008 Machinery Safety

PREMIER PLASTIC COMPANY
SOP FOR SAFETY OF & FROM MACHINES

DOCUMENT CODE: 008 DOCUMENT STATUS: RELEASED
ISSUE DATE :25/08/2019 CREATED BY: HSSE DEPARTMENT
REVISION DATE: APPROVED BY: GENERAL MANAGER
REVISION NUMBER: 00 RECHECKED BY: COMMMERCIAL MANAGER
1. OBJECTIVE:
The purpose of this Health, Safety and Environmental (HSE) Standard Operating Procedure
(SOP) is to provide program to control safety risks associated with operation and maintenance
of machinery or equipment.
Workplace activities such as operation, installing, setting up, adjusting, inspecting, modifying
and maintaining or servicing of machines or equipment could expose workers to the
unexpected energization or start –up of the equipment or other extreme hazards unless
appropriate precautions are taken.
There are numerous potential hazards around machinery and equipment, such as cutting
edges, gears, chains, revolving shafts, rotating blades and levers which could lead to:
 Entanglement
 Shearing or puncture from sharp objection
 Impact
 Cutting
 Electrocution
 Physical injury ranging from minor lacerations to amputation
 Crushing injuries
 Entrapment
 Fatality
2. SCOPE:
The requirements outlined in this SOP are applicable to all Premier Plastic Company
employees, business units, contractors, and visitors who are working for Premier Plastic
Company and conducting work in the premises.
3. DEFINITIONS & ABBREVIATIONS:
HAZARD A LIKELIHOOD OR RISK OF HARM OR INJURY.

SAFETY GUARD A BARRIER BETWEEN THE MOVING PARTS OF MACHINE &
OPERATOR.
PPC PREMIER PLASTIC COMPANY
PPC/HSSE/SOP/008/REV 0 DATED 25 AUGUST, 2019 Page 1 of 6

“Printed copies of this document are uncontrolled”
HSSE HEALTH, SAFETY, SECURITY AND ENVIRONMENT

WHMIS WORKPLACE HAZARDOUS MATERIAL INFORMATION SYSTEM
MSD MUSCULO SKELETAL DISORDER
IER INDUSTRIAL ESTABLISHMENT
JHSC JOINT HEALTH AND SAFETY COMMITTEE
RESPONSIBILITY: All employees/Operators/helpers
ACCOUNTABILITY: Plant manager/supervisor/maintenance
VERIFICATION: HSSE Representative
4. MACHINE SAFETY:
Today people are still becoming injured, sick or killed as a result of hazards around machinery and
equipment in every industry. Many of these accidents are caused by human error.
4.1 WORKPLACE EQUIPMENT HAZARD

There are two categories of machinery hazard as identified in BS EN ISO 12001-1:
 Mechanical Hazard – resulting due to direct contact with moving parts of machines.
(E.g. entanglement, crushing, cutting, friction or abrasion, impact, ejection, injury by
emission of air or fluid).
 Non- Mechanical Hazard – associated with the usage of machines often with its work
environment and other aspects of the machine’s operation.
(E.g. electricity, heat, noise, vibration, manual handling, access hazard, radiation and
chemical hazard).
4.2 CONTROLS
The best way to avoid machinery hazard is by separating the machinery from reachability of
people, which can be achieved by-
 Distance – Separating the people from the machine.

 Barrier – Denying access to the machine through specific barriers.
 Time – Disabling the equipment under risk during the time of access.

4.3 SAFEGUARDING MACHINERY

Types of guards and protective control devices to prevent access to the dangerous part of a
machine or to stop the moving parts before any part of a person enters the danger zone –
 Fixed guards – Physical barrier, not connected to machine controls and

requires a tool to remove it.
 Interlocked guards – Linked with machine controls and cannot be opened
when the
machine is in dangerous condition.
 Adjustable guards – It can be fixed or automatic adjustable. Used to
accommodate a range of material sizes.
 Protection devices – switches off the machine upon contact or when the light beam is
broken. Does not prevents access to dangerous parts of machinery but if
operating correctly, stops the movement of any dangerous part of
machinery before any part of a person enters a danger zone,
E.g. Trip devices, Photo electric safety system (light beam), pressure sensitive
mats, etc.
 Emergency stop controls – Emergency stop controls are designed
to stop machinery operation immediately to control situation that
arise due to accidental obstruction of body parts trapped in
machine or materials getting stuck. It has to be used only when
normal stopping conditions are inadequate and should be
positioned where it is easily visible and accessible to the workers.
Different forms of emergency stop controls are-
1) Mushroom-headed buttons
2) Bars
3) Levers
4) kick-patterns
 Hold-to-run control devices – The operator has to hold the control device at all times for
to operate the machine. Release of the device will cause the
machine to shut off during any emergency situation.
 Other Protection Appliances – Jigs (fixed device designed to
retain a work piece in a particular position).
Holder (simple hand held device that secures the work piece).
Push sticks (is a device to push the work piece through the
equipment).
4.4 FACTORS TO BE CONSIDERD FOR APPROPRIATE SELECTION AND DESIGN OF GUARDING

 Is compatible with the process, e.g. Resistant to dust, chemical, etc.

 Is of good construction.
 Has adequate strength.
 Is situated at a safe distance from the danger zone.
 Does not restrict operator’s view of the hazard.
 Is not easy to by-pass.
4.5 INFORMATION, INSTRUCTION, TRAINING AND SUPERVISION

Organizational and behavioural controls are also necessary, e.g. safe systems of work, permit-to-
work, discipline, etc. information, instruction, training and supervision should include:
 How the machine is to be operated
 Who will operate the machine
 When it will be cleaned
 When it will be serviced
 Action to take in emergency
 Acton to be taken in case of breakdown
 How, and to whom, report faults.
4.6 HIERARCHY OF MEASURES
To select the appropriate guard the following hierarchy of measures must be considered, a
combination of below precautions may be necessary to prevent machinery hazard:
 Fixed guard enclosing every dangerous part.
 Interlocked guards.
 Adjustable/self-adjusting guards
 Trip devices.
 Protective appliance
 Provision of IITS.
5. CONDUCTING MAINTENANCE SAFELY

The person performing the maintenance task may face certain risk therefore in order to avoid undue
risks, following points must be considered to minimize risk and complete the task safely.
 Safely Isolating /locking off sources of energy

 Use of permit-to-work system in high risk situation, e.g. whole body access to a machine.
 Prevent unauthorized entry to work area.
 Safe system of work and safe means of access.
 Use of competent personnel.
 Use of personal protective equipment.
6. RESPONSIBILITIES OF OPERATORS
 Only operate if authorized to use.
 Follow instruction and training.
 Only use for its intended purpose.
 Carry out safety checks before use.
 Not use if it is unsafe.
 Report defects immediately.
 Not use under influence of drugs or alcohol.
 Keep equipment clean and in safe order.
7. REFERENCES & RECORDS
 Daily Safety checklist for injection molding machine – PPC/HSSE/F 020/Rev. 1 Dated 25/1/2021
 Daily Safety checklist for extrusion blow molding machine – PPC/HSSE/F 021/Rev. 1 Dated 25/1/2021
 Daily Safety checklist for pet stretch molding machine – PPC/HSSE/F 022/Rev. 1 Dated 25/1/2021
 Daily Safety checklist for wad fixing machine – PPC/HSSE/F 023/Rev. 1 Dated 25/1/2021
 Daily Safety checklist for Sleeving machine – PPC/HSSE/F 024/Rev. 1 Dated 25/1/2021
Rev. No. Rev. Date Rev. Detail Need of Rev. Applicable from
1 25/1/2021 Change in daily safety checklist Revised Risk Assessment 25/1/2021
PPC/HSSE/F18/Rev. 1 Dated 25/1/2021





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PREMIER PLASTIC COMPANY

SOP FOR SAFETY OF & FROM MACHINES

3. DEFINITIONS & ABBREVIATIONS:

HAZARD A LIKELIHOOD OR RISK OF HARM OR INJURY.

PPC/HSSE/SOP/008/REV 0 DATED 25 AUGUST, 2019 Page 1 of 6

HSSE HEALTH, SAFETY, SECURITY AND ENVIRONMENT

RESPONSIBILITY: All employees/Operators/helpers

ACCOUNTABILITY: Plant manager/supervisor/maintenance

VERIFICATION: HSSE Representative

4.1 WORKPLACE EQUIPMENT HAZARD

 Distance – Separating the people from the machine.

PPC/HSSE/SOP/008/REV 0 DATED 25 AUGUST, 2019 Page 2 of 6

4.3 SAFEGUARDING MACHINERY

 Fixed guards – Physical barrier, not connected to machine controls and

PPC/HSSE/SOP/008/REV 0 DATED 25 AUGUST, 2019 Page 3 of 6

 Is compatible with the process, e.g. Resistant to dust, chemical, etc.

4.5 INFORMATION, INSTRUCTION, TRAINING AND SUPERVISION

4.6 HIERARCHY OF MEASURES

5. CONDUCTING MAINTENANCE SAFELY

PPC/HSSE/SOP/008/REV 0 DATED 25 AUGUST, 2019 Page 4 of 6

3 25/1/2021 Change in daily safety checklist Revised Risk Assessment 25/1/2021

4 25/1/2021 Change in daily safety checklist Revised Risk Assessment 25/1/2021

5 25/1/2021 Change in daily safety checklist Revised Risk Assessment 25/1/2021

PPC/HSSE/SOP/008/REV 0 DATED 25 AUGUST, 2019 Page 5 of 6

PPC/HSSE/F22/Rev. 1 Dated 25/1/2021

PPC/HSSE/SOP/008/REV 0 DATED 25 AUGUST, 2019 Page 6 of 6

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