TechArchive

This article was originally written in the period 1995-2000

Although produced primarily for the rubber industry, Be On Your Guard is a publication which is relevant to many other manufacturing industries.

Be on your guard, a guide to the importance of risk assessment on machinery safety and accident prevention, was prepared by the Rubber Industry Advisory Committee (RUBIAC) of the Health and Safety Commission.

The guidance aims to help comply with the law on machinery safety and focuses on the importance of risk assessment in accident prevention. It provides detailed step-by-step advice on how to apply the principles. The booklet is aimed at employers, but is equally useful to supervisors, maintenance staff, safety representatives and machinery operators.

Machinery accidents are the main cause of serious injuries to workers in the rubber industry, where in common with many other industries, much of the machinery used is extremely powerful, with the potential to inflict permanent disfigurement, maiming or death. Such accidents most commonly result in fractures and bruising of the hand, wrist and arm, though in many cases, far more serious injuries result. 40% of major injuries involve amputation.

Employers providing machinery for use in a factory for the first time after 31 December 1992 are required by to ensure that it complies with the UK Regulations, which implement the European Machinery Directive. The Directive is intended to ensure that only safe machines are marketed in the European Union. The Regulations do not place duties on employers putting new machinery into use, but rather on the manufacturers, importers and suppliers of most machines to ensure and declare that they are safe and meet the essential health and safety requirements specified in the Regulations.

Risk assessment is required under the Management of health and Safety Regulations 1992. A hazard is a source of possible injury. The risk is the chance, great or small, that someone will be injured by the hazard. The term “risk assessment” simply means looking at how injury could be caused by contact with machinery and the chance that someone could be injured in this way, so that you can decide whether you have taken enough precautions or should do more to prevent injury. There are five steps that risk assessment can be broken down into.

It is important that employees are consulted at all stages in the assessment. They should be involved in identifying hazards at their machines and in devising suitable safeguards and safe operating procedures.

Identifying the hazards involves recognising the moving parts of the machinery, either powered or with the potential to move, for example under gravity. And does the movement create a hazard? Types of mechanical hazard to look for include crushing, shearing, cutting, entanglement, drawing-in (nips), impact, stabbing or puncture, friction or abrasion. Are there any static parts of the machine, such as blades, which may present a mechanical hazard?

Who might be injured by the hazards? Consider not only production operatives but maintenance and cleaning staff, visitors. Pay particular attention to lone workers and young or inexperienced staff.

How might an injury occur? Include installation and dismantling of machinery. Look at how the work is actually done, rather than how it should be done, or how you think it’s done. Identify any situations where the usual safeguards cannot be relied upon, such as the removal of guards during maintenance work.

Priority should be given to high risks – meaning those which could result in serious injury or which could affect several people. In some cases, it will be possible to remove or reduce the risk of injury by changes to the machine itself or to the way the work is done. Where the risk of injury cannot be eliminated completely, guards or other safety devices which are effective in preventing access to dangerous parts should be provided. Any residual risks which cannot be controlled by engineering means should be minimised by the use of safe systems of work and by appropriate selection and adequate training, instruction and supervision of employees.

Some design-related preventative methods include:

• Increasing the gap (trapping point) between adjacent conveyor systems;
• Reducing the speed, pressure and/or torque;
• Easily identifiable emergency stop buttons;
• Clear operating controls;
• Shrouding start buttons and pedals;
• Avoid excessive noise, heat and vibration to reduce stress on the operator.
• Arranging for machines to be fed and cleaned automatically
• Providing fixed guards wherever possible, otherwise interlocking guards;
• Use of pressure mats and photoelectric devices where fixed guards are not practical.

Guarding standards must comply with industry guidance or represent acknowledged good practice. Where guards or other protective devices cannot give full protection, work holders, jigs or push sticks should be used wherever practicable. Guards and other safety devices must be checked regularly and maintained in effective working order.

Any company with five or more employees should record the significant findings of a risk assessment. These should include the significant hazards, who is at risk and the preventive and protective measures taken to control the risks. Employees and safety representatives should be kept fully informed of the findings of the assessment.

Risk assessment is not a once-and-for-all activity. Work involving machinery must be monitored to ensure that the assessment remains valid.

• Copies of HSC’s Rubber Advisory Committee “Be On Your Guard – a Risk Assessment Approach to Machinery Safety in the Rubber Industry” are available from HSE Books, PO Box 1999, Sudbury, Suffolk CO10 6FS, price (UK pounds)8.50. Telephone: 01787 881165.