machine safety for injection molding machines occupational safety and health administration the...
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![Page 1: Machine Safety for Injection Molding Machines Occupational Safety and Health Administration The Society of the Plastics Industry, Inc. A Presentation of](https://reader036.vdocuments.us/reader036/viewer/2022062717/56649e195503460f94b056ff/html5/thumbnails/1.jpg)
Machine Safety for Injection Molding Machines
OccupationalSafety and HealthAdministration
The Societyof the PlasticsIndustry, Inc.
A Presentation of the OSHA-SPI Alliance
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Course Objectives• Identify the types of injuries that can
occur while operating injection molding machines
• Describe the possible causes of these injuries
• Identify ways to safely operate injection molding machines
• Recognize the importance of a total safety and health approach
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Reasons to Focus on Injuries in the Injection Molding
Process
• High injury/illness rates
• OSHA citations
• National Emphasis Program
• Site-Specific Targeting
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Types of Injuries
• Fatalities
• Amputations
• Avulsions
• Fractures
• Cuts and bruises
• Sprains and strains
• Burns
• Electric shock
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Some Causes of Injuries
• Reaching around, under, over or through guards into hazardous areas
• Removing or bypassing guards
• Reaching into equipment to remove stuck parts
• Not using LOTO procedures
• Machine/equipment malfunctions
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
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
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Injection Molding Machinery
• Horizontal injection molding machine (HIMM)
• Vertical injection molding machine (VIMM)
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Vertical Injection Molding Machines - VIMMs
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
VIMMs
• Combinations of vertical and horizontal clamp and injection configurations of machines
• Regardless of the configuration of the machine, basic machine guarding and good safe work practices must be applied– Point of operation– Other moving machine parts
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
VIMMs: Unique Hazards and Issues
• Gravity
• Plastic splatter/missing insert
• Flying inserts
• Unexpected bystander interventions
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Horizontal Injection Molding Machines - HIMMs
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
HIMMs: Mechanical Hazards
• Point of operation
• Pinch points
• Nip points
• Rotating parts
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Potential Injuries from Mechanical Hazards
• Fatalities• Amputations• Avulsions• Crushing injuries• Fractures
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Safety Guards and Devices
• Types of guards and devices • Movable guards with interlocks• Fixed barrier guards• Presence-sensing devices
• Mechanical safety bars • Locations of guards
– Over moving equipment – Around electrical hazards– Around thermal hazards
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Operator’s Gate
• Equipped with redundant interlocks– Electrical– Hydraulic– Mechanical safety bar
• Allows the machine to operate only when the gate is closed
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Electrical Interlock
• Allows the electrical system to operate and close the clamp
• Actuated when the operator’s gate is opened or closed
• Prevents clamp from closing when the operator’s gate is open
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Hydraulic Interlock
• Actuated by opening or closing the operator’s gate
• Each hydraulic IMM requires at least one
• Prevents clamp from closing when the operator’s gate is open
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
• Prevents clamp from closing when the operator’s gate is open
• Must have at least one mechanical device on all IMM’s
Mechanical Safety Device
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Other Guarding
• Rear guard• Top guard• Parts discharge
guard• Feed opening guard
• Electrical system guards
• Purge guard• Injection barrel
cover
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Rear Guard
• Prevents clamp from closing when interlocked rear guard is opened
• Should have at least two interlocks
• Prevents access to mold areas
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Top Guard
• Required if operator can reach over the top of the machine and into hazardous areas
• Should be interlocked if movable
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Top Guards (cont’d)
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Parts Discharge Guard
• Keeps employees from reaching under operator’s gate and into the danger zone
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Purge Protection
• Covers the nozzle and purging area
• In combination with PPE, minimizes exposure to molten plastic during purging
• Window allows observation through purge guard, if equipped
• Should be equipped with an interlock
Purge guard
Safety window
Barrel cover
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Injection Barrel Cover
• Protects from exposure to high voltage and high temperatures
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
How to Protect Yourself
• Recognize the hazards in the job you are doing
• Understand the requirements for guarding machines
• Implement guarding solutions
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Virtual Safety Tour
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Emergency Stop
Know:
• Where it is located
• What it controls
• When to use it
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Signs and Warnings
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Colors used with Safety Signs have meaning!
DANGER
White Lettering/Red Background
WARNING
Black Lettering/Orange Background
CAUTIONBlack Lettering/Yellow
Background
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
High Voltage
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Rotating Screw
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
High Temperature
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
High Pressure
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Robots
• Used to automate repetitive or hazardous tasks
• Must be guarded to prevent workers from entering or reaching into hazardous areas
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
The Robot
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Our sincere thanks to:
• United Southern Industries, Inc.
• OSHA Region V
• The OSHA Training Institute
• OSHA’s Salt Lake Technical Center
• Paulson Training Programs, Inc.
• The Society of the Plastics Industry, Inc.
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OccupationalSafety and HealthAdministration
The Society of the PlasticsIndustry, Inc.
Questions?