INTRODUCTION

OF SAFETY
DISTI
L DISTIL EDUCATION AND TECHNOLOGY PVT.
LTD.
INTRODUCTION

Generally accidents do not happen; they are caused. Most accidents are avoidable.
A good craftsman, having knowledge of various safety precautions, can avoid
accidents to himself and to his fellow workers and protect the equipment from
damage.
To achieve this, it is essential that every person should follow safety procedures in a
workshop which broadly classified into 3 categories -
General Safety , Personal Safety and Machine Safety .
GENERAL SAFETY

Always be sure that all machines have effective and properly working guards that
are always in place when machines are operating.
 Do not lean against the machines and other equipments .
 Do not run in the shop , Don't talk to others when they are operating a machine.
 Concentrate on the work and do not talk unnecessarily while operating the
machine.
Be sure you have sufficient light to see clearly.
Get first aid immediately for any injury.
PERSONAL SAFETY
Clothing and Safety Equipment are very important at work place -
 Always wear safety glasses, goggles, or face shields designed for the type of work when
operating any machine.
Wear clothing suited for the job – Shoes , Apron , Hand Gloves , Face Shield etc .
Do not wear rings, watches, bracelets, or other loose jewelry or clothing like full sleeves
shirts that could get caught in moving machinery.
Always remove gloves before turning on or operating any machine.
 If material is rough or sharp and gloves must be worn, place or handle material with
machine turned off.
MACHINE SAFETY
Replace guards immediately after any repairs.
 Do not attempt to oil, clean, adjust or repair any machine while it is running. Stop the
machine and lock the power switch in the "Off" position.
Always see that work and cutting tools on any machine are clamped securely before
starting.
Remove all wrenches from machine after completing setup.
Use only cutters that are correctly ground and in good condition
Check speeds and feeds and feed work against direction in which cutter is rotating.
 Keep hands away from work when machining.
Always use face shield or goggles even if grinder is provided with protective glass
shields.
SAFETY
There are basic rules one should follow at workplace –
Keep work areas regularly clean and arranged .
Use the proper tools and equipment according to machines and raw material .
Always wear proper PPE while working at the work place .
Never work on running machines or equipments .
Make sure that equipments are labelled properly .
Pass information regarding any type of hazards to the higher management .
Always ensure about the uneven hazards while working at workplace .
 Always follow the instructions by management at workplace .
PERSONAL PROTECTIVE EQUIPMENT
The Occupational Safety and Health Administration (OSHA) requires that employers
protect their employees from workplace hazards that can cause injury.
Different categories of PPE are used at different levels of hazardous worksites
The general equipments for personal protections are –
Helmet
 Hand Gloves as per specified works .
 Welding Shield / Face Shield
 Apron as per specified works .
 Eye Glass as per specified works .
 Ear Buds
 Safety Shoes
5’S
5’S is a philosophy and a way of organizing and managing the workspace and work
flow with the intent to improve efficiency by eliminating waste, improving flow and
reducing process unreasonableness.
History of 5’S - The word “5S(five S)” was generalized in 1980’s in manufacturing
sector in Japan, as Toyota Production System (TPS) became famous in the sector
and “5S activities” were set as one of the bases of TPS . Service industry started to
used “5S” in 1990’s
5’S can be done by Team work improvement through everyone’s participation .
5’S
FIVE S JAPANESE NAME ENGLISH NAME

FIRST S SEIRI SORT

SECOND S SEITON SET

THIRD S SEISO SHINE

FOURTH S SEIKETSU STANDARDIZE

FIFTH S SITSUKE SUSTAIN

5’S
SORT - Focuses on eliminating unnecessary items from the workplace • Categorize
equipment, furniture, tool in your working place into the following 3 categories -
Necessary , Unnecessary and May not necessary.
Examples of sorting out
Place “Red tag” for categorization of items to identify unnecessary items
Move unnecessary items( broken tools, obsolete jigs and fixtures, scrap and excess raw
material etc.) to central stored area
Free up valuable floor space (Space utilization)
Finding abnormality of equipment and tools (Out of order, missing parts etc.)
5’S
Set in Order - “Set” is based on finding efficient and effective storage of
necessary items. Apply “Can see, Can take out, and Can return” philosophy . This
will save time and energy to look for something.
Examples of setting in Order –
Labeling , numbering, zoning for clear identification of storage areas to keep
necessary items .
Set necessary items matching with workflow to minimize unnecessary movement
and transportation time.
5’S
Shine – Cleaning or Sweeping activities are called as Shine.
Examples –
Daily sweeping and mopping of floor, bathroom, corridor etc.
Regular cleaning and maintenance of equipment and tools
Periodical check for changes in equipment and the service area such as: leaks,
vibration, misalignment, breakage etc.
IPC activities such as hand hygiene, waste segregation are also part of shine.
5’S
Standardize - Maintain an environment where S1 to S3 are implemented in the
same manner throughout the organization .
Examples of Standardize –
 Work instructions, Standard Operating Procedures (SOPs).
 Checklist development and regular usage for SOPs.
 Mechanism and format development for ordering supplies, reporting etc.
 Color coding for waste segregation • Standardized common symbols .
5’S

Sustain - Maintain S1-S4 through discipline, commitment and empowerment . It

focuses on defining a new mindset and a standard in workplace .
Examples –
Regular progress reporting and training .
 Regular evaluation of 5S activities for continuos improvements
 Appreciation, recognition and awarding on good 5S activities
 Reminder using 5S corner, new letters, good practice sheet etc.
BENEFITS OF 5’S

Visible results enhance the generation of more and new ideas

 The workplace gets cleaned up and better organized
 Shop Floor and office operations become easier and safer
 Results are visible to everyone - insiders and outsiders
 People are naturally disciplined
 People take pride in their clean and organized workplace
 As a result the company’s good image generates more better
TARGETS OF 5’S

Zero changeovers leading to product/ service diversification

Zero defects leading to higher quality
Zero waste leading to lower cost
Zero delays leading to on time delivery
Zero injuries promoting safety and bringing better maintenance
FIRST AID

First aid is the provision of initial care for an illness or injury. Certain self limiting
illnesses or minor injuries may not require further medical care after the first aid
intervention.
The basic objectives of First Aid are:
to give immediate care.
to protect the casualty from further harm.
to relieve pain.
to promote recovery.
The recovery is promoted as the heart rate goes down, which in turn prevents blood
loss from the victim’s body.
RESPONSE TO EMERGENCIES
Power and System Failure –
Don’t get panic .
Don’t create unusual activities which leads to misguide to others.
Press the emergency switch off of the machinery near to you.
Always try to find a safe exit and help others to get out .
Always try to stay away from hanging equipments like cranes , Vertical machines.
RESPONSE TO EMERGENCIES

Fire –
 Don’t get panic and run away .
Cut off the electrical mains near to the fire.
Use nearby fire extinguisher according to the grade of fire.
 Class A are used for fires in ordinary combustibles such as wood and paper.
 Class B are used for flammable liquids such as grease , gasoline and oil.
 Class C are used for electrically energized fires.
 Class D are used for combustible metals such as magnesium, titanium and sodium.
ELECTRICAL MAINTENANCE

The operations which are performed in electrical maintenance are-

Review of power inlets and outlets .
Review of electric connections (wires , cables , fuse ) etc.
Electromechanical machines (WIRE EDM , LASER CUTTING MACHINES) .
Electrical Boards and Circuits .
Monitoring of Electrical Damage .
ELECTRICAL MAINTENANCE

Generally, there are Preventive Maintenance , Predictive Maintenance and Break

Down Maintenance . The operations are categorized in these types of maintenance
to make the maintenance work in proper flow and keep the plant break down and
accidentally free .
PPE used in Electrical Mains are-
Helmets .
Hand Gloves .
Eye Glass .
Safety Shoes.
Insulated hand and foot to restrict flow of current .