INTRODUCTION FOR SAFE PRACTICE DURING MACHINE MAINTENANCE TRAINING

Maintenance is a high-risk activity with specific hazards and risks and these include working alongside a running process and in close contact with machinery. During normal operation, automation typically diminishes the likelihood of human error that can lead to accidents. In maintenance activities, contrary to normal operation, direct contact between the worker and machine cannot be reduced substantially – maintenance is an activity where workers need to be in close contact with processes. Maintenance often involves unusual work, non-routine tasks and it is often performed in exceptional conditions, such as working in confined spaces. Maintenance operations typically include both disassembly and reassembly, often involving complicated machinery. This can be associated with a greater risk of human error, increasing the accident risk.

Maintenance-related accidents are a serious cause of concern. For example, analysis of data from recent years indicates that 25-30% of manufacturing industry fatalities in Great Britain were related to maintenance activity. Undertaking maintenance activities can potentially expose the workers involved (and others) to all sorts of hazards, but there are four issues that merit particular attention because of the severity of the harm that could be involved, and because they are commonly encountered during plant and building maintenance.

The machinery user should ensure that workers given the task of using work equipment receive adequate training, including training on any risks that its use may entail. It is especially important in the case of workers carrying out repairs, modifications, and maintenance or servicing tasks

This course will provide an overview of the legislative position on steps should be taken to manage any risks arising from maintenance activity. It will also cover the technical and procedural aspects by those who are competent to do the maintenance work, who need to be provided with sufficient information, instruction and training

PARTICIPANT PROFILE

Designed to benefit anyone required to undertake mechanical maintenance on production/process equipment. This course is equally suitable for production operatives or for craft personnel already involved in maintenance activities.

TYPICAL ATTENDEES INCLUDE

• Senior managers
• Project and design engineers
• Duty holders and maintenance engineers
• Health & Safety professionals
• Anyone else involved in the purchasing, using and maintenance of machinery and equipment

BENEFITS OF ATTENDING

On completion of the course, participants will be able to

• Understand the principles of preventive and first-line maintenance
• Apply safe working practices
• Apply Five basic rules for safe maintenance
• Describe a range of mechanical faults and plan suitable courses of action
• Describe what a workplace hazard is
• Identify different ways to evaluate worksite hazards
• Describe what an machine and equipment inspection is and the major points of an inspection process
• Identify why measurement is needed in a safety and health management system

PROGRAMME SCHEDULE

Programme Schedule (Day 1)

Programme Schedule (Day 2)

COURSE CONTENT

Introduction

• OSH Hazard & Risk
• Accident Prevention related with Machine Safety

Key principles of machinery and equipment safety

• Type of Equipment/Tools Hazards
• Type of Machine Hazards
• Electrical & Mechanical hazards
• Other hazards

Machine Legislation

• Malaysia legislation on Machine Safety
• International legislation on Machine Safety

Risk assessment and control related with User

• Risk control of machinery and equipment hazards
• Risk control of general hazards
• Risk control of mechanical hazards

International Machine Safety Standard

• EU Machinery Directive (2006/42/EC).
• EN standards and changes (present and future)
• The manufacturer and supplier responsibilities of a machine
• Functional safety– EN ISO 13849-1 and EN 62061

Procurement on Machine

• Consulting workers and workplace health and safety representatives
• Purchasing machinery and equipment list
• Information and guidance on Plant, Machine, Equipment, Tools and Substances
• Type of maintenance activities

Risk assessment and control related with User

• Other mechanical hazard risk control options
• Risk control of non-mechanical hazards
• Personal protective equipment
• Risk control of access hazards

Maintenance Personnel Safety Management

• Define “maintenance”
• Identify examples of equipment maintenance in a production facility
• Identify and describe general maintenance guidelines for workers
• Identify and describe typical hazards presented to maintenance workers
• Describe three different methods to ensure the immobilization of equipment
• Describe maintenance guidelines for vehicles
• Describe safety guidelines for using hand tools such as pry bars, hammers, and axes
• Describe safety guidelines for using power tools and cutting torches
• Describe safety guidelines for welding, working on conveyors, and line breaking
• Describe good housekeeping practice

Contractor Safety Management for Machine Maintenance

• Planning and selecting contractors – practical arrangements and methods;
• Establishing project interface agreements, documentation and HSE Project Plan;
• Managing contractors’ compliance, with the HSE Project Plan, on day-to-day basis
• Monitoring – keeping track of contractor’s performance;
• Reviewing and learning – contractor management, deciding what needs to be improved

Hazardous Energy

• Hazardous Energy
• Hazardous Energy Control

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