HUM Safety and Environment

Equipment Safety Management

HUM Equipment Safety Management

Safety policy and action guidelines

Equipment safety procedure

PUWER Equipment assessment

High level risk assessments

Isolation and lockoff

Lifting equipment

Abrasive wheels

Vibration

Fire

Permit to work & Authority to run

Equipment Layout

Gas welding

Noise

Risk assessment

Risk assessments

Legislation

Documents and checklists

Operation standards

Audits and tours

Design / CAPEX assessment

Manual Handling

HUM Equipment Safety Management - Legislation

Health and safety At Work etc Act 1974

HUM Equipment Safety Management

Safety policy and action guidelines

Equipment safety procedure

PUWER Equipment assessment

High level risk assessments

Isolation and lockoff

Lifting equipment

Abrasive wheels

Vibration

Fire

Permit to work & Authority to run

Equipment Layout

Gas welding

Noise

Risk assessment

Risk assessments

Legislation

Procedures

Operation standards

Audits and tours

Design / CAPEX assessment

Manual Handling

HUM Equipment Safety Management - Policy

SAFETY POLICY - STATEMENT

HUM will ensure a healthy and safe working environment by incorporating safety into the daily work processes and equipment, and by achieving relevant legal compliance. All associates have a responsibility for their own health and safety and that of others, and must follow HUM’s safe systems of work.

THERE CAN BE NO PRODUCTION WITHOUT SAFETY Action Guidelines Equipment - HUM will ensure that all equipment is designed and installed for safe operation, achieves European and national safety standards, is assessed prior to use and is maintained to ensure continued safe operation.

HUM Equipment Safety Management

Safety policy and action guidelines

Equipment safety procedure

PUWER Equipment assessment

High level risk assessments

Isolation and lockoff

Lifting equipment

Abrasive wheels

Vibration

Fire

Permit to work & Authority to run

Equipment Layout

Gas welding

Noise

Risk assessment

Risk assessments

Legislation

Procedures

Operation standards

Audits and tours

Design / CAPEX assessment

Manual Handling

HUM Equipment Safety Management – High Level Risk assessment

HUM Equipment Safety Management

Safety policy and action guidelines

Equipment safety procedure

PUWER Equipment assessment

High level risk assessments

Isolation and lockoff

Lifting equipment

Abrasive wheels

Vibration

Fire

Permit to work & Authority to run

Equipment Layout

Gas welding

Noise

Risk assessment

Risk assessments

Legislation

Procedures

Operation standards

Audits and tours

Design / CAPEX assessment

Manual Handling

HUM Equipment Safety Management – Procedures

HUM Equipment Safety Management

Safety policy and action guidelines

Equipment safety procedure

PUWER Equipment assessment

High level risk assessments

Isolation and lockoff

Lifting equipment

Abrasive wheels

Vibration

Fire

Permit to work & Authority to run

Equipment Layout

Gas welding

Noise

Risk assessment

Risk assessments

Legislation

Procedures

Operation standards

Audits and tours

Design / CAPEX assessment

Manual Handling

HUM Equipment Safety Management - Audits

HUM Equipment Safety Management – Risk assessments

HUM Equipment Safety Management – PUWER assessments

Work equipment :

Description :

Date assessment :

Assessed by :

Yes No Yes No

Has a risk assessment been completed to select the most suitable equipment

for the task? This must assess the risks to operators, maintenance personnel

and others who work with the equipment.

Has Honda know how and industry best practice guidance been used in the

equipment design and specification?

Are assessments for critical machine parts contained in the Technical File, are

they fit for purpose?

Is the durability of parts and materials suitable for the work situation foreseen?

Have ergonomic considerations such as light operating controls and working

height, reach and posture been included in the equipment design? Anything

moved or clamped by hand should have suitable hand grips.

Does the location and installation of the equipment minimise risks to the user

and maintenance personnel? Is there sufficient access space? Have trap points

around the equipment been eliminated?

Can all chemicals or substances used or produced by the equipment be supplied

or removed safely? Is there protection against oxygen deficiency in pits and

confined spaces?

If flammable atmospheres or wet and slippery conditions are present, does the

design take this into account?

Is there adequate ventilation in place to remove any fumes that maybe emitted.

Is the work equipment maintained in efficient working order and in good repair.

This is a visual health check of the process. Guards missing, items damaged /

loose?

Is there a register of the machine highlighting which areas require and who

should maintain what part of the machine? (ie PS, Tooling, Die Maintenance,

Production)

Is there a maintenance log of the work carried out, who carried out the work, the

date of the check and a list of problems found and countermeasures introduced

with dates?

Are the maintenance schedules up to date. Does this demonstrate compliance

to the agreed maintenance schedules?

Is there a daily start-up check sheet for each of the processes and does it

include checks on safety devices, (Electronic Guards, Extraction and

Maintenance of PPE etc, where required)

Yes No Yes No

Has an electrical installation test certificate been issued including earth bonding

and adequate guarding of live accessible contacts

Have lightguard conformance certificates been issued including separation

distances to BS EN 999?

Is there a process map / register of the equipment in place highlighting area's of

Specific Risk?

Is access / use of these area's / processes limited to those maintenance, setting

and users who have had suitable and sufficient training?

Are operation standards available, include safety and environment care points

and signed by the operators on each shift? Are there op standards for

foreseeable abnormal situations?

Are maintenance manuals, instructions and information readily available in

English?

Has operator and maintenance personnel training on equipment been completed

and records kept?

If the work equipment was first put into service after 31st December 1992, is it

CE marked and is the mark displayed?

If the work equipment was first put into service after 31st December 1992, is

there a declaration of conformity or declaration of incorporation? (does it include

LVD & EMC)

Yes No Yes No

Have adequate measures been taken to prevent access to all dangerous parts

and potential trap points of the work equipment / process? If guarding or doors

to hazardous areas are opened for regular intervention are interlocks in place to

prevent exposure to hazard?

Are guards robust, durable and see through? It must be difficult to bypass or

misuse the guards.

Can guards only be removed by means of an interlock system or with the use of

a tool. If the guards are unfastened, will they swing open or fall off?

Are all guards situated at sufficient distances from the danger zone preventing

such hazards as leaning / reaching over the top, hand entry through the guards

etc. The guards should be positioned to prevent crushing risks inside the

machine.

Are all maintenance entry points protected by trapped key exchange interlock

system which allows a key to be taken by the operator inside the machine to

prevent persons being trapped inside?

Have jigs, holders or push sticks been provided for use with machinery where it

is not practicable to put fixed guarding.

Is it constructed to allow work necessary for replacement parts and

maintenance.

Are guards capable of containing ejected parts from the process? Are there

mechanical stops on linear motions to prevent overruns? Does the guarding

system contain weld splatter?

Is dust, gas or liquid created by the machine safely vented or contained?

Are extreme hot or cold areas guarded and are suitable materials used in the

construction?

Yes No Yes No

Is fireproof construction used in a flammable area?

Is it possible to start work equipment only by deliberate action?

Does this also apply to restart it after a stoppage? (ie following a failure the

machine / line will not start automatically)

Does this also apply for the control of a significant change in the operating

conditions (speed, pressure, etc.), when it entails a hazard?

Are the controls / control panel located in such away as to minimise the risk of

accidental start ups or actions?

Are control button labels and control screen instructions consistent with their

resulting function?

Is the work equipment fitted with a control to stop it in a safe condition and in a

safe manner? (Further information on the categories of the stop function may be

found in BS EN 60204-1)

Is each workstation fitted with a control to stop some or all of the work

equipment?

Does the stop control take priority over any operating or start control?

When the work equipment or the dangerous parts of it have stopped, is the

energy supply of the actuators concerned depressurised, (EG Hydraulics,

pneumatics or stored energy) Ensure this doesn't compromise safety ie

suspended loads, grippers or breaking systems.

Is an appropriate emergency stop fitted, is it in good condition? Does it latch?

Does it stop the machine as expected in a controlled manner, affecting a rapid

response including upstream and downstream machinery if appropriate?

Yes No Yes No

Is there an E/Stop at each control point and at other appropriate locations to

enable quick action (Number and location of mutiple E/Stops to be determined

by risk assessment)

After an emergency stop, has all motive power such as air pressure been

removed?

If the E/Stop circuit does not operate with redundancy, is there a system of work

in place to control this risk? (Ie. Periodic operational check)

If the E/Stop circuit is not completely hard wired, does it employ a “Safety PLC”?

(Ie. Not standard PLC / Software)

Are all controls clearly visible, identifiable and appropriately marked (ie. E/Stop -

Red Button on yellow background – Use details from BS EN 60204-1 as

guidance)?

Can the controls be operated by an associate wearing gloves or other PPE?

Are controls located outside danger zones?

Are controls located in such a way that they do not expose the operator to any

risk when used?

If not reasonably practical for the operator at the control position to ensure there

is no-one at risk, has a system of work been devised and used, if so is it

working? (Ie. Audible / visual warnings)

If regular entry is required which involves entry into or removal of, or opening of

safe guards for maintenance are interlocks or similar devices in place.

Is failure of the control system likely to put the operator or any other people, to

any Health & Safety risk?

Is there an explanation or indication of how the control system works?

Is there a drawing of the control system and list of components that form the

control system? (Ie. E/Stop matrix, Control Matrix + Drawings etc)

Yes No Yes No

Does the component list reflect the actual components fitted?

Does the control system work as described above?

Is there a history of failure or reported faults?

Does a failure of any part of the control system lead to a fail safe condition

Does the control system respond to the input controls and operate in the

particular manner expected from the input controls?

If the control system has been modified, have the modifications been recorded

and agreed? Have abuse tests been conducted and the results documented?

When assessing new equipment, does the control system follow BS EN 60204-1

& BS EN 13849-1? Have the SIL levels been determined from BS EN 62061.

(Most equipment at HUM will be SIL level 3)

If in some modes the machine works with its protection devices neutralised, is

auto operation disabled and slow speeds only permitted using hold to run

controls?

Following an interruption or re-establishment of power supply, will the machine

remain at rest until deliberately restarted and will protection devices and control

interlocks remain effective?

Is it possible to isolate the work equipment from all its energy sources? (eg.

Pneumatics, Electricity, Steam)

Are these means to isolate, clearly identifiable and readily accessible?

Are these means to isolate, lockable?

Can energy sources be reconnected without causing risk to health or safety?

Is the effectiveness of the isolation device checked / maintained?

Can stored energy be safely dissipated or made safe by other means?

Yes No Yes No

Description item

Requirement

applicable?

Requirement met?

Check method

Comment

Regulation 4 Suitability of work equipment

Check methodComment

Regulation 6 Installation inspections

Regulation 9 Training

Description item

Requirement

applicable?

Requirement met?

Regulation 11 Dangerous parts of machinery

Regulation 15 Stop Controls

Description item

Requirement

applicable?

Requirement met?

Comment

Description item

CommentCheck method

CommentCheck method

Regulation 5 Maintenance

Regulation 7 Specific Risks and Restriction in Use

Regulation 8 Information and Instructions

Check method

Regulation 10 Conformity with Community Requirements

Requirement

applicable?

Requirement met?

Description item

Requirement

applicable?

Requirement met?

Regulation 13 High or low temperature

CommentCheck method

Regulation 12 Protection against specific hazards

Regulation 14 Controls for starting or making a significant change in operating conditions

Regulation 16 Emergency stop

Requirement

applicable?

Requirement met?

Description item

Requirement

applicable?

Requirement met?

CommentCheck method

Description item

Regulation 17 Controls

Regulation 18 Control Systems (Hydraulic, Pneumatic, Electrical etc.)

Regulation 19 Isolation from sources of energy

ASSESSMENT of THE MINIMUM HEALTH AND SAFETY REQUIREMENTS

as required by the

PUWER Group Assessment (Ref. - HS/D/P22/17FEB06)

Dangerous Substances and Explosive Atmospheres Regulations

The Regulatory Reform (Fire Safety) Order

Pressure Systems Safety Regulations

Lifting Operations and Lifting Equipment Regulations

Provision and Use of Work Equipment Regulations

Amended by 95/63/EC and 2001/45/EC

PUWER is an approximation of the WORK EQUIPMENT DIRECTIVE 89/655/EEC

If so answer the following:

HUM Equipment Safety Management – Design & CAPEX

HUM Equipment Safety Management

Safety policy and action guidelines

Equipment safety procedure

PUWER Equipment assessment

High level risk assessments

Isolation and lockoff

Lifting equipment

Abrasive wheels

Vibration

Fire

Permit to work & Authority to run

Equipment Layout

Gas welding

Noise

Risk assessment

Risk assessments

Legislation

Procedures

Operation standards

Audits and tours

Design / CAPEX assessment

Manual Handling

Low Accident Rate Minimal EL claims Legal Compliance

HUM Safety and Environment

Equipment Safety Management

Any Questions