Safety&Environment-ChapterDD-1SafetyandEnvironmentSafetyandEnvironmentSafetyandEnvironmentSafetyandEnvironmentThischapterisavailableforsponsorship.Forinformationcontactalkennedy@usa.netPreventingUnsafeActsSafetyexpertsagree:thevastmajorityofindustrialaccidentsarecausedbyunsafeacts,notunsafeconditions.Therefore,whileequipmentcondition,guards,andsafetyfeaturesarestillextremelyimportant,thesafetyprogrammustalwaysfocusontheindividualworker---insuringthateachworkeriswelltrained,alert,andfocusedonalwaysworkinginasafemanner.Keepingworkersalerttosafetyandproperlymotivatedisaconstantchallengeformanagement.Onesolutionistoholdregularmeetingsforreviewingsafetyrulesand/orrecentaccidentsandnearmisses.Meetwithallworkersonacrew-by-crewbasis,evenifonlyfor5or10minutesatthebeginningoftheshift.Promotions,contests,andother“gimmicks”mayworkiftheycankeeptheworkersalerttoavoidingunsafeacts.Trainingfornewworkersandregularre-trainingarealsoimportant---fewnewly-hiredworkersarriveattheplantgatewithanyunderstandingofindustrialsafety.Eachnewworkermustbeputthroughaperiodofformalsafetytraining,withperformanceevaluatedjustasforanyotherpartofthejob.Thenaperiodicreviewofthetrainingisneededtomaintainawareness.AccidentReporting,Investigation,andFollow-upEveryinjuryornear-missaccidentintheplantmustbereportedandinvestigated,nomatterhowsmall.Onlybyfollowinguponsmallincidentsisitpossibletoreduceoreliminatethemajorones.H.W.Heinrichin1931proposedthatinjuriesoccurinadistributionresemblingapyramid;foreverymajorinjury(top)therewillbe29minor-to-seriousinjuries(middle)and300near-misses(onthebottom).Managersoftenmakethemistakeoftryingtoeliminateonlythetopofthepyramidwithoutworkingonthebase.Whilethatapproachmayseemcosteffective,infactitisawasteoftimeandmoney.Itisonlypossibletoshrinkthetopofthepyramidbyreducingthebase.So,itisimportantforeveryminorinjuryornear-missbereportedandinvestigated,andforactiontobetakentopreventrecurrence.Whenminorandmedium-severityaccidentsandinjuriesareminimized,themajoroneswillalsodecrease.And,theinvestigationsandfollow-upactionswilleventuallyresultinaneffectiveon-goingsafetyprogram.HHUUMMAANNBBEEHHAAVVIIOOUURRHowaccidentshappen…anyonecanbetracedbacktothesefewcauses…•Idon’tknow….•Idon’tcare….•Iamnottrained….•Iknowbutignore….•Igetaccustomed….•Igrowintobadhabits….CommentbyHansBohde,EECConference,2002FigureD-1:H.W.Heinrich’sInjuryFrequencyPyramidSafety&Environment-ChapterDD-2CommonHazardsintheExtrusionPlant1Themostcommonhazardsintheextrusionplantarewellknown.Followingisabriefreview,withrecommendationsforminimizingtheirimpactonplantoperations.ExtrusionToolingThefollowingrulesforsafeoperationofextrusiontoolswereofferedbyBillMasonandMelMolitor2:•Neverextrudeusingcoldorroomtemperaturetools.•Neverlookintotheexitendofadiewhenapplyingextrusionload.•Neveruseimproperlysupporteddies,backers,andbolsters.•Alwaysusesafetydevicesandshields.•Caution-Manyextrusiondiesandsupporttoolsaresubjectedtostressesatorneartheyieldstrengthofthesteel,allowingforlittleornosafetyfactor.Alwaysadheretorigidsafetypractices.•Neveruseabadeyeboltforliftingadie,andalwaysmakesuretheeyeboltisscrewedinatleast4or5fullturns.•Bewareoffirewhenapplyinglubricants(waxorgrease)tohotdiesandtooling.Toolingbreakagehascausedmanyseriousinjuriesduetoflyingshrapnel.Diesgenerallyareundertheirhigheststressduringbreakoutoftheext...
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