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Machine Safety for Injection Molding Machines

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Machine Safety for Injection Molding Machines Occupational Safety and Health Administration A Presentation of the OSHA-SPI Alliance The Society of the Plastics – PowerPoint PPT presentation

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Title: Machine Safety for Injection Molding Machines


1
Machine Safety for Injection Molding Machines
A Presentation of the OSHA-SPI Alliance
2
Course Objectives
  • Identify the types of injuries that can occur
    while operating injection molding machines
  • Describe the possible causes of these injuries
  • Identify ways to safely operate injection molding
    machines
  • Recognize the importance of a total safety and
    health approach

3
Reasons to Focus on Injuries in the Injection
Molding Process
  • High injury/illness rates
  • OSHA citations
  • National Emphasis Program
  • Site-Specific Targeting

4
Types of Injuries
  • Fatalities
  • Amputations
  • Avulsions
  • Fractures
  • Cuts and bruises
  • Sprains and strains
  • Burns
  • Electric shock

5
Some Causes of Injuries
  • Reaching around, under, over or through guards
    into hazardous areas
  • Removing or bypassing guards
  • Reaching into equipment to remove stuck parts
  • Not using LOTO procedures
  • Machine/equipment malfunctions

6
Causes of Injuries (contd)
  • Lack of recognition of hazards of the job
  • Lack of familiarity with the equipment
  • Inadequate training, comprehension, or both
  • Operating machines with missing or inoperable
    guards and improper or inadequate machine
    maintenance

7
Injection Molding Machinery
  • Horizontal injection molding machine (HIMM)
  • Vertical injection molding machine (VIMM)

8
Vertical Injection Molding Machines - VIMMs
9
VIMMs
  • Combinations of vertical and horizontal clamp and
    injection configurations of machines
  • Regardless of the configuration of the machine,
    basic machine guarding and good safe work
    practices must be applied
  • Point of operation
  • Other moving machine parts

10
VIMMs Unique Hazards and Issues
  • Gravity
  • Plastic splatter/missing insert
  • Flying inserts
  • Unexpected bystander interventions

11
Horizontal Injection Molding Machines - HIMMs
12
HIMMs Mechanical Hazards
  • Point of operation
  • Pinch points
  • Nip points
  • Rotating parts

13
Potential Injuries from Mechanical Hazards
  • Fatalities
  • Amputations
  • Avulsions
  • Crushing injuries
  • Fractures

14
Safety Guards and Devices
  • Types of guards and devices
  • Movable guards with interlocks
  • Fixed barrier guards
  • Presence-sensing devices
  • Mechanical safety bars
  • Locations of guards
  • Over moving equipment
  • Around electrical hazards
  • Around thermal hazards

15
Operators Gate
  • Equipped with redundant interlocks
  • Electrical
  • Hydraulic
  • Mechanical safety bar
  • Allows the machine to operate only when the gate
    is closed

16
Electrical Interlock
  • Allows the electrical system to operate and close
    the clamp
  • Actuated when the operators gate is opened or
    closed
  • Prevents clamp from closing when the operators
    gate is open

17
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18
Hydraulic Interlock
  • Actuated by opening or closing the operators
    gate
  • Each hydraulic IMM requires at least one
  • Prevents clamp from closing when the operators
    gate is open

19
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20
Mechanical Safety Device
  • Prevents clamp from closing when the operators
    gate is open
  • Must have at least one mechanical device on all
    IMMs

21
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22
Other Guarding
  • Rear guard
  • Top guard
  • Parts discharge guard
  • Feed opening guard
  • Electrical system guards
  • Purge guard
  • Injection barrel cover

23
Rear Guard
  • Prevents clamp from closing when interlocked rear
    guard is opened
  • Should have at least two interlocks
  • Prevents access to mold areas

24
Top Guard
  • Required if operator can reach over the top of
    the machine and into hazardous areas
  • Should be interlocked if movable

25
Top Guards (contd)
26
Parts Discharge Guard
  • Keeps employees from reaching under operators
    gate and into the danger zone

27
Purge Protection
Purge guard
  • Covers the nozzle and purging area
  • In combination with PPE, minimizes exposure to
    molten plastic during purging
  • Window allows observation through purge guard, if
    equipped
  • Should be equipped with an interlock

Safety window
Barrel cover
28
Injection Barrel Cover
  • Protects from exposure to high voltage and high
    temperatures

29
How to Protect Yourself
  • Recognize the hazards in the job you are doing
  • Understand the requirements for guarding machines
  • Implement guarding solutions

30
Virtual Safety Tour
31
Emergency Stop
  • Know
  • Where it is located
  • What it controls
  • When to use it

32
Signs and Warnings
33
Colors used with Safety Signs have meaning!
DANGER
White Lettering/Red Background
WARNING
Black Lettering/Orange Background
CAUTION
Black Lettering/Yellow Background
34
High Voltage
35
Rotating Screw
36
High Temperature
37
High Pressure
38
Robots
  • Used to automate repetitive or hazardous tasks
  • Must be guarded to prevent workers from entering
    or reaching into hazardous areas

39
The Robot
40
Our sincere thanks to
  • United Southern Industries, Inc.
  • OSHA Region V
  • The OSHA Training Institute
  • OSHAs Salt Lake Technical Center
  • Paulson Training Programs, Inc.
  • The Society of the Plastics Industry, Inc.

41
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