Environment Safety & Health

BFF4911

MECHANICAL HAZARD
 Lesson Outcomes

1. Describe the characteristics of mechanical

hazard,
2. Examples of mechanical hazard
3. Precautions to control mechanical hazard.
TYPES OF INDUSTRIAL HAZARDS
 Injuries
A person may be injured at mechanical equipment
through:

i. Coming into contact with it, or being trapped

between the machinery or any fixed structure;
ii. Being struck by, or becoming entangled in motion in
the equipment/machineries;
iii.Being struck by parts of the tools / machineries
ejected from them;
iv. Being struck by the work piece during the machining;
 ACCIDENT CASES

SEGAMAT: Seorang pekerja kilang maut apabila tersepit pada rantai mesin di sebuah kilang
memproses buah kelapa sawit di Jalan Genuang, di sini hari ini.
Anggota bomba dan penyelamat yang dipanggil mengambil masa kira-kira 30 minit untuk
mengeluarkan mayat Gan Kian Beng, 57.
Jurucakap Pusat Gerakan Operasi (PGO) Jabatan Bomba dan Penyelamat Malaysia (JBPM) Bandar
Baru berkata, pihaknya menerima panggilan kecemasan tentang kejadian pada pukul 3.18 petang.

Never forget about safety…

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Common mechanical injuries
Cutting
&
tearing

Puncturing Shearing
Common
Mechanical
injury
hazards

Straining
& Crushing
spraining
 Warning:
 For power tools, wrong selection & incorrect use is
important in increasing the percentage number of
accidents;
 Materials handling equipment are dangerous if not being
managed or maintained properly.

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 Introduction

Crushed hands and arms, severed fingers, blindness - the list

of possible machinery-related injuries is as long as it is
horrifying. Safeguards are essential for protecting workers
from needless and preventable injuries.

A good rule to remember is: Any machine part, function, or

process which may cause injury must be safeguarded.

Where the operation of a machine can injure the operator or

other workers, the hazard must be controlled or eliminated.
Causes of Machine Accidents

1. Negligence
2. Not using Lockout/Tagout
3. Unauthorized persons doing
maintenance or using the machines
4. Missing parts or loose machine guards
 Where Mechanical Hazards Occur?

• Point of operation
• All parts of the machine which move, such as:
• flywheels, pulleys, belts, couplings, chains, cranks,
gears, etc.
• feed mechanisms and auxiliary parts of the machine
• In-running nip points
Point of Operation

That point where work is performed on the

material, such as cutting, shaping, boring, or
forming of stock must be guarded.
Rotating Parts

Copyright © NIOSH 2006 13 / 73

In-Running Nip Points
A point of convergence between
two rolling parts, or a rolling part
and a stationary part, where all or
part of the human body could
become trapped and injured.

Rotating
cylinders Belt and
pulley

Chain and
sprocket
Rack and
pinion

Copyright © NIOSH 2006 14 / 73

 MACHINE SAFEGUARD
 Can be found at the point of operation, the power
transmission apparatus or at the area of transverse
motion.

TYPES OF GUARDS

i. Fixed Guards

• A permanent part of the machine

• Usually made of sheet metal, screen,
bars or other material which will
withstand the anticipated impact
• Preferred type of guard.

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 Fixed Guards

Advantages Limitations

 Can be constructed to suit Can be limited to specific

many specific applications operations

 In-plant construction is often Machine adjustment and repair

possible often require its removal, thereby
necessitating other means of
 Can provide maximum protection for maintenance
protection personnel

 Usually requires minimum

maintenance

 Can be suitable to high

production, repetitive
operations

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ii. Interlocked Guard

• Usually connected to a mechanism that will cut off the

power automatically
• Could use electrical, mechanical or hydraulic systems
• Operation relies on a manual reset system

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 Interlocked Guard

Advantages Limitations

• Can provide maximum • Requires careful adjustment

protection and maintenance

• Allows access to the machine • May be easy to disengage

for removing jams without time
consuming removal of the
fixed guards

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iii) Adjustable Guard

• Very flexible to accommodate various types of stock.

• Manually adjusted

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 Adjustable Guard
Advantages
• Can be constructed to suit
many specific applications
• Can be adjusted to admit
varying sizes of stock
Limitations
• Hands may enter danger area -
protection may not be complete
at all times
• May require frequent
maintenance and/or adjustment
• The guard may be made
ineffective by the operator
• May interfere with visibility
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iv) Self-Adjusting

• The opening is determined by

the movement of the stock
through the guard.
• Does not always provide
maximum protection.

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 Self-Adjusting

Advantages Limitations

• Off-the-shelf guards are often • Does not always provide

commercially available maximum protection

• May interfere with visibility

• May require frequent

maintenance and adjustment

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 FATALITIES
 Many fatalities have resulted from
employees getting caught in rotating shafts
such as well boring drills, lathes & saw
blades.

UNSAFE CONDITIONS

Transmission system
Unguarded saw blade
should be guarded 23
 POWER-DRIVEN MACHINES’ GUARDING

Using a gate system to keep hands out Using a wire guard to stop the
of the point of operation area. machine when a worker gets
too close.
The operator must push both This cable will stop the
buttons at the top of the machine when it is pulled.
machine to insure that his
hands are not in the point of
operation area
The tripod type bar on top of This safety bar will stop the
this machine can be grabbed machine if the worker gets too
by a worker to stop the close to the operation area.
machine.
A shield of safety glass prevents
sparks and particles from
striking the worker.
The operator must press This operator has wrist cuffs
both of the control attached to her arms to keep her
buttons at the same time from putting them in harms way.
to operate this press.
 Power Tool Hazards
 All hazards involved in the use of power
tools can be prevented by following five
basic safety rules:
• Keep all tools in good condition
with regular maintenance.
• Use the right tool for the job.
• Examine each tool for damage
before use.
• Operate according to the
manufacturer's instructions.
• Provide and use the proper
protective equipment.

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 FORKLIFT SAFETY
Forklifts are useful for moving raw materials, tools and equipment in
many industries.
These accidents result from:
• Lack of operator training
• Poor maintenance of the forklift
• No safe systems of work

OPERATORS
 Selection of operators
 Physical and mental fitness
 Training
Basic, job specific & familiarisation
 Authorisation to operate
• Written permission
• Driver competency – Certificate & continuous assessment
• Lockable ignition & key holder
 MAINTENANCE
 Must do daily checking on system & main components

System :  Components :
• Hydraulics • Tyre pressure
• Brakes
• Battery
• Brakes / hand break
• Lights • Horn
• Steering • Lights / beacon
• Fuel

SYSTEM OF WORKS
 DO NOT! :
• Pick up a load if someone is standing close
• Allow people to walk underneath the load
• Try to pick up an unsuitable load
• Leave a lift truck unattended with the engine running
• Drive forward if visibility is impaired by a load.
 How to operate a Forklift
Safely
• Keep arms and legs inside the truck
• Handle only stable loads
• Keep speed low - you may have to stop
• Be careful when making sharp turns
with a raised load
• If a load blocks your view, travel in reverse
• No riders, unless there’s an approved seat
• Don’t drive with forks raised
• Wear safety belts or other restraint devices

MOSH - MATERIAL HANDLING 32 / 60

 How to drive the forklift on an incline/ramp?

• When driving an empty truck,

travel in reverse up an incline,
and forward down an incline.
Always make sure the forks
pointing downhill/downwards

• If you are driving a loaded truck,

travel forward up an incline, and
backward down an incline.
Always make sure the forks

Click to
watch

demo
the
pointing uphill/upwards

33 / 60
Forklift hazards

 Overturning
 Overloading
 Collisions
 Silent operation of the electrically powered forklift truck – can
make pedestrians unaware of its presence
 Uneven road surface
 Overhead obstruction
 Loss of load

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DO’S:

• Only issue keys to authorised drivers

• On completion of work, park the forklift in designated
area
• Be careful with pedestrians / obey site rules / speed
limits
• Sound horn at potential danger spots
• Stop before entering a building, sound horn then
proceed
• Avoid violent breaking
• Always travel with the forks roughly 150 mm above
ground level
• Before raising a load check overhead for obstructions.
THANK YOU

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