GURU NANAK TOOLS DOC. NO.
- GNT-OCP-017
REV. N0 - 01
Title: Operational Control Procedure for
All Operations in Press Shop REV. DATE 04.04.2025
1.0 Title: - Operational Control Procedure for All Operations in Press Shop
2.0 Purpose: -To establish safe operating procedures in order to control and minimize the damage to
human life, health, company property and environment which is apply to all types of power
presses including press brakes, except when used for working hot metal.
3.0 Responsibility: - HR Head/ Safety Officer
4.0 Definition: - For the purpose of this SOP—
(a) “Fixed fencing” means fencing provided for the tools of a power press being fencing which has no moving part
associated with or dependent upon the mechanism of a power and includes that part of a closed tool which acts
as a guard;
(b) “Power press” means a machine used in metal or other industries for pressing, blanking, raising, drawing
and similar purposes;
(c) “Safety device” means the fencing and any other safeguard provided for the tools of a power press.
5.0 STARTING AND STOPPING MECHANISM: - The starting and stopping mechanism shall be
provided with a safety stop so as to prevent over running of the press or descent of the ram during
tool setting, etc. Following are the mechanism are available in Our machines: -
For starting of machine: - Starter of the machine
For stopping of machine during break / shift end: - Starter of the machine
For stopping of machine during any emergency: - Emergency button of the machine
6.0 PROTECTION OF TOOL AND DIE: -
Each Press shall be provided a fixed guard with a slip plate on the underside enclosing the
front side of the tool. Moving cam guards shall be available on the press wherever
Curtain sensor are not feasible aur possible.
Press shall be provided a Curtain Sensor/ Poke Yoke/Photon receiver on all side wherever
there is a involvement of man during production.
Die setting blocks shall be used in press shop to prevent accidents during any working on
loaded tool on press.
For Press in which both sides, operator is doing work on part and involvement of body
parts are in between the tool bottom & down plate then two hand push buttons shall be
available for both sides to prevent the accident while performing operation.
7.0 EXAMINATION AND TESTING OF POWER PRESSES AND SAFETY DEVICES: -
(1) No power press or safety device shall be taken into use in any factory for the first time in
that factory or in case of a safety device for the first time on any press power, unless it has
been thoroughly examined and tested, in the case of a power press, after installation in
the factory, or in the case of a safety device, when in position on the power press in
connection with which it is to be used.
Prepared By :- Reviewed By: Approved By:- Issue No.- 02
Issue Date:- 04.04.2025
GURU NANAK TOOLS DOC. NO.- GNT-OCP-017
REV. N0 - 01
Title: Operational Control Procedure for
All Operations in Press Shop REV. DATE 04.04.2025
(2) No power press shall be used unless it has been thoroughly examined and tested by a
competent person (L-2 ~L4 operator/ supervisor/Maintenance supervisor)
(3) No power press shall be used unless every safety device/ Poke yoke/ Sensor other than
fixed fencing been thoroughly examined and tested by a competent person (L-2 ~L4
operator/ supervisor/Maintenance supervisor)
(4) The competent person carrying out an examination and test under the foregoing
provisions shall make a report of the examination (Daily Machine Check sheet & PM check
as per Plan)
8.0 SAFETY PROTOCOLS IN PRESS SHOP: -
Personal Protective Equipment (PPE): Mandate the use of appropriate PPE As per
PPE matrix MS-HRD-WI-003.
Traffic Management: Establish clear gangways in the shop floor to prevent
collisions and ensure safe movement of material movement forklift, pallets,
trolley and personnel.
8.1 Tool Loading & Unloading On Press Machine: -
Verify and document the condition and quantity of tools before loading as per
defined identification on tool.
The tool shall be picked for loading of Ok condition only, if not ok then handover
to tool room
Follow the instruction defined in GNT/MNT/WI/01 WI FOR TOOL LOADING &
GNT/MNT/WI/012 TOOL CHANGING WI
9.0 INSPECTION AND TEST OF SAFETY DEVICES: -
(1) No power press shall be used after the setting, re-setting or adjustment of the tools thereon
unless
a person appointed or authorised for the specific operation on press shop to judge the
machine setting & inspection of product (Quality /Production Supervisor)
a Competent Person tested every safety device thereon while it is in position on power
press ( L2~L4 Operator/ Prod. Supervisor/ Maintenance Supervisor) in Daily Poke Yoke
check sheet for machine & Tool.
a Skilled Manpower is deputed for the said operation (L2 ~ L4). Skill Matrix shall be
available of the said person.
10.0 IDENTIFICATION OF POWER PRESSES AND SAFETY DEVICES: -
For the purpose of identification every power press and every safety device provided for
the same shall be distinctively and plainly marked.
Prepared By :- Reviewed By: Approved By:- Issue No.- 02
Issue Date:- 04.04.2025
GURU NANAK TOOLS DOC. NO.- GNT-OCP-017
REV. N0 - 01
Title: Operational Control Procedure for
All Operations in Press Shop REV. DATE 04.04.2025
Machine Number, Poke Yoke Number, Sensor number Shall be provided on each machine.
11. TRAINING AND INSTRUCTIONS TO OPERATORS: -
The operators shall be trained and instructed in the safe method of work before starting
work on any power press.
Min Skill Level shall be achieved by operator to perform any operation on machine.
General Safety, 4M, Abnormal Situation, Poke yoke, Fire Safety knowledge shall be
provided to Manpower to handle the emergency & abnormal situation during production.
12 REFERENCE RECORDS: -
GNT/MNT/F/22 DAILY MACHINE CHECKSHEET
GNT/MNT/F/35 POKE YOKE DAILY CHECKSHEET
MS-PRD-WI-008 WI FOR TOOL LOADING
MS-PRD-WI-018 TOOL CHANGING WI
GNT/SF/D/04 PPE MATRIX
GNT/HR/F/04 SKILL MATRIX
Prepared By :- Reviewed By: Approved By:- Issue No.- 02
Issue Date:- 04.04.2025
