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Metal product manufacturing industry Sheet metal/plate rolling machines

What are the problems associated withsheet metal/plate rolling machines?Sheet metal/plate rolling machines are

extremely dangerous, especially because it isnot generally practicable to have the rollersguarded with a solid structure (e.g. fixedguard). Often the operators hands are caughtand drawn into the counter-rotating rollers,usually during the initial feeding of the workpiece. A large number of incidents involvingsheet metal/plate rolling machines haveresulted in amputations and other seriousinjuries, with a large proportion of them beingassociated with the operator wearing gloves.Additionally, it is not uncommon for a person

walking past the machine to slip, trip or falland find that their hands have been caught inthe machine.

Source: Health and Safety Executive, UK

How can you address the problem?A combination of safety devices (trip devices,emergency stops, hold-to-run controls, etc.)and administrative measures should be usedto protect the operator and anyone near themachine.

Note: Safety devices that should be used willnot directly prevent a person from havingtheir fingers, hands or other body partsentangled or entrapped in the machine, butare intended to minimise the likelihood andseverity of injury by stopping the machine inthe quickest way possible. Machines shouldhave hold-to-run controls, which only allowmovement of the rollers when the control isheld in the run position. On releasing thecontrol, it should automatically return to thestop position.

Trip devices, such as kick bars or panels andtrip wires, should be in place on both sides of

the machine and should be interlocked withthe control circuit.

Braking systems should be provided in orderto prevent the risk of overrunning, due toinertia.

An emergency stop button should beprovided at the machine control console andany other workstation. These should be thelock-in type, so the machine cannot berestarted until it has been reset manually. On

resetting the emergency stop button, themachine should not start until the normal startcontrol is operated.

As with any type of plant and equipment,other controls should be in place tocomplement guarding, such as:

instruction, information and training

supervision inspection and maintenance

safe work procedures personal protective equipment (PPE).

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Workplace Health and Safety Queensland, Department of Justice and Attorney-General

Information guide Metal manufacturing: Sheet metal/plate rolling machinesPN10257 Version 2. Last updated January 2010

Operators should be given comprehensivetrainingand instruction to ensure they arecompletely familiar with the machine, itscontrols, guards and safety devices, hazardsassociated with the machine and any othercontrol measures. Extra care should be takento ensure that each operator fully

understands and can demonstrate the safeoperation of the machine. Furthermore, extraattention should be paid to young andinexperienced workers and workers returningfrom absence.

Supervision needs to be provided, based onthe competence of the operator (e.g. directand constant supervision for a new worker)and complexity of the task being performed.

Inspection and maintenance of the

machine, including guards and other criticalsafety parts, must be done regularly. Forguards and safety devices, this should bedone at the start of each day or shift andwhenever there is a change to the machinesworking configuration. The peopleresponsible for inspection and maintenanceshould be familiar with the machine and allrequirements as per manufacturesspecifications (found in the manufacturersinstruction manual).

Maintenance activities should only be carriedout when the machine is fully isolated andlocked-out from all power (electrical,hydraulic and pneumatic) sources andappropriate warning signs should be securelyattached to the controls.

Manufacturers and suppliers have anobligation to provide relevant information. Ifyou dont have the information you needabout the machine, contact the manufactureror supplier.

Safe work procedures should be written to

cover such things as inspection andmaintenance, cleaning, safe operation of themachine, emergency situations, reportingfaults and defects immediately. Of particularimportance, as part of safe work procedures,is to ensure:

use of gloves with fingertips and thewearing of loose fitting clothing isprohibited.

work pieces are held far enough backfrom the edge being fed into the rollers toallow for

in-feed speed. the area around the machine is well-lit

and free of materials which may causeslips, trips and falls.

Refer to AS 4024, which provides detailedinformation about machinery use andsafeguarding.

For further information on plant andequipmentand other workplace health andsafety issues call 1300 369 915 or visit

www.deir.qld.gov.au.

The State of Queensland (Department of Justice and Attorney-General) 2011

Copyright protects this document. The State of Queensland has no objection to this material being reproduced, but asserts its right to be recognised asauthor of the original material and the right to have the material unaltered.

The material presented in this publication is distributed by the Queensland Government as an information source only. The State of Queensland makes nostatements, representations, or warranties about the accuracy or completeness of the information contained in this publication, and the reader should notrely on it. The Queensland Government disclaims all responsibility and all liability (including, without limitation, liability in negligence) for all expenses,losses, damages and costs you might incur as a result of the information being inaccurate or incomplete in any way, and for any reason.