SAFETY WITH MACHINES

Sun, 18 Feb 2018 12:46:13 +0000

With Mark Kunda

A MACHINE will always be a machine. Machines never invite people to go near them. People choose to go near. So every time you are near a machine, keep machine safety in mind. A machine, if not handled safely, can kill you.

The state of most machines in Zambian companies pose many health and safety risks to workers. Most companies in our country have obsolete machines. These machines have been modified beyond recognition. They can’t even be operated using the manufacturer’s manual! Such machines have machine controls which are dysfunctional and sensors are bypassed. Operators use shortcuts to operate these machines. They have memorized what to do. Operators operate these machines through guesswork without any Standard Operating Procedure.

These machines have damaged machine control buttons. The control panels are cracked. Missing bolts and nuts are never replaced. In certain cases, bolts and nuts are replaced with ropes and wires to tighten the machine parts. Electric cables run around the machine loosely. They are not properly secured. Some of them are not even properly insulated. Often times, these machines are installed in poorly lit and poorly ventilated areas.

These machines are not cleaned regularly. Product spillages are never cleaned. Oil leaks are never sealed. The waste generated by the machine is left to accumulate. These machines are rarely inspected and they are poorly maintained. Sometimes correct spares needed to repair the machine are never available. This forces the maintenance workers to use quick fix methods to simply get the machine into production such as tying a machine with a wire or a rope instead of using correct bolts and nuts.

This state of affairs make the machines very unsafe to workers. Changes in technology is forcing companies to reduce on the number of employees and switch to machines. A machine by definition is designed to make work easier. Machines produce more and faster than human beings. Machines have their own advantages over human beings. Machines don’t complain. They don’t get tired. They don’t require maternity or study leave. They don’t go on strike. They don’t demand salary increment or promotion. Machines don’t report for work under the influence of alcohol. They don’t lie or give excuses. Machines won’t steal products or raw material. Even when you suddenly replace it, a machine won’t report you to industrial court for ‘unfair dismissal’. Despite all these advantages, machines pose many risks to workers.

Machine safety is a responsibility of both the manufacturer and the user. The most effective way to make a machine safe is to incorporate safety in the design of the machine. Therefore manufacturers are required by law to ensure that they do everything practically possible to make the machine safe for the user. In this article, my focus is not on what the manufacturer but you the user. I want to highlight what users ought to do to ensure safety with machines. Users include both management who procure the machine and the shop floor workers who work with these machines.

Safety with machines for the user starts by acquiring a safe machine. Safety must be guaranteed at every phase of the life of the machine which include designing, installation, operation, maintenance and finally discarding once the machine is permanently out of service.

When you decide to acquire a new machine, you should consider the following questions. What job do we want the machine to perform? What type of machine can effectively perform this task? Where and how will the machine be used? Who will be using the machine? What level of competency is required to operate or maintain the machine? What safety and health hazards will the machine create? How will the safety and health hazards be controlled?

Investing in a new machine must make business sense. Answering the above questions will help you to be clear on what level of technology of equipment and skills level of your workers will meet your operational targets.  It’s pointless to invest in a technologically sophisticated machine with a very fast speed when all that you need is just a quarter of that speed to exceed your market demand. The above questions will also help you to conduct a risk assessment to identify potential safety and health hazards that the machine may create. The risk assessment will help you to identify control measures to manage the risks.

Let’s look at three steps you can take to ensure safety with machines. The first step to ensure that you have a safe machine. A safe machine ought to have safe machine controls. Machine controls help the operator to control the machine safely and make it do what he or she wants it to do. A machine can injure the operator. But the operator cannot injure the machine. It’s people that get injured, not machines. For the operator to safely operate the machine, the machine must be fitted with easily-to-reach controls, clear markings and adequate warning signs.

Safe machine controls must have the following characteristics. They must be easy-to-reach and easy-to-use. This means that the operator must not struggle to reach a particular control button. Machine controls should not allow the machine to operate accidentally. Accidental start-up of the machine is one of the leading causes of workplace accidents. Machine controls must move in the same direction as the motion being control. If you want the machine to rotate clockwise, the control switch should be able to rotate in the clockwise direction activate the rotation. Similarly if you want the machine to move up, the control switch should move up to activate the upward movement of the machine. Matching the direction of the controls and the direction of the intended motion helps the operator prevent operational errors which might result in accidents. Machine controls must be standardized with varying modes, shapes, colours and direction of movement to prevent operating a wrong control. Lack of standards causes confusion during machine operation. All the machine controls must be clearly labeled to show what they do. Last but not the least, every machine must have a safe means of isolating it from the source of power.

All the machine controls must be maintained in a good working condition. Damaged controls must be repaired or replaced immediately. Never de-activate machine safety devices. Modern machine comes with safety features such as sensors, emergency buttons, machine guards and interlocking guards. These safety devices are put on the machine for a purpose. Do not destroy them. Don’t operate the machine using safety devices such as stopping a machine using a photoelectric sensor instead of using a normal stop button.

The second step to ensure safe operation. Safe operation requires a safe operator. A safe operator is one who is competently trained. Operating a machine without training is an offense. Every operator must be trained and authorized to operate the machine. Knowing how to press ON and OFF buttons to start and stop the machine is not enough. It takes more to be a competent machine operator. Training is important for both the managers and workers. In case of a machine accident, the first thing labour inspectors will ask for is whether the operator was trained and authorized to operate the machine. So if the employer didn’t provide formal training to the operator, it becomes a serious offense. If the employer simply verbally authorized you to operate machine without formal training and you cause an accident, the employer may blame it on you that you were operating machine without authorization. Therefore, as an operator ensure that you receive formal training and authorization to operate the machine. Training will also improve your self-confidence.

When operating the machine, follow the Standard Operating Procedure or Standard Work Instructions. As an operator, take time to study them and follow them. If you discover something needs to be changed, propose the change to your manager. Don’t just make the change privately. Use manufacturer’s manual as well. The manual will teach you the correct way to operate and clean the machine. It will also teach the maintenance staff the correct way to maintain the machine. Never throw away the manual.

The third step is to ensure safe maintenance. Most of what I mentioned above for the operator applies to the maintenance workers as well. Maintenance workers also must be trained and authorized to repair or service a particular machine. They must also read the manual and they should follow the Standard Work Instructions.

As an artisan responsible for machine maintenance, ensure that you use recommended spares. Avoid using spares from an obsolete machine to replace on the current machine. If two machines which are similar are broken down, some artisans have a tendency of getting spares from one of the machines to repair the other. This practice must be avoided. A machine which is not running is not a source of spares. Replace machine guards every time you finish servicing the machine. Do not by-pass sensors. Ensure that all safety devices are always in good working condition.

The general advice to both operating and maintenance workers is that a machine will always be a machine.  A machine can’t tell the difference between bones and stones. It can crash both bones and stones in the same way. Always be alert and observe safety. Always use right tools and wear suitable PPE correctly. Conduct safety checks on your machine before you start operating it. Always ensure good housekeeping.

Never become too familiar with your machine. Play with people, not with machines. Avoid horseplay. Horseplay must be reserved for play parks. A workplace is not a place for playing but a place for working. Avoid leaving the machine unattended to. Monitor machine instruments and gauges closely. Avoid unnecessary changing of machine settings. Avoid over-speeding the machine. Don’t force the machine to function beyond its capacity.

Regularly inspect the machine and report or resolve all potential problems. Take time to identify and resolve potential failures before they turn into breakdowns. Avoid hiding machine problems. Hiding a problem is a problem, not a solution.  A problem will never solve itself. If you fail to resolve the problem, call for help. Operate and maintain the machines safely. Don’t just live, live safely. Until next week, stay safe. Zambia needs you.

The author is the CEO of SafetyFocus, a safety company committed to providing safety training and consultancy.

For your comments, contact the author on cell +260 975 255770 or email: marksucceed@gmail.com

Mark Kunda—Safety Consultant