1、I Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-W 3535789 0279362 L5T I PUBLICATIONS IN THE SAFETY IN INDUSTRY SERIES MECHANICAL AND PHYSICAL HAZARDS SERIES Bulletin 216: Bulletin 219 : Bulletin 231: Bulletin 232: Bulletin 239 : Bulletin 240: Bulle
2、tin 246: Bulletin 256: Bulletin 110: Control of Electrical Shock Hazards. (Rev. 1968). 15 pp. 20 cents. Mechanical Handling of Materials. 1960. 29 pp. 15 cents. Personal Protective Equipment, 1961. 26 pp. 15 cents. Fire Protection for the Safety Man. 1961. 25 pp. 15 cents. Mechanics for the Safety M
3、an. (Rev. 1969). 21 pp. 25 cents. Rigging Cargo Gear. (Rev. 1969). 29 pp. 25 cents. Maintenance and Safety. (Rev. 1969). 15 pp. 15 cents. Static Electricity. (Rev. 1969). 20 pp. 20 cents. Teach Them To Lift. (Rev. 1965). 22 pp. 15 cents. ENVIRONMENTAL AND CHEMICAL HAZARDS SERIES Bulletin211: Control
4、 of the Physical Environment. (Rev. 1969). 13 pp. 15 cents. Bulletin 222: Chemistry for the Safety iMan. (Rev. 1968). 26 pp. 25 cents. Bulletin 226: Respiratory Protective Equipment. 1961. 34 pp. 20 cents. Bulletin 241: Chlorine Handling in Stevedoring Operations. 1962. 9 pp. 15 cents. Bulletin259:
5、The Use and Handling of Compressed Gases. (Rev. 1969). 30 pp. 25 cents. Bulletin 265: The Inorganic Acids. (Rev. 1969). 27 pp. 25 cents. Bulletin 304: Shipboard Ventilation for Hazardous Atmospheres. 1967. 29 pp. 30 cents. ORGANIZATION AND ADMINISTRATION SERIES Bulletin 223: The Consultative Approac
6、h to Safety. 1960. 9 pp. 15 cents. Bulletin 247: Fundamentals of Accident Prevention. (Rev. 1969). 14 pp. 15 cents. Bulletin 255: Using Injury Statistics. (Rev. 1969). 20 pp. 20 cents. CONSTRUCTION SERIES Bulletin 273: Planning for Safety on the Jobsite. 1966. 41 pp. 25 cents. For sale by the Superi
7、ntendent of Documents, U.S. Qovernment Printing Office Washington, D.C. 20402 - Price 20 cents Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-W 3515789 0279363 O96 W maintenance and safety U.S. DEPARTMENT OF LABOR WAGE AND LABOR STANDARDS ADMINISTRA
8、TION BUREAU OF LABOR STANDARDS Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-3535789 O279364 T22 CONTENTS Page 2 :I 4 4 5 8 8 11 11 11 13 13 14 iii Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-35
9、15789 0279365 969 W Safety in Industry MECHANICAL AND PHYSICAL HAZARDS MAINTENANCE AND SAFETY HIS bulletin, is one of a series on “Safety iii Industry” as related T to mechanical and physical hazards. It is concerned with an im- portant aspect of accident prevention often overlooked, that of main- t
10、enance. It is intended to enable persons concerned with programing or supervising maintenance to recognize opportunities for applying an approach different from routine maintenance operations. This different approach is known as preventive maintenance. Some of the more usual and common maintenance s
11、ituations are described together with the production and safety possibilities involved. Broad principles of control are suggested. * Proper maintenance assures maximum operating time of equipment at a minimum cost, with the safest working conditions for operating and maintenance personnel. , Mainten
12、ance may operate in two ways : (i) routine, repetitive maintenance necessary on a day-by-day basis to keep equipment clean niid operating; and (2) preventive inainte- iiance which involves overhaul of equipment in one degree or another on a predetermined schedule before breakdown occurs. Some over-
13、lapping is usually involved. In fact, both types of maintenance are usually carried out by the same organization or department, and with the same personnel. They differ only in the way they operate. Routine maintenance is primarily to keep equipment and the York- place in the same operating conditio
14、n without a major change. If the conditions are good, maintenaiice keeps them that way. If con- ditions are not good, routine maintenance will not improve them. Preventive maintenance has a different purpose. It aims to prevent conditions from arising which could result .in costly delays due to the
15、breakdown of equipment. Such coiiclitioiis are detected through inspection, or are prevented by means of periodic oreihaul or replace- ment. 1 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-3515789 02791bb BT5 A good illustration of preventive maint
16、enance fundamentals is found in commercial airline operations. Close inspection of the air- craft is made after every trip, a more detailed inspection after a fixed number of hours, and a complete overhaul at the end of a specified number of flying hours. Exteiisive records are kept, on findings of
17、each inspection, and repairs or replacements are made on the basis of the need indicated by the inspection. Many items are corrected upon report of the pilot, most of them before malfunction or failure occurs. The inspections or overhauls provide a sound basis for sched- uling work to avoid rush han
18、dling of emergency jobs involving excessive overtime. Industrial preventive maintenance follows somewhat the same pat- tern. But because industrial operations embrace z greater number of variety of situations, the program must be integrated with produc- tion procedure to be effective in providing ma
19、ximum benefits. POOR MAINTENANCE CAUSES ACCIDENTS Unsafe conditions are at times due to insufficient or improper main- tenance and result in accidents causing either injuries to personnel or costly property dama.ge 01 both. And accidents involving mainte- nance workers may be due directly to the fac
20、t that the maintenance is done on an emergency basis without the necessary time for planning and doing the work safely. By lessening the chance of breakdown, preventive maintenance reduces the likelihood that an emergency will occur. Instances in which poor maintenance may lead to accidental injury
21、or damage to equipment are numerous. The following are typical examples : Roughness, slipperiness, holes, splinters, poor patching, lack of nonslip surf aces, damaged scaffold planks, defective ladders. Dull cutting edges, niusliroomed heads, broken handles. broken insulation on electric cords, inad
22、equate grounding f acilities. Guards broken or missing, giitirds out of ad- justment, interlocks not operating. Clutcli slipping, defective brakes. defective starting or stopping devices, defective machine feeding devices. TTiisafe wiring, loose comectioiis, broken iiisulation, overloaded circuits,
23、oversize fixes, grounds defect ive. Floors and Working Surfaces. Tools. Machine Guards. Machine Parts and Controls. Electrical Equipment. 2 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-3535789 0279367 733 Hoisting Equipment. Ropes, cable, and chai
24、ns worn, limit switches inoperative, sheaves worn, brakes defective, steering def ec- tive, emergency stopping devices inoper a t ive. Lighting. Winclon-s dirty, lights aiid reflectors dirty, burned out lights. Ventluton. Kot. properly adjusteci, screens aiid filters not. re- placed, overloaded. ROU
25、TINE MAINTENANCE *4s previously mentioned, routhe maintenance is for the purpose of maintaining the status quo rather than detecting and correcting con- ditions which may cause future trouble. When a condition is un- covered which points to future breakdown it should be routinely repaired, but, all
26、too often repairs are made after the breakdown occurs. Routine maintenance involves a variety of things-oiling of machinery, disposal of scrap, inspecting condition of tools, a general cleanup, minor repairs of machines and equipment due to breakdown, aiid other like activities. The fact that mainte
27、nance is routine in nature does not detract from its importance, either in maintaining production or preventing in- juries. It is an important activity, and a good maintenance program will go a long way in creating an efficient and safe working environ- iiieiit. But a goocl iiitiiiiteiiaiice program
28、 slioulci be plniiiied aiicl orgaiiizecl iii the sanie way as any other activity. Iii plaiiiiiiig ancl organizing, coiisider at least these five steps : 1. 2. 3. 4. I o * Develop effect ive maintenance procedures to cover all mainte- nance activities. Formulate work schedules to cover repetitive ope
29、rations, such as lubrication of machines, cleaning wiiidows and lighting fixtures, clisposal of scrap, etc. Establish a procedure for handling iioiirepetitive jobs such as repairs and installation of machines. Arrange, iii cooperatioii with operating departments, to have spare parts on linnd dieil i
30、ieeclecl for repairs. Develop a followup system to assure that procedures and sched- ules are followed. The importance of mainteiiaiice should not be underestimated, and when properly plaiiiied and organized, it can be a factor in con- trolling accidents. 3 Provided by IHSNot for ResaleNo reproducti
31、on or networking permitted without license from IHS-,-,-= 3535789 0279368 678 PREVENTIVE MAINTENANCE Prei-entive maintenance may be defined as an orderly, uniform, continuous, pla.niied, and scheduled procedure to prevent breakdown aiid prolong tlie useful life of equipment and buildings. Some advan
32、tages to be gained from preventive maintenance are : 1. Decrease of downtime of equipment due to breakdown. 2. Reduced repair costs. 3; Increase in life of the equipment. 4. Provides safer working conditions. Iii determining whether a system of preventive nmiiiteiiance is worthwhile, the answer to t
33、lie following questions can aid in reacli- ing a decision. 1. Does the cost in iiispectioii exceed the. cost of repair and valiie of 2. Will the normal life of the eqiiipment exceed the need without 3. Does good condition of equipment contribute to safe working 4. Is tlie eqiiipnieiit critical to th
34、e process? fi. Is standby equipment available for continuation of the process in If the answer to questions i? 2, or 5 is “Yes,” the need for preveii- tive maintenance is doubtful. If the answer to 3 or 4 is “Yes,” the need is at once apparent. TJnder most conditions preventive mainte- naiice is nec
35、essary to maintain produc.tion facilities, and it is almost alwtys necessary to eliminate dangerous conditions involving me- dian ic a1 equipment dow nt.ime ? preventive maintenance ? conditions ? case of failure? Steps in a Preventive Maintenance Program Siiccessful preventive maintenance in iiidus
36、try involves at least the 1. Regular ,ryatemntic impections of all machines, equipment, and 2. A progmm .of penodzc repiacement of essential equipment or 3. 1Ceepin.g recods of inspections, replacements, and findings. 4. Repairs and replacements as indicated from inspections, or in following factors
37、 : premises. parts. accordance wit.11 replacement schedules. 4 - PROBLEM HARD COPT Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-3535789 0279369 504 5. Follow-through to evaluate progress. These a.re discussed in detail in the following sections :
38、Regular Systematic Inspections Inspections should constitute a regular and routine part of every preventive maintenance program. Inspections should be made pe- riodically at intervals depending on the equipment and the extent of use. For example, in metalworking operations, punch presses may re- qui
39、re inspection and adjustment daily, on every shift in some cases, while squaring shears or bending brakes in the same plant could be inspected weekly or monthly. Conveyors, exhaust systems, cables aiicl tackle, materials-handling devices, power traiisinissioii appa- ratus, elevators, boilers, and po
40、werplant should be i nspectecl periodi- cally according to usage and need. Inspections should be conducted according to specific routine, and can be guided through the use of forms or checklists. Inspections are intended to evaluate physical conditions and to establish what must be done as correctio
41、ns or replacements. Preventive maintenance iiispectioiis slioiilcl not be confused with otlier typs of plant, safety inspect ions. Preventive maintenance in- spections are made periodically-yerly, iiioiitlily, weekly, perhaps daily-of specific machines or workplaces by personnel of the main- tenance
42、 crew. Machines, equipment, or Tvorkplaces selected for pre- veiitive maintenance inspections are -those tliat are subjected to except.ioiially liarci wear, or are of a kind tliat, should failure occur, woulcl result in serious trouble either iii loss of production or in u- cidents. A list. of areas
43、 where preventive maintenance inspections slioulct be macle is suggested. This slioiild not be considered all-indu- sive, but. rather as a sample or typical list applicable to most plants. For convenience, these areas liave been grouped together under tllree main headings. 1. Building, Premises, Fac
44、ilities a. Drives, Walks, Parking Areas Ciirbs marked ? Surfaces in goocl coiiclitioii 3 Traffic directional mwkers iii pltwe 3 Shrubbery trimmed aiicl without. aiiy blind corners ? Settling, separation, deflection ? Leaks at footings, wall opeiiiiigs, roof 3 Breaks in concrete sections ? Loose bric
45、ks, cracks iii w.alls ? b. Walls and Roofs 5 - . . . . . -_ ._-I- - PROBLEM HARP) COPY Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-_ 3535789 0279170 226 c. Floors and Stairs Surfaces rough aiid spliiitered ! Treads worn or uneven ? Floors slipper
46、y from wixiiig ? Noiislip surf aces sat isf nctory in hazard areas ? CL Fire Doors, Fire klw:pes, Spriiiklers Fusible links 011 fire doors in operating coiidit.ioii ? Door counterweights free ? Outside fire escapes clear, good wiiclitioii ? Sprinkler lieads clear ? Extinguishers serviced to date 3 e
47、. Illumin (z t 1011 Luminaires cleaned regularly ? Adequate light iiig values iiiaiii t aiiied ! IViiidows, skylights cleaiiecl r.epiil:ii*ly ! 2. Production Facilities and Storage Areas a. Aisles, Work Areas Clearance limit. mnrkiiigs stttisfact ory ? Aisles wide eiiough for trucks, stock movenieii
48、t ? b. Veiitilation Velocity aiid pressure tests made oil booths, taiilcs, exlinust systems ? Records kept of iiispectioiis ? Filters, collectors, piping cleaned aiid maintained satisf acto- rily ? o. Electrical Equipment Grounds tested regulnrly ? Exposed energized coiidtictors ! General wirinr sst
49、isf actory ? 9 Motors aiid switches protected from tr:i%c ? Fuse boxes locked? Fuse capacities correct for vircui t s ? Circuits tested for overloads ? Exteiision cords iii goocl coiicli t ioii ? Machines servicecl 011 s:cliecliile ! Repni rs up - t o- cla t e ? Guards adequate, in place, properly adjusted? Power controls well marked, accessible for operator? Safety devices opera
