machine unit shall be conspicuously posted.

A. Special voluntary inspection and checks before starting work

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 The special voluntary inspection based on the inspection items, inspection methods and
judgment standards stipulated in the periodical voluntary inspection guidelines for power-
driven press machine shall be established and checks shall be fully implemented before the
start of work.

B. Safety inspections

In order to maintain the safety and functions of machines and equipment, safety inspection
manuals shall be prepared that stipulate the personnel in charge of inspection, specific
inspection items, inspection methods, judgment standards for acceptance and rejection
decisions, inspection timing (frequency), etc., and such inspection shall be fully
implemented on the basis of such manual.

The definite implementation of these inspections shall be confirmed by the press machine
operation chief, etc.

C. Early detection of abnormalities (faults) and countermeasures

Any abnormalities observed as the result of said safety inspections and special voluntary
inspection, or any abnormalities (faults) detected during work processes shall be reported to
a superior manager such as a foreman. In such an event, the foreman, etc., receiving such a
report shall immediately suspend the work, and take appropriate repair steps by contacting
outside specialist organizations such as the manufacturer of the press machine if necessary.

2.4 Promoting press machine safety:

(1) Steps to secure the safety of press machine

In preventing press machine accident, it is necessary to limit the number of press machine
units that require other safety measures as much as possible. Safety steps involving the
installation of safety device shall be taken only in cases in which the usage of the
fundamental measure alone is difficult due to the nature of work.

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As steps to prevent any body part from entering the danger limit, safety measures that
include one or more of the following shall be adopted: using press machine equipped with
safety enclosures (i.e., those that enclose the danger limit, thus preventing hands and fingers
from entering); the use of safety dies (i.e., metal dies constructed with an aperture of 8 mm
or less, thus preventing any body part from entering); using exclusive press machine (i.e.,
those that can be used for specific purposes only, and which have a structure that prevents
any body part from entering the danger limit); or using automatic press machine (i.e., those
in which the materials are automatically fed and discharged).

However, in case it is difficult to take steps to prevent hands from entering the danger limit,
such as the need for large apertures for feeding and discharging materials due to the nature
of work, safety press machine equipped with a safety mechanism at the time of
manufacturing shall be used.

Only in cases in which it is difficult to take the steps prescribed above due to the nature of
work, the following safety device shall be installed: units with movable barriers (safety
device); unit with two-hand control (safety device); unit with photoelectric beams (safety
device); unit with pull-out function (safety device); or unit with sweeping functions (safety
device). In addition, efforts shall be made to further improve safety by installing multiple
safety devices or using a structure that does not allow safety features to be easily removed or
deactivated.

With respect to the installation of such safety device, care shall be taken to ensure that
enclosure-type safety device cover all moving parts of the machine except for apertures
where materials are inserted or removed.

(2) Appropriate selection and management of safety device

The appropriate selection and use of safety device shall be thoroughly carried out on the
basis of type of industries.

(3) Switching from foot-pedal to both-hand push button operation

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As many accidents still occur in the case of press machine operated by foot-pedals, it is
important to switch from foot-pedal operation to push button operation requiring both hands
for press machine that involve not only positive clutch but also for friction clutch as well. In
making such a switchover, it is necessary to improve the metal die or use a pedestal for
operation that requires holding the processing object by hand. In this connection,
implementing the switchover from foot-pedal operation of press machine with friction
clutch to push buttons that require both hands shall be positively.

In switching press machine with positive clutch to two-handed push-button operation, there
are many cases in which it is generally difficult to secure a safe distance. As installations of
this type do not conform, due attention must be given in such cases to the appropriate use of
pull-out safety device.

(4) Improving the safety of press machine operation

In addition to promoting the safety of press machine, safety device and related equipment in
order to prevent press machine accidents, work standards shall be prepared and efforts shall
be made to ensure that all operation are organized and implemented on the basis of these
work standards. Such work standards shall cover not only regular operation, but also non-
regular operation such as safety inspections, steps at the time of abnormalities, and the
installation and adjustment of metal dies and safety device.

(5) Using proper metal dies

In order to prevent accidents caused by the scattering of metal parts from dies broken at the
time of processing, metal dies shall be properly designed and manufactured on the basis of
the technical guidelines concerning the safety standards for metal dies used in press machine
and inspection shall be carried out before use, and appropriate life-cycle management shall
be implemented.

In addition, in order to prevent accidents during operation to replace metal dies (which are
heavy objects), appropriate safety measures such as reducing the manual labor in handling
metal dies shall be carried out.

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 (6) Securing safety at the manufacturing and installation stages

Press machine, safety device and metal die manufacturers shall make efforts to conform to
the structural standards as well as make efforts to manufacture safer press machine, etc. In
addition, they shall establish maintenance structures that can appropriately deal with repair
requests from user.

2.5 Safety Educations:

The legally required safety education programs such as education for press machine
operators at the time of hiring as well as special education related to such topics as handling
metal dies shall be fully implemented. In addition, positive steps shall be taken to encourage
participation in safety and health seminars for management executives, skill improvement
courses for press machine operation chief, and safety education for press machine operators.

All of these educational programs shall be conducted on a systematic basis.

3 Carrying out voluntary safety activities,

(1) Affiliated company groups

In affiliated company group which conduct press machine operation such as general
machinery and tool manufacturing, automobile manufacturing and electric machinery and
tool manufacturing, voluntary safety management activities led by the parent company shall
be carried out by installing a safety consultative organization, observing all related laws and
regulations, and implementing safety education for press machine operator in affiliated
company.

(2) Small and medium-sized workplace

Small and medium-sized workplace shall examine the possibility of utilizing the industrial
safety and health loan system, the small and medium-sized safety and health activity

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 promotion subsidy system for company group, etc., and positively introducing technologies
concerning safety from the outside.

(3) Press machine accident prevention conferences, etc.

Small and medium-sized workplace in particular shall be encouraged to participate in press

machine accident prevention conference, etc., conducted by accident prevention
organizations, press-related industry association, etc., and voluntary safety management
activities by member workplace shall be activated by preparing press machine accident and
improvement case files, preparing model work standards and safety inspection manuals, and
implementing voluntary safety patrols. Efforts shall be made to spread these activities not
only to workplace represented in such conference, but also to other local workplace that
conduct related operation.

2.6 Action plan on time scale

 Visit to industry in summer for 20 days.

 Find different problem related to our industry.

 Select the most important problem of our industry.

 Find maximum available solutions for selected problem of our industry.

 Select best expected solution from the available solutions.

 Create documentation report to offer an agenda for addressing industry needs and
improving workplace safety.

 Actual result analysis from our addressing documentation report.

 Conclusion.

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 CHAPTER: 3. LITERATURE REVIEW

The basic types of mechanical action or motion that must be guarded are found in many
machines in many industries. Current applications of each technique are shown in accompanying
illustrations of specific operations and machines. The concepts described here may, with due
care, be transferred to different machines with similar motions. Any moving part creates a hazard
and guarding eliminates or controls the hazard.

Occupational safety and health training remains a fundamental element in workplace hazard
control programs. As our training objectives, recognition of job hazards, learning safe work
practices and appreciating other preventive measures are expected to contribute to the goal of
reducing occupational risk of injury. This report reviews data found in the literature reflecting
the significance of training in meeting these kinds of objectives and outcomes. As will be seen,
there is much positive evidence but the results seem very selective and highly qualified. An
analysis to identify factors underlying a successful training experience is also presented and does
confirm basic principles of learning. Here too, however, important gaps are noted in the available
data related to our industry which is medium scale industry.

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A Literature Review Prepared by Alexander Cohen, PhD and Michael J. Colligan, PhD said that
More than 100 Occupational Safety and Health Administration (OSHA) standards for hazard
control in the workplace contain requirements for safety mechanism aimed at reducing risk
factors for injury; others limit certain jobs to persons deemed competent by virtue of special
safety mechanism.

A literature review was undertaken to assess the merits of such safety rules to achieve this
objective and to sort out factors of consequence. The review focused heavily on published
reports, primarily drawn from the period 1980 through 1996, wherein training was used as an
intervention effort to reduce risk of work-related injury. Eighty (80) such reports were found and
gave overwhelming evidence to show the merits of training in increasing worker knowledge of
job hazards, and in effecting safer work place and other positive actions in a wide array of
worksites. Reports from select surveys and investigations of worker injuries and workplace
fatalities were also accessed with many implicating lack of training and safety mechanism as a
contributing factor to the mishaps. In still other studies, workplace safety mechanism devoted to
showed linkage to reduced worker injury rates, suggesting that even this kind of safety
mechanism has benefits to job safety overall.

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 CHAPTER: 4. IMPLEMENTATION OF PROJECT WORK

4.1 Proposed varies system for safety in Mechanical Press Machine

4.1.1 Machine Guarding:

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 workers 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 workers to safely observe system components. In other instances,
workers 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 workers from accessing danger areas.

Types of Machine Guards:

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(1) Fixed:-

Method of Safeguarding: Barrier that allows for stock feeding but does not permit operator
to reach the danger area.

Fig.4.1 (a) Fixed Guard on a Power Press

Advantages:
• Can be constructed to suit many applications.
• Permanently encloses the point of operation or hazard area.
• Provides protection against machine repeat.
• Allows simple, in-plant construction, with minimal maintenance.

Limitations
• Sometimes not practical for changing production runs involving different size stock or
feeding methods.
• Machine adjustment and repair often require guard removal.
• Other means of protecting maintenance personnel often required
(Lockout/tagout).

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(2) Adjustable:-

Method of Safeguarding: Barrier that adjusts for a variety of production operations.

Fig.4.1 (b) Power Press with an Adjustable Barrier Guard

Advantages
• Can be constructed to suit many applications.
• Can be adjusted to admit varying stock sizes.

Limitations

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 • May require frequent maintenance or adjustment.
• Operator may make guard ineffective.

(3) Self- Adjusting:-

Method of Safeguarding: Barrier that moves according to the size of the stock entering
point of operation. Guard is in place when machine is at rest and pushes away when stock
enters the point of operation.

Advantages
• Off-the-shelf guards are often commercially available.

Limitations
• Does not provide maximum protection.
• May require frequent maintenance and adjustment.

(4) Interlocking Barrier Guards:-

Method of Safeguarding: Shuts off or disengages power and prevents machine start-up
when guard is open should allow for inching of machine.

Advantages

• Allows access for some minor servicing work, in accordance with the lockout/ tagout
exception, without time-consuming removal of fixed guards.

Limitations
• May require periodic maintenance or adjustment.

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• Movable sections cannot be used for manual feeding.
• Some designs may be easy to defeat.
• Interlock control circuitry may not be used for all maintenance and servicing work.

4.1.2 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. Other safeguarding devices
(probe detection and safety edge devices) that merely detect, instead of prevent,
inadvertent access to a hazard are not considered primary safeguards.

(1) Pullback Devices:-

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Method of Safeguarding: Cords connected to operator’s wrists and linked mechanically
to the machine automatically withdraw the hands from the point of operation during the
machine cycle.

Fig.4.1(c) Pullback Device on a Power Press

Advantages

• Allows the hands to enter the point of operation for feeding and removal.
• Provides protection even in the event of mechanical repeat.

Limitations

37
• Close supervision ensures proper use and adjustment. Must be inspected prior to each
operator change or machine set-up.
• Limits operator’s movement and may obstruct their work space.
• Operator may easily make device ineffective by not adjusting the device properly.

(2) Restraint Devices:-

Method of Safeguarding: Wrists are connected by cords and secured to fixed anchor
points which limit operator’s hands from reaching the point of operation at any time.

Advantage

• Simple, few moving parts; requires little maintenance.

• Operator cannot reach into the danger area.
• Little risk of mechanical failure; provides protection even in the event of mechanical
repeat.

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 Fig.4.1 (d) Restraint Device on a Power Press

Limitations

• Close supervision required to ensure proper use and adjustment.

• Operator must use hand tools to enter the point of operation.
• Limits the movement of the operator; may obstruct work space around operator.
• Operator may easily make device ineffective by disconnecting the device.

(3) Presence- Sensing Devices:-

Method of Safeguarding: Interlock into the machine’s control system to stop operation
when the sensing field (photoelectric, radio frequency, or electromagnetic) is disturbed.

Advantages

39
• Adjusts to fit different stock sizes.
• Allows access to load and unload the machine.
• Allows access to the guarded area for maintenance and set-up activities.

Fig.4.1 (e) Presence- Sensing Devices

Limitations

• Restricted to machines that stop operating cycle before operator can reach into danger
area (e.g., machines with partial revolution clutches or hydraulic machines).
• Must be carefully maintained and adjusted.
• Does not protect operator in the event of a mechanical failure.
• Operator may make device ineffective.

(4) Two- Hand Trip:-

Method of Safeguarding: Requires concurrent use of both hands, prevents them from
being in danger area when machine cycle starts.

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Advantages

• Operator’s hands are at a predetermined safety distance.

• Can be adapted to multiple operations.
• No obstruction to hand feeding.

Fig.4.1 (f) Two-hand Trip Device

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 Fig.4.1 (g) Two-hand Trip Device

Limitations

• Operator may make devices without antitiedown ineffective.

• Protects the operator only.
• Sometimes impractical because distance requirements may reduce production below
acceptable level.
• May require adjustment with tooling changes.
• Requires anti-repeat feature.

(5) Movable gate: - A unique safeguarding application using interlocking is the movable
gate device. It is commonly used to provide protection to an operator when hand-feeding
parts into a punch press.
Method of Safeguarding: When the machine completes its cycle or returns to top of
stroke (in the case of a power press), the gate automatically opens, allowing the operator
to remove the formed part. The operator then places a feed stock (blank) into the machine
and activates the controls to start another cycle. This can be done with either a foot
control, a single hand control, or even two-hand controls (preferred). The gate must close
before the machine can cycle. A low-pressure air cylinder attached to the gate performs
this closing function. If there are any obstructions under the gate (such as the operator’s
hands), the gate will not fully close. The interlock switch will prevent further machine
operation until the obstruction has been removed and the controls reset.
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Advantages

• Simple, few moving parts; requires little maintenance.

• Operator cannot reach into the danger area.
• No obstruction to hand feeding.

Fig.4.1 (h) Movable gate mounted on a punch press.

Limitations

• Protects the operator hands only.

• May require adjustment with tooling changes.
• Operator may make device ineffective.
• Requires little maintenance.

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 CHAPTER: 5. EXPECTED RESULT

By our best effort until now we can find out maximum optimum solutions available for our
industrial defined problem which is indicated in our report. This shows that going on right
time scale steps as we decided earlier. Due to time limit we cannot select one of the best
solutions from available solutions and not prepare documentation report for addressing
industries. but according to our progress on time scale we will complete our remaining work
in next semester and select expected result during ongoing semester that means best Safety
mechanism (safety guard) for our industry. Prepare report, which indicate our selection is
best and then offer this report to industry with all relevant data So that industry can trust on
us and approved our report. Then after, we will analyse actual work if there is any problem
regarding to our proposal, we will solved it.

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 REFERENCES

1. Alexander Cohen, PhD and Michael J. Colligan, PhD, Final Report, Safety
Sciences, San Diego CA, NIOSH Contract 210-81-3102, Nat’l Inst Occup
Safe & Hlth, Morgantown, WVA 1990.

2. Ray Asfahl, C., “Industrial Safety and Health Management”, 5th Edition,
Prentice Hall, April 1998.

3. Garde, G., “The Effects of Mode of Operation on Press Safety,” Professional

Safety, March 1975.

4. Bentley R, Horstman SW. A counseling program for worker protection from

Sapstan solution. Final Report, University of Washington Seattle, WA 1986.

5. Jensen, R. C. and T. J. Pizatella (1986), Critical Review of Studies to

Support Safe-Distance Formula for Power Press Actuation Mechanisms.
Trends in Ergonomics/Human Factors III, North Holland : Elsevier Science
Publ.

6. Aliasgar, A.; Sastry, O.K.; Hampapur, S.B.; Kamat, S.S.; Vyshak, K.V.
(2010) “Safety system for a press machine ”, 2010 2nd International
Conference on Mechanical and Electrical Technology (ICMET), Page(s):
673 – 677.

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