Health and Safety Webinar Injection Moulding: Safe Working and Maintenance Peter Kirkham, BILLION UK LTD The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Introduction • Consideration of Maintenance Access starts when you install your machine • Think about the needs to enable the Production Process for your applications • How to deal with modifications needed to machine guarding systems to install peripheral equipment • Consider requirements for production / mould changeovers • Think about the requirements for routine or periodic maintenance for EVERY part of the production cell • Any specific apparatus used for access should ideally be CE approved for the task or at least fully risk assessed and documented The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Machine Installation • • Space required for complete tiebar removal Space required for product removal (front or rear) Space required for access to electrical controls Space required for injection unit travel to include >1 m clearance to prevent crushing The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Machine Installation • • Space required for mould loading or / and fitting of robot take-off device Space required for fitting of material handling equipment to be accounted for entire stroke of the injection unit The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Machine Installation In general terms a clear space of >0. 8 m should be provided all around the machine. The encumbered space must include peripheral equipment used by the production cell The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Production Process Access to the material hopper for loading and draining The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk Automatic vacuum loading system
Production Process Products not suited to gravity evacuation Removal by an operator The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk Automated robot cell
Production Process Permanent clear access must always be maintained to the electrical isolator and all emergency stops The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Production Process ‘Air Blast’ circuits fitted to the machine for air ejection can normally operate with the guard open, therefore air cylinders on tooling MUST NOT be connected to these circuits. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Modification to Machine Safety • Users may need to modify the safety systems of an existing machine to allow integration of peripherals. • If the end user modifies the machine in any way, then the CE Certification can be invalidated. • Theoretically, the modified machine will then need to be reassessed by an authorised body. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Why modify the machine? The guarding system provided to the machine well may need modifying to fit a conveyor or chute? The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Why modify the machine? The guarding on top of the platen may need to be modified to fit a robot? The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Why modify the machine When installing platen mount beam robots the guarding system MUST extend to cover the working area of the robot outside the machine. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Why modify the machine The machine may require to operate with the rear guard open to facilitate a rear side entry automation system. In this case a new guarding system is installed around the cell and the electrical rear guard safety rewired to the access door. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Why modify the machine Here we can see guards cut away to provide a passage for cooling hoses to the mould. This type of modification MUST NOT be done. Machine suppliers can provide solutions: The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Practical safety advice • Document the changes you have made to the machine safety systems. • Produce a Risk Assessment for the machine as delivered and score against the modified condition to ensure that all additional risk is considered. • Always involve equipment suppliers when analysing risk for modifications. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Production Changeover Clamps Access required to clamp / bolt mould to machine platens The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk Auto clamps Automated clamping systems reduce need for access
Production Changeover Connection of mould services can require access inside the machine The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk Machine suppliers can provide reachable manifolds to ease making connections
Production Changeover Automated tiebar removal systems are available for larger machines where headroom is restricted The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Production Changeover Purge cooling tray Material purging is a dangerous operation. Enclosed nozzle guarding is mandatory, although removal of the hot purging from the machine is high risk The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Production Changeover Hopper access for cleaning and simple maintenance may be possible with a specifically designed secure ladder with other PPE. Where there is a need for the operator to carry load, then an access platform will be required. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Maintenance • Machine lubrication is normally automated on modern machines with buffer reservoirs easily accessible. PPE should be considered if in contact with lubricants. • Any maintenance or repair associated to hot surfaces such as the injection screw / barrel must be fully risk assessed and will require appropriate PPE. • Any work to be undertaken on live electrical circuits or pressurised hydraulic systems will require relevant qualification, risk assessment and PPE. All tasks should be run under a Permit to Work system. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Maintenance Accumulators used on hydraulic machines fall within the ‘Pressure Vessel Regulations’ requiring re-certification or replacement every 10 years. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Maintenance High pressure hydraulic hoses must be restrained to prevent ‘whipping’ if they burst. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Maintenance Hydraulic hoses should always be replaced when they show signs of weeping or damage The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Maintenance Guards removed for maintenance or repair MUST always be replaced. Barrel guard removed The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk Mould area well guard removed
Specific Access Equipment Work zone and access means defined by labels on the machine The last amendment to EN 201 engages machinery manufacturers to reduce the risks of slips, trips and falls in the work area by assessing operational tasks, defining working zones and proposing solutions as the equipment supplier: The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Specific Access Equipment Operational tasks are defined as: • • Mould loading / unloading Mould fixing Connection of mould services Opening and closing of the material feed • Material loading and drain • Access to remove purging • Nozzle changes The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Specific Access Equipment Suppliers must be able to provide access solutions, which are CE approved for the identified operational tasks. These are usually sold as accessories. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Specific Access Equipment Access equipment specifically adapted to the machine may also be possible either on a new order or by retrofit, although in every case it will be necessary for the whole machine / cell to be re-certified and a new Technical Manual created to include the modification The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Specific Access Equipment • The supplier should reasonably and generically define operational / frequent tasks. • The supplier must offer safe solutions for the customer to carry out the tasks with an appropriate cost. • The customer is not obliged to accept the supplier’s offer and can elect to take on the access responsibility themselves. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Specific Access Equipment Where peripheral equipment such as a robot or material handling system are fitted to the machine, then due consideration must be given to their ‘Operational Access’ The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Specific Access Equipment Universal people lifts can be a good solution in diverse situations, although users need to be licenced and complete periodic refresher training The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Specific Access Equipment The machine should be fitted with appropriately positioned and clearly visible warning signs for identified risks, for example: • Hot surface – Risk of burns • Dangerous zones – Risk of slips, trips or falls • Electromagnetic fields The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Summary • Remember access assessment starts with your installation plan in your environment. • Don’t forget to consider all the equipment within the production cell. • Always document changes to safety systems • Always consider options to reduce or negate the need for access to danger areas. • Discuss options for access equipment available from suppliers to meet your needs. The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
Health and Safety Webinar 2017 Thank You For Your Attention Pete Kirkham BILLION UK LTD Any Questions? The UK’s Leading Plastics Trade Federation Stronger Together | www. bpf. co. uk
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