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Shop Safety Standard

(Handout)

OBJECTIVE

Observance and enforcement of essential safety rules prevent accidents and

improve working conditions. Accident is a part of all operations, not a separate job.
Each workman is responsible for observing safety rules and for tying to prevent
accidents. Since rules cannot be written to cover instance, good judgment by
foreman and workman is essential.

GENERAL SAFETY PRECAUTION

1. CONDUCT OF WORKMEN

a. Warning fellow workmen. Workers should be instructed to warn fellow

workers who accidentally or knowingly get into dangerous positions. These mutual
warnings protect not only the person warned but also the rest of the crew. Some
members of a gang are less experienced than others and may not realize the danger
of their working positions.

b. Horseplay. Horseplay, wrestling, scuffling, practical jokes, or

unnecessary conversation must be avoided during duty hours.

c. Intoxicating Liquors. The use of intoxicating liquor during working

hours is forbidden. Workers using intoxicants on the job are subject to dismissal
because they are less capable of handling themselves safely, creating a hazard for
the whole work crew.

2. REPORTING UNUSUAL CONDITIONS

All unusual conditions of any kind in shops or any working areas that may be
in any way affecting the continuity of service or endanger life or property must be
reported promptly to the supervisor. Necessary protective steps should be taken
immediately even if stopping other work is necessary.

To insure proper safety precautions, the following housekeeping rules must

be followed.

a. Material and tools must not be placed where they can be stumbled
over or where they can fall on someone. . The materials should not be placed
against a platform, which is not positively capable of withstanding the additional
weight. It must not be learned any support where they are likely to jarred loose and
fall.

b. Material must be piled neatly so it does not fall over.

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c. Greasy waste or rags, oil-soaked or paint-covered cloth, or other

inflammable material must be placed in approved waste can for frequent disposal by
incineration or other suitable procedure.

d. Grease or oil spilled or any floor must be cleaned up at once.

e. At the end of the day, the work materials and tools must be cleared
away and stored in a safe place on the job or returned to the truck or stock room.
f. Open holes must be guarded or covered. If left over night, they must
be completely barricaded and lighted with warning lights.

g. Sand, gravel, or ashes should be used to insure firm footing on jobs

where men are like to slip.

3. TOOLS AND EQUIPMENT

The safety precautions given below apply for tools and equipment.

a. Hand tools

(1) Select right tool for job. Avoid using makeshift.

(2) Never use tools with cracked or broken handles. Without handles
or with cracked or broken heads. Replace such tools with new ones.

(3) Keep all keen-edged tools sharp because they are safer sharp than
dull. Store them safely when not in use.

(4) Avoid using hammer on highly tempered tools, such as drills, files,
etc., because chips may fly into the face and hands.

(5) Use right size wrench for job. Face jaws of adjustable wrench in
direction of pull.

(6) Never use a wrench on a running motor. Stop machine. Remove

all tools before starting again.

(7) Never use any tool in such a way that hands or body can be injured
if tool slips.

(8) See that pipe-wrench jaws are sharp so they can not be slip.

b. Goggles

(1) Goggles must be thoroughly washed with soap and water before
being worn by another person.

(2) Goggles must be worn if performing tinning or soldering lugs or

large joints, chipping, breaking, or drilling cone etc., stone, or other material where

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ships are likely to fly, doing any work like to cause flying chips and particles, and
welding.

4. HANDLING TOOLS AND EQUIPMENT

The following safety rules apply when tools and equipment are being handled.

a. Do not throw tools and materials up or down to workmen on a different

level. Raise all lower them by hand lines or in canvass tools bags or buckets.

b. When tools or materials are raised or lowered, stand clear at all times
and avoid coming directly under any load until it is properly placed and secured.

c. When moving heavy loads on inclines, use ropes or suckle to control

the motion. See that workmen do not stand on the downhill side.

d. To lift heavy material or equipment used only approved hoisting

apparatus capable of carrying the load safety. Rope off areas immediately below.
Display warning signs and guard the area properly.

SAFETY IN THE SHOP

Safety is a matter of common sense and good work habits. The worker who
learns the proper way on how to use tools, learns the safety to use it.

Good work habit should be learned at the beginning. The auto mechanic
works with such a diversity of tools and equipment that she is exposed to m ore
hazards than the shop worker in general. Within minutes the mechanic may work
with hand tools, power tools, and then, perhaps have to more some very heavy piece
of machinery such as and on line or an entire automobile with al lifting device.

It is a common sense, or example, to pay that people shouldn’t smoke round

open containers of gasoline. The man busy with a job may think that it’s all right to
permit gasoline to stand in an open container for a few minutes while he finishes a
job. He feels that the risk is slight. If the shop burns down it makes little difference
that the risk was slight. A mechanic is not paid to take changes and no employer will
want him to risk his life to save a few pennies on a job. The man who takes the little
short cuts and gets away with them is the one who eventually ends up with a serious
injury.

Remember that your shop is not a playground. A little joke can become a
large accident. Moving machinery has no sense of humor. It performs that most
jobs in the same way time whether it is working on a piece of metal or habit of flesh.
Some general rules to follow are:

1. Be neat and clean in your work.

2. Learn the proper way to use equipment and stick to it.
3. Look where you are going and what you are doing.
4. Be deliberate in your work. It doesn’t pay to make moves around
equipment.
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5. Never use any “short cuts” that involves taking a risk. No matter how
small.
6. Be wary of the man who is a careless worker, who takes risk he causes
as many accidents for others as he does for himself.

Engineers have shown that the efficient worker is the one who is safety
conscious. He turns out good workman, just important, stays healthy to continue
working. Remember that an accident can cost many days of lost pay in addition to
any injury suffered. Since the auto shop involves special hazards, you must know
the safe procedures for auto repair work.

Most of the dangers for an auto mechanic involve a running engine,

chemicals, of lifting and moving heavy part. Road test also involves some hazards.

WORKING AROUND THE ENGINE

Whenever you work on a running engine of one that has just been shut off,
move carefully and deliberately. Be careful around all moving parts and remember
that there are many hot parts on a running engine or one that has been running
recently. Some of the things to be one the alert for are:

1. The fan and fuel belts. The fan itself can cause serve injury if it hits
you. If the engine is running fast, the fan can strike you with a great force. NEVER
STAND OVER ON AROUND THE RAN WITH IN ENGINE IS BEING RACED. A
crashed blade can leave its hub and cause a fatal injury; KEEP FINGERS, RAGS,
NO CLOTHING AWAY FROM THE MOVING FAN BELT.

2. Carburetor and Fuel Lines. New people thick of the carburetor as

potentially dangerous. If an engine backfires the air cleaner is off of the carburetor, a
flame two or three feet long can shoot out the carburetor, throat. NEVER USE AN
OPEN CAN OR GAS TO PRIME A CARBURETOR. Use “squirt” type oil can when
priming the carburetor throat. It also removes the danger of a can of gas catching
fire and being thrown in panic.

IF YOU REPLACE ANY PART OF THE FUEL SYSTEM, CRANK THE

ENGINE A NEW TYPES WITH A REMOTE STARTER SWITCHES AND CHECK
FOR ANY LEAKS. This is particularly important if the engine should have an electric
fuel pump. Electric fuel pumps will keep pumping as long as they have current and
encounter no back pressure.

3. Ignition High-Voltage Circuit. DON’T GRAB THE SPARK PLUG

WIRES OF THE COIL TO CONTRIBUTOR WIRE WITH YOUR BARE HANDS
WHEN THE ENGINE IS RUNNING. The voltage in the system could be fatal to
someone with a weak heart. A healthy person probably makes him jerk his hand
back. He could then his hot manifold, a hot radiator, the fan or the fan belt.

4. Radiator. When the engine is not, exercise extreme caution when

removing the radiator cap. It is best to drag a heavy cloth over the cap when
removing it. This protects your against any squirting when the cap is turned. Turn
the cap only one quarter of a turn so that it cannot pour off.
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If engine is overheated, it is best to let it cool off before trying to remove the
radiator cap. Some caps have a pressure release device on top. Push this and hold
it until all the pressure is released. The car is then safe to remove. Always treat the
radiator as if it were not.

5. Manifold and Exhaust. ALWAYS THREAT THE MANIFOLD AND

EXHAUST SYSTEM AS IF THEY WERE NOT. This is a good point to remember
when working under a car just brought in off of the road.

Exhaust fume is poisonous. Even a small amount of exhaust fumes in the air
can cause severe headache. ALWAYS BE SURE THAT THE WORK AREA IS
WELL VENTILATED. BE SURE TO CONNECT AN EXHAUST TUBE, IF
AVAILABLE, TO THE ENGINE EXHAUST BEFORE RUNNING THE ENGINE IN
THE SHOP.

The Hood. ALWAYS PROP THE HOOD OPEN WITH A STICK WHEN
WORKING ON AN ENGINE. When doing major work with the engine in the car, it is
safer and more convenient to take a few minutes to remove the hood.

WORKING WITH CHEMICALS

The two most common chemicals in the auto industry are gasoline and oil.
Most accident with chemicals in the industry are related to the obvious fact that
gasoline burns and lubricants are slippers. The rest have to do with toxic and
corrosive effects of chemicals.

1. Fire. Some of the dangers of working with a gasoline near a running

engine have been covered in the previous section. A common cause of fires is the
draining of a gas tank or fuel lines into an open pan and the n leaving it uncovered.

ALWAYS STORE GASOLINE AND OTHER FLAMMABLE LIQUIDS IN

CLOSED CONTAINER. Never use gasoline or any other flammable liquid as a
cleaner.

Follow all safety procedures when working with welding equipment.

Remember that the pure oxygen can cause a fire to spread with explosive force.
Always wear goggles when welding. NEVER LOOK DIRECTLY INTO A WELDING
FLAME WITH THE NAKED EYE.

If welding repairs are required or near the gas tank, DRAIN IT AND EITHER
FILLS IT WITH WATER OR BLOW IT OUT WITH COMPRESSED AIR. An empty
tank full of fumes is much more flammable and explosive than one containing
flammable liquids. The gas tank is usually removed from the car before being
welded.
KNOW WHERE THE FIRE EXTINGUISHER AND THE FIRE EXITS ARE. Do
not try to be heroic in fighting a fire. It is safe to put out small fire with buckets of
sand and hand extinguisher but larger fires have a way of spreading with amazing
speed and leading to explosions.

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DON’T GET INTO A CONFINED AREA WITH A BARBON TETRACHLORIDE

TYPE EXTINGUISHER. RAGS, WHICH HAVE BEEN SOAKE DIN FLAMMABLE
LIQUIDS SHOULD BE STORED IN CLOSED CONTAINERS, R PUT IN OUSIDE
TRUST CONTAINERS. Spontaneous combustion of greasy rags is still the most
common cause of fires.

NEVER SMOKE WHILE YOU ARE WORKING AND SMOKE ONLY IN

DESIGNATED AREAS.

1. Oil and other lubricants. ALWAYS KEEP YOUR WORK AREA

CLEAN. Oil and grease on the floor can cause someone to slip and fall. Tools that
are oily can cause you to lose your grip. Wear goggles when working under a car
keep oil and dirt from your eyes.

If you should have occasion to work with oxyacetylene welding equipment,

MAKE SURE THAT THERE ARE NO OIL PRODUCTS ON YOUR WORK AREA.
Oil and oxygen make an explosive mixture.

2. Battery acid. BATTERY ACID, IF IT GETS IN YOUR EYES, CAN

CAUSE IMMEDIATE DAMAGE. If you get accident yourself wash it away with
plenty of clean water, the material which builds upon battery terminals will reform as
acid when dissolved should be neutralized by washing with a baking soda and water
solution. DON’T SMOKE AROUND A BATTERY BEING CHARGED. IT GIVES
OFF HYDROGEN WHICH IS EXTREMELY EXPLOSIVE.

3. When mixing acid always put, slowly, the acid into the water. Mixing it
in the reverse order can cause it to boil and spatter with the force of an explosion.

4. Solvents and Fumes. Always work in well ventilated areas when

working with cleaning solutions, glues, gasoline or any other chemicals which give
off strong fumes.

CARBON TETRACHLORIDE AS A LIQUID OR GAS IS EXTREMELY TOXIC,

NEVER INHALE THE FUMES AND NEVER GET ANY IN YOUR MOUTH.

5. Many compound much as tetraethyl lead found in anti-knock gasoline

are cumulative poisons. Taking them into your system in small amount over a period
of years can result in liver damage and other harmful effects. Keep this in mind
when siphoning gasoline.

6. Hydraulic fluid. HYDRAULIC FLUID CAN BE BLINDING exercise care

when bleeding brakes and working ground hydraulic lines. NEVER DISCONNECT A
POWER ACCESSORY HYDRAULIC LINE WHILE THE ENGINE IS RUNNING.

FIRST AID

Treat all injuries, major and minor as soon as possible. A mechanical should
never overlook a minor out or burn because his work offers so many sources of
infection.
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Such things as battery acid and lime should be washed off immediately on
contact. Any solution which is acid or caustic should be removed of rinsing
deliberately with water.

Do not use grease or butter on burns. If a burn blisters, the blisters will
eventually break. When this happens, the grease or butter will be a source of
infection. If salted butter is used, there will be extreme pain. In general, if an injury
requires more than minor attention, see a nurse or a doctor.

Accidents – is a mishap that interrupts an operator or activity and cause

injury, loss of life or damage of property.

Two cause of accidents:

1. Contributing causes

a. Supervise Safety Performance

1) Safety instructions inadequate

2) Safety rules not enforced
3) Safety not planned as part of the job
4) Hazards not corrected
5) Safety devices not provided

b. Mental Condition of Person

1) Lack of safety awareness

2) Improper attitudes
3) Slow mental reaction
4) Lack of emotional stability
5) Nervous

c. Physical condition of person

1) Extreme fatigue
2) Poor eyesight
3) Physical unqualified for job
4) Crippled

2. Immediate Causes:

a. Unsafe acts

1) Protective equipment of guard provided but not used.

2) Hazardous method of handling equipment.
3) Improper tools or equipment used
4) Hazardous movement
5) Horseplay

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b. Unsafe condition

1) Ineffective safety device

2) No safety device although one is needed
3) Hazardous housekeeping
4) Defective equipment
5) Improper dress or apparel for job

Contributing and immediate cause will cost:

a. Delay in production and spoilage

b. Minor injuries
c. Major injuries
d. Time lost

INDUSTRIAL SAFETY AND ACCIDENT PREVENTION

OBJECTIVES

1. To develop awareness and safety consciousness in supervisors by

insuring the safety of workers.

2. To acquaint and assist supervisor in effective application of accidents-

prevention program.

ACCIDENT PREVENTION

Safety has been as freedom from accident and industrial safety is thought as
the planning and minimizing of accident.
On the other hand, accident is defined as mishap that interrupts an operation
or activity. It is happening that gives no warning at all. It may result in personal
injury or loss of life, and damage to industrial property.

There are two main reasons why accident should be prevented:

1. Human side – the avoidance of human suffering

2. Economic side – minimizing or elimination of interruption of normal
operation and damage to property.

Can Accident be prevented?

There is a saying that goes “an injury prevented is a benefaction, an injury

compensated, an apology”.
Accident prevention is defined is an integrated program, a series of
coordinated activities directed toward the control of unsafe personal performance
and unsafe mechanical conditions, based on certain knowledge, attitudes and
abilities. It has been a science and art. It represents above all things, control of
man’s performance, machine performance, and physical environment.
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Many believe that accidents cannot be prevented. They can only be minimizing:

1. Industrial injuries result only from accidents.

2. Accidents are caused only by:

a. The unsafe acts of person

b. Exposure to unsafe mechanical conditions.

3. Unsafe conditions and actions are caused only faults of person.

4. Faults of person are created by environment or acquired by
inheritance.

Again, according to the group, a preventable accident is one of the factors in a

sequence that results in an injury as shown in the diagram on the board.

Invariably, the injury is caused by an accident and the accident in turn is

always the result of the factor that immediately precedes it. An analysis of this
sequence is as follows:

1. The injury is caused by the action of preceding factor.

2. The unsafe act and mechanical hazards constitute the control factor in
the accident sequence.
3. The removal of the central factor makes the action of preceding factors
ineffective.

Four basic steps in Preventing Accidents:

A. Set a good examples

1. Follow all safety regulations

2. Show to tell-practice what you preach
3. Do not put accident prevention too far down in your list of daily
tasks
4. Do not permit violations of safety regulations

B. Make instructions clear and complete

1. Include accident prevention instruction as a part of job
instruction
2. Be certain that your people understand your safety instructions
3. Have employee explain back to you each safety instruction
4. Give a reason WHY for each safety instruction
5. Do not depend on employee’s learning safety from a rule book

C. Keep all safety devices in proper use

1. Impress each employee on the value of safety devices
2. Be certain that safety devices worn are comfortable and will not
cause general safety indifference on the part of the wearer.
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D. Follow-up safety instructions

1. Keep employees safety conscious be regular safety contact

2. Watch constantly to detect unsafe practices
3. Never stop safety instructions
4. Keep safety posters, bulletins and instructions posted up to
date.

E. Never ignore a violation of safety instructions

Enforcement of safety regulations is a must. Discipline is necessary. When a

superior talks to at least one of his men everyday, safety becomes a personal matter
between each worker and the supervisor. A plan where discipline means lack of
control – and without with control – any safety program is pretty meaningless talk.
Consistent enforcement of the rules is the key.

What accident prevention accomplishes?

1. Saving life and limb

2. Continuity of service
3. Insurance premium reductions
4. Increased production
5. Decreased labor turn-over
6. Improved labor-management relation

A supervisor’s creed for Accident Prevention:

“I BELIEVE IN SAVING LIVES, ARMS, EYES, LEGS, AND HUMAN SUFFERING”.

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