Materials Handling

Materials handling

Handling and storing materials involve diverse operations like hoisting tons of steel with a crane; driving a truck loaded with roofing sheets; carrying bags or materials manually; and stacking palletized fibre bags or other materials.

The efficient handling and storing of materials are vital to industry. These operations provide a continuous flow of parts and assemblies through the workplace and ensure that materials are available when needed. Unfortunately, the improper handling and storing of materials often result in costly injuries.

It is every one’s responsibility to examine the workplace to detect any unsafe condition, unsafe practice, unsafe equipment and take corrective action. The employer must work out appropriate solution and implement them without any delay. The employee must report it to the concerned superior and follow up till an appropriate solution is implemented.

Potential injuries which can occur while handling materials manually.

·         Strains and sprains from lifting loads improperly or from carrying loads that are either too large or too heavy,

·          Fractures and bruises caused by being struck by materials or by being caught in pinch points, and

·         Cuts and bruises caused by falling materials that have been improperly stored or by incorrectly cutting ties or other securing devices.  

Precautions for manual handling.

When moving materials manually, workers should attach handles or holders to loads. In addition, workers should always wear appropriate personal protective equipment and use proper lifting techniques. To prevent injury from oversize loads, workers should seek help in the following:

·         When a load is so bulky that employees cannot properly grasp or lift it,

·         When employees cannot see around or over a load, or

·         When employees cannot safely handle a load.

Using the following personal protective equipment prevents needless injuries when manually moving materials:

·         Hand and forearm protection, such as gloves, for loads with sharp or rough edges.

·         Eye protection.

·         Steel-toed safety shoes or boots.

Precautions for stacking materials.

Falling materials and collapsing loads can lead to fatal accidents.

·         Stack no more than 10 feet height if manual handling is employed.

·         Ensure that the stacks are stable and self-supporting.

·         Do not store pipes and bars in racks that face main aisles to avoid creating a hazard when removing them.

·         Stack bags in interlocking rows to keep them secure. Refer the figure below.

                                                                               

Precautions for hand pallet trucks.

·         Don’t use them on sloping steel surfaces.

·         Don’t use them on uneven or soft surfaces.

·         Ensure that all the wheels are always in contact with the working surface.

Precautions for forklift trucks.

·         Only trained and certified operators must operate forklift trucks.

·         Before starting the operation check the truck thoroughly and ensure all the warning systems work properly.

·         When not in use, leave the truck with forks fully lowered and rest on ground; switch off the engine, apply hand brake, and remove the key.

·         Drive the truck only in authorized areas avoiding pedestrians and other vehicles.

·         Avoid sharp bends and overhear obstructions as far as possible.

·         Do not operate the truck on excessive gradients.

·         Do not overload the truck.

·         Correctly place the loads and secure them.

·         Always keep the forks in lowered position with the mast tilted slightly backward.

·         Avoid transporting non-standard, unpacked, and excessively wide loads.

·         Do not use any home-made attachments for the truck.

·         Do not carry any passenger on the truck.

·         Don’t allow pedestrians to walk underneath the load.

·         Avoid rapid acceleration, hard braking, and sharp cornering.

·         Do not place extra weight on the rear of the forklift to compensate overload.

Precautions for cranes.

·         Do not leave cranes unattended with suspending loads.

·         Do not use cranes for any purposes other than for lifting in a vertical plane.

·         Avoid load swing and snatch loading.

·         Ensure that the wire ropes are in good condition without any broken strands and apply proper lubrication to them.

·         Ensure that the hook lock (safety latch) is in good working condition.

·         Always lift the load few inches, wait and check the brake quality and then proceed to lift.

Note. The precautions recommended above are not exhaustive and are general in nature. Additional precautions and right procedures should be worked out and applied for different establishments.

Work Permit System

Work permit

A work permit system is a formal written system used to control and carry out  certain types of work that are potentially hazardous. A work permit  is a document which specifies the work to be done and the precautions to be taken. It forms an essential part of safe systems of work for many maintenance activities. They allow work to start only after safe procedures have been defined and they provide a clear record that all foreseeable hazards have been considered.

A permit is needed when maintenance work can only be carried out if normal safeguards are dropped or when new hazards are introduced by the work. Examples are, entry into vessels, hot work and pipeline breaking.

What needs to be done.

Don’t assume that your system is a good one just because you have not yet had a serious accident. You should critically review your system and ask yourself the following questions.

Information
❒ Is the work permit system fully documented, laying down:
- how the system works;
- the jobs it is to be used for;
- the responsibilities and training of those involved; and
- how to check its operation?
❒ Is there clear identification of who may authorise particular jobs (and any limits to their authority)?
❒ Is there clear identification of who is responsible for specifying the necessary precautions (ex.  isolation, emergency arrangements, etc)?
❒ Is the permit form clearly laid out?
❒ Does it avoid statements or questions which could be ambiguous or misleading?
❒ Is it designed to allow for use in unusual circumstances?
❒ Does it cover contractors?

Hazards and precautions
❒ Does the system require the removal of hazards and, where this is not reasonably practicable, effective control?

❒ Does the permit state the precautions that have been taken and those that are needed while work is in progress? For instance, are isolations specified and is it clear what personal protective equipment should be used?
❒ Do the precautions cover residual hazards and those that might be introduced by the work, ex. welding fume and vapour from cleaning solvents?

There can be different types of work permits depending on the type of work to be carried out. Following are some of the common ones:

·         A ‘general work permit’ used for the control over access to the premises, or the works area such as for maintenance work

·         A ‘electrical work permit’ used to control any work on electrical systems (either live or dead)

·         A ‘hot work permit’ used to control any work that has the potential to create a fire risk (for example, cutting, grinding or welding activities)

·         A ‘work at height permit’ for controlling work involving access to all types of roofs and working at heights more than 2 metre.

·         A ‘hazardous substance permit’ used for the control of work activities using or liable to expose people to hazardous substances such as asbestos

·         A ‘lone worker permit’ used to ensure the safety of any contractor who may be working alone.

·         A ‘confined space entry permit’ is used for the works to be carried out in confines spaces like working inside a storage tank.

·         A ‘ground disturbance permit’ is used for any excavation, digging, trenching, or soil removal activity.  

Requirements of the work permit system.

The following are the basic rules for the work permit system:

·         The permit must specify clearly who is to do the work, the time for which it is valid, the work to be done and the necessary precautions

·         Until the permit is cancelled, it supersedes all other instructions

·         During the period covered, no unauthorised persons must work at any place or on any plant within the work area controlled by the permit

·         No person must carry out any work not provided for in the permit

·         If there is to be a change in work activities, the permit must be amended or cancelled by the originator of the permit

Normal procedure.

The work to be carried out is normally planned well in advance in consultation with the departments that will get affected. The procedure for carrying out the planned work, is clearly defined and the persons to carry out the work are designated. The total time required for completion of the work will also be worked out and required allowances will be added to the same.

On the day of carrying out the work, the leader responsible for the work will coordinate with the other supporting people. He will get the work permit filled and authorized by the relevant authority. After getting the authorized work permit he will ensure that all precautions are carried out and the personal protective equipment are worn before starting the work. He will employ the designated persons for the job.

Once the job is completed, he will ensure that normalcy is restored by reversing the changes that have been made for safe working. He will also clean the area by removing residues and other debris. After ensuring that everything is normal he will close the permit.   

Depending on the plant, the work permit can have number of copies. The closed work permits are neatly filed and maintained by the respective department heads.

A very simple, sample work permit is given below.

Safety Code – Electrical

Safety code – Electrical.

In any factory, the major hazard is electricity. It can lead to disasters if not handled properly. Following are the general tips to work safely with electricity. Read them carefully and follow them for your safety and safety of others.

Electric motor.

• Ensure that all the motors are connected securely with two separate and independent earths. Use adequate size of wire / flat for the same.
• Ensure that all the motors are having cooling fan fitted.
• Ensure that the motor fans are covered properly with the fan cover.
• Ensure that the cables are terminated properly with cable glands.
• Ensure that the terminal box is fitted with the cover properly.
• Ensure that the terminal box does not have any opening left out. If there is an unused opening, cover it with an insulating plate.
• Ensure that the connections are made properly either with lugs or loops.
• Ensure that the cable is clamped properly.
• Do not start any electric motor if there is no guard for the drive. Example: Coupling, sprocket, pulley, etc.
• Never set the over load relay beyond the full load current of the motor in case of DOL starter and 0.58 times full load current in case of star delta starter.
• If a motor trips out, first check whether there are any mechanical restrictions before re-starting the same.
• Ensure that the motor is fitted with a suitable protective guard wherever there is a possibility of exposure to water.

Switch board / control panels.

• Ensure that all the switch boards are connected with two separate and independent earths.
• Ensure that the boards are maintained free of dust.
• Never leave any of the doors open.
• Never leave any openings (cable entry, panel cut out, etc) as it is. Cover them with plates of appropriate size.
• Ensure that all the cables are terminated properly with appropriate glands.
• Ensure that rubber mate of correct size is spread in front of all the switch boards.
• Ensure that all the doors of panels are always kept closed.
• Do not allow any switch fuse unit / switch to remain open. Ensure that the door is always closed.
• Do not make any temporary connections from the board without proper termination and do not leave the door open.
• Ensure that the connections are secure with proper lugs or loops.
• Ensure that the trench below the switch board, if any,  is clean and free from debris.
• Ensure that the meters are working properly. Replace the defective ones immediately.
• Do not permit unauthorised persons to work in the panels / switch boards. Do not allow them to enter into the enclosures.

Welding transformer.

• Ensure that the connection is made through a good metal clad plug of appropriate rating.
• Use proper earth connection from the socket.
• Use an appropriate capacity MCB in the transformer to control the supply. It should be a double pole one.
• Ensure that the earth electrode for the job is securely connected to the transformer terminal.
• The other end of the earth electrode must have a clamp which will avoid electric sparks and will ensure rigid connection.
• Ensure that the welding cable is properly secured to the terminal.
• Ensure that the other end of the cable is properly connected with a welding holder of appropriate rating.
• Do not use welding cable with punctured insulation; either repair the puncture or replace the cable.

Power plugs.

• Ensure that all the power connections are connections are made through MCBs of appropriate ratings.
• Within the factory shed, always use metal clad plugs only; it is mandatory.
• Within the factory shed do not use wooden switch boards. Use always MS boards with proper earthing.
• Ensure that the socket covers are in place and are used when the plug is not in use.
• Frequently check the sockets and plugs for loose connection and pitting. Take corrective action if there is a problem. The frequency can be once a week for plugs where heavy equipment like welding transformers are connected.

Portable tools.

• Ensure that portable tools with metallic body are connected with good earthing.
• Do not permit joints in the supply cable.
• Always use a trailing cable for connection.
• Never use ordinary PVC insulated wires for connection. Use unarmoured cables.
• Ensure that the power supply circuit contains ELCB of appropriate rating with 300 mA sensitivity.
• Never allow operators to roll the power supply cable around their bodies.
• Observe sparking in carbon brushes and take remedial action.

General.

• Always keep energy conservation in mind. Switch off the idle machines through the respective operator and report the same to the supervisor in-charge.
• Do not allow lights to be ON whenever they are not required.
• Monitor the energy consumption of different sections at regular intervals.
• Always look for deviations with respect to safety practices and correct them on the spot.
• Do not operate any equipment without proper safety arrangements like earthing, guard, short circuit protection, overload protection, etc.

Safety Code – Mechanical

Safety code – Mechanical.

There are many mechanical hazards present in a factory. We have to be extremely careful and behave appropriately to avert accidents. Read the following tips and follow them without fail.

General.

• Always maintain your work area clean and tidy. Do not allow substances like oil, grease, etc to remain on the floor.
• After completion of every job, clear the area without fail. Do not leave anything (bolts, nuts, bearing wrappers, etc) on the work spot.
• Do not run any equipment without appropriate safety guards for the rotating / moving / reciprocating parts.
• Always keep safety in mind while working and do not take any undue risks.
• Always ask for clarification if you have doubts. Stop the work and do not proceed further until your doubt gets cleared.
• Always carry out the work by following the prescribed procedures. If you do not know the procedure or the procedure is not available, ask the person who allotted the work to you.
• Never run in the shop floor. You can get toppled.
• Do not walk over running conveyors however slow they are. Always use the over bridges or appropriate crossing points to cross the same. If it is not available, report it to your superior.
• Always wear safety shoes.

 Working at a height.

• For all practical purposes, you should consider any height above six feet as dangerous.
• Use appropriate personal protective equipment like safety belt when you work at a height.
• Get an approved work permit, from the concerned authority, before starting the work at height.
• Use ladders with all steps and in good working condition.
• If there is a problem in the hand rail of a ladder, report it immediately to the supervisor.
• While climbing, climb one step at a time.
• While working at a height, ensure that there is an observer at the floor level watching you.
• Ensure that the observer is capable of taking appropriate decisions in case of any eventuality.
• Have a proper support for you while working at height. This will allow you to focus on the job without any concern.
• When you work over asbestos cement roofs, always use a cat ladder to walk above the sheets. The cat ladder should be of appropriate design suitable for the roof you are working with. Do not run over the roof.
• Never drop anything (like spanner, bolt, nut, etc) from the height while you are working.

  

Arc welding.

• Do not touch live electrical parts.
• Wear dry and hole-free insulating gloves while welding.
• Take special care while welding in damp areas; avoid it as far as possible.
• Confirm that the body of the welding transformer is properly earthed before using it.
• Use correct sized metal clad plugs for connecting the welding transformer.
• Protect the electrical cable from hot metal and sparks. Keep them free of oil, grease and joints.
• Periodically inspect the cabled for damages and insulation failures. Get the faults rectified through authorized electrical personnel.
• Do not use damaged, undersized cables.
• Do not touch the electrode if you are in contact with the work or ground or another electrode from a different machine.
• Maintain the transformer in good condition. Repair or replace the damaged parts at once.
• Keep all the covers and enclosures in place.
• Clamp the earth electrode to the work piece securely. Use insulated clamps.
• Do not connect more than one electrode or work cable to any single terminal.
• Do not touch hot parts bare handed. Use proper tools for the same.
• Welding, chipping, and wire brushing cause sparks and flying metal. Wear safety glasses / goggles to prevent mishaps.
• Always use helmet with proper welding glass while welding.
• Don’t breathe welding fumes as they can be hazardous to your health.
• While working in a confined space wear an air-supplied respirator. Always have a trained watch-person nearby.
• Use protective screens or barriers to protect others from flash, glare, and sparks. Warn others not to watch the arc.
• Welding in closed containers such as paint cans, oil drums can cause them explode. Do not weld in closed containers.
• Flying sparks, hot work piece can cause fires and burns. Keep fire buckets and fire extinguishers handy.

Gas cylinders.

• Gas cylinders contain gas under high pressure. If damaged, it can explode. Handle them carefully.
• Protect gas cylinders from mechanical damage, excessive heat, open flames, sparks and arcs.
• Always store the cylinders in upright position and secure them properly.
• Never drape a welding torch over gas cylinders.
• Never allow a welding electrode to touch any cylinder.
• Never weld on a pressurized cylinder. It will explode.
• Always use correct size and correct quality regulators, hoses, fittings and torches.
• Turn your face away from the valve outlet when you open it.
• Always place the protective cap above the valve, if it is not in use.
• Store the cylinders in their respective marked places – empty and full in their respective places.
• Do not place the cylinders close to open flames and arcs.
• Once the job is complete, shift the cylinder to its designated place. Do not leave it where you worked.
• Do not use damaged hoses. Get them changed immediately.
• At the end of the day, roll the hoses properly and hand over it to the in-charge.
• Do not leave the hose or regulator in the cylinder while leaving at the end of the day. Remove them and hand over to the in-charge.

  

Diesel engine & Diesel Generating (DG) sets.

• Fuel can cause fire or explosion. After stopping the engine, allow it to cool before carrying out any work involving fuel.
• Do not allow fuel to spill out or leak. Clean up immediately.
• Keep away from moving parts like fans, belts and rotors.
• Keep all doors of the sound-proof enclosure, panels, covers, and guards closed and securely in place.
• Keep hands, hair, loose clothing, and tools away from moving parts.
• Don’t open the radiator plug immediately after stopping the engine. Hot steam will come out which can cause severe burns. Allow the water pump to run continuously and observe the water temperature. When it comes down reasonably (around 40 degree), you can safely open the radiator cover.
• Do not allow tools to cause sparks while working in a battery.
• Stop the engine before disconnecting the battery.
• Never run the engine without battery in the circuit since this may prevent protection circuit from functioning.
• Always maintain good ventilation in the room.
• Do not remove doors, covers or guards while the engine is ON.

Ladder Safety

Ladder safety

Working on and around ladders is hazardous. Ladders are the major sources of injuries and fatalities in construction industry. The hazards associated with ladders include:

·         Falls from ladders

·         Struck by falling ladders

·         Struck by materials falling from ladders

·         Tripping over ladders

·         Striking persons or objects while carrying ladders

·         Contact with electrical equipment

Observe the following rules.

·         Maintain ladders free of oil, grease, and other slipping hazards.

·         Ensure that the ladder is fitted with rubber or other suitable non-slip material at feet.

·         Do not load ladders beyond their maximum capacity.

·         Use ladders only for their designated purpose.

·         Use ladders only on stable and level surfaces.

·         Secure ladders placed in areas like passages, doorways or driveways where they can be displaced by workplace activities. Or use a barricade to keep activities away from the ladder.

·         Keep areas around the top and bottom of ladder clear from obstacles.

·         Do not move, shift or extend ladder when in use.

·         Do not carry objects or loads that could cause loss of balance and falling.

·         Ladder steps must be parallel, level, and uniformly spaced.

·         Ladders must not be tied or fastened together to extend the length.

·         Ensure the ladder has a ratio of height to horizontal distance from wall of 4:1.

                                                     

·         Inspect the ladder for damage before each use.

·         Always maintain three point of contact when climbing or descending the ladder. This means two hands and one foot, or two feet and one hand.

·         Never lean or reach away from the ladder while using it.

• When climbing down, remain facing the ladder and climb to the bottom rung before stepping off.

·         Always climb one step at a time.

Avoid the following dangerous practices.