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Machine Guarding for Plastic Sheet and Roll Stock Extrusion

The Society of the Plastics Industry, Inc. Machine Guarding for Plastic Sheet and Roll Stock Extrusion. A Presentation of the SPI-OSHA Alliance. (Screen Capture of Website). (Screen Capture of Website). Course Objectives.

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Machine Guarding for Plastic Sheet and Roll Stock Extrusion

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  1. The Society of the Plastics Industry, Inc. Machine Guarding for Plastic Sheet and Roll Stock Extrusion A Presentation of the SPI-OSHA Alliance

  2. (Screen Capture of Website)

  3. (Screen Capture of Website)

  4. Course Objectives • Identify the types of injuries that can occur while operating plastics sheet and roll stock extrusion equipment • Describe the possible causes of these injuries • Identify ways to safely operate plastic extrusion equipment • Recognize the importance of a total safety and health approach

  5. (Screen Capture of Website)

  6. Reasons to Focus on Injuries in the Extrusion Process • High injury/illness rates • OSHA citations • National Emphasis Program on Amputations • Site-Specific Targeting • High workers compensation costs

  7. Fatalities Amputations Avulsions Fractures Burns Cuts and bruises Sprains and strains Electric shock Types of Injuries

  8. Some Causes of Injuries • Reaching around, under, over or through guards into hazardous areas • Removing or bypassing guards • Inadequate temperature monitoring during cleanup • Not using LOTO procedures • Machine/equipment malfunctions

  9. Causes of Injuries(cont’d) • Lack of recognition of hazards of the job • Lack of familiarity with the equipment • Inadequate training, comprehension, or both • Operating machines with missing or inoperable guards and improper or inadequate machine maintenance • Lack of proper PPE • Loose clothing around winding equipment

  10. Schematic of Extruder

  11. Schematic of Extrusion Process

  12. Feed Tubes Roll Stack Trim Knives Pull/Nip Rolls Shear Winder Grinder Risk Areas

  13. Feed Tubes

  14. Accident #1Third-Degree Skin Burns • Two employees were cleaning the feed pipe for a line extruder • Resin in the feed pipe hardened during shutdown • Employee heated the feed pipe to soften the plastic for 30 minutes • The employee pulled plastic plug at bottom of feed pipe • Hot plastic sprayed out causing 2nd & 3rd degree burns

  15. Roll Stack

  16. Accident # 2Fatality • Machine operator was threading plastic film through rolls of film extruder line when he got caught between top and bottom rolls • Skull fracture and head trauma resulted in his death

  17. Trim Knives pivoting blade guard trim knife

  18. Trim Knives

  19. Trim Knives

  20. Trim Knife Guarding

  21. Trim Knife Blade Disposal

  22. Pull-Roll Nips Sturdy metal mesh in guard Emergency stop pull cord

  23. Shear

  24. Shear

  25. Winder

  26. Accident #3Fatality Employee was splicing plastic on new extruder winder rolls to get it started • drawstring on hooded sweatshirt got caught in roll • employee died by asphyxia

  27. Grinder Guarding • Guarding by: • Enclosure over moving components • Anti-kickback flaps in feed throat • Proximity guarding – distance from feed chute to rotating knives Proximity Guarding

  28. Safety Guards and Devices • Types of guards and devices • Movable guards with interlocks • Fixed barrier or proximity guards • Presence-sensing device • Locations of guards • Over/around moving equipment • Around electrical hazards • Around thermal hazards • Around cut hazards

  29. Movable Guards with Interlocks • Allows the electrical system to operate • Actuated when the interlocked guard is closed or opened • Prevents machine from operating when the guard is open Electrical Interlock Switch

  30. Interlocked Guard Emergency stop pull cable Electrical interlock switch

  31. Electrical Interlock Operation

  32. Fixed Barrier Guards • Prevent contact with the hazard Yellow fixed guard

  33. Fixed Barrier Guards Wing guards Guard over moving machine components

  34. Fixed Barrier Guards

  35. Presence Sensing Devices • Safety mat • Light curtain

  36. Presence Sensing Devices Safety Mat

  37. Safety Guards and Devices Light Curtain

  38. How to Protect Yourself • Recognize the hazards in the job you are doing • Understand the requirements for guarding machines • Implement guarding solutions

  39. Emergency Stop Button • Know: • Where they are located • What they control • When to use them

  40. Emergency Stop Cable • Know: • Where they are located • What they control • When to use them

  41. Signs and Warnings

  42. Colors used with Safety Signs have meaning! DANGER White Lettering/Red Background WARNING Black Lettering/Orange Background CAUTION Black Lettering/Yellow Background

  43. High Voltage

  44. Rotating Screw

  45. High Temperature

  46. High Pressure

  47. Crushing Fingers

  48. Amputated Fingers

  49. References for Extrusion Safety • ANSI B11.TR3-2000 Risk Assessment and Risk Reduction - A Guide to Estimate, Evaluate and Reduce Risks Associated with Machine Tools • ANSI B11.19-2003 Performance Criteria for Safeguarding • ANSI/SPI B151.7-1996 Plastics Machinery - Plastics Extrusion Machines - Requirements for the Manufacture, Care and Use • ANSI/SPI B151.5-2000 Plastic Film and Sheet Winding Machinery - Manufacture, Care, and Use • ANSI/SPI B151.20-1999 Plastic Sheet Production Machinery - Manufacture, Care and Use • ANSI Standards are available at the following web site: www.ansi.org • SPI Guide to Extruded Plastic Sheet Products, www.plasticsheet.org/Guide/index.htm

  50. OSHA's Site-Specific Targeting (SST) Program OSHA's Site-Specific Targeting (SST) program selects for inspection individual worksites with the nation's highest lost workday injury and illness rates based on data reported by more than 80,000 employers surveyed by the agency. In April of this year, OSHA announced that its site-specific targeting plan for 2006 would focus on approximately 14,000 worksites with higher than average injury and illness rates for unannounced comprehensive safety and health inspections over the coming year. The 14,000 identified sites are establishments located in stated covered by Federal OSHA. This year's program was announced on April 21, 2006 and will initially cover worksites that reported 6 or more injuries or illnesses resulting in days away from work, restricted work activity, or job transfer for every 100 full-time workers (known as the DART rate). The average national DART rate in 2004 for private industry was 2.5. Over the past eight years, OSHA has used a site-specific targeting inspection program based on injury and illness data. This year's program stems from the agency's Data Initiative for 2005, which surveyed approximately 80,000 employers to attain their injury and illness numbers for 2004.

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