Unit IC: Suggested Answers to Revision Questions, IC1-IC5

Element IC5: Work Equipment (General)

Question 1
Any five from the following criteria:
• Clearly visible.
• Appropriately marked.
• Positioned for safe operation.
• Designed so that movement of the control is consistent with the effect required.
• Located outside the danger zone, except for certain controls, e.g. emergency stop.
• Positioned so that their operation cannot cause additional risk.
• Designed to prevent unintentional operation.
• Made to withstand foreseeable strain, particularly emergency controls.
• Fitted with dials, etc. if required for safe operation.
• Starting of the machine can only be by means of the control, particularly after adverse conditions, e.g. a power cut.
• Stopping devices should be fitted.
• Emergency stopping devices should be fitted, clearly marked and to work effectively.
• The control must override any part of the system except the emergency control.
• Any fault or failure must not lead to danger.
• Interactive software must be user-friendly to the operator.

Question 2
Factors relating to location of controls are:
• Minimise the number of controls; the fewer there are, the less chance of the wrong one being operated.
• Arrange them to encourage a range of postures for the operator, which allows movement to keep the body ‘fresh’.
• Arrange them so that the sequence of operations is in an arc, so that the control layout is representative of the process.
• Where large forces are required to be exerted, use foot pedals or have power assistance.
• Have a clear distinction between normal and emergency controls.
• Keep consistent groupings of displays and controls; ideally the display should be above the control.
• Prevent accidental operation by recessing or shielding the control or by distance to prevent them being knocked by an
elbow, etc.

Question 3
A number of precautions to prevent accidental operation can be taken:
• Recessing the control.
• Orientating the control so that the normal direction from which any accidental activation may occur will not cause it to
be operated.
• Covering the control with a hinged cover.
• Locking the control.
• Operationally sequencing a set of controls.
• Increasing control distance.

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Question 4
The factors that need to be considered when identifying the risks associated with the use of work equipment include:
• Initial integrity.
• The location where it will be used.
• The purpose for which it will be used.
• Incorrect installation or re-installation.
• Deterioration.
• Other exceptional circumstances which could affect its safe operation.

Question 5
• Initial integrity:
–– Equipment should be suitable, by design, construction or adaptation, for the actual work it is provided for to do.
When first providing work equipment for use in the workplace, the employer should make sure that it has been
made to the requirements of any prescribed standards.
• The place where it will be used:
–– The location in which the work equipment is to be used should be assessed to take account of any risks that may
arise from the particular circumstances.
• The purpose for which it will be used:
–– This requirement concerns each particular process for which the work equipment is to be used and the conditions
under which it will be used. The equipment should be suitable for the process and conditions of use.

Question 6
• Eliminate the risks created by the use of work equipment through careful selection.
• Employ ‘hardware’ (physical) measures such as:
–– Suitable guards.
–– Protection devices.
–– Markings and warning devices.
–– System control devices, such as emergency stop buttons.
–– Personal protective equipment.
• Employ ‘software‘ measures such as:
–– Following safe systems of work.
–– Ensuring maintenance is only performed when equipment is shut down.
–– Provision of information, instruction and training.

Question 7
Precautions might include:
• Suitable means of access.
• Physical isolation of the equipment.
• Portable lighting (a torch or low-voltage lead lamp may often be sufficient) where necessary.
• Ventilation, including local exhaust ventilation (LEV).
• Use of suitable tools (possibly substituting electrically powered tools with pneumatic tools in certain environments).
• Not carrying out work in situ and instead removing items to be worked on in a more suitable location.
• Blocking or shoring-up moving parts to prevent unexpected movement.

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• Providing suitable protective equipment to reduce the effects of hazardous substances, sharp objects, hot surfaces, etc.

Question 8
(a) Advantages:
• Safer operation.
• Reduced downtime and lost production.
• Increased reliability of equipment.
• Failure rate predictions.
• Rapid turnaround of parts.
• Maintenance carried out at times of least disruption.
• Reduced risk from planned maintenance operations.
(b) Disadvantages:
• Over-maintenance, with reduced efficiency.
• High costs of parts still with useful life.
• Management time for planning and operating schedules.
• Over-familiarity with tasks leading to complacency.
• Higher skill level.
• Increased storage requirements for spare parts.

Question 9
Factors to be considered in developing a planned maintenance programme for safety-critical components include:
• Importance in the process.
• Failure during the production process.
• Machine complexity.
• Relationship with other machines.
• Availability of replacement equipment.
• Identification of critical components.
• Environmental factors.
• Maintenance capability within the company.
• Maintainability within the design of the machine.
• Unknown factors.

Question 10
The factors to be considered when determining inspection regimes for work equipment include:
• The type of equipment:
–– Are there safety-related parts which are necessary for safe operation of equipment? For example, overload warning
devices and limit switches.
• Where it is used:
–– Is the equipment used in a hostile environment where hot, cold wet or corrosive environments may accelerate
deterioration?
• How it is used:
–– The nature, frequency and duration of use will determine the extent of wear and tear and the likelihood of
deterioration. In addition, equipment regularly dismantled and re-assembled will require inspection to ensure that
it has been installed correctly and is safe to operate.

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Question 11
Competence can be defined as the ability to undertake responsibilities and perform activities to a recognised standard on a
regular basis. It is a combination of skills, experience and knowledge.
Training is an important component of establishing competence but is not sufficient on its own. For example, consolidation
of knowledge and skills through training is a key part of developing competence.

Question 12
Circumstances when training is likely to be required include:
• Induction.
• Changes in work activities.
• Introduction of new technology or new equipment.
• Changes in systems of work.
• Refresher training.

Question 13
Where an activity is carried out by highly competent staff and the degree of risk is low, then self-supervision will be
adequate. However, where competence levels are low and the work activity involves a significant level of risk, then close
supervision will be required to ensure that the work is carried out safely. Some supervision of fully competent individuals
will always be needed to ensure that standards are being met consistently.

Question 14
Woodworking machine operators require specific training because the risks associated with the use of woodworking
machinery are high. The machines rely on high-speed sharp cutters to do the job and in many cases those cutters are
exposed to enable the machining process to take place. Additionally, many machines are still hand-fed.
All training schemes should include the following elements:
• General - instruction in the safety skills and knowledge common to woodworking processes.
• Machine-specific - practical instruction in the safe operation of the machine, including in particular:
–– The dangers arising from the machine and any limitations as to its use.
–– The main causes of accidents and relevant safe working practices, including the correct use of guards, protection
devices, appliances and the use of the manual brake where fitted.
• Familiarisation - on-the-job training under close supervision.

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