11/03/2019

Seminar Keselamatan dan Kesihatan Pekerjaan Negeri

Pulau Pinang tahun 2019
anjuran
Jabatan Keselamatan dan Kesihatan Pekerjaan Pulau Pinang
dengan kerjasama
Federation Of Malaysia Manufacturers

Tajuk Ceramah : The use of LOTO at Press Machine

Pada : 21 Mac 2019
Penceramah : Mohd Fadglullah bin Ibrahim

FADGLULLAH IBRAHIM (FAD)

Consultant/Trainer
http://www.linkedin.com/in/fadh-ibrahim-487620b4
Education Background:
Parks College of St Louis University USA
• Bachelor Science in Aerospace Engineering
• Bachelor of Science in Aeronautics – Aircraft Maintenance Engineering

Crestcom International, Colorado, USA

• Bullet Proof Manager Training Series

Career Experience (1989-2014)

 Norma Pacific Asia- Area Sales Manager Malaysia
 TRACOMA HOLDINGS BERHAD – Group General Manager
 PROFEN Sdn Bhd – General Manager
 PROTON Bhd – Quality Control Executive
 AIROD Sdn Bhd – Systems Research Engineer
 JJ&W Aircraft Services Corp – Product Support Engineer
PROGRAMME NAME BODY/ORGANIZATION PARTICIPANT

INDUSTRY PRODUCTIVITY SPECIALIST MALAYSIA PRODUCTIVITY ORGANIZATION SENIOR MANAGEMENT, BUSINESS

OWNERS, MIDDLE MANAGEMENT

TOTAL PRODUCTIVE MAINTAINANCE CENTRE FOR INSTRUCTOR AND ADVANCE DIRECTOR, LECTURERS FROM TECHNICAL
SKILLS TRAINING (CIAST) TRAINING INSTITUTION AND CENTRES

GUIDELINES ON SAFE USE OF PRESS
MACHINE
LEAN PRODUCTION SYSTEM and 5S
AUTOMOTIVE INDUSTRY CERTIFICATION
ENGINEERING
INDUSTRY PROFESSIONAL CERTIFICATE
DEPARMENT OF SAFETY AND HEALTH
(JABATAN KESELAMATAN DAN KESIHATAN
PEKERJAAN)
MALAYSIAN PRODUCTIVITY CORPORATION,
MANUFACTURING COMPANIES
MALAYSIAN AUTOMOTIVE INSTITUTE
MALAYSIAN AUTOMOTIVE INSTITUTE
DIRECTORS, ASSISTANT DIRECTOR,
SECTION HEAD AND OFFICERS
DIRECTOR, GENERAL MANAGERS,
MANAGERS, ENGINEEERS, SUPERVISORS,
LINE LEADERS
GRADUATES FROM UNIVERSITIES
STUDENTS FROM POLYTECHNICS, ILP AND
SCHOOL LEAVERS

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OBJEKTIF : LOTO system in Press Machine

1) To provide common knowledge on the application of LOTO system in
Press Machine operation to the new and existing employee thus will
reduce accident and promote safety culture.
( Memberi pengetahuan yang seragam terhadap penggunaan system LOTO semasa
pengendalian Mesin Himpit kepada pekerja baru dan sedia ada bagi mengurangkan
kemalangan dan mengalakkan amalan keselamatan)

2) To comply with DOSH’s Guidelines on safe use of Press Machine

(ISBN 978-983-2014-80-5)
(Mematuhi Panduan kesalamatan penggunaan mesin himpit oleh Jabatan
Keselamatan Dan Kesihatan Pekerjaan)

3) To comply to the Factory And Machinery Act (FMA) on the training and
competency requirement.
(Mematuhi Akta Kilang dan Jentera berkenaan latihan dan kompetesi
mengendalikan jentera) 3

Manufacturing Technical Training & Consultancy.

2014
(LPSB)

2015
(LPSB)

2016
(LPSB)

2017
(LPSLP)

2018
(LPSLP) AUTO PRIMA COLLEGE

2018
(LPSLP) PENANG SKILL DEVELOPMENT CORPORATION

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MODULE COVERAGE

Convergence Lean Production System with I4.0 pillars

ROADMAP of Lean Production System
Additive
LPS KAIZEN Manufacturing

StepⅢ ③；Pull production ( & JIT ) Solve

②；Takt（Tact) time production problem
①；Flow production (process )

Stabilization of Process / Quality Analyse

＊ Process Control (Capacity & Planning) problem
StepⅡ
＊ Quality Control (Quality Gate & Feedback)
＊ PM (M/C Breakdown Reduction)
Find
＊ Skill Practical Training
problem

Management of workplace (Fundamental) Prevent

StepⅠ
＊Safety ＊5S（2S→4S→5S) ＊Rule & Standard (SOP) problem

＊ Visual Management (MIERUKA) ＊Training & Education

Corporate policy (Top management decision) Supply

( Ref. MAJAICO Book ) Chain

Training and consultation

Class room training

DOJO training

Factory training Factory consultation

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Recruiting new operator, technician and engineer

Studen
t Automotive Employe
Industry e

Student
recruitment Note : After 6 month absorb to industri

Student Customize Practical

training training training
- Rawang
- Sabah
Filter:1
- Serawak
- Interview
- Kelantan
- Company visit.
- Kedah

Automotive
Industry Filter:2
Evaluation
Filter:1 – meeting expectation of student
Filter:2 – meeting expectation of company MAI Resource Centre (MAIRC)
Purpose to improve retention rate. Bukit Beruntung

Practical training at MAI Resource Centre (MAIRC)

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Mechanical press machine categories

Maut =47 THUK = 1007 HUK = 93

Source :
10

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STATISTIK KEMALANGAN MENURUT KES YANG DI SIASAT (2017)

Maut =47 THUK = 1007 HUK = 93

Source :
11

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13
LPS

Jentera yang digunakan oleh syarikat-syarikat

Dalam jangka jentera yang digunakan oleh syarikat-syarikat , terdapat 391 maklum balas
yang diterima daripada responden , yang semua dari industri logam / pembuatan .
Kebanyakan syarikat mempunyai lebih daripada satu jenis mesin untuk operasi proses
mereka. Peratusan ini menunjukkan penggunaan mesin himpit mempunyai responden
paling tinggi. Jadual di bawah menunjukkan bahawa peratusan keseluruhan responden
untuk jenis jentera yang digunakan oleh syarikat mereka .

Machine Number Percent

Abrasive Wheels 24 6.14

Lathes 55 14.07

Milling Machines 57 14.58

Rolling Mills 37 9.46

Forging Machines 28 7.16

Mechanical Shears 50 12.79

Power Presses 75 19.18

Others 65 16.62
Total 391 100
14
LPS

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Subject matter
expert

Vendor (Tier-1)
Li Chin (S.E.A) Sdn Bhd (Malaysia)
- Press machine maker 15

DOSH workshop on Press Machine Safety Guide Line:

Meeting : 3 rd Team member :
Date : 5~7 Nov 2014 • DOSH Putrajaya
Veneu : Bukit Merah • MAI
• Leading Platform
• Proton
• Perodua
• PHN
• Li Chin

Leading Platform present

Proton present Perodua present 16

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Part 7
Safety Feature of Press
Machine
&
LOTO application

20

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Press Machine Safety Feature

– Full Revolution Clutch & Brake

21

Safety Feature type 1

Restraint device with hand feeding tool.

The restraint (hold out) device utilizes cables or straps that are attached to the operator’s hands
at a fixes point. The cables or straps must be adjusted to let the operator’s hand travel within a
predetermined safe area. There is no extending or retracting action involved. Consequently,
hand-feeding tools are often necessary if the operation involves placing and removing work
piece in the press work area (hazard area).

22

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Safety Feature

Hand feeding tool.

Furnish and enforce the use of a hand tool for freeing and removing stuck work or scrap
pieces from the die, so that an employee need not reach into the point of operation for
such purposes.

23

Safety Feature type 2

Pullback Device
Pullback devices utilise a series of cables attached to the operator’s hands, wrists, and/or arms. This
type of device is primarily used on machines with stroking action. When the slide/ram is up between
cycles, the operator is allowed access to the press work area (hazard zone)

24

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Press Machine Safety Feature

– Part Revolution Clutch & Brake

25

Pneumatic actuator Clutch & Brake

Main Motor
Flywheel
Drive gear

FRL
(Filter Regulator Air Tank
Lubricator)
Clutch and Brake

Press
control
valve
Safety feature
control circuit

Double
Push Start
Button

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7 Types of Safety Feature and it control circuit

Emergency
Operation Safety Stop Button
Selector Block
Switch
+ LOTO

L1 Press safety
Power Power
Main valve
On Off
Motor
Double Push
Connect to Clutch
Start Button. & Brake.
MCR

Press safety
valve
CR1
Safety
fixed/interlock
CR1
fence
Example electrical logic control
fixed

Light curtain
sensor.
Gate safety plug. interlock
+ LOTO LPS

Side view Top view

0o
6) Dies safety
3) Light curtain block
270o 90o sensor

180o
2) Double push
start button

1) Selector switch 7) Emergency stop

button

4) Gate Safety Plug 5) Safety interlock

(robot automation) fence (shutter)
H-Frame moving bolster

Side view 3) Light curtain Top view

sensor 4) Gate Safety Plug
(robot automation)
Safety
Curtain 2) Double push
start button

1) Selector switch

6) Dies safety
7) Emergency stop block
button 5) Safety fixed
fence
C-Frame LPS

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SAFETY FEATURE

NO 1:
OPERATION SELECTOR SWITCH

29
LPS

Safety feature

Emergency
Operation Safety Stop Button
Selector Block
Switch
+ LOTO
NO : 1
L1
Power
On
Power
Off
Main Clutch
Motor
&
Double Push
Start Button. Brake
MCR

Press safety
valve
CR1
Safety
fixed/interlock
CR1
fence + LOTO
Example electrical logic control
fixed

Light curtain
sensor.
Gate safety plug. interlock
+ LOTO LPS

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SAFETY FEATURE NO 1: OPERATION SELECTOR SWITCH

Medium / Large Press

loading
operator
Unloading
operator

To ensure only trained personal verify the

Selector safety of machine and human at each mode
switch of operation ( Inching / 1 cycle / off /
continue / adjust)

LPS

SAFETY FEATURE NO 1: OPERATION SELECTOR SWITCH

Small Press
Safety Block
area

Selector
switch

LPS

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SAFETY FEATURE NO 1: OPERATION SELECTOR SWITCH

LPS

SAFETY FEATURE

NO 2:
SAFETY CURTAIN SENSOR

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Safety feature

Emergency
Operation Safety Stop Button
Selector Block
Switch
+ LOTO
NO : 1
L1
Power
On
Power
Off
Main Clutch
Motor
&
Double Push
Start Button. Brake
MCR

Press safety
valve
CR1
Safety
fixed/interlock
CR1
fence
Example electrical logic control
fixed
NO : 2
Light curtain
sensor.
Gate safety plug. interlock
+ LOTO LPS

SAFETY CURTAIN SENSOR

H-Frame (large press)
Immediately
0o
brake the slide C-Frame (small press)
if human 270o 90o

entering press
work area 180o
Safety
Safety Curtain
when slide Curtain
moving
downward.

Safety
Curtain

Safety Safety
Curtain Curtain

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SAFETY CURTAIN SENSOR

LOCATION AND HOW SAFETY CURTAIN SENSOR WORK.

Safety
curtain

SAFETY CURTAIN SENSOR

DISTANCE OF SAFETY CURTAIN

Selector key to WARNING

(Active or Bypass)

Active Production mode

Bypass Press maintenance Indicator
only light KEY ALWAYS KEEP
BY PRESS MAINTENANCE

Red indicator ON when block the sensor

Green indicator ON
beam or sensor malfunction, slide
when no blocking
immediately stop.

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SAFETY CURTAIN SENSOR

INSTALLATION OF THE SAFETY CURTAIN.

The curtain light

sensor cover
minimum 80% of
the slide stroke
and located at
the center line of
the feed level
line.

Feed Level

Bolster Height

D = minimum distance between the

slide and the curtain light sensor.

SAFETY CURTAIN SENSOR

DISTANCE OF SAFETY CURTAIN

Beam axe of beam type safety

press machine is positioned at
distant point from safety distance of
dangerous limit. The safety distance
D
is defined by following formula as
same as two hand operation safety
press machine. D

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SAFETY CURTAIN SENSOR

Safety Safety
Curtain Safety Safety
Curtain
Curtain Curtain

Note : Safety curtain securely fence the dangerous zone for every
person employed as per section 15 FMA.

Example : By Pass SAFETY CURTAIN SENSOR

Unsafe Act : Operation with foot switch witch out curtain sensor.

What happen unconsciously step

pedal while hand still inside !!!

42

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SAFETY FEATURE

NO 3:
DOUBLE PUSH START BUTTON

43
LPS

Safety feature

Emergency
Operation Safety Stop Button
Selector Block
Switch
+ LOTO
NO : 1
L1
Power
On
Power
Off
Main Clutch
Motor
&
Double Push
Start Button. Brake
NO : 3 MCR

Press safety
valve
CR1
Safety
fixed/interlock
CR1
fence
Example electrical logic control
fixed
NO : 2
Light curtain
sensor.
Gate safety plug. interlock
+ LOTO LPS

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DOUBLE PUSH START BUTTON

H-Frame (large press)
0o
C-Frame (small press)
Double
Push 270o 90o
Start
Button
(1st layer) 180o

LPS

DOUBLE PUSH START BUTTON

Safety Feature Purpose

Feature 2 : To ensure both hand push the start button and safe away
Double Push Start Button from press work area.

Specification :
1) Button with ring our cover guide.
2) Both button distance > 550mm.
3) With Emergency Stop Button.
4) With simultaneous function.
5) With Anti – repeat function.
6) Dedicated fixed location.

LPS

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DOUBLE PUSH START BUTTON

Simultaneous function
(Anti-tie-down)
Tie-down with
heavy metal block Finger

Tie-down
Finger

LPS

DOUBLE PUSH START BUTTON

WRONG PUSH BUTTON :

NG Ring
guard
OK Ring
guard
Push
button

Ring guard lower than

Push push button
button
Ring guard higher
than push button Bringing action

OK
Cover guard

Push
button

Cover guard higher

than push button

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DOUBLE PUSH START BUTTON

Bringing action

≥ 550 mm

LPS

DOUBLE PUSH START BUTTON

Double Push Button location is fixed.

NG

OK
NG

LPS

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FOOT SWITCH OPERATION

1) Must have Guard / Cover 2) Must operate in 1 cycle
mode only (anti-repeat) .
Foot Switch
Manual feeding accident
High possibility
machine user press foot
3) Must support with 2nd
layer of safety
feature whichever applicable : switch when finger
- Feeding stand and guide for strip material feeding nut manually.
- Hand tool (feeding tool) for loose material
- Curtain light sensor for loose material
This is unsafe
Pinch at finger act.

LPS

SAFETY FEATURE

NO 4:
SAFETY BLOCK
+ LOTO

52
LPS

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Safety feature

NO : 4 Emergency
Operation Safety Stop Button
Selector Block
Switch
+ LOTO
NO : 1
L1
Power
On
Power
Off
Main Clutch
Motor
&
Double Push
Start Button. Brake
NO : 3 MCR

Press safety
valve
CR1
Safety
fixed/interlock
CR1
fence
Example electrical logic control
fixed
NO : 2
Light curtain
sensor.
Gate safety plug. interlock
+ LOTO LPS

SAFETY BLOCK PLUG + LOTO

Main motor
Safety Plug + LOTO : “OFF”

If plug pull off the Main motor that

Flywheel
spin the Flywheel will OFF and Flywheel
Clutch & Brake
Brake activated and stop the spinning.
Flywheel Brake
“ON”

Chain :
Connecting Safety Plug
and Safety Block.

Safety Block :
to support the weight
of slide and upper dies
If the brake slip. 54
LPS

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SAFETY BLOCK PLUG + LOTO

Drive shaft brake by spring and friction disc

Brake slip due to wear and tear.

Slip
Waooh !!
Upper slide suddenly
came down !!

PRESS MACHINE

SAFETY BLOCK PLUG + LOTO

Always ensure use Dies Safety Block when working under dies regardless
maintenance, production or quality. Safety Plug :
If plug pull off the Main motor that
Even if brake failure, it always keeps safe condition. spin the Flywheel will OFF and Flywheel
Brake activated and stop the spinning.

Brake + Safety Block ( Stopper )

Safety Block !
setting OK !!

Chain :
Connecting Safety Plug
and Safety Block.

Safety Block :
to support the weight
PRESS MACHINE of slide and upper dies
If the brake slip.
OK

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SAFETY BLOCK PLUG + LOTO

Safety Work
In Dies

Dies
Safety Block
with safety plug

Safety Block
area

LPS

SAFETY BLOCK PLUG + LOTO

Safety Work
In Dies Safety Block
With out safety
plug

Safety Block
area

LPS

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SAFETY BLOCK PLUG + LOTO

SOP (SAFETY OPERATION PROCEDURE)

PASTIKAN 5 LNGKAH KESELAMATAN DIPATUHI SEBELUM AKTIVITI DALAM DIES
DIJALANKAN
ENSURE 5 SAFETY STEP FOLLOWED BEFORE DIES ACTIVITY PROGRESS

(5)
(5) LOTO HENDAKLAH DIPASANG PADA
SOCKET SAFETY BLOCK
(5) LOTO MUST APPLY AT SOKET SAFETY
PLUG 59

SAFETY BLOCK

SAFETY BLOCK
&
PLUG
+ LOTO

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SAFETY BLOCK PLUG + LOTO

Why need LOTO ?

Gate
Safety
Fence
SAFETY BLOCK
PLUG + LOTO
61

SAFETY FEATURE

NO 5:
EMERGENCY STOP BUTTON

62

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Safety feature

NO : 4 Emergency
Operation Safety Stop Button
Selector Block
Switch
+ LOTO NO : 5
NO : 1
L1
Power
On
Power
Off
Main Clutch
Motor
&
Double Push
Start Button. Brake
NO : 3 MCR

Press safety
valve
CR1
Safety
fixed/interlock
CR1
fence
Example electrical logic control
fixed
NO : 2
Light curtain
sensor.
Gate safety plug. interlock
+ LOTO LPS

7) EMERGENCY STOP BUTTON

Top View cross section
5) Emergency
stop button

Dies Scrap Hooper

Up-right Bolster

64
Stamping Shop Safety

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EMERGENCY STOP BUTTON

E-stop
button.

E-stop
button.

EMERGENCY STOP BUTTON

EMERGENCY STOP BUTTON

1 EMERGENCY STOP BUTTON AT EACH UPRIGHT

PRESS DOWN
TO STOP THE MACHINE

TURN CLOCKWISE
TO RESET THE MACHINE66
1 EMERGENCY STOP BUTTON AT PORTABLE PUSH BUTTON Stamping Shop Safety

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SAFETY FEATURE
NO 6:
GATE SAFETY PLUG
+ LOTO

67

Safety feature

NO : 4 Emergency
Operation Safety Stop Button
Selector Block
Switch
+ LOTO NO : 5
NO : 1
L1
Power
On
Power
Off
Main Clutch
Motor
&
Double Push
Start Button. Brake
NO : 3 MCR

Press safety
valve
CR1
Safety
fixed/interlock
CR1
fence
Example electrical logic control
fixed
NO : 2
Light curtain NO : 6
sensor.
Gate safety plug. interlock
+ LOTO

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GATE SAFETY PLUG + LOTO

Gate
Safety
Fence

Safety
Plug +
69
LOTO

GATE SAFETY PLUG + LOTO

Robot
automation
handling

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GATE SAFETY PLUG + LOTO

Entering safely into robot automation press line

DOOR PLUG
2-PLUG for
1 DOOR
※

INSIDE

※
OUTSIDE
SAFETY PLUG FOR STAFF
TO HOLD

Safety Plug
Chain length (X) should To
be short to prevent power curcuit
people to access through
the door gap.
During Plug-off,
During Plug-off, main power is
manpowernot cannot switch
available on
to switch-on

71

GATE SAFETY PLUG + LOTO

LOTO
Latch
with
Padlock

LOTO latch

72

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SAFETY FEATURE

NO 7:
SAFETY SHUTTER/FENCE MACHINE

73

Safety feature

NO : 4 Emergency
Operation Safety Stop Button
Selector Block
Switch
+ LOTO NO : 5
NO : 1
L1
Power
On
Power
Off
Main Clutch
Motor
&
Double Push
Start Button. Brake
NO : 3 MCR

Press safety
valve
CR1
Safety
fixed/interlock
CR1
fence
Example electrical logic control NO : 7 fixed
NO : 2
Light curtain NO : 6
sensor.
Gate safety plug. interlock
+ LOTO

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SAFETY SHUTTER/FENCE MACHINE

H-Frame (large press)

0o
C-Frame (small press)
270o 90o

180o

Safety movable
fence (with interlock sensor) Safety fixed
Fence

loader unloader

loader
&
Moving
unloader
Bolster

Fix
Bed

SAFETY SHUTTER/FENCE MACHINE

SAFETY FENCE FOR AUTOMATIC SAFETY FENCE FOR MANUAL

FEEDING PRESS OPERATION. FEEDING PRESS OPERATION.

Safety fence

76

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SAFETY SHUTTER/FENCE MACHINE

SAFETY SHUTTER FOR MOVING BOLSTER PRESS MACHINE

INTERLOCK LOCK

MESIN HANYA AKAN BEROPERASI JIKA SAFETY FENCE TELAH DITURUNKAN

DAN DIKUNCI
MACHINE WILL NOT OPERATE IF SAFETY FENCE IS DOWN AND LOCKED
MESIN TIDAK AKAN BEROPERASI JIKA SAFETY FENCE
BERADA DI ATAS
MACHINE WILL NOT OPERATE IF SAFETY FENCE IS UP
77
Stamping Shop Safety

Part 8 – Safe Operating Procedures.

A. Personal Protective Equipment (PPE)
B. Before Operation.
C. During Operation.
D. Finish Operation.
E. Changing Dies Operation
F. Press Maintenance Operation.

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Safe Operating Procedure (SOP)

F. Press Maintenance Operation

No Tindakan keselamatan
1 Pastikan anda telah baca dan faham
maklumat di dalam technical,operation
dan safety manual yang telah disediakan
oleh machine maker.
2 Letakkan “WARNING TAG” pada
operation panel bila hendak memulakan
kerja baik pulih.
3 Pastikan bekalan elektrik dimatikan dan
compress air supply, hydraulic supply dan
water supply di tutup dan dibuang
tenaganya. Mesti menggunakan system
LOTO pada sumber sumber tenaga ini.
4 Digalakan setiap kerja kerja baikpulih
dilakukan berdua.
5 Sekiranya kawasan berbahaya disediakan
safety plug/safety key bawalah bersama
ketika memasuki kawasan tersebut.
6 Semua pengadangan keselamatan
hendaklah di pasang semula selepas
kerja baikpulih selesai.
Mengapa?
Manual tersebut menunjukkan cara yang
betul dan selamat menjalan kerja kerja
baikpulih
Dapat memberi tahu kerja kerja baikpulih
sedang dilakukan dan dilarang berbuat apa
apa pada operation panel.
Sebarang kesilapan akan menyebabkan
sumber tenaga ini mengerakkan sesuatu
yang merbahaya. LOTO mematikan bekalan
tenaga ini dan mengelak orang yang tidak
berkenaan menyambung bekalan.
Rakan akan bertindak memberi bantuan
melibatkan keselamatan
Memastikan tiada sesiapa boleh
menghidupkan mesin semasa anda berada
didalam kawasan bahaya.
Memastikan bahagian yang merbahaya tidak
boleh disentuh atau dihampiri.

Safe Operating Procedure (SOP)

F. Press Maintenance Operation
Langkah 2:
Perkara yang perlu dibuat Mengapa ?
Setkan selector ke mode OFF, simpan Dapat memberi tahu kerja kerja baikpulih sedang
kunci dan letakkan “WARNING TAG” pada dilakukan dan dilarang berbuat apa apa pada
operation panel bila hendak memulakan operation panel.
kerja baik pulih.

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Safe Operating Procedure (SOP)

E. Press Maintenance Operation. PRESS MAINTENANCE

SAFETY (LOTO)
PMT 43064

1) AIR 3) COOLING
COMPRESSOR SYSTEM
LOTO LOTO
LOTO LOTO

2) ELECTRICAL
SYSTEM 5) HYDRAULIC
OIL

4) LUBRICATION
OIL 6) SCRAP CONVEYOR

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Safe Operating Procedure (SOP)

E. Press Maintenance Operation.

LOTO (Lock Out, Tag Out)

83

THE END
THANK YOU

Shairul Baki Bin Mohamad Saleh

shairul@leading-platform.com
019-6691269

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