Question

Scenario 2: Hunter Molding Machine (Machine Guarding)

While operating a Hunter molding machine, it is necessary for a single operator to reach inside the machine to adjust the pattern or blow it off to ensure that it is free of particles or other debris that will create deformed parts. This function is conducted once every 75 minutes, 8.5 hours per day. The molding pattern is placed on the holder by the machine, which then automatically rotates the pattern 180 degrees before the molding sand is compressed on the pattern, and then this process is repeated to ensure a two-sided mold is created. When the molds are compressed and then separated, the operator must reach inside the machine to clean the pattern by blowing compressed air onto the mold. The foundry supervisor is concerned that there is a potential for the operator to be caught in the rotating pattern holder, causing an amputation. He has asked for your help to provide a control measure to prevent any possible injuries to the operators. Note: A physical barrier between the operator and the pattern holder is not possible or feasible due to production activities. Please see the photographs below as a reference.

Answer 1

In Hunter molding machine it is necessary for a single operator to reach inside the machine to adjust the pattern or blow it off to ensure that it is free of particles or other debris that will create deformed parts even sometimes during service and maintenance of machine.

Amputation or crushing injuries, burns, cuts may occur

• when the hands or limbs is placed between mold halves.
• if the operator reaches while the interlock has been removed or bypassed like for a part that is stuck.
• Inadvertently reaches around over into hazardous area.
• May be operator is new and not familiar with equipments.
• Relying on interlock which may be6 inoperable or missing.
• While removing guards and safeguards.
• Hands or limbs caught in machine while loosening trapped materials.
• Sometimes burning of hand or limbs from hot mold.

As machine operates 8.5hours per day each function is conducted once every 75 minutes and production activities can't be disturbed by using any kind of physical barrier etc.

Following control measures can be adopted to avoid injuries causing amputations to operator:

• Providing safety hazards training to the operators and workers who will work with it.working procedures and equipment knowledge.
• Following lockout Tagout (LOTO) during service and maintenancewhiel removing or bypassing a guard or safety device, or Place any part of the body into the mold area or an danger zone.
• Wearing appropriate personal protective equipment (PPE), such as a heat-resistant gloves, long-sleeved shirt and eye/face protection, when necessary.
• Access the mold cavity via the operator's gate and do not remove a fixed guard during normal operation.
• Movable parts must be fasten with interlock.
• Avoid reaching over/around moving equipments.
• Attention of supervisors and assisting operators and making them aware of possible injuries and advice to avoid.
• Following OSHA guidelines.
• Using proper PPE's and maintaining sufficient distance from rotating pattern holder while cleaning using compressed air.