General Safety Protocols on Manufacturing Plant

General Safety
Protocols on a
Manufacturing Plant

Manufacturing Plant
• Factory – raw materials – finished products
• Production on a large scale
• Uses manpower, machines, chemicals, etc.
• Heavy, Light, High Tech

PERSONS INVOLVED IN
MANUFACTURING AND THEIR
RESPONSIBILITIES
• Officers – ensures the business to comply
with safety standard, has appropriate resources,
and uses reasonable processes
• Workers – take care for own health and safety and
not adversely affect the health and safety of other
persons.
– comply with any reasonable instruction and
cooperate with any reasonable policy or procedure
relating to health and safety at the workplace.

PERSONS INVOLVED IN
RESPONSIBILITIES
• Designers – eliminating hazards and risks before
plant is introduced in the workplace and provide
specific information to the manufacturer
• Manufacturers – advise the designer of any hazards
you identify during manufacture and ensure that the
hazards are not incorporated into the manufacture of
the plant

PERSONS INVOLVED IN
RESPONSIBILITIES
• Importers and Suppliers
– take steps to obtain information from the
manufacturer
– pass this information on when supplying the
plant
• Installers – sets up, assembles, places in position
and connects or otherwise makes plant ready
for use.

IDENTIFYING HAZARDS
- involves finding all of the things and situations that could
potentially cause harm to people. Hazards associated
with plant generally arise from:
• The plant itself: For example, hazards associated with a
forklift would include hazards relating to its mobility; its
electrical, hydraulic and mechanical power sources; its
moving parts; its load-carrying capacity and operator
protection.
• How and where the plant is used: The forklift, for example,
may have hazards arising from the kind of loads it is
used to lift, the size of the area in which it is used and
the slope or evenness of the ground.

THE HIERARCHY OF RISK CONTROL
1. Elimination - The most effective control measure
is to remove the hazard or hazardous work
practice associated with the plant
2. Substitution - substitute the plant (or hazardous
parts of it) with plant that is safer
3. Isolation - separate the hazardous plant from
people, either by distance or physical barrier
4. Engineering controls - include modifications to
tools or equipment, for example installing
guards to prevent contact with moving parts of
machinery or installing a roll over protective
structure on a tractor

Safety Concerns on Plants
• Selection of Plant
- select plant that is suitable for the intended use along
with the right equipment for the job
- identify risks and possible hazards in the plant and provide
proper maintenance, installation and operation of
equipments according to proper instructions
• Instruction, Training and Supervision
- provide workers and other persons who are to use the plant
with information, training, instruction or supervision that
is necessary to protect them from risks arising from the
use of plant
- make sure workers are competent, trained, qualified and
know the proper work procedures including the case of
emergencies

• Inspection and Testing
- must be carried out regularly by an authorized person to
check if the plant and its equipments still falls under
safety standards
- factors to consider includes condition, suitability, location,
and abnormal situations
• Maintenance, Repair and Cleaning
- ensure that plant is maintained and repaired according to
the manufacturer’s specifications or, in the absence of
such specifications, in accordance with a competent
person’s recommendations
- make sure that plant should be isolated and shutdown
before maintenance, service or cleaning commences

• Reports
- inspections report
- unusual findings
- records and statistics
- recommendations (if asked)

SPECIFIC CONTROL MEASURES
1. Guarding
a. Permanently Fixed Physical Barriers - physical barriers
designed to be welded or incorporated into the body of
the machine such that the plant's power transmission
cannot be accessed during normal operation,
maintenance or cleaning.

1. Guarding
b. Interlocked Physical Barriers - An interlock guard is
connected to the plant's operational controls so that the
plant is prevented from operating until the guard is
closed. The guard cannot be opened or removed until the
dangerous parts of the machine have fully come to rest.

1. Guarding
c. Physical Barriers Fixed in Position - such as perimeter
fences securely fixed in position to prevent access to
dangerous areas. Any access points, for example gates
and doors, should be secured with a lock or interlocking
system

1. Guarding
d. Presence Sensing Systems – systems that can detect
when a person (or part of a person’s body) enters the
danger zone and stops the machine.

2. Operator Controls
- suitably identified so as to indicate their nature, function and
direction of operation
- located so they can be readily and conveniently operated
- located or guarded to prevent unintentional activation, and
- able to be locked into the “off” position to enable
disconnection from power.

3. Emergency Stops
- be prominent, clearly and durably marked, for example
‘EMERGENCY STOP – PRESS’
- immediately accessible to each operator of the plant,
- have handles, bars or push buttons that are coloured red
- not be adversely affected by electrical or electronic circuit
malfunction.

4. Warning devices
a. Audible devices - fitted to warn of forward or reversing
movement, then emit a high pitched intermittent sound
activated when the gear or drive lever is engaged
b. Motion sensors - also warn with sound and are sensitive to
movement and are activated by motion in any direction
c. Lights - wired to operate continuously or in hazard mode by
flashing to warn of forward and reversing movement

5. Pedestrian Safety
• Pedestrian Policy
A pedestrian’s safety depends on being responsible for his
or her own well being.
Pedestrians have the "right-of-way", but must exercise
caution and NOT walk into the path
of moving vehicles.

5. Pedestrian Safety
• Pedestrian Rules
1. Running is not allowed on-site or in parking lots, except
when there is a need to escape an unsafe situation
and/or respond to an emergency.
2. Pedestrians must recognize their personal responsibility
in a pedestrian/vehicle interaction. By establishing
eye contact with the vehicle operator, the pedestrian
will help in this interaction.
3. Use a free hand to hold handrails when ascending and
descending stairways. If there is no alternative to
carrying something with both hands, pre-plan safety
into your activity and use extreme caution.
4. Always ascend and descend stairways one step at a time.

6. Personnel Protection
a. Foot Protection Rules - these rules apply to all personnel.
1. Unless excepted, safety shoes are to be worn in all
operating/maintenance areas.
2. Toecaps are acceptable for short-term use until approved
safety shoes are obtained.
3. All SAFETY shoes are to meet the current ANSI Standard
Z41.
EXCEPTION: The only exception to these rules on foot
protection applies to visitors and tours (short-term visitors) that
may enter areas requiring foot protection. These persons are
exempted by reason that they will not be performing work and
will be accompanied by a visitor’s host who will not allow such
persons to expose themselves to any foot hazard.

b. Policy on Head Protection - Head protection must be worn
in designated "Hard Hat" areas and where the potential
exists for head injuries.
Head Protection Rules
- to be worn in the correct manner
- hard hats are to meet the current ANSI standard,
minimum class “B”, they must be in good condition
and are not to be painted or contain holes.
- welding hood or face shield
- chemical goggles

c. Hand Protection
- Glove selection is based
on the hazard the hand is
exposed to.
- Check with your Standard
Procedures work
instruction and safety rules
for the specific glove for the
task you are to perform

d. Eye and Ear Protection
- Side shields are a
required part of all safety
glasses.
- Ear Protection is required
in designated “Ear
Protection” areas

e. Policy on Hair and
Clothing
- Hairs which extends
below eyebrows or collar
must be contained
- Wear any specified
clothing and do not wear
sleeveless shirts, loose
clothing, thin fabrics or
loose jewelry anywhere
the plant.

RIGHTS AND RESPONSIBILITIES
1.Employer
Responsibility:
• Ensure health and safety of employees and of other
workers at your workplace. Correct any hazardous
workplace conditions
• Establish occupational health and safety policies and an
Occupational Health and Safety (OHS) Program
• Inform management, supervisors and workers about
their roles and responsibilities in providing a safe and
healthy workplace
• Provide specific direction and delegate authority to those
responsible for health and safety
• Provide workers with the information, instruction, training
and supervision necessary to ensure their health and
safety

1. Employer
Rights:
• Use safe work procedures
• Report any unsafe conditions in the workplace
• Wear their personal protective equipment (PPE) at
all times
• Inform the Employer of any physical or mental
conditions that may impair their ability to perform their
jobs safely
• Not enter or remain in workplace if impaired by the
effects of drugs, alcohol or other substances

2. Employee
Responsibilities
• Learn and follow safe work procedures
• Be alert to hazards/problems; report them to
supervisor/employer
• Use protective equipment, devices and clothing
• Cooperate with joint committee or worker health and
safety representative
• Perform work in a safe manner. Do not engage in
horseplay or work while impaired by alcohol, drugs or
other causes

• Refuse work if you believe it would create an undue
hazard to the health and safety of yourself or another
person.
• Report the unsafe condition to your supervisor or
employer

2. Employee
Rights
• Work in a safe working environment
• Receive proper health and safety information, training
and instruction
• Use well-maintained and functioning PPE
• Exercise any right or carry out health and safety
responsibilities without fear of discrimination
• Participate in workplace health and safety committees,
activities and investigations
• Refuse unsafe work

General Safety Protocols on Manufacturing Plant

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