A CASE STUDY ON JOB SAFETY ANALYSIS IN

FOUNDRY PROCESS

A thesis submitted in partial fulfilment of the requirements

For the award of the degree of

Master of Engineering

in

Industrial Safety Engineering

Submitted by

THAMOTHARAN K (194IS113)

in
MECHANICAL DEPARTMENT

BANNARI AMMAN INSTITUTE OF TECHNOLOGY (An Autonomous

Institution Affiliated to Anna University, Chennai)
SATHYAMANGALAM-638401 ANNA
UNIVERSITY: CHENNAI 600 025

MAY 2021

i
 BONAFIDE CERTIFICATE

This to certify that the report on Project work titled “A CASE STUDY ON JOB

SAFETY ANALYSIS IN FOUNDRY PROCESS” is a bonafide record of the work

done by THAMOTHARAN K (194IS113) Partial fulfilment of the requirements

for the award of the degree of Master of Engineering in Industrial Safety

Engineering of the BANNARI AMMAN INSTITUTE OF TECHNOLOGY,

SATHYAMANGALAM, during the year 2019-2021

Dr. SASIKUMAR C, Mr. JISHIN JAYAN T,

Head of the Department Supervisor

Department of Mechanical Engineering Assistant Professor, Industrial Safety Engineering

Bannari Amman Institute of Technology Department of Mechanical Engineering
Sathyamangalam-638401. Bannari Amman Institute of Technology

Sathyamangalam-638401

Submitted for Viva Voce examination held on ……………

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 DECLARATION

We affirm that the project work titled “A CASE STUDY ON JOB SAFETY ANALYSIS
IN FOUNDRY PROCESS” being submitted in partial fulfilment for the award of
the degree of Master of Engineering in Industrial Safety Engineering
(Department of Mechanical Engineering) is the record of original work done by
us under the guidance of Mr.jishin jayan T, Supervisor, Assistant Professor
Industrial Safety Engineering Department of Mechanical Engineering, BIT
Sathyamangalam. It has not formed a part of any other project work(s) submitted
for the award of any degree or diploma, either in this or any other University.

THAMOTHARAN K
(194IS113)

I certify that the declaration made above by the candidates is true.

Mr. JISHIN JAYAN T,

Supervisor
Assistant Professor, Industrial Safety Engineering
Department of Mechanical Engineering
Bannari Amman Institute of Technology
Sathyamangalam - 638 401

iii
 ACKNOWLEDGEMENT

I would like to enunciate heartfelt thanks to our esteemed Chairman Dr

Balasubramaniam S V, and the respected Director Dr Vijaykumar M P, for providing

excellent facilities and support during the course of study in this institute.

I am grateful to Dr Sasikumar C, Professor and Head of the Department, Mechanical

Engineering for his valuable suggestions to carry out the project work successfully.

I wish to express our sincere thanks to the Professor-in-Charge of Industrial Safety

Engineering Mr.jishin jayan T, Assistant Professor for his constructive ideas,

inspirations, encouragement and much needed technical support extended to

complete our project work.

I would like to thank our friends, faculty and non-teaching staff who have directly and

indirectly contributed to the success of this project.

Sincerely,

THAMOTHARAN K
(194IS113)

iv
 ABSTRACT

Hazards in the foundry process have been identified and suitable prevention or
control measures for each job tasks are recommended. To identify the hazards of
each job tasks with the aim of minimizing the workers injury, ergonomics problem
and also occupational illnesses in the work place. Engineering or manufacturing
industries involve a large number of accidents compared to other industries
because they often use hazardous machinery to convert raw material into finished
product. Implementing JSA for the foundry process will reduce the hazards to an
acceptable limit. Approximately more than 50% of hazards are eliminated using
the JSA Methodology. The JSA method critically assesses the various potential
threats encounter in the workplace.

Key words: health hazard, foundry, furnace, Workers exposure, Metal fumes,
Pollution, Noise risk, PPEs.

v
 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO.

ACKNOWLEDGEMENT

LIST OF TABLES

LIST OF FIGURES

LIST OF ABBREVIATIONS

ABSTRACT

1 INTRODUCTION 1
1.1 ABOUT COMPANY 1

2 LITERATURE REVIEW 2

3 3.1 Products 8

3.2 quality, safety, health& environmental policy 11

3.3 company mission and vision 13

3.4 plant process layout 13

3.5 manufacturing process-foundry 13

3.5.1 metal charging 13

3.5.2 melting of raw material in inducton furnace 14

3.5.3 metal testing process 14

3.5.4 knock-out process 15

3.5.5 sand preparation and sand conditioning 15

3.5.6 preparation of sand moulds and cores 15

3.5.7 magnesium treatment to the metal 16

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 3.5.8 pouring of molten metal in the sand moulds 16

3.5.9 cooling and separation of castings 16

3.5.10 surface finishing of the castings 17

3.5.11 quality testing 17

3.6 Machine specification 18

3.7 machinary used 19

3.7.1 induction furnace 19

3.7.2 EOT crane 23

3.7.3 forklift 24

3.7.4 Electromagnetic crane 26

3.7.5 core shooting machine 27

3.7.6 Muller machine 29

4 OBJECTIVES 30

5 METHODOLOGY 30

5.1 Methodology involved in JSA 31

5.1.1 choosing the job to be analyzed 31

5.1.2 split the job into series of steps or task 31

5.1.3 identify all the potential hazards involved in 32

each job tasks
5.1.4 develop prevention or control measures for each 32
job tasks
5.1.5 follow the preventive measures, periodically 34
review and update if necessary

6 RESULT AND DISCUSSION 34

6.1 JSA for various jobs 35

6.2 furnace area 35

6.2.1 electromagnetic crane 35

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 6.2.2 EOT crane 36
6.2.3 manual material handling 38
6.2.4 furnace melting operation 39
6.2.5 pouring process 40
6.2.6 cleaning process
41
6.3 shell core area
42
6.3.1 muller machining process
42
6.3.2 manual shell core making
43
6.3.3 shell core shooter machine
44
6.3.4 shell core storing process
45
6.4 storage area
46
6.4.1 loading & unloading activities
48
6.4.2 dispatch area
6.4.3 gas cylinder handling activities 49

6.4.4 material handling 49

6.4.5 forklift activities 50

7 RESULT AND CONCLUSION 51

8 References 54

viii
 LIST OF TABLES

TABLE TITLE PAGE NO.

1 Machinery specification 18

2 JSA for electromagnetic crane 35

3 JSA for EOT crane 37

4 JSA for manual material handling 38

5 JSA for furnace melting operation 39

6 JSA for pouring process 41

7 JSA for cleaning process 42

8 JSA for Muller machine 43

9 JSA for manual shell core making process 44

10 JSA for shell core shooter machine 45

JSA for shell core storing process
11 45
JSA for loading & unloading activities
12 47
JSA for dispatch area
13 48
JSA for gas cylinder handling activities
14 49
JSA for material handling
15 50
JSA for forklift activities
16 51

ix
 LIST OF FIGURES

FIGURE TITLE PAGE NO.

1 Plummer block 8

2 Torque plate 9

3 Brake shoe 9

4 Differential housing 10

5 Fuel injection housing 10

6 Induction furnace 21

7 Induction furnace operation 21

8 Working principle of an induction furnace 23

9 EOT crane 24

10 Forklift 25

11 Electromagnetic crane 26

12 Core shooter machine 28

13 Muller machine 29

14 Belt conveyor 52

15 Vibratory conveyor 53

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 LIST OF ABBREVIATIONS

JSA Job Safety Analysis

EOT electric overhead travelling crane

WLL working load limit

MT Metric ton

PPE Personal protective equipment

OSH occupational health and safety

MSD musculoskeletal disorder

OSHA Occupational Health and Safety Administrative

SWL safe working load

xi
 CHAPTER 1

INTRODUCTION
1.1 ABOUT COMPANY
JOTHI GROUP of Companies, located in trichy, Tamilnadu, India, which is owned by
Mr.j.paul., it is one of the medium scale foundry company since 1973 with two manufacturing
units.

Jothi Malleables Private Limited was estatblished in the year of 1973 with expansions in
1980, 1997 and 2003 to cater to the requirements of Insulator, Tractor and Tiller, Automobile,
Valve and General Engineering Industries. In 2003 JMPL installed a fully automatic moulding
line with DISA MATCH 130 Moulding Machine along with Sand Plant, Sand Multi Controller
and Dust Collectors to become a state of the art and environment friendly with a capacity to
produce 6000 M.T per annum.

1
Foundry safety refers to ‘The management of all operations, and events within a Foundry Industry, for
protecting its employees and assets by minimizing hazards, risks, accidents and near misses.’ The
Foundry Industry is the most dangerous, Hazardous industry, because the workers working in the
foundry industry have to deal with very high temperature molten metals. Also the dusty, noisy
atmosphere is very dangerous for health. Dealing with foundry atmosphere is very difficult and
without following safety rules and regulation, it is impossible. Hence those activities should be
performed with good judgment and caution. Every company should train their workers how to deal
with Hazards, and provide them proper ‘Personal Protective Equipments (PPE).

2
 CHAPTER 2

LITERRATURE REVIEW

Elena Stefana, Paola Cocca (Published: 17 December 2019) Environmental impact and use
of energy and materials are relevant topics in companies. To achieve energy savings and enhance
environmental performance, managers can invest in technologies (technical measures) and/or
implement management practices (low-cost and non-technical measures). This paper focuses on
energy and environmental management practices in foundry, which is a particularly energy-intensive
industry producing significant carbon dioxide emissions. We conducted a scoping review of scientific
publications and technical documents to identify practices that enable energy efficiency improvement
and adverse environmental impact reduction in cast iron foundries using coreless induction furnaces.
The review returned 399 practices, which we categorised according to the process step of application
and theme. We developed a hierarchy to classify the practices according to their sustainability. The
results show that the practices proposed in the literature focus mainly on avoiding or reducing
resource consumption, rather than on recovering residual value. The intended contribution is to
promote the adoption of management practices as an effective lever to increase energy efficiency and
reduce environmental impacts, while also providing a summary of current knowledge to facilitate the
identification of areas for further research. The review could also support foundry managers in the
selection and prioritisation of the practices to adopt.

Zakaria.A.M., Noweir, K.H.( Vol. 80 No.3 & 4, 2005) The working environment of foundries is
hazardous and characterized by multiple simultaneous chemical, physical and mechanical hazards
exposure, which would lead to injuries of foundry workers. The aim of the present work is to evaluate
occupational hazards in four foundries, two in Alexandria: El Nasr and Ramsis, and two in Behira: Misr
Spinning and Weaving and Misr Rayon companies. Levels of total and respirable dust, free silica % in
total dust and lead concentration in total and respirable dust; NO2, SO2 and CO concentrations; noise
and heat stress levels have been determined in the present work. Occupational injuries data were
analyzed in a three years period from 1998 to 2000. The results of the present work revealed; 1. The
levels of total dust and respirable dust exceeded the threshold limit values at knockout and cleaning
3
operations at El Nasr Company. 2. Free silica percentage exceeded permissible levels in all operations
except pouring in El Nasr Company. 3. CO levels in Misr Spinning and Weaving Company were higher
than threshold levels. 4. Noise levels in knockout and cleaning operations at the four companies were
exceeding the threshold limit values. 5. Heat stress levels in melting and pouring operations in El Nasr
and in pouring operation in Ramsis Company were higher than the maximum permissible levels. 6.
The age group 31-40 years has recorded the highest average incidence rate of injuries of age groups
(P<0.01). 7. Lower extremities and higher extremities have recorded the highest average incidence
rate in the four companies (P<0.001-P<0.01 respectively). 8. Transportation and lifting was the main
cause of injury in the four companies (P<0.05). 9. Faulty action and striking against was the main mean
of injury in the four companies (P<0.01). 10. Ramsis Company has the highest average incidence rate
in almost all injuries parameters and indices (frequency rate and severity rate) (P<0.05-P<0.001). The
present work is a massive survey, which highlights the occupational hazards in Egyptian foundries.

Shekhar Choudhary (Volume 4, Issue 09, March 2018) Indian construction industry is
passing through very unique phase. Massive infrastructure like, National Highway, Dam construction
for Irrigation, Airports up-gradation for Tourism of domestic & International tourists, Urban rapid
transportation like Metros, Bus Rapid Transport system Flyover poised to grow exponentially within
last 10 years. This situation leads to excellent opportunities for the construction industry in terms of
business opportunity. This also leads to Indian economic growth even through FDI. Many national
constructions housed such as Hindustan Construction Company, DLF, Tata projects and Larson & Turbo
limited actively managing projects in India & Aboard. Job safety analysis (JSA) was one of the great
methods used for the purpose of safety analysis. Here we approach the method on construction area
and also elaborate our results. We are here provide a vast knowledge of various hazards developed in
the construction department with their brief study and also give knowledge of solving and overcoming
these hazards.

K.M. Maneesh (Volume 4 Issue 8, August 2015) This paper studies and analyzes the safety
aspects by identifying existing or potential job hazards in the workplace. The project was carried out in
a public sector foundry industry. The objective of the project was to eliminate and prevent hazards at
workplace and to increase the production and profit of the company by minimising casting defects.

4
Accident history of the company was studied, it was found that burning injury during casting process
has the highest rate of disabling injuries and illness and the main reason for the injuries was due to
the defects in the mould. Pareto chart and cause effect diagram are effective tools for casting defect
analysis. The design of experiments was used to analyze the sand related defects in green sand
casting. The green sand related process parameters considered are, moisture content, green
compression strength and permeability. For optimization of the process parameters, Taguchi based L9
orthogonal array was used for the experimental purpose and analysis was carried out using Minitab
software.

Marcela G. Ribeiro (Volume 136, Issue 3, 25 August 2006) In Brazil, problems regarding
protection from hazardous substances in small-sized enterprises are similar to those observed in
many other countries. Looking for a simple tool to assess and control such exposures, FUNDACENTRO
has started in 2005 a pilot-project to implement the International Chemical Control Toolkit. During
the series of visits to foundries, it was observed that although many changes have occurred in foundry
technology, occupational exposures to silica dust and metal fumes continue to occur, due to a lack of
perception of occupational exposure in the work environment. After introducing the Chemical Toolkit
concept to the foundry work group, it was possible to show that the activities undertaken to improve
the management of chemicals, according to its concept, will support companies in fulfilling
government legislations related to chemical management, occupational health and safety, and
environmental impact. In the following meetings, the foundry work group and FUNDACENTRO
research team will identify "inadequate work situations". Based on the Chemical Toolkit,
improvement measures will be proposed. Afterwards, a survey will verify the efficiency of those
measures in the control of hazards and consequently on the management of chemicals. This step is
now in course.

Christopher T. Mgonja (Vol. 4 Issue 6, June 2017) Some heavy metals have bio-importance as
trace elements but, the biotoxic effects of many of them in human biochemistry are of great concern.
Hence, there is the need for proper understanding of the conditions, such as the concentrations and
oxidation states, which make them harmful, and how biotoxicity occurs. It is also important to know
their sources, leaching processes, chemical conversions and their modes of deposition to pollute the

5
environment, which essentially supports lives. Literature sources point to the fact that these metals
are released into the environment by both natural and anthropogenic sources, especially mining and
industrial activities, and automobile exhausts (for lead). They leach into underground waters, moving
along water pathways and eventually depositing in the aquifer, or are washed away by run-off into
surface waters thereby resulting in water and subsequently soil pollution. Poisoning and toxicity in
animals occur frequently through exchange and co-ordination mechanisms. When ingested, they
combine with the body's biomolecules, like proteins and enzymes to form stable biotoxic compounds,
thereby mutilating their structures and hindering them from the bioreactions of their functions. This
paper reviews certain heavy metals and their biotoxic effects on man and the mechanisms of their
biochemical activities.

Duruibe(April 2005) Integrating environment development, as the objective of the research in this
paper, is to define a model to implement and monitor the key indicators of energy use efficiency as an
instrument of an effective environmental and energy management in the metal sector in Bosnia and
Herzegovina (B&H). The used environmental data contribute to a more efficient use of energy as well
as to a reduction of emissions and effects on the environment.

Jeshua Sargetis (Spring 2016) An evaluation of current industrial hygiene practices were
performed at a foundry located in the Northwestern United States. The foundry was evaluated for
respirable and inhalable manganese, respirable crystalline silica and noise exposure. Personal
breathing zone sampling was performed using proper safety and health practices on workers in the
foundry and around the entire facility. Results showed that workers were being exposed to respirable
manganese but not inhalable manganese. Bulk crystalline silica sampling was performed and personal
breathing zone sampling was performed as a follow up to certain control measures which showed low
concentrations. Area noise sampling was conducted in various parts of the facility and personal noise
dosimetry was performed on workers in all areas of the facility. Noise exposure above the OSHA PEL
was found in a few sites but most of the limits were above the OSHA Hearing Conservation criterion.
Few locations were over the NIOSH and ACGIH criterions. Engineering control measures included a
ventilation system being installed above the furnaces, for metal fume control, the paving of a back lot

6
to reduce exogenous crystalline silica from the foundry. Hearing protection, along with the inclusion of
a revised hearing conservation program, was also implemented for reduced worker exposure.

Christopher T (Vol. 4 Issue 6, June 2017) The working environment of foundries is hazardous
and characterized by multiple simultaneous chemical, physical and mechanical hazards exposure,
which would lead to injuries of foundry workers. Health risks from working in the foundry industry
include exposure to molten metal fume (foundry fume), heat and spray mists. In addition to these
hazards; some foundry workers work with dusts produced by casting sand, fettlings and kiln linings,
which contain silica and, when dry, produce silica dust known as respirable crystalline silica (RCS). This
paper provides an overview of foundry industry and hazards, health effects and safety measures. It
presents the information currently available from different published research works and involves the
group of people that can be affected by foundry hazards including foundry workers and nearby
workers. It further indicates how the foundry industry contributes to environmental pollution.
Through this review, it has been revealed from different studies that hazards in foundries are many
and very dangerous both to foundry workers’ health and to the environment which eventually affect
the wider population.

Manu Khare ( august 2016) Sand casting, also known as sand moulded casting, is a metal casting
process characterized by using sand as the mould material. Over 60% of all metal castings are
produced via sand casting process. Sand control is the key to good foundry sand practice. It is very
important to note that almost 70% of total casting defects occur due to an improper quality of sand
mould. Hence, many industries want to use the fresh sand for the moulding purpose. However, due to
environmental concerns there is a need to investigate the applicability of return sand for sand
moulding. This paper investigates the possibility of using ‘used’ or ‘return’ sand for the mould
preparation. Several combinations of return sand and other additives have been experimentally
investigated for moisture content, compressive strength, hardness, and permeability and the
optimum combination has been selected. The results have shown that up to 80% of return sand could
be used with optimum combination of other additives giving relatively high compressive strength and
permeability. This would give significant reduction in sand cost and also better utility of return sand as
a step towards sustainable manufacturing

7
 CHAPTER - 3
3.1. PRODUCTS
JOTHI GROUP manufactures all auto mobile spare parts like fuel injection housing,
differential housing, flange halfs, brake shoe, torque plate, Plummer block etc.,

We are manufacture all automobile product based on the customer requirements, there are 22
types of alloy combination are used to manufacture the product. Main alloys such as,

 Carbon

 Silicon

 Nickel

 Chromium

 Magnesium

 Manganese

 Phosphorus

 Copper

Fig.1.plummer block

13
Fig.2.torque plate

Fig.3.brake shoe

14
 Fig.4.differential housing

Fig.5.fuel injection housing

3.2. QUALITY, SAFETY, HEALTH & ENVIRONMENTAL POLICY

We are committed to our growth with the satisfaction of our customers through

15
  Quality products and services
 On time delivery
 Development of products
 Engagement of personnel
 Protection of the environment
 Prevention of pollution and
 Prevention of health and safety incidents

This is achieved through Total Productive Maintenance (TPM) practices with the
emphasis on

 Creating awareness on quality, safety, health and environment

 Creating values to customers (Lean management)
 Development of suppliers, technology, processes and equipment
 Education and training
 Multi skill enhancement
 Safe and clean environment

 Elimination of health and safety hazards and reducing the risk associated
 Periodic health monitoring of employees
 Loss elimination and cost reduction
 Ensuring employee participation

3.3. COMPANY MISSION AND VISION

Mission is to deliver world class products at affordable prices on time to the
customers.

Vision is to be the most preferred brand while ensuring the long term health and
progress of JOTHI GROUP through continuous improvement and suitable policies.

3.4. PLANT PROCESS LAYOUT

16
3.5. MANUFACTURING PROCESS-FOUNDRY

3.5.1. METAL CHARGING

Furnace charging systems are designed to deliver charge material to the furnace quickly to allow for
maximum utilization of the melting system. We offer a variety of systems for assembling and moving
scrap and other charge materials to the melt deck and into the furnace. These systems include
charge buckets, belt conveyors and vibratory, pivoting, traversing and holding conveyors. Manual
charging and most magnets have difficulty keeping pace with large induction furnaces that are able
to melt a full charge in less than 30 minutes. Furnace charging systems are available in various
configurations and modes of motion. In general, popular charging system options are belt conveyors,
buckets and vibrating conveyors.

3.5.2. MELTING OF RAW MATERIAL IN INDUCTION FURNACE

17
The raw materials charged into induction furnaces are Pig iron, steel scrap, sorrel metal, ferro alloy
and graphite, foundry rejects and returns. Depending upon the type of castings to be produced the
proportion of raw materials is varied.

The raw materials are charged into the medium frequency 5 tonne capacity induction furnace and
melted to molten state by inducing electric current. Medium frequency melting has been chosen as
there is more flexibility, comparatively less installation cost and no heel metal is required in the
crucible before switching on to melt. Similarly, while tapping, the entire crucible can be emptied,
fresh charge added without loss of time for each cycle of melting. The added advantage in induction
melting is, if there is power interruption, the metal can be allowed to be solidified and on resumption
of power supply, the solidified metal can be re-melted.

3.5.3. METAL TESTING PROCESS

we are using a hot dip method of measuring the temperature of the hot liquid bath inside the
induction furnace by using thermocouple. Is there any other method of measuring the temperature of
the hot molten metal in the furnace? we thought of using infrared measurement temperature
equipment but as slag is formed on top of the liquid metal ,temperature received could have an error.
we require to measure up to 1700 degree Celsius.

3.5.4. KNOCK-OUT PROCESS

In investment casting, the term knockout refers to the process of removing the ceramic mold from the
casting. after the poured casting have cooled to an acceptable temperature, they are transferred to
the knockout area. Having served its purpose, the ceramic molds are broken off the casting utilizing a
combination of jackhammer-like tools and manual force. While the process is violent, loud and messy,
it effectively yields near-net-shape parts ready for the next step in investment casting.

3.5.5 SAND PREPARATION AND SAND CONDITIONING

Moulds of the required shape and size are prepared under Green sand moulding process. Under this
process the required washed, dried and graded sand procured from outside is mixed with bentonite

18
(clay) and coal dust, which acts as a binding material and water. Then they are thoroughly mixed in
Intensive Mixer.

Sand Conditioning is very important as there should be proper permeability to allow the gases to
escape and we should also get the right mould hardness to get quality castings without sand defects
like sand drops, blow holes etc.

The surface finish of the casting also depends upon to a certain extent on proper sand conditioning.
After proper conditioning of the sand, it is transferred to a storage hopper by means of conveyors.
From the hopper the sand is transported using conveyors to the individual moulding machine
hoppers. Proper metal to sand ratios will be adopted and the requisite quantity of fresh sand will be
added in each mixing cycle. Similarly, the unwanted sand in each cycle will be discarded also.

3.5.6. PREPARATION OF SAND MOULDS AND CORES

Fully automatic Programmable Logic Circuit (PLC) based sand plant with Sand Multi Controller checks
and adjusts the compatibility and strength of every batch of the sand mixture before moulding so as
to send only accepted quality of sand into the system. Fully automatic moulding line with High
Pressure Match plate Moulding machines, with an average production rate of about 350 moulds/hr,
DISAMATIC 130B for making vertical flask less moulds with dimension of 535 x 650 x 120 – 395 mm (H
x W x T).Fully automatic moulding line with High Pressure flask less vertical plotted moulding
machine, with an average production rate of about 350 moulds/hr, DISAMATIC 2013B for making
vertical flask less moulds with dimension of 535 x 650 x 120 – 395 mm (H x W x T).Fully automatic and
semi-automatic core box machines along with shell core making facilities are available. The core box
with core print is anchored and supported adequately.

3.5.7. MAGNESIUM TREATMENT TO THE METAL

In case of grey iron there is no treatment of metal involved. However, in the case of SG Iron, in
converter vessel the molten metal with the right composition of other elements has to be treated
with pure magnesium of the required percentage. This alloy reacts with the molten metal which
when solidified gives properties of steel in physical strength and the properties of cast iron are
retained.
19
3.5.8. POURING OF MOLTEN METAL IN THE SAND MOULDS

In grey iron castings the melted iron from the furnaces is tapped into ladles and then poured in the
sand moulds. For SG iron castings preparation, the converter treated molten metal is then poured in
pressurized pouring furnace for pouring into moulds. At automatic mould conveyor liquid metal from
press pour poured in to the moved at about 1420 oC after completion of pouring mould in to
synchronized belt conveyor continuously. After two (2) hrs. mould is falling in to vibrator.

3.5.9. COOLING AND SEPERATION OF CASTINGS

After pouring the molten metal into the sand moulds, which is allowed to cooling for two (2) hour.
After cooling the mould and casting are knockout at vibrator and fall in to the DISA Cool drum. At
DISA Cool drum the sand from the casting completely separated. Water sprayed in to the drum for
cooling the sand then through the perforated holes sand is separated and travelled through serious
of belt conveyors to reach the returned sand hopper. Casting came out from the drum and fall on the
metallic conveyor, and goes to the shot-blasting machines.

3.5.10 SURFACE FINISHING OF THE CASTINGS

Shot blasting is the most efficient and mechanical method of removing the unwanted particles.
Casting is hung from hooks in a moving conveyor inside a chamber. The particles of shot are thrown
at the casting by means of centrifugal force and steel balls are placed through the conveyor bucket on
the rotating vanes and blasted in to the chamber and hanged castings are cleaned. This method has
preening effect on the surface and it makes the surface bright and shiny. The rejected casting will be
returned to the melting department for re-melting. Eight (8) shot blasting machines are available now
and it will be increased to eleven (11) after the proposed expansion.

20
Grinding is usually performed using portable or stationary pedestal grinders. After shot blast, the
excess materials and parting line flashes are removed by grinding then the castings are sent for
further process.

3.5.11. QUALITY TESTING

All the castings are tested for dimension, visual, physical test, hardness, X-ray, ultrasonic and other
required properties. Good castings are sent to dispatch section for packing and partial castings will be
sent to powder coating/painting area for further coating and then machining process.

3.6 MACHINE SPECIFICATION

MACHINE NUMBER CAPACITY

INDUCTUON FURNACE 3 500KG
INDUCTION FURNACE 2 1500KG
INDUCTION FURNACE 2 1000KG
EOT CRANE 3 3TON
ELECTRO MAGNETIC 2 3TON
CRANE
FORKLIFT 6 2000KG
SAND MIXTURE 1 1650KG

Table 1. Machinery specification

21
3.7 MACHINARY USED

3.7.1 INDUCTION FURNACE

An induction furnace is an electrical furnace wherein the warmth is applied by induction
warming of metal. Induction furnace limits range from short of what one kilogram to 100 tons,
also, are used to mellow iron and steel, copper, aluminum, and significant metals. The potential
gain of the acceptance heater is an ideal, energy-capable and well-controllable melting measure
stood out from most various techniques for metal dissolving. Most current foundries use this
sort of heater, and now moreover more iron foundries are displacing vaults with acceptance
heaters to mellow project iron, as the past produce a ton of buildup and various pollutions.
Since no roundabout section or consuming is used, the temperature of the material is no higher
than expected to mellow it; this can hinder loss of significant alloying parts. The one critical
impediment to acceptance heater use in a foundry is the shortfall of refining limit; charge
materials ought to be perfect of oxidation things and of a known design and some alloying
segments may be lost in light of oxidation (and ought to be re-added to the condense).

Activity

1. Melt

2. Water-cooled coil

3. Yokes

4. Crucible

An induction furnace comprises of a nonconductive cauldron holding the charge of metal to be

liquefied, encircled by a loop of copper wire. An amazing exchanging current move through the
wire. The loop makes a quickly switching attractive field that infiltrates the metal. The attractive
field actuates vortex flows, roundabout electric flows, inside the metal, by electromagnetic
induction. The whirlpool flows, moving through the electrical obstruction of the mass metal,
heat it by Joule warming. In ferromagnetic materials like iron, the material may likewise be

22
warmed by attractive hysteresis, the inversion of the atomic attractive dipoles in the metal.
When liquefied, the whirlpool flows cause incredible blending of the dissolve, guaranteeing
great blending.

A benefit of induction heating is that the heat is produced inside the furnace's charge itself as
opposed to applied by a consuming fuel or other outside heat source, which can be significant
in applications where pollution is an issue. Working frequencies range from utility recurrence
(50 or 60 Hz) to 400 kHz or higher, normally relying upon the material being liquefied, the limit
(volume) of the furnace and the liquefying speed required. For the most part, the more modest
the volume of the melts, the higher the recurrence of the furnace utilized; this is because of the
skin profundity which is a proportion of the distance an exchanging current can enter
underneath the outside of a conductor. For a similar conductivity, the higher frequencies have a
shallow skin profundity—that is less infiltration into the liquefy. Lower frequencies can produce
mixing or choppiness in the metal. A preheated, one-ton furnace dissolving iron can soften cold
charge to tapping preparation inside 60 minutes. Force supplies range from 10 kW to 42 MW,
with liquefy sizes of 20 kg to 65 tons of metal individually. A working induction furnace for the
most part discharges a murmur or a whimper (because of fluctuating attractive powers and
magnetostriction), the pitch of which can be utilized by administrators to distinguish whether
the furnace is working effectively or at what force level.

23
 Fig 6. Induction Furnace

Fig 7.induction furnace operation

The induction warming deals with the guideline of transformer activity. The transformer
working guideline depends on the "Faraday's law of electromagnetic induction". This exchanges

24
the electrical energy from primary side to the secondary side (circuit) of the transformer. The
functioning standard of induction furnace is like the eddy current loss in transformer.

This loss is disseminated as heat in the transformer centers. On the off chance that such a
misfortune as warmth is used in warming of materials, at that point it will be valuable to warm
up the charge.

While rotating current streams in a conductor, it produces switching attractive field.

In the event that any curl is set in this turning around attractive field, an emf will prompt in it.
Like the emf prompted in the auxiliary of a transformer. This exchange of electric energy from
essential twisting to the optional twisting by electromagnetic induction is used to shape the
heat.

The heat developed in the charge mainly depends upon the accompanying elements:

(i)The power drawn by the charge.

(il) Supply voltage and current

(iii) The resistance of the charge.

The force relies on the voltage, power recurrence and the obstruction of the charge, power

attracted is equivalent to V2/R. In this way, to create adequate measure of warmth for one liter
of the charge,

1)Resistance of the charge should be low which s conceivable just with metal.

2)Voltage should be higher which is gotten by utilizing higher motion and higher frequency.

25
 Fig 8: Working principle of an Induction Furnace

3.7.2. EOT CRANE

Foundry Crane is additionally called Ladle Crane, it is huge projecting lifting gear on lifting and
unloading steel ladle in foundry workshop, every now and again utilized in high temperature,
high residue and related unforgiving conditions, with high wellbeing execution and high
working-level, for the most part isolated into double shaft double track, four-bar four-track or
four-pillar six-rail structures.

Twofold support twofold track single streetcar structure is for the most part utilized for little
weight foundry crane under 160 tons, comprises of streetcar, scaffold, crane and streetcar
voyaging instrument and electric control framework, and so on. A total of 7 cranes each with a
capacity of 10T is used in the moulding lines.

26
 Fig 9. EOT crane

3.7.3 FORKLIFT
A forklift (also called lift truck, jitney, fork truck, fork hoist, and forklift truck) is a powered
industrial truck used to lift and move materials over short distances. The forklift was developed
in the early 20th century by various companies, including Clark, which made transmissions,
and Yale & Towne Manufacturing, which made hoists. Since World War II, the use and
development of the forklift truck have greatly expanded worldwide. Forklifts have become an
indispensable piece of equipment in manufacturing and warehousing.

Forklift control and capabilities

Forklift hydraulics are controlled either with levers directly manipulating the hydraulic valves or
by electrically controlled actuators, using smaller "finger" levers for control. The latter allows
forklift designers more freedom in ergonomic design.

Forklift trucks are available in many variations and load capacities. In a typical warehouse
setting, most forklifts have load capacities between one and five tons. Larger machines, up to 50
tons lift capacity, are used for lifting heavier loads, including loaded shipping containers.

In addition to a control to raise and lower the forks (also known as blades or tines), the operator
can tilt the mast to compensate for a load's tendency to angle the blades toward the ground

27
and risk slipping off the forks. Tilt also provides a limited ability to operate on non-level ground.
Skilled forklift operators annually compete in obstacle and timed challenges at regional forklift
rodeos.

Fig 10. forklift

3.7.4 ELECTRO MAGNETIC CRANE

MW5 series lifting electromagnets for cranes are appropriate for projected ingot, steel ball, pig
iron, machine chip, different sorts of steel scraps, return scraps, trimming, baling scraps, etc in
foundry industrial facilities and iron powder in coal washeries. During slag removal measure, it
can eliminate enormous size of iron at introductory advance. Outlet box has two chambers, an
extra-thick bumper and an enemy of turn setting. There are three excitation alternatives:
appraised voltage DC220V; solid excitation; over excitation. A total of 3 cranes with a capacity
of 5T each is used in the raw material loading/ unloading area.

28
 FIG 11. Electromagnetic crane

3.7.5 CORE SHOOTING MACHINE

Here, the core sand is shot into the core box at high speed which leads to a sudden expansion of
a limited volume of compressed air. Due to this, the filling process is associated with a
certain compaction of the mold material. Both damp and dry mold materials can be shot into
cold or hot core boxes depending on the procedure. Using core production according to the cold
box process as an example, the way in which a core shooting machine works is explained below:
The mold material fed in after the machine bunker has be prepared. It is then shot into
the core box. The core box is clamped hydraulically which prevents the core box from moving
during shooting and gassing. The clamping and separating devices can be changed so that it is
possible to work with vertically and horizontally core boxes. After the mold material has been
shot via the shooting unit which is pressed on the core box, the hardening device is brought in
and the hardening process is carried out. The separating process then begins. The movable part
of the core box is turned and the core is pushed out of the solid core box part onto the

29
transport belt (Film). The molding tools can be made of wood, plastic or metal. The choice of
material is dependent on the size of the series. The gassing plate must be sealed well and
constructed in such a way that the hardening gas can penetrate all areas of the core evenly. Air
vents which ensure a good, even ventilation of the core must be brought into the core boxes.
The larger the ventilation cross section, the lower the flow resistance during gassing and the
faster.The core hardens.

The core boxes are constructed in such a way that the ventilation cross sections (core box vents)
cover 3 to 5% of the core box surface. The core boxes can be laid out as a closed or open
system. In a closed system, residual catalyst and scavenging air are collected in the core box
itself and then fed to the exhausting plant. In an open system, the excess catalyst escapes from
the core box and is extracted by an air curtain which prevents it from flowing into the
surrounding air and is fed to the disposal equipment.

Fig 12. Core shooting machine

30
3.7.6 MULLER MACHINE
Sand Mix Muller Machine is most popular in all type and size of Foundry. ... It works on the
principal to achieve better green strength & permeability possible with the given Mixture. The
Study Chassis is robustly constructed from heavy section M.S. capable of continuous heavy &
hard use.
USAGE
A machine for mixing sand and binders by a kneading and squeezing action for use in sand
molds. The mixture is usually sand, clay, and water, but synthetic chemical binders may be
used

Fig 13. Muller machine

31
 CHAPTER 4

OBJECTIVES
 To minimize or prevent the incidents/accidents
 To enable the organizational safety performance and achieve safety goals
are in the place
 To eliminate or control the hazards of all activities to an acceptable limit

32
 CHAPTER 5
METHODOLOGY
A Job Safety Analysis provides step-by-step approach to implementing the
preventive measures that reduce or eliminate and mitigate hazards. It is one of the
identification of hazards and risk analysis method (David D Glenn, 2011). It is a
dynamic technique for ensuring the health and safety in workplace and Muchamad
Sugarindra told it focuses on the direct interconnection between the worker, the job
tasks, the tools, the equipments, the materials and the work environment. The JSA
technique provides a route or way of identify work-related hazards and determine
suitable preventive safety measures.

JSA is applicable for all types of jobs and it is a best way to determine and
establish proper work procedures is to perform job safety analysis. It helps reduce
employee illness and injury, increased quality and productivity, proper material
handling technique, proper sequence of work practices and reduced worker’s
compensation costs, allows for better working conditions including ventilation and
lighting (Occupational Health and Safety Administrative- Department of Labour, 2002).

5.1 METHODOLOGY INVOLVED IN JSA

JSA is an analytical or systematic approach and it consists of following five steps

 Choosing the job to be analyzed

 Split the job into series of steps or tasks
 Identify all the potential hazards involved in each job tasks
 Develop prevention or control measures for each job tasks
 Follow the preventive measures, periodically review and update if necessary

5.1.1 Choosing the job to be analyzed

The motor manufacturing process involves many processes such as grinding, pressing,
CNC turning, and etc. Muchamad Sugarindra, Muhammad Ragil Suryoputro and Adi

33
Tiya Novitasari, 2017) choosing a job based on highest severity rate, near miss cases,
non-routine job tasks, repetitive jobs, past incidents or accident history and
possibility for injury or incidents with serious consequences, introducing new methods
and procedures, jobs with loss of productivity, excessive generation of waste, the job
was done by new people, and also introduction of new tools, raw materials and
equipment. The motor manufacturing process therefore chooses to conduct job safety
analysis.

5.1.2 Split the job into series of steps or tasks

Process involves number of operations and operation involves the number of job
tasks. Jobs must be divided into basic steps or tasks in the proper order. Divide the job
into tasks based on the knowledge of the particular job. The best method way to split the
job is to observe when employees are working. The fact that completing a specific task
involves proper work sequences is nothing but Standard Operating Procedure (SOP).
For example, the grinding operation divided the following sequence of job tasks by
Malgorzata Kowalczyk
Task 1: Connecting machine to the power
source Task 2: Pick up the component
Task 3: Mounting the component in
machine Task 4: Start the machine
Task 5: Perform grinding operation
Task 6: Remove and replace the component

5.1.3 Identify all the potential hazards involved in each job tasks

This step involves identifying all potential hazards (health hazards and
machinery hazards) in the motor manufacturing process. The person analyzing should
carefully observe all the possibilities of accidents in every job tasks. To identify hazards,
he must watch the activities as many times as may be required and also have discuss
with workers and concern for others who are knowledgeable about a particular job and

34
also discuss with the employee any incidents, difficulty of doing the work, improvement
required for particular job. The following types of hazards are identified by (Guidelines
for safe use of machinery, 2014)

 Mechanical hazard: Entanglement (contact with nip point), crushing, cutting

 Chemical hazard : Inhalation of welding fumes, paint fumes, metal fumes
 Physical hazard : Slip and trip, temperature, vibration, slippery floors
 Ergonomic hazard : Awkward posture, improper lifting, excessive pushing
 Electrical hazard : Electric shock, electrocution

5.1.4 Develop prevention or control measures for each job tasks

The final step of the JSA involves how to eliminate or reduce the identified
hazards. Hierarchy of hazards control is used to determining the preventive or control
measures identified it consists of following five steps
 Eliminate the hazard

This eliminates hazards physically and is a very effective way to control

the hazards. Replacing an existing process, modifying or changing new tools or
equipment, choosing another method, using LOTO technique by (Oregon OSHA
guide) to controlling hazardous energy these are eliminate the hazards. For example hot
burns caused by fall of the welding component provide a stopper at the worktable to
prevent the fall of hot object.
 Substitute the hazard

It changes or alters the hazards. Substituting the hazard with a less

hazardous or non hazardous substance. But it does not create the new hazards after
implementing or introducing new substance. For example, replacing lead based paint
with acrylic paint.
 Engineering control

This is next best way to control the hazards and which does not eliminate
hazards but isolates people from the hazards which mean a physical barricade between
the worker and hazard. It includes the provisions of local exhaust ventilation (LEV)

35
system by (Health and Safety Executive, 1999) provide machine guarding system and
adding safety devices. For example provide a fixed guard to the chain drive and sprocket
to prevent it from hazardous area (nip point).
 Administrative control
Administrative control means changing the way of people work. This
includes modifying the work procedure (adding or changing contents), training for
employees and establishing warning signs or labels to protect against hazards, provide
rest pause cycle and rotational jobs. For example establishing warning signs in the hot
work area to prevent hot objects from touching.

 Personal Protective Equipment (PPE)

It is least effective way to control or reduce the hazards by JHA guide.

The PPE is a simple or small device that prevents employees from injury. In some
accidents, the PPE can provide 100% protection. In some accidents, the severity of the
injury will be reduced. For example, handling with sharp objects, using of leather gloves
and can give user comfort and doing spray painting wearing half- face mask by
(Guidance Notes on Paint Spraying, 2003)

5.1.5 Follow the preventive measures, periodically review and

update if necessary
After implementing preventive measures, workers are forced to follow these
preventive measures and employers must communicate to all workers. It should be
reviewed the after each incidents and updated with JSA on changes made in the process
and others.

36
 CHAPTER 6
RESULTS AND DISCUSSION
The project was done in foundry industry and recommendations are given each
job tasks for prevent the hazards such as amputation, stuck between objects, penetration
of sharp edges, awkward position, fall of objects, electric shock, inhalation of welding
fumes, inhalation of chemical, inhalation burring fumes, hitting the stationary object,
slip/trip hazards, hot burns, respiratory problems and others. By using this tool of Job
Safety Analysis, we can minimize the risks during the job tasks.

6.1 JSA FOR VARIOUS JOBS

JSA were carried out the processes such as material storing, melting, pouring,
sand mixing, sand blasting, welding, manual material handling, testing, dispatching,
transporting, EOT crane operation, forklift operation, electromagnetic crane operation,
casting operation, shell core making, gas cylinder,


6.2 FURNACE AREA
6.2.1 Electromagnetic crane
Sequence of job steps Potential hazards Preventive measures

Pick the raw material and
lifting by using
electromagnetic crane
Rope wear and tear may be
occurs.
Incase power goes off the
material may fall down
causing damage to property
or injury and fatal to person.
Regularly check crane
checklist by crane operator.
Arrange alternative power
(generator) source while using
electromagnetic crane.
Person stand 10 feet away
from the material.

Fencing the storage place.

37
Moving the raw material
towards container
Placing the raw material to
container
Crane maintenance work
Table 2. JSA for electromagnetic crane
6.2.2 EOT crane
Sequence of job steps
Crane hook connected with
container
Lifting the container
Material fall from height due
to Hit on the nearest material, furnace area.
it may causes injury to
labours.
If crane operator
Forgetting touch the place
button on the remote, it
causes material fall from
height and damage the
property.
Placing Material hit on the
container edge and scattered
to the surrounding surface.
It may causes injury to
labours.
Labour Fall from height may
be occurs.
Potential hazards
Container falling may be
occurs, due to improper hook
hanging on 4 corners of
container.
Cutting of wire rope while
lifting causes damage of
property and may be injured
to workers.
38
Keep good housekeeping in
To give training awareness
from the crane to employee.
Not to place any material in
crane path way.
Employees must wear proper
PPEs.
( helmet, gloves, goggles)
Operate the crane, if material
is closer to container body
then only operator press
placing button.
Labour must wear safety belt
and helmet and other PPEs.
Preventive measures
Container must be hanging
each 4 corners properly then
only crane lifting the material.
Must check Lifting container
weight within crane lifting
capacity.

Moving the container towards
furnace area
Placing the container near to
the furnace
Table 3. JSA for EOT crane
6.2.3 Manual material handling
Sequence of job steps
Pick the raw material from
container manually
Keep the load and move
towards furnace
Container hit on the
obstacles. it causes damage of operate crane activities.
the material.
Operator moves container
with over speed. It causes
damage property and
material.
Careless of employee, slip and
trip may be occurs due to hit
on the container.
Potential hazards
Employees carry a scrab
material to our hand, it may
cause hand injury.
Hit the leg on obstacles it
cause employee fall down
39
Crane Periodically
maintenance is must to be
followed.
Crane checklist is regularly
checked by the crane
operator.
Follow SWL properly.
Authorized person only
Operate the crane with
limited speed.
Container storing place is
separate from employee walk
way.
Preventive measures
Employee wear gloves while
manual material handling is
must.
Using belt conveyor for
transporting the material.
To keep the proper cleaning
work and good housekeeping.
 near to the furnace. Must Wear proper PPEs.
(goggles, gloves, safety jacket
and safety shoes)

Using the belt conveyor for

carry a load towards to the
furnace.

If the employee put the raw

Put the raw material to the material to the furnace, fire Avoid Closed and semi closed
furnace manually flash take place surrounding container to put the furnace.
of furnace area. To use vibrator for put the
material to the furnace.

Must use vibration conveyor

for put the raw material into
the furnace.

Table 4. JSA for Manual material handling

6.2.4 Furnace melting operation

Sequence of job steps Potential hazards Preventive measures

Temperature checking Heat radiation is affected Furnace should be guarded by

employee body. fencing.

In case of any slip and trip Employee must wear heat

occurs employee fall into the resistance jacket and goggles
furnace. and PPEs.

Alloy composition checking In case of any slip and trip Employee must wear heat
occurs employee fall into the resistance jacket and goggles
furnace. and PPEs.

Heat radiation is affected Furnace should be guarded by

employee body. fencing.

Operator till the furnace for Fire flash takes place due to Don’t put closed or semi
fully combustion. non-combustion of material. closed container to the

40

Grinding process
Table 5. JSA for furnace melting operation
6.2.5 Pouring process
Sequence of job steps
Movement of ladle towards
the furnace
Tilt the furnace for pouring
the molten metal into ladle.
Pouring the molten metal into
the line ladle
In grinding process employee
hand injury may be occurs.
Potential hazards
High speed of ladle
movement is Chance to Ladle
hit on the employee and
induction furnace.
It leads to causes injury to
employee.
In case of ladle movement is
slow; molten metal from the
furnace is spills to
surrounding .it causes burn
injury to employee.
Molten metal scattering to
the surrounding area due to
41
furnace .because, if any oil or
water content inside the
container it makes fire flash.
Particular authorized person
only working in grinding
machine.
We must wear proper PPEs.
(gloves, goggles ,etc,.)
Preventive measures
Induction training must be
conduct the employee for
aware from the furnace
operation.
Authorized person only
operate ladle with proper
speed.
When the ladle is place on the
furnace, siren alarm is on by
ladle operator, here after
furnace operator tilt the
furnace for pouring.
Employee must wear heat
resistance jacket and face
shield, safety shoes and all
PPEs.
Must Keep distance from
ladle.
 improper setting of line ladle
and Over filling of molten
metal on line ladle, it
scattering the surrounding
area.
Must wear safety shoes, heat
resistance jacket, gloves and
all PPEs.

It causes harm to employee.

Pouring of molten metal from If pouring molten metal from
line ladle into treatment ladle. the line ladle, the treatment
ladle is slightly oscillation
molten metal is scattering to
the surrounding area.
When the Oscillation is stop in
treatment ladle, here after
only pouring molten metal
from line ladle.
Use properly all PPEs.

Remove the unmolded metal Molten metal is spill on Use lengthy things to handle
in the line ladle. employee’s legs. and remove unmolded metal
from ladle.

Wear proper PPEs.

Movement of treatment ladle
towards to the sand molding
line.
Ladle is hit on the obstacles
due to blind spot.
We are facing some kind of
accident while moving the
ladle.
If treatment ladle is moving
before employee check the
path of ladle way and blind
spot.

Tilt the treatment ladle for
pouring the molten metal into
the sand mould.
Spilling of molten metal take
place and molten metal
scatter ladle operator body.
Keep distance from the
casting.
Cover entire body with fire
and heat resistance jackets,
must wear safety shoes.

Table 6. JSA for Pouring operation

42
6.2.6 Cleaning process
Sequence of job steps
Chip and waste removing
from the furnace area
Cleaning the induction
furnace
Slag removal
Table 7. JSA for cleaning process
6.3 SHELL CORE AREA
6.3.1 Muller machining process
Sequence of job steps
Resin oil and catalyst powder
mixing process
Potential hazards
Trip and fall take place in
furnace area due to poor
cleaning.
Coming in contact with
protruded waste.
Hand harm take place when
furnace in heat condition.
Molten metal splashing
Exposure to high
temperature.
Potential hazards
Inhalation of catalyst power it
causes respiratory problems
to employees.
Slip and trip hazard in Muller
machine.
43
Preventive measures
Maintain Proper cleaning and
housekeeping.
Must Use gloves for cleaning
process of chip and waste.
Employee must clean inside
the furnace only shutdown
and maintenance day.
Must wear Body armor, and
proper PPEs.
Preventive measures
Must wear face mask while
handling catalyst powder
Saree wearing Lady
employees not to work in this
Muller machine because of
Muller machine have one
ladder.
Employee claim the ladder

Collect the sand from Muller
machine.
Table 8. .JSA for Muller machining process
6.3.2 Manual shell core making-hand molding
Sequence of job steps
Store the sand into the table.
Mixing sodium silicate oil and
silica sand.
Dump sand manually into the
die.
Co2 gas insert to the die.
Manual material handling
which cause musculoskeletal
disorder.
Dust flying in sand mixing area Proper Material handling
it affects employee
respiratory problems.
Potential hazards
Employee stores the sand
manually and handles the
sand with their hands.
It causes musculoskeletal
disorder.
In case of inhalation of sand,
it causes health problem of
employee.
Employee dumps the sand
into the die manually, and it
creates respiratory problems
among foundry workers.
In case of over leakage co2
gas employee affect by
headaches, dizziness and loss
of consciousness.
44
here after put the sand into
the Muller machine.
Must wear face mask to avoid
respiratory problems from
sand mixing.
steps to be followed.
Preventive measures
To use belt conveyor for
transport the sand.
It reduces the muscle injury.
To use respirator while
handling mixing of sands and
wear hand gloves.
To use face mask while dump
the sand into the die.
It reduces the respiratory
problems.
Check your appliances
regularly.
If you detect a gas leak, turn

Cores remove from die.
Table 9. JSA for manual shell core making process
6.3.3 Shell core shooter machine
Sequence of job steps
Apply oil in the machine die.
Switch on the machine
Collect the core from the
machine.
Core removes from die
manually and stored in rack.
Inhalation of sand is a serious
health concern.
Potential hazards
Fumes developed due to
using lubrication oil in the die.
Continuously inhalation of
fumes, It causes breathing
problem.
Injury due to contact with
rotating parts can be severe.
in running nip point hazards
are caused by the rotating
parts on machinery.
Slowly rotating machine can
pull hair and cloth towards
machine direction.
It affects hand injury.
It makes respiratory
problems.
45
off the gas supply.
Wear safety goggles with side
shield.
Must wear skin protection
PPEs.
Preventive measures
Fumes collector must used in
shell core shooter machine.
Use local exhaust ventilation
system.
Install vacuum dust-collector
bag in machine.
Revolving machinery
Keep 1 meter distance from
the machine.
Shell core machine must be
needed proper wiring &
guarding.
If collect the core from die,
employee must use heat
resistance gloves.
Use respirator while handling

shell core hardening process We are mixing solvent to
(firing) apply on core, for hardening.
If any easily flammable
material near to this place, it
catch fire easily.
Table 10. JSA for Shell core shooter machine
6.3.4 Shell core storing process
Sequence of job steps Potential hazards
Storing Core fall down and
Shell core store into the rack damage property.
from shooter machine.
Loading & unloading of shell Material handling injuries can
core lost productivity and decrease
employee morale.
Table 11. JSA for shell core storing process
6.4 STORAGE AREA
6.4.1 Loading & unloading activities :(white sand)
Sequence of job steps Potential hazards
Vehicle Transportation for If vehicle come reverse inside
46
machine to avoid respiratory
problems.
Employee must knows
knowledge about fire
extinguisher.
Wear fire-resistance
protective clothing.
Preventive measures
Shell core to store in rack
within the rack capacity.
Rack is separate from forklift
path because of reduce
forklift accident.
Use the right steps to loading
& unloading activities.
Rack should be guarded
.
Preventive measures
To keep proper housekeeping
unloading raw material
Vehicle door opening
Pick the raw material from the to improper handling of
vehicle
Move the raw material to
storage area
the compound, accident may inside the company storage
be occur due to blind spot and area.
obstacles.
Chance to hit to the person
If the vehicle back door is
open any person on the edge
of the truck, may chance to
fall down.
If truck back door is open by
one person the material fall
over that person.
Hand tear may be occurs due
materials.
Material fall down hazard
occurs.
Accident may be occurs due
to any obstacles in the moving in the moving path.
47
Vehicle driver must want one
assistance to guide the
direction of the vehicle path.
Vehicle reverse horn must
required.
Hand break must applied.
If the Vehicle door is open
the worker must watch the
top of the vehicle, if no
worker is in the top , here
after he open the vehicle
door.
Two or three people must
open the vehicle door.
To use proper hand gloves for
using manual material
handling.
to use hand trolley and
conveyor to unload the
material.
Management must tell about
Proper material handling
techniques effectively.
Maintain good housekeeping

Place the raw material on
storage area
Conveyor operation
Table 12. JSA for loading & unloading activities
6.4.2 Dispatch area
Sequence of job steps
Storing dispatch materials
Lifting dispatch material
path.
Material fall down hazards
occurs due to improper
storing of material.
A cleaning cloth or clothing
gets caught in the conveyor
and pulls fingers or hands into
the conveyor.
Improperly guarded gear,
sprocket and chain drives,
horizontal and vertical
shafting, belts and pulleys,
and power transmission
coupling.
Falling materials or object
from height.
Potential hazards
Heat radiation hazard
Container fall down hazard
48
To store the material one by
one properly in storage area.
Tells the knowledge about
conveyor to the workers.
Specific trained person only
work near to the conveyor.
Periodically check the
conveyor guards are in good
condition.
Don’t wear full coat dresses.
Don’t over load it.
Avoid work in underground
of the conveyor.
Preventive measures
To must wear heat resistance
clothes.
Container storage should be
free from working area.
Regularly check container
 take place. weight is not exceeding to
crane capacity.

Must close the container door

properly.

Placing dispatch material Material fall down occurs. Crane operator place the
container slowly to smooth
surface .

Table 13. JSA for dispatch area

6.4.3 Gas Cylinder handling activities

Sequence of job steps Potential hazards Preventive measures

Transportation of gas cylinder Improper transportation We are using Cylinder trolley

(Rolling) for transportation the cylinder
from one place to another
place.

Cylinder blasting will happen. Don’t dump the cylinder from

the height.

Storage of cylinder in working Placing flammable cylinder Must Proper permit to work is
area near furnace area followed by the company.
Exposure of cylinder to high
temperature.

Rolling of cylinder occurs. Cylinder should be must in

vertical manner and it should
be locked by chain.

Table 14 . JSA for gas cylinder handling activities

49
6.4.4 Material handling
Sequence of job steps
Oil and solvent handling
activities.
Chemical handling process.
Table 15. JSA for material handling
Potential hazards
Fire hazard due to oil spillage
because of high flash point.
Many solvents emit enough
vapor to form flammable
mixtures with air. Any spark,
even from static electricity,
can cause a fire.
health hazard may be occurs.
50
Preventive measures
Employee must knowledge
about how to handling
hazardous oil and awareness
from oil and solvent handling.
Before opening or dispensing
solvents or fuels, make sure
the containers are grounded,
either with ground wires,
metal to metal contact
between containers, or direct
contact with the ground.
Handle solvents in well-
ventilated areas and keep
containers closed when not in
use.
Always label all containers
with chemicals.
Use protective equipments
for eye protection and make
sure to wear a laboratory
coat.
Avoid intentional smelling,
inhaling and tasting of
chemicals.
6.4.5 Forklift activities
Sequence of job steps
Driving of forklift
Lifting material using fork
Transporting the material
Unloading the material
Table 16. JSA for forklift activities
Potential hazards
Break failure may be occurs.
Not proper Training to driver.
Reverse blind spot hazard
Improper lifting leading to
material damage.
Speed limit, turning at high
speed leading toppling of
forklift.
Improper unloading of
material from fork on to
uneven surface.
51
Preventive measures
Daily start work before
checking of forklift checklist.
Monthly maintenance is must.
Forklift driver conform Fork is
properly attached to
container, here after lift the
material.
Authorized person only drive
the forklift.
Driver drive forklift within
18mph inside the company
premises.
while turning use the horn.
Must watch unloading area it
is smooth, here after place
the container here.
 CHAPTER - 7
RESULT AND CONCLUSION
The preventive measures have been identified and it shall be communicated to all
employees who are carrying out in different hazardous operation. Encouraging the workers
to be aware of occupational health and safety and to use safety measures efficiently. In
order to create health and safety, industry should follow hierarchy of controls which
include elimination, substitution, engineering controls, administrative controls and personal
protective equipment. The following recommendations are given below
 Modifying the workstation to avoid ergonomic problems
 Correct PPE for correct jobs
 Conduct medical checkups for workers periodically
 Preventive maintenance should be carried out periodically to avoid
breakdown maintenance
 Provide essential equipment such as first aid kit, fire alarms, safety
alarms and sprinklers in the event of an emergency

Furnace is considered to be the most hazardous so, the workers are suggested not to
handle the metal manually for charging in the furnace. We following the suggestions can
be used as an alternative for charging metal into the furnace.

Belt Conveyors

Belt conveyors provide an effective way to move charge material from a lower level to a higher
level, such as from a scrap storage area to a holding hopper on the melt deck. They are fast,
quiet and generate minimal dust.

52
 Fig 14. Belt conveyor

Vibratory Conveyors

Vibratory conveyors are the most versatile and rugged of all furnace charging systems. They
may be in fixed positions for holding, consolidating, weighing (with optional weigh frame and
load cells) and transferring charge materials, or they may be extremely mobile. In addition,
vibrating conveyors have been built to traverse, pivot and index, all in the same unit. As a
result, this mobility enables a vibratory conveyor to service any number of furnaces. Largely
unaffected by heat, vibrating conveyors are ideal for feeding charge materials directly into an
induction furnace that typically run at full power during the charging process.

Fig 15. Vibratory conveyor

53
 CHAPTER - 8
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