M1283

Industrial safety
Fall 2023

Safety improvement
 Introduction
To improve safety at workplace it is needed to work on the three lines of
defense against health hazards:
A) Engineering controls
B) Administrative or work practice controls
C) Personal protective equipment
Engineering controls deal directly with the hazard by removing it,
ventilating it, suppressing it, or otherwise rendering the workplace safe
and healthful.
A) Engineering controls includes applying ergonomic by:
➢ Workplace (Health, Safety and Welfare) Regulations
➢ Health and Safety (Display Screen Equipment) Regulations
➢ Manual Handling Operations Regulations
➢ Noise at Work Regulations
➢ Ionizing Radiations Regulations
 Workstation ergonomic design improvements
• Ergonomics is the study of the interaction between workers and their
work in the broadest sense, in that it encompasses the whole system
surrounding the work process.
• It is concerned with the work organization, process and design of the
workplace and work methods as it is with work equipment.
• The common definitions of ergonomics, the ‘man–machine interface’
or ‘fitting the machine to the man rather than vice versa’.
• It is concerned about the physical and mental capabilities of an
individual as well as their understanding of the job under
consideration.
 Workstation ergonomic
• Ergonomics includes the limitations of the worker in terms of skill
level, perception and other personal factors in the overall design of
the job and the system supporting and surrounding it.
• The scope of ergonomics and an ergonomic assessment is very wide
incorporating the following areas of study:
➢ personal factors of the worker, in particular physical, mental and
intellectual abilities, body dimensions and competence in the task
required
➢ the machine and associated equipment under examination
➢ the interface between the worker and the machine – controls,
instrument panel or gauges and any aids including seating
arrangements and hand tools
➢environmental issues affecting the work process such as lighting,
temperature, humidity, noise and atmospheric pollutants
➢ the interaction between the worker and the task, such as the
production rate, posture and system of working
 Workstation ergonomic , Contd.
➢ the task or job itself – the design of a safe system of work, checking
that the job is not too strenuous or repetitive and the development of
suitable training packages
➢ the organization of the work, such as shift work, breaks and
supervision
• The reduction of the possibility of human error is one of the major
aims of ergonomics and an ergonomic assessment. An important part
of an ergonomic study is to design the workstation or equipment to fi
t the worker.
• The physical measurement of the human body and an understanding
of the variations in these measurements between people is essential.
Such a study is known as anthropometry, which is defined as the
scientific measurement of the human body and its movement.
• Since there are considerable variations in, for example, the heights of
people, it is common for some part of the workstation to be variable
• (e.g. an adjustable seat)
Workstation design
 The Control of Vibration at Work
Hand-held vibrating machinery (such as pneumatic drills, sanders and
grinders, powered lawn mowers and strimmer and chainsaws) can
produce health risks from hand–arm or whole body vibrations.

Injuries which can be caused by hand-arm vibration

 The Control of Vibration at Work
The Control of Vibration at Work Regulations introduce, for both hand-
arm and whole-body vibration, a daily exposure limit and action values:
1. For hand-arm vibration
(a) the daily exposure limit value normalized to an 8-hour reference
period is 5 m/s2
(b) the daily exposure action value normalized to an 8-hour reference
period is 2.5 m/s2
2. For whole-body vibration
(a) the daily exposure limit value normalized to an 8-hour reference
period is 1.15 m/s2
(b) the daily exposure action value normalized to an 8-hour reference
period is 0.5 m/s2
An exposure limit value must not be exceeded. If an exposure action
value is exceeded, then action must be taken to reduce the value. The
expression A(8) is added to the exposure limit or action value to denote
that it is an average value spread over an 8-hour working day.
 The Control of Vibration at Work
• There are several ways to ascertain the size of the vibration generated
by equipment and machines.
• Manufacturers must declare vibration emission values for portable
hand-held and hand guided machines and provide information on risks.
Other important sources for vibration information include scientific
and technical journals, trade associations and on-line databases.
• Experience shown that the vibration level is higher in practice than that
quoted by many manufacturers. The reasons for this discrepancy may
be that:
➤the equipment is not well maintained
➤the equipment is not suitable for the material being worked
➤ the accessories are not appropriate or badly fitted, or
➤ the operative is not using the tool properly.
Important measures which should be taken to reduce the risks associated
with hand-arm vibration:
 Risks reduction with hand-arm vibration
1. avoid, whenever possible, the need for vibration equipment
2. undertake a risk assessment which includes a soundly based estimate
of the employees’ exposure to vibration
3. develop a good maintenance regime for tools and machinery. This may
involve ensuring that tools are regularly sharpened, worn components are
replaced or engines are regularly tuned and adjusted
4. introduce a work pattern that reduces the time exposure to vibration
5. issue employees with gloves and warm clothing. There is a debate as
to whether anti-vibration gloves are really effective but it is agreed that
warm clothing helps with blood circulation which reduces the risk of
vibration white finger. Care must be taken so that the tool does not cool
the hand of the operator, and
6. introduce a reporting system for employees to use so that concerns and
any symptoms can be recorded and investigated.
 Display screen equipment (DSE)
• Eye strain is a particular problem for people who spend a large
proportion of their working day using display screen equipment.
• A survey has indicated that up to 90% of DSE users complain of eye
fatigue. Unnecessary eye strain can be reduced by:
➤ Train staff in the correct use of the equipment
➤ Ensure that a font size of at least 12 is used on the screen, and
➤ Regular breaks away from the screen (every 20 minutes)
The screen should be adjustable in tilt angle and screen brightness and
contrast.
Finally, the lighting around the workstation is important. It should be
bright enough to allow documents to be read easily but not too bright so
that either headaches are caused or there are reflective glares on the
computer screen.
 Workplace environment
Workplace environment:
1. Ventilation,
2. Heating and temperature,
3. Lighting,
4. Workstations and Seating.
Ventilation
Should be effective and sufficient and free of any impurity and air inlets
should be sited clear of any potential contaminant.
Heating and temperature
During working hours, the temperature in all workplaces inside buildings
shall be reasonable (not uncomfortably high or low). ‘Reasonable’ is
defined in the Approved ( at least 16ºC, up to 28ºC).
 Workplace environment
Lighting
Suitable and sufficient lighting and this shall be natural lighting so far as
is reasonably practicable.
Suitable and sufficient emergency lighting must also be provided and
maintained in any room where workers are particularly exposed to
danger in the event of a failure of artificial lighting (normally due to a
power cut and/or a fire).
Light levels are
measured in
illuminance, having
units of lux (lx), using
a light meter.
Poor lighting levels will
increase the risk of
accidents such as slips,
trips and falls.
 Workstations and seating
• Work must be done safely and comfortably. The worker should be at a
suitable height relative to the work surface and there should be no need
for excessive bending and stretching.
• Workers must not be expected to stand for long periods of time
particularly on solid floors.
• A suitable seat should be provided when a substantial part of the task
can or must be done sitting.
• The seat should, where possible, provide adequate support for the lower
back and a footrest provided for any worker whose feet cannot be
placed flat on the floor.
• It should be made of materials suitable for the environment, be stable
and, possibly, have arm rests.
• It is also worth noting that sitting for prolonged periods can present
health risks, such as blood circulation and pressure problems, vertebral
and muscular damage.
 Noise
The main purpose of the Noise
Regulations is to control noise levels
rather than measuring them. This
involves the better design of machines,
equipment and work processes, ensuring
that personal protective equipment is
correctly worn and employees are given
adequate training and health
surveillance.
The vibrations cause a pressure wave.
The ear may detect vibrations which
vary from 20 to 20000 (typically 50–
16000 Hertz – Hz).
Sound travels through air at a finite
speed (342 m/s at 20ºC and sea level).
Noise normally describes loud, sudden,
harsh or irritating sounds.
 Health effects of noise
• It can lead to ear damage; temporary (acute) or permanent (chronic)
There are three principal acute effects:
➤ temporary threshold shift – caused by short excessive noise exposures
and affects the cochlea by reducing the flow of nerve impulses to the
brain. The result is a slight deafness, which is reversible when the
noise is removed
➤ tinnitus – is a ringing in the ears caused by an intense and sustained
high noise level. The ringing sensation continues for up to 24 hours
after the noise has ceased
➤ acute acoustic trauma – caused by a very loud noise such as an
explosion. It affects either the eardrum or the bones in the middle ear
and is usually reversible.
• Severe explosive sounds can permanently damage the eardrum.
• Occupational noise can also lead to one of the following three chronic
hearing effects: noise-induced hearing loss, permanent threshold
shift, tinnitus
 Noise control techniques
• In addition to reduced time exposure of employees to the noise source,
there is a simple hierarchy of control
➤ Reduction of noise at
source (e.g. replace solid
tires with rubber tires or
replace diesel engines with
electric motors)
➤ Reduction of noise levels
received by the employee
(attenuation) (Re-location,
Enclosure, Absorption walls,
Damping, Silencers)
➤ Personal protective
equipment, which should
only be used when the
above two remedies are
insufficient.
 Ionizing Radiations
• Extremes of temperature: At high temperatures, the body has more difficulty in
maintaining its natural temperature unless sweating can take place and therefore water
must be replaced by drinking. If the surrounding air has high humidity, evaporation of
the sweat cannot take place and the body begins to overheat. This leads to heart strain
and, in extreme cases, heat stroke.
➤ At low temperatures, the body will lose heat too rapidly and the extremities of the
body will become very cold leading to frostbite and possibly the loss of limbs.
• Ionizing radiation: emitted from radioactive materials, either in the form of directly
ionizing alpha and beta particles or indirectly ionizing X- and gamma rays or
neutrons. It has a high energy potential and an ability to penetrate, ionize and damage
body tissue and organs.
• Acute exposure can cause, dependent on the size of the dose, blood cell changes,
nausea and vomiting, skin burns and blistering, collapse and death. Chronic exposure
can lead to anemia, leukemia and other forms of cancer.
• Sources of ionizing radiation: nuclear industry, medical centers (hospitals and
research centers) and educational centers. Radioactive processes are used for the
treatment of cancers and radioactive isotopes are used for many different types of
scientific research. X-rays are used extensively in hospitals, but they are also used in
industry for nondestructive testing (e.g. crack detection in welds). Smoke detectors,
used in most workplaces, also use ionizing radiations.
B) Guarding the equipment
Guarding the equipment
Machine Guarding
 Mechanical hazards
• All parts of the machine which move while the machine is working can
cause mechanical hazards. These can include reciprocating, rotating,
and transverse moving parts, as well as feed mechanisms and auxiliary
parts of the machine.
1. Point of operation
2. Power transmission
3. In-running nip points
4. Rotating or reciprocating machine parts
5. Flying chips, sparks, or parts
Many machines throw off chips or sparks.
One means of protecting workers from flying
chips and sparks is by personal protective
equipment. But this is not nearly as effective
as using machine guards
 Machine Guarding, Contd.
• Guarding By Location Or Distance: The easiest and cleverest way to guard
a machine is not to use any physical guard but, to design the machine or
operation so as to position the dangerous parts where no one will be exposed
to the danger.
• Tagouts and Lockouts: A surprising number of industrial machine accidents
occur not when the machine is in operation, but when it is down for repair.
• The tagout system is a simple system that involves the use of a “tag” clipped
on to the on- off switch or control box.
The lockout system utilizes locks for which the
maintenance person is the only one with a key.
• Zero Mechanical State: Machines can quietly hold
dangerous energy even when they are turned off.
Various forms of energy can be stored, such as
pneumatic or hydraulic pressure, electrically charged
capacitors, spring tension or compression, or kinetic
energy from flywheel rotation.
 Machine Guarding, Contd.
• Interlocks: Like what cause clothes dryers to stop rotation as soon as the door
is opened, and thus comply with industry safety standards for revolving
drums, barrels, and containers.
• Trip bars: stop the machine if the operator
falls into or trespasses into the danger zone.
• Fan blade guards: OSHA
(Occupational Safety and Health
Administration) standard requires that
fan blades have guards whose
openings do not exceed 1/2 inch.
• Anchoring fixed machinery: required for all machines designed for a fixed
location. Machines that have reciprocating motions, such as presses, have a
tendency to "walk" unless securely anchored.
• Safeguarding the Point Of Operation: One principle of machine guarding is
the maximum permissible opening size. If the guard is immediately adjacent
to the danger zone, no opening should be large enough to permit a finger to
reach through.
Machine Guarding, Contd.
 Machine Guarding
• Presence-sensing devices: One type uses a bank of photoelectric cells to set
up a light screen, the penetration of which will immediately stop the ram. It
becomes a game for workers to defeat these devices. Some workers aim
flashlights or other sources of light to maintain the sensors in an energized
condition. Sometimes ordinary ambient light in the factory may keep sensors
energized. The infrared frequencies rather than in the visible light spectrum
may have some advantages. Presence sensing device sometimes uses a
conductor to set up an electro-magnetic field in its vicinity.
 Machine Guarding
• Hold-outs: Hold-outs look almost exactly like pullbacks, but the big difference is that
the hold-out reach is fixed and does not permit the operator to reach in at all, even
between strokes of the machine.
• Two-hand controls: Require both hands to operate the controls, or so the theory goes
the next figure illustrates a two hand control device and some of the features that
attempt to prevent the worker from defeating the device. The machine will stop if
released.
 C) Personal protective equipment
Protective Clothing:
• Chemical protection coverall
• Coverall
• Leather Welder’s Apron
• Steel Toe
(Foot protection)

Face Protection includes:

• Visor carriers in both cap-attachable and
brow guard styles with a wide range of
visors.
Head Protection
• Hard hats
Head and Face
Protection
• Face shield with
Helmet
 Personal protective equipment, Contd.
Hearing Protection
• Earplugs
• Earmuffs
Disposable Ear Plugs Reusable Ear Plugs Ear Muffs

Hand Protection
Work gloves must be job fitted to ensure that they are comfortable and
suited to the task at hand.

Cut Resistant Chemical Resistant Insulated/Welding/ Temperature Resistant