C6.2 machinery hazards

Question 1

Drills

Answer 1

entanglement
cuts
ejection of drill bit / work piece
hand puncture

Question 2

Circular saws

Answer 2

entanglement
cuts from handling blades
cuts from rotating blade
ejected waste material (sawdust in eyes, inhaling)

Question 3

Guillotines

Answer 3

cuts from blade
cuts from shearing action as blade passes fixed point
crush injuries from clamp used to hold down material
cuts from handling guillotined material

Question 4

Disc sanders

Answer 4

abrasion from contact with disc
entanglement
dusts

Question 5

abrasive wheels

Answer 5

friction / abrasion from rotating wheel
entanglement
drawing in of hands between wheel and fixed work rest
ejection of material into eye
ejection of hot particles
ejection of work piece
rupture of wheel

Question 6

lathes

Answer 6

entanglement
friction burns from contact with rotating workpiece
drawing in of hands between rotating piece and fixed tool
ejected waste
ejection of hot particles
ejection of work piece
ejection of chuck key if not removed

Question 7

automatic doors / gates

Answer 7

crushing
shearing where overlapping parts pass over each other
impact hazards where open outwards
drawing in to rollers etc
entanglement with rollers

Question 8

power presses

Answer 8

crushing
shearing as moving parts pass over guides
impact from descending press
entanglement with rotating parts (crank shaft)
ejection of work piece
injection of hydraulic fluid from leaking pressure system

Question 9

power tools

Answer 9

cuts
eye injury from waste material
battery acid
petrol ignition
compressed air

Question 10

non-mechanical machinery hazards

Answer 10

noise
vibration
electricity
thermal (high / low temp)
radiation
hazardous materials / substances
ergonomic
environmental

Question 11

robot hazards

Answer 11

unpredictable movements when setting up
impact / collision
crush / trap
stored energy
instability / falling over
ejection
arm dropping
noise
welding arc flash
dust
fumes
aberrant behaviour = unintentional movement

Question 12

advantages of robots

Answer 12

precision
high repeatability
no fatigue issues
cost effective
longer continuous working
flexibility

Question 13

robot control measures

Answer 13

fencing / access control
PTW / SSW when in danger zone
planned maintenance
fail to safe
emergency stops
trip switches
light beams
duplicate systems
software testing
operator / maintenance training
safe distance between robot arm and other structures

Question 14

causes of robot aberrant behaviour

Answer 14

programming error
programme change affects another programme
electromagnetic interference
power failure
mechanical damage
hydraulic failure
corrosion

Question 15

computer numerically controlled machines (CNC)

Answer 15

lathes
milling machines
drills
routers
punch presses

repetitive jobs
cutting complex shapes

Question 16

advantages of CNC machine

Answer 16

repeating
accurate
unmanned machines
easy to programme
avoid human error
cheap production of items

Question 17

power tool control measures

Answer 17

regular maintenance
right tool for job
pre-use check
use as per manufacturer instructions
use guards
do not remove guards when toll is in use
use correct PPE
keep cutting tools sharp
keep work area tidy
removed damaged equipment from use
do not carry by power cables
keep cables away from heat / oil / sharp edges
cables not trip hazards

Question 18

abrasive wheel control measures

Answer 18

guard covers spindle
proper wheel alignment
keep within safety parameters of disc speed / type
stand to side of wheel until at full speed
eye / face protection

Question 19

pneumatic air tool control measures

Answer 19

tool fastened securely to air line

secondary safety connection, e.g. chain

Question 20

jack control measures

Answer 20

use on firm level surface
place against a level surface
lubricate regularly
LOLER inspections
pre-use checks
do not exceed SWL
do not exceed jack stop indicator