LATHES RISK ASSESSMENT PLEASE REFER TO THE ATTACHED DOCUMENT FOR MORE DETAILS TO THE RISKS WHILST USING THE LATHES
RISK ASSESSMENT TITLE
DATE
REVISION NUMBER
WORK SITE
LATHES
31/08/2019
001
DAM ROAD, BARTON UPON HUMBER, NORTH LINCOLNSHIRE, DN18 5AS
ITEM TAG NUMBER
COLLAT001 COLLAT002 COLLAT003 COLLAT004
RISK RATING
LIKELIHOOD OF HARM 1 VERY UNLIKELY
2 UNLIKELY
3 – 50% LIKELIHOOD
4 - LIKELY
5 - VERY LIKELY / CERTAINTY
1 - MINOR INJURY OR ILLNESS
LOW
LOW
MEDIUM
MEDIUM
HIGH
2 - MODERATE INJURY OR ILLNESS
LOW
LOW
MEDIUM
MEDIUM
HIGH
3 - “7 DAY INJURY” OR ILLNESS
LOW
MEDIUM
MEDIUM
HIGH
HIGH
4 - MAJOR INJURY OR ILLNESS
LOW
MEDIUM
MEDIUM
HIGH
HIGH
5 - FATALITY
LOW
MEDIUM
HIGH
HIGH
HIGH
SEVERITY
RISK RATING
ACTION TO FOLLOW
LOW
ENSURE CONTROL MEASURES IN PLACE ARE MAINTAINED.
MEDIUM
IMPLEMENT CONTROL MEASURES RECOMMENDED
HIGH
STOP OR RESTRICT ACTIVITY AND MAKE IMPLEMENT ADDITIONAL CONTROL MEASURES IMMEDIATELY
OVERALL RISK
ELECTROCUTION AND ENTRAPMENT
N
OPERATORS
3
5
H
2
MOUNTING THE CHUCK AND LOADING AND UNLOADING THE WORK PIECE
MANUAL HANDLING INJURIES E.G. FROM HEAVY WORK PIECE, CUTS TO FINGERS, CRUSHING FINGERS
N
OPERATORS
3
4
M
3
APPROACHING THE LATHE / ENTERING THE ENCLOSURE WHEN
BODY PARTS COMING INTO CONTACT WITH THE MOVING PARTS OF THE MACHINERY,
N
OPERATORS
3
5
H
HAZARD
DESCRIPTION OF CONTROL MEASURES
CARRY OUT PRE-USE CHECKS BEFORE START UP REPORT ANY DEFECTS TO MANAGEMENT ASAP ENSURE ELECTRICAL CONNECTIONS ARE NOT EXPOSED ENSURE ALL MOVING PARTS ARE COVERED OR GUARDED CHECK THE OPERATION AND CONDITION OF GUARDS DO NOT USE THE MACHINE IF DEFECTS ARE IDENTIFIED ONLY TRAINED, COMPETENT AND AUTHORISED PERSONS ARE ABLE TO USE THE LATHES. USE MECHANICAL LIFTING DEVICES FOR LIFTING HEAVY LOADS WHERE POSSIBLE MANUAL HANDLING AWARENESS TRAINING TO BE CARRIED OUT CARRY OUT CHECK FOR SHARP EDGES BEFORE HANDLING WORK PIECES PPE - WEAR CUT RESISTANT GLOVES AND SAFETY GLASSES ONLY TRAINED, COMPETENT AND AUTHORISED PERSONS ARE ABLE TO USE THE LATHES.
CONTROL MEASURES EXIST/ REQUIRED
RESIDUAL RISK
SEVERITY
PRE-USE INSPECTION AND SWITCH ON
TASK
SEVERITY
LIKELIHOOD
1
No.
RESIDUAL RISK
LIKELIHOOD
WHO / WHAT IS AT RISK
CONDITION (NORMAL/ABNORMAL/ EMERGENCY)
OVERALL RISK (UNCONTROLLED)
EXIST
1
5
L
MANUAL HANDLING TRAINING FOR STAFF REQUIRED
2
4
M
EXIST
1
5
L
RESIDUAL RISK
4
SETTING UP OR REMOVING WORK PIECE, OPERATING MACHINE, TAKING MEASUREMENTS FROM WORK PIECE
METAL CUTTINGS FLYING FROM THE MACHINE LEADING TO EYE AND HAND INJURIES. PHYSICAL CONTACT WITH MOVING PARTS OF THE MACHINE OR WORK PIECE.
N
OPERATORS
3
5
H
ONLY TRAINED, COMPETENT AND AUTHORISED PERSONS ARE ABLE TO USE THE LATHES. ENSURE ALL PARTS AND TOOLING ARE STATIONARY BEFORE ENTERING OR REACHING INTO THE MOVING / ROTATING AREA OF THE MACHINE, TAKING INTO ACCOUNT ANY TOOLING FITTED TO THE REVOLVING TOOL POST. ENSURE LIGHTING IS SUFFICIENT FOR THE TASK PPE – WEAR SAFETY GLASSES, CUT RESISTANT GLOVES, OVERALLS AND SAFETY BOOTS
EXIST
1
5
L
5.
SECURING THE WORK PIECE INTO THE CHUCK
WORK PIECE BEING EJECTED FROM THE CHUCK DURING MACHINING. ENTRAPMENT LEADING
N
OPERATORS OTHER STAFF VISITORS ASSETS
3
4
M
ONLY TRAINED, COMPETENT AND AUTHORISED PERSONS ARE ABLE TO USE THE LATHES. THE JAWS OF THE CHUCK ARE TO BE FULLY TIGHTENED UNTIL THE WORK
EXIST
1
5
L
HAZARD
OVERALL RISK
WHICH COULD LEAD TO ENTRAPMENT, DRAWING IN ETC
TASK
SEVERITY
SETTING UP THE MATERIAL
No.
LIKELIHOOD
SEVERITY
RESIDUAL RISK
LIKELIHOOD
WHO / WHAT IS AT RISK
CONDITION (NORMAL/ABNORMAL/ EMERGENCY)
OVERALL RISK (UNCONTROLLED)
DESCRIPTION OF CONTROL MEASURES
CONTROL MEASURES EXIST/ REQUIRED
ENSURE THAT ALL PARTS OF THE MACHINE ARE STATIONARY WHEN THE OPERATOR NEEDS TO BE IN DIRECT CONTACT WITH THE MACHINE I.E. DURING SET UP AND DISMOUNT DURING LATHE OPERATION, ENSURE THAT BODILY CONTACT IS PREVENTED BY GUARDING
LIKELIHOOD
SEVERITY
RESIDUAL RISK
3
5
H
ONLY TRAINED, COMPETENT AND AUTHORISED PERSONS ARE ABLE TO USE THE LATHES. ENSURE ALL GUARDING IS IN GOOD CONDITION. USED AND POSITIONED CORRECTLY TO PROVIDE MAXIMUM PROTECTION. ENSURE PASSERS-BY DO NOT COME INTO THE VICINITY OF THE LATHE WHEN ITS’ IN USE. CHUCK GUARD TO BE IN PLACE BEFORE STARTING THE MACHINE ENSURE THE MACHINE IS SET TO OPTIMUM PERFORMANCE AND CUTTING DEPTH COOLANT TO BE APPLIED TO THE WORK PIECE IF REQUIRED NEVER WRAP AN EMERY CLOTH AROUND A ROTATING WORK PIECE TO POLISH IT.
EXIST
1
5
L
CUTS TO HANDS OR FACE, EYE INJURY. ENTANGLEMENT
N
OPERATORS
3
4
H
ENSURE THE MACHINE IS STOPPED BEFORE REMOVING SWARF. ENSURE THE APPROPRIATE PPE IS WORN I.E. SAFETY GLASSES AND CUT RESISTANT GLOVES.
EXIST
1
4
L
OVERALL RISK
OPERATORS OTHER STAFF VISITORS
SEVERITY
N
TO BROKEN OR AMPUTATED FINGERS
6
MACHINING WORK PIECE OR POLISHING / CLEANING USING EMERY CLOTH
7
CLEANING THE MACHINE AND REMOVING SWARF
RESIDUAL RISK
INJURY FROM FLYING CUTTINGS, SWARF, DUST CREATION. ENTRAPMENT LEADING TO BROKEN OR AMPUTATED FINGERS
HAZARD
LIKELIHOOD
TASK
WHO / WHAT IS AT RISK
No.
CONDITION (NORMAL/ABNORMAL/ EMERGENCY)
OVERALL RISK (UNCONTROLLED)
DESCRIPTION OF CONTROL MEASURES
CONTROL MEASURES EXIST/ REQUIRED
PIECE IS SECURE. THE CHUCK KEY IS THEN REMOVED
USE OF COOLANTS / CUTTING FLUIDS
10
NOISE
OVERALL RISK
SEVERITY
N
OPERATORS OTHER STAFF VISITORS
3
3
M
EXPOSURE TO COOLANTS AND CUTTING FLUIDS CAN CAUSE SKIN IRRITATION OR SKIN DISEASE HEARING LOSS OR DAMAGE
N
OPERATORS, OTHER STAFF
3
3
M
N
OPERATORS OTHER STAFF VISITORS
4
3
M
TOOLS E.G. RAKES / HOOKS MUST BE USED TO REMOVE SWARF. NEVER REMOVE SWARF BY HAND DISPOSE OF SWARF INTO THE CORRECT CONTAINERS / SKIPS USE GOOD HOUSEKEEPING PROCEDURES ENSURE SPILLS ARE CLEANED UP ASAP AFTER USE RETURN ALL TOOLS, PARTS COMPONENTS ETC TO THE CORRECT LOCATION FOR STORAGE ENSURE THE WORK AREA IS FREE FROM OBSTRUCTIONS, CABLES, HOSES, SPILLS ETC PPE – ALL PERSONNEL IN THE FACTORY AREA TO WEAR SAFETY FOOTWEAR PPE – OPERATOR TO USE BARRIER CREAMS AND WEAR CHEMICAL RESISTANT GLOVES AND SAFETY GLOVES TO MINIMISE SKIN CONTACT EAR DEFENDERS ARE AVAILABLE FOR USE
CONTROL MEASURES EXIST/ REQUIRED
RESIDUAL RISK
9
SLIPS, TRIPS, FALLS IMPACT INJURIES
DESCRIPTION OF CONTROL MEASURES
SEVERITY
MOVING AROUND THE WORK AREA
RESIDUAL RISK
LIKELIHOOD
8
HAZARD
LIKELIHOOD
TASK
WHO / WHAT IS AT RISK
No.
CONDITION (NORMAL/ABNORMAL/ EMERGENCY)
OVERALL RISK (UNCONTROLLED)
EXIST
1
3
L
COSHH ASSESSMENTS FOR COOLANTS AND CUTTING FLUIDS REQUIRED
2
3
M
AN OCCUPATIONAL NOISE SURVEY IS REQUIRED IN THE WORKSHOP
3
3
M
OPERATORS OTHER STAFF VISITORS
3
5
H
NO OPERATOR TO UNDERTAKE ANY ELECTRICAL / MECHANICAL MAINTENANCE PROCEDURE. OPERATOR MAINTENANCE IS RESTRICTED TO PREVENTATIVE MAINTENANCE (CHECKING OIL LEVELS, SLIDEWAY LUBRICATION ETC AS WELL AS GENERAL CLEANING AND SWARF REMOVAL. ONLY TRAINED, COMPETENT, AUTHORISED PERSONNEL TO CARRY OUT MAINTENANCE ACTIVITIES. LOCKING OFF PROCEDURES – LOCKOUTS AND ISOLATION TO BE UNDERTAKEN BY AUTHORISED PERSONNEL ONLY GOOD STANDARDS OF HOUSEKEEPING TO BE ADOPTED TO AVOID SLIPS, TRIPS, FALLS DISPOSE OF ANY WASTE INTO THE CORRECT CONTAINERS / SKIPS.
CONTROL MEASURES EXIST/ REQUIRED
RESIDUAL RISK
N
DESCRIPTION OF CONTROL MEASURES
SEVERITY
SERIOUS OR FATAL INJURY. SLIPS, TRIPS, FALLS
RESIDUAL RISK
LIKELIHOOD
MAINTENANCE OF THE MACHINE
OVERALL RISK
11
SEVERITY
HAZARD
LIKELIHOOD
TASK
WHO / WHAT IS AT RISK
No.
CONDITION (NORMAL/ABNORMAL/ EMERGENCY)
OVERALL RISK (UNCONTROLLED)
EXIST
1
5
L
STANDARD OPERATING PROCEDURE
DATE
REVISION NUMBER
LATHES
31/08/2019
001
LOCATION
DAM ROAD, BARTON-UPON-HUMBER, NORTH LINCOLNSHIRE, DN18 5AS
1.
INTRODUCTION
This SOP covers the Lathes located in the factory
2.
OPERATOR
Only trained, authorised, competent personnel are to operate the lathes. Records of authorised/competent personnel are maintained on the workshop skills matrix.
3.
PRE-STARTUP SAFETY CHECKS
Before starting work on the machine carry out the safety checks to ensure that the Lathe is in safe working order. Report any faults or defects to management ASAP
4.
HEALTH & SAFETY
Before using the Lathe make yourself aware of the contents of the general risk assessment on display at the machine and comply with the requirements. Ensure that you have the appropriate Personnel Protective Equipment (PPE) e.g. safety glasses, safety footwear, overall, cut resistant gloves etc. It is recommended that ear defenders are worn in the vicinity of noisy machinery. If you require additional or replacement PPE, see management.
5.
LATHE OPERATION
Only trained, competent and authorised persons are able to use the lathes. Use mechanical lifting devices for lifting heavy loads (work pieces) where possible Carry out check for sharp edges before handling work pieces Ensure that all parts of the machine are stationary when the operator needs to be in direct contact with the machine i.e. during set up and dismount During lathe operation, ensure that bodily contact is prevented by guarding Ensure all parts and tooling are stationary before entering or reaching into the moving / rotating area of the machine, taking into account any tooling fitted to the revolving tool post. When securing the work piece into the chuck, the jaws of the chuck are to be fully tightened until the work piece is secure. The chuck key is then removed Ensure all guarding is in good condition. Used and positioned correctly to provide maximum protection. Ensure passers-by do not come into the vicinity of the lathe when it is in use. Chuck guard to be in place before starting the machine Ensure the machine is set to optimum performance and cutting depth Coolant to be applied to the work piece if required Never wrap an emery cloth around a rotating work piece to polish it. Ensure the machine is stopped before removing swarf. Ensure the appropriate PPE is worn i.e. safety glasses and cut resistant gloves. Tools e.g. rakes / hooks must be used to remove swarf. Never remove swarf by hand Dispose of swarf into the correct containers / skips Use good housekeeping procedures
Ensure spills are cleaned up ASAP After use return all tools, parts components etc to the correct location for storage Ensure the work area is free from obstructions, cables, hoses, spills etc When using cutting fluids, use barrier creams and wear chemical resistant gloves and safety gloves to minimise skin contact
6.
LATHE MAINTENANCE & CLEANING
No operator to undertake any electrical / mechanical maintenance procedure. Only trained, competent, authorised personnel to carry out maintenance activities. Operator maintenance is restricted to preventative maintenance (checking oil levels, slideway lubrication etc as well as general cleaning and swarf removal. Locking off procedures – lock-outs and isolation to be undertaken by authorised personnel only Good standards of housekeeping to be adopted to avoid slips, trips, falls Ensure the machine is stopped before removing swarf. Ensure the appropriate PPE is worn i.e. safety glasses and cut resistant gloves. Tools e.g. rakes / hooks must be used to remove swarf. Never remove swarf by hand Dispose of any waste into the correct containers / skips.
7.
REFERENCES
Lathes Risk Assessment