PROJECT PREPARED BY:

GUIDE :
MAYUR VAGHASIYA.
PROF. NIRAV
(090370119013)
GANDHI
APURV LALPURWALA.
(090370119012)
REPRESENTATIVE RAVIRAJ DESAI.
OF (090370119017)
INDUSTRY: PRARTHAN
 RAJUBHAI JAISWAL RAMBHAPURWALA.
(090370119090)
PARUL INSITITUTE OF ENNG. &. TECH.,
LIMDA .
MECHANICAL DEPARTMENT.

Project Team:ME-06
PROJECT DURATION:- APRIL 2012-APRIL 2013
  CONTENTS
1. ABSTRACT

2. ACTION PLAN ON TIME SCALE

3. INTRODUCTION TO PROJECT

4. PROJECT OBJECTIVES

5. HISTORY OF THE WORK

6. LITERATURE REVIEW

7. IMPLEMENTATION OF PROJECT WORK

8. EXPECTED RESULT

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

 So we proposed mechanism to an industry which

attach to mechanical press machine and this mechanism
functioning fulfill when worker hand operate this mechanism with
press machine, so insure worker hands are outside the accident
zone. Due to this proposes safety mechanism worker hands are
safe and protected from any accidental injury. This project
proposes safety mechanism with improved response time on
industrial machineries than existing machine guards.
 2. ACTION PLAN ON TIME SCALE
 Visit to industry in summer for 20 days.
 Find different problem related to our industry.
 Select the most important problem of our industry.
 Find maximum available solutions for selected problem of our
industry.
 Select best expected solution from the available solutions.
 Create documentation report to offer an agenda for addressing
industry needs and improving workplace safety.
 Actual result analysis from our addressing documentation report.
 Conclusion.
 3. INTRODUCTION TO PROJECT
BASIC INFORMATION OF INDUSTRY:-

• LK Industries is the manufacturer of various Chassis Parts, Clutch &

lever, Door Part, Exhaust Systems and Accessories and also
manufacture automotive components Stampings & Pipe Assembly.

• In 1982, LK was established in vadodara to manufacture heavy sheet

metal parts/fabrication.

• L.K. industry is medium scale industry.

 INTRODUCTION :-

• Now a days, all responsible industries recognize the duty of care

they owe their employees. In every way, therefore, creating a
safe industrial environment is a wise investment.

• Main content of our industrial defined problem is to manage

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

 Safety Risks associated with

• Mechanical hazards
• Non-mechanical hazards
• Access hazards
Safety Problem Associate with Press Machine operation

Punching Action (Fig.1(a)) begins

when power causes the machine to
hit a slide (ram) to stamp or blank
metal or other material.

Bending Action (Fig.19(b)) is

power applied to a slide to draw or Fig.1 (a) Punching Action
stamp metal or other materials in a
bending motion.

• The hazard occurs at the point

of operation where the employee
typically inserts, holds, or
withdraws the stock by hand.
Fig.1(b) Bending Action
 Introduction to Problem:-

1. Worker’s Safety Problem in Press Machine:

An appraisal of the state of safety measures with respect to
press machine involved in accidents reveals that those lacking hands
safety devices. An examination of the behavior of workers at the time
of accidents indicates that many accidents involved unsafe activities,
such as using one's hands instead of hand tools and/or removing
safety device. Such accidents show a slow declining trend while the
total number of press machine accidents has been decreasing.
2. Lack of Selection of Proper Safety Mechanism (Safety Guard)
in Industry:

There are many safety mechanism available in market, but

problem arise for small and medium scale industries to select safety
mechanism which depends on worker’s interest, efficiency,
productivity, cost effectiveness and easy to use for a longer time.
 4. PROJECT OBJECTIVES
 Select optimum safety mechanism (Safety guard) out of
available safety mechanisms.

 It reduces the problem of hand safety for workers.

 Safety mechanism should be cost effective for small and

medium scale industries (our industry).

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

 Maintenance of safety mechanism should be lower.

 It is also proven to less affect productivity when it is

practically installed on the machine.
 5. HISTORY OF THE WORK
• It is in the public interest to reduce or eliminate the unreasonable
number of mechanical power press operator injuries. A disabled worker
is not cost-effective in our society. Moreover, these injuries are
unacceptable from a human factor perspective, especially when there are
reasonable methods to prevent these injuries.

• The results of our project indicate the critical importance of

human factors engineering principles in press operator accident
causation. Human factors are the primary causation factor, and press
safeguarding is the second causation factor.
 6. LITERATURE REVIEW
• Occupational safety and health training remains a fundamental
element in workplace hazard control programs. As our training
objectives, recognition of job hazards, learning safe work practices and
appreciating other preventive measures are expected to contribute to
the goal of reducing occupational risk of injury.

• This report reviews data found in the literature reflecting the

significance of training in meeting these kinds of objectives and
outcomes. As will be seen, there is much positive evidence but the
results seem very selective and highly qualified. Here too, however,
important gaps are noted in the available data related to our industry
which is medium scale industry.
• A Literature Review Prepared by Alexander Cohen, PhD and
Michael J. Colligan, PhD said that More than 100 Occupational
Safety and Health Administration (OSHA) standards for hazard
control in the workplace contain requirements for safety mechanism
aimed at reducing risk factors for injury; others limit certain jobs to
persons deemed competent by virtue of special safety mechanism.

• Reports from select surveys and investigations of worker

injuries and workplace fatalities were also accessed with many
implicating lack of training and safety mechanism as a contributing
factor to the mishaps. In still other studies, workplace safety
mechanism devoted to showed linkage to reduced worker injury rates,
suggesting that even this kind of safety mechanism has benefits to job
safety overall.
 7. IMPLEMENTATION OF PROJECT WORK
Proposed varies system for safety in Mechanical Press Machine

1) Machine Guarding:

 Types of Machine Guards:

1. Fixed:- Barrier that allows for stock feeding but does not permit
operator to reach the danger area.

2. Adjustable:- Barrier that adjusts for a variety of production

operations.

3. Self- Adjusting:- Barrier that moves according to the size of the

stock entering point of operation. Guard is in place when machine is
at rest and pushes away when stock enters the point of operation.
4. Interlocking Barrier Guards:- Shuts off or disengages power
and prevents machine start-up when guard is open should allow
for inching of machine.

2) Safeguarding Devices: Safeguarding devices are controls or

attachments that, when properly designed, applied and used, usually
prevent inadvertent access by employees to hazardous machine areas
by:
• Preventing hazardous machine component operation if your hand or
body part is inadvertently placed in the danger area;
• Restraining or withdrawing your hands from the danger area during
machine operation;
• Requiring the use of both of your hands on machine controls (or the
use of one hand if the control is mounted at a safe distance from the
danger area) that are mounted at a predetermined safety distance; or
• Providing a barrier which is synchronized with the operating cycle in
order to prevent entry to the danger area during the hazardous part of
the cycle
(1) Pullback Devices:- Cords
connected to operator’s wrists and
linked mechanically to the machine
automatically withdraw the hands
from the point of operation during the
machine cycle.

(2) Restraint Devices:- Wrists are

connected by cords and secured to
fixed anchor points which limit
operator’s hands from reaching the
point of operation at any time.
(3) Presence- Sensing Devices:- Interlock
into the machine’s control system to stop
operation when the sensing field
(photoelectric, radio frequency, or
electromagnetic) is disturbed.

(4) Two- Hand Trip:- : Requires

concurrent use of both hands, prevents
them from being in danger area when
machine cycle starts.
(5) Movable gate:-

When the machine completes its cycle or returns to top of

stroke (in the case of a power press), the gate automatically opens,
allowing the operator to remove the formed part.
The operator then places a feed
stock (blank) into the machine
and activates the controls to
start another cycle. This can be
done with either a foot control,
a single hand control, or even
two-hand controls (preferred).
The gate must close before the
machine can cycle.
 8. EXPECTED RESULT
• By our best effort until now we can find out maximum solutions
available for our industrial defined problem which is indicated in our
report. This shows that going on right time scale steps as we decided
earlier.
• Due to time limit we cannot select one of the best solutions from
available solutions and not prepare documentation report for addressing
industries. but according to our progress on time scale we will complete
our remaining work in next semester and select expected result during
ongoing semester that means best Safety mechanism (safety guard) for
our industry.
• Prepare report, which indicate our selection is best and then offer
this report to industry with all relevant data So that industry can trust on
us and approved our report. Then after, we will analyze actual work if
there is any problem regarding to our proposal, we will solved it.
 REFERENCES

• Alexander Cohen, PhD and Michael J. Colligan, PhD, Final

Report, Safety Sciences, San Diego CA, NIOSH Contract 210-81-
3102, Nat’l Inst Occup Safe & Hlth, Morgantown, WVA 1990.

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

Professional Safety, March 1975.

• Bentley R, Horstman SW. A counseling program for worker

protection from Sapstan solution. Final Report, University of
Washington Seattle, WA 1986.
• Jensen, R. C. and T. J. Pizatella (1986), Critical Review of
Studies to Support Safe-Distance Formula for Power Press
Actuation Mechanisms. Trends in Ergonomics/Human Factors III,
North Holland : Elsevier Science Publ.

• Ray Asfahl, C., “Industrial Safety and Health Management”, 5th

Edition, Prentice Hall, April 1998.

• Aliasgar, A.; Sastry, O.K.; Hampapur, S.B.; Kamat, S.S.;

Vyshak, K.V. (2010) “Safety system for a press machine ”, 2010
2nd International Conference on Mechanical and Electrical
Technology (ICMET), Page(s): 673 – 677.