Metalworking Machine Guidance

DESCRIPTION

The term metalworking machine applies to numerous different types of machinery used not only for machining metals, but also some ceramics, plastics and other materials composed partly of any of those materials.

Safe guarding of metalworking machines is covered by the Provision and Use of Work Equipment Regulations.

Metalworking machines usually fall into the following categories:

• any sawing machine designed to be fitted with one or more circular blade
• any sawing machine designed to be fitted with a blade in the form of a continuous band or strip
• automatic and semi-automatic lathes
• boring machines
• drills - single pillar drills and semi-automatic multi point drills
• milling machines
• abrasive disc cutters/routers.

Note: power presses are considered separately.

MAIN HAZARDS

The main hazards associated with the use of metalworking machines will vary with the type of machine, the machine application and the material being machined, but may include:

1. The risk of personal injury as a result of accidental contact with a rotating blade or cutter or other moving machine part.
2. The risk of personal injury as a result of accidental contact or entanglement with the workpiece.
3. The risk of eye injury as a result of swarf, filings or other fragments being ejected during the machining operation.
4. The risk of noise induced hearing loss as a result of exposure to excessive noise levels.
5. The risk of damage to the nasal tract and respiratory system as a result of exposure to excessive airborne dust concentrations.
6. The risk of skin damage resulting in dermatitis or more serious ill health as a result of inadequately controlled exposure to coolant or lubricants.

PROVISION AND USE OF WORK EQUIPMENT REGULATIONS

Suitability of Equipment

1. Metalworking machinery must be suitable for the tasks and processes for which it is to be used. The equipment must be suitable by its design, construction or its adaptation, and be in a suitable location. In particular, it must be suitable for the process and conditions of use. For example, some operations can be carried out by more than one machine, but may be of lower risk on one machine than another, e.g. cutting a hole in thin plate on a properly guarded pillar drill may be safer than using a power press that may be inadequately set for a single job.
2. Tools must not be run at speeds greater than the safe working speed marked on them or specified by the manufacturers/suppliers.
3. Tools must be selected for use on the material being machined, since inappropriate tools choice can result in significant damage to machinery and consequent injury.

Maintenance

1. Metalworking machines must be maintained so that any deterioration in their performance does not put people at risk. There is no legal requirement to keep a log of maintenance, but this is recommended for high-risk machinery.
2. Maintenance should ensure that:
   • work tables are smooth and free of damage
   • mechanical feed systems track and run smoothly
   • guards are freely adjustable and fulfil their safety function
   • protection devices are in effective working order
   • tools are sharp and not damaged
   • toolholders move freely and function safely
   • protection appliances (jigs, holders, push-sticks) are undamaged and fit for use.

CONTROL MEASURES

Dangerous Parts of Machinery

1. The guarding of machinery is covered by the Provision and Use of Work Equipment Regulations.
2. Every employer must ensure that measures are taken to:
   • prevent access to any dangerous part of a machine or rotating stock-bar
   • to stop the movement of any dangerous part of machinery or rotating stock-bar before any person enters a danger zone.
3. All guards and protection devices provided must:
   • be suitable for the purpose for which they are provided.
   • be of good construction, sound material and adequate strength
   • be maintained in an efficient state, in efficient working order and in good repair
   • not give rise to any increased risk to health or safety
   • not be easily bypassed or disabled
   • be situated at sufficient distance from the danger zone
   • not unduly restrict the view of the operating cycle of the machinery, where such a view is necessary.
   • be so constructed or adapted that they allow operations necessary to fit or replace parts and for maintenance work, restricting access so that it is allowed only to the area where the work is to be carried out and, if possible, without having to dismantle the guard or protection device.
4. The measures that may have to be taken must be considered in the following order of priority:

1. fixed, enclosed guards
2. other guards and protection devices
3. protection appliances (jigs, holders, push sticks etc.)
4. the provision of information, instruction, training and supervision.

Basic Safety Rules for all Metalworking Machines

1. Ensure that all cutters and blades are guarded as far as reasonably practicable and the guards are correctly adjusted and secured into position.
2. Ensure that all cutters and blades are maintained in a sharp condition and are correctly set.
3. Ensure that the machine is adequately maintained.
4. Ensure that adequate lighting is available at each machine.
5. Ensure that there is an effective means of isolating the machine from any power supply.
6. Ensure that there is adequate working space around each machine.
7. Ensure that the dust extraction system fitted to the machine is operating efficiently, is adequately maintained and regularly inspected as required under the Control of Substances Hazardous to Health (COSHH) Regulations.
8. Ensure that where practicable mechanical feed systems are used.
9. Ensure that all machines other than portable machines are securely fixed to ensure stability.
10. Ensure that effective provision is made for securing and maintaining a reasonable temperature in every workroom in which metalworking machines are being used.
11. Where necessary reduce noise levels as far as reasonably practicable, as required under the Noise at Work Regulations.

Housekeeping

1. Good housekeeping aids production as well as being an essential safety requirement.
2. Keep the area around each machine clear of obstructions.
3. Provide suitable safe racks, stands or boxes for feedstock and finished items.
4. Keep the floor areas level and in good repair.
5. Check that floors, especially where operators stand, do not become slippery with coolant or lubricant. If spillages occur, ensure they are absorbed as soon as possible, then clear the absorbent to ensure the floor remains clear and free from debris.
6. Put waste into bins which should be cleared away when full.
7. Keep extraction systems working effectively (note that certain metals will be reclaimed, and separate storage bins should be provided for collecting swarf and off-cuts).
8. Mark gangways and fire exits clearly and keep them clear.
9. Where trailing cables are in use, make sure that they do not create a safety hazard.

Basic Safety Rules for all Persons who Operate Metalworking Machines.

1. Always wear suitable clothing which will not catch in cutters or other moving parts. Clothing with tight fitting cuffs is advised.
2. Always wear appropriate personal protective equipment ensuring that it is suitable for the purpose and maintained in good condition.
3. Always use the safety devices provided and ensure that guards are correctly adjusted.
4. Only operate machines that you are authorised and adequately trained to work.
5. When feeding material never reach into the machine.
6. Never reach inside the guard to carry out any adjustment, cleaning operation or attempt to remove any obstruction whilst the cutter/blade is rotating.
7. Never carry out unauthorised repairs or modifications to the machine or any of the associated equipment.
8. Immediately report any fault on the machine or any of the associated equipment to your supervisor.
9. Always ensure that the machine is switched off when not in use and isolated before any major adjustment, cleaning or maintenance is carried out.
10. Do not carry out any adjustment or maintenance on the machine unless you are competent i.e. have sufficient knowledge, skill and experience to be able to perform the work effectively.
11. Never distract the attention of any person operating any metalworking machine.
12. Ensure that safe working procedures are agreed and implemented for each machine.

INFORMATION

1. Because of the inherent dangers in metalworking machines the operators must be provided with all relevant information and instructions on how to use them safely, and be trained adequately.
2. Where relevant, the information and instruction should include:
   • the speed, range type and dimensions of tools suitable for the machine
   • any limitations on the materials that can be worked on the machine
   • procedures relating to the repair or replacement of any guard or protection device
   • the availability, suitability and use of any additional protection device protection appliance
   • the correct procedures to be followed for setting and adjusting operations
   • safe methods of handling tools
   • correct procedures for start-up and shutdown, isolation and how to discharge any residual energy
   • procedures for cleaning saw blades by hand
   • procedures for adjusting any guard, tool, clamp or other part of a machine.

TRAINING

1. No person can be employed on any kind of work at a metalworking machine unless they have been sufficiently trained or are undergoing training under the adequate supervision of a competent person.
2. Any person being trained must be fully instructed in the dangers associated with the machine and the safety precautions to be observed.
3. Any person being trained to operate any metalworking machine must also be instructed in the methods of operation, the correct use of guards and other safety devices including the means of isolation in the event of an emergency.
4. Any person under the age of 18 years is not permitted to operate the following machines unless he/she have successfully completed an approved course of training and hold the appropriate certification or are required to do so a part of the training course:

1. Any sawing machine fitted with a circular blade.
2. Any planing machine for surfacing which is not mechanically fed.
3. Any vertical spindle moulding machine.

5. The person supervising any person under training must be competent to do so, have a thorough knowledge and experience of the working of the machine, the dangers associated with the machine, the correct use of safety devices and the safety precautions to be observed.

PROTECTION AGAINST SPECIFIC HAZARDS

Ejected Material/disintegration

1. Adequate measures must be taken to control 'kickback'. Where power feeds are used they should be of a sufficient size and rating to overcome the forces of kickback.
2. Guarding at the machine should provide a sufficient degree of protection in the event of cutter/tool disintegration or cutter ejection. Such risks should be minimised by the use of well-maintained proprietary tools.
3. Guarding at the machine must also eliminate (where possible) or minimise risks associated with metal fragments and offcuts being ejected from the workpiece. This is particularly important where brittle metals are being machined.

Braking Devices

1. Metalworking machines can run at very high speeds and take a long time to slow to a halt. Workers are frequently injured by rotating tools that have been turned off but that have not come to a complete halt. Unless the machines have a rundown time of 10 seconds or less, or the effect of braking could be detrimental to the integrity of the machinery or the machines are built in conformity with a harmonised European standard that does not require braking devices, braking devices should be fitted to machines where a risk assessment shows this to be necessary.
2. Braking devices should be fitted as soon as possible to all the above machines and no later than the times specified within the Regulations.

For further information or assistance please contact Croner Consulting (formerly IRPC).

See also:

Work Equipment Policy.

Work Equipment (New) Procedure.

Work Equipment (Existing) Procedure.