SHAPING MACHINE
SCOPE This document is to be completed for staff and student use of machinery, plant & equipment as a part of a school curriculum activity or program.
Refer to the ITD Guidelines for further staff advice on the risk management process for practical ITD curriculum activities in schools.
Plant / Equipment Description: Teachers / Leaders:
Room Locations:
Assessment Date: Review Date:
N.B. This assessment can remain active for up to 5 years. However, an annual monitoring & review process should be undertaken and recorded – refer to the last page of this document.
Below are the details of the manufacturing or production processes attributed to this item of equipment categorised by their assessed inherent risk levels (refer to the Equipment / Process Risk Matrix). The actions required for approval for each level of inherent risk are mandatory.
Inherent Risk Level Details of Process Action Required / Approval When light machining with material clamped down or held in a vice and when the table is supported by the table support. When tightening the vice or clamping work, care needs to be taken to avoid injuring hands. Document controls in planning When trimming with light cuts as the clapper documents and/or complete box correctly drops 20 mm prior to this Plant Risk Assessment. Medium commencement of each stroke and clears 10mm at the end of each stroke. Consider obtaining parental When entrapment of fingers, clothing and long permission. hair can be minimised. When ejected metal particles can be minimised. Eye protection is always vital. When inexperienced students can be appropriately supervised at all times.
When heavy machining with the material A Plant Risk Assessment is correctly clamped down or held in a vice and required to be completed. when the table supported by the table support. Principal or Classified Officer When machining harder metals. (i.e. DP, HOD, HOC, HOSES) High When applying heavier cuts on any metal as approval prior to conducting the clapper box correctly drops 20 mm prior to this activity is required. commencement of each stroke and clears Obtaining parental permission 10mm at the end of each stroke. is recommended.
DETE - Organisational Health Unit Issued: November, 2013. V3 Page 1 of 8 Uncontrolled when printed Minimum Standards
Minimum Qualifications and Experience Listed below are the general “Minimum” recommendations for the management of this Plant / Equipment. Indicate the minimum management controls.
Registered teachers with experience, ability and competency in the safe use of this plant / equipment (indicate one or more of the following):
Specific knowledge of the safe and correct use of this plant / equipment;
Experience (i.e. previous involvement and familiarity) in the safe use of this plant / equipment;
Demonstrated expertise, ability and competency with this plant / equipment;
Documented qualifications relating to the use of this plant / equipment ( e.g. in a staff profile ) OR An adult staff member or leader, other than a registered teacher, with :
Expertise in the safe and correct use of this plant / equipment; Documented qualifications that demonstrate experience, ability and competency in the safe use of this plant / equipment.
Will any ITD staff require initial and/or ongoing training for the safe use of this plant / equipment ? If yes, give details:
Will students be operating this plant / equipment ?
If yes, state how student use of this plant / equipment will be managed ( e.g. Workshop Safety Induction ) Give details:
Further information if required:
Minimum Control Requirements
Supporting documentation available in the school on this plant / equipment includes: Operators Manual Safe Operating Procedures – (SOP) Equipment Maintenance Records – (EMR)
A process for recording student safety induction ( link to example )
A process for recording staff training & experience – e.g. ITD Staff Profile ( link to example )
All guards are in place & in good working order for this plant / equipment
Safe Working Zones are defined for this plant / equipment (e.g. yellow lines and / or appropriate signage) Suitable personal protective equipment (PPE) is available to be used by all operators This plant / equipment complies with relevant safety standards
Further information if required:
DETE - Organisational Health Unit Issued: November, 2013. V3 Page 2 of 8 Uncontrolled when printed Hazards and Control Measures
Listed below are indicative hazards/risks and suggested control measures. They are by no means exhaustive lists. Add details of any other hazards/risks or additional controls you intend to implement. Indicate the Control Measures adopted. Detail their implementation and any additional controls required.
Details of how this will Hazards/Risks Hierarchy of Recommended Yes No be implemented Control Measures ( and any additional controls )
Exposure to Rotating 1. Where possible, potentially hazardous or Moving Parts: plant, machinery and processes, including Entanglement & shaping machines, are substituted or Entrapment replaced with less hazardous alternatives. Could hair, clothing, ties, 2. All necessary shaping machine guards & jewellery or other materials safety devices are in place protecting become entangled with workers from all moving parts. moving parts of plant or materials in motion? 3. Micro switches are fitted that cut off power Striking when covers or guards are opened. Could anyone be struck by 4. Stroke Adjustment is always checked moving objects such as the before winding the cutting tool closer to the workpiece being ejected, or by work or engaging the clutch. the unexpected or uncontrolled movement of the 5. “Lock Out” or warning “Danger” tags are plant or workpiece? affixed to all shaping machines under repair or maintenance preventing workers Crushing & Pinching from using the equipment. Could anyone be crushed or pinched due to falling, 6. Staff & student training is provided to uncontrolled or unexpected minimise exposure to these hazards. movement of plant or its load 7. Safe operating procedures (SOP’s) for all tipping or rolling over, or shaping machines are available & clearly contact with moving parts displayed. during testing, inspection or maintenance? 8. “Safe Working Zones” around all shaping Shearing machines are clearly defined by yellow safety lines – (or similar). Can body parts be cut off between two parts of the 9. Emphasis is placed on the requirement for plant, or between a part of the plant operators to remove all jewellery, plant & the workpiece or tuck in loose clothing & tie back long hair. structure? Cutting, Stabbing 10. All appropriate and approved & Puncturing personal protective equipment (PPE) is used where required. Can anyone be cut, stabbed or punctured by coming into contact with moving plant or parts, or objects such as ejected workpiece or waste?
Slips, Trips, Falls & 1. Slip resistant flooring is encouraged. Abrasions: Regular checks are made for unsafe wear & damage. Inspections are made for any Can anyone using the plant or power leads or coolant hoses, etc. in the vicinity of the plant, slip, trip or fall due to the working 2. Procedures are in place for the disposal of environment or other factors? all waste materials around the shaping e.g. Poor housekeeping, dust machine. on floors, slippery or uneven 3. Staff training is provided to minimise work surfaces, power cables exposure to these hazards. across work areas causing injuries & abrasions?
DETE - Organisational Health Unit Issued: November, 2013. V3 Page 3 of 8 Uncontrolled when printed Details of how this will Hazards/Risks Hierarchy of Recommended Yes No be implemented Control Measures ( and any additional controls )
Environmental: 1. Shaping machines are regularly inspected & maintained to help minimise the risk of Noise exposures to these hazards. Is it likely that the normal 2. All shaping machine maintenance is operation of this plant will documented in a register - (EMR’s). produce excessive noise levels? 3. Exposure to noisy ITD workshop Dust, Fumes & environments is monitored & evaluated Vapours regularly for all workers. Is it likely there will be airborne 4. Engineering controls (or physical changes) dust particles, toxic fumes or such as mandatory machinery guarding or volatile vapours produced & any protective safety screens & enclosures therefore be present in the are in place in all workspaces & all in good workspace? working condition.
Lighting 5. Staff & student training is provided to Is there insufficient lighting to minimise exposure to these hazards. operate this plant in a safe Good lighting is provided to all workspaces manner? Is there a possible 6. strobe lighting effect caused & this is maintained on a regular basis. by faulty fluorescent tubes in Fluorescent tubes are checked & replaced the workspace? as required. 7. All appropriate and approved personal protective equipment (PPE) is used where required.
Electrical: 1. All shaping machines have a wall or machine mounted isolating switch that Can the operator be injured by disconnects all motive power. electrical shock due to 2. All shaping machines are fitted with a working near or contacting Direct on Line (DOL) Start/Stop switch - with damaged or poorly (Red & Green buttons). maintained live electrical conductors such as power 3. Emergency stop buttons are mounted outlets, extension leads, prominently where necessary. safety switches, starters & 4. “Lock Out” or warning “Danger” tags are isolators or casual water on affixed to all shaping machines under the floor near plant & repair or maintenance preventing workers machinery? from using the equipment.
5. Visually checks are made of all electrical switches, plugs & power leads, etc.
6. Electrical safety inspections, testing & tagging, etc. are completed regularly as per guidelines for all shaping machines.
7. Electrical maintenance on all plant & equipment, including shaping machines, is documented in EMR’s.
DETE - Organisational Health Unit Issued: November, 2013. V3 Page 4 of 8 Uncontrolled when printed Details of how this will Hazards/Risks Hierarchy of Recommended Yes No be implemented Control Measures ( and any additional controls )
Exposure: 1. All shaping machines are regularly maintained to help minimise the risk of Friction exposures to these hazards. 2. All shaping machine maintenance is Is the plant likely to generate documented in a register - (EMR’s). heat by friction? Could the plant operator accidentally 3. Any hazardous waste materials or toxic come into contact with moving dusts & fumes resulting from this metal materials or machinery machining process are monitored and components resulting in managed. friction burns to the skin, particularly hands? 4. Staff & student training is provided to minimise exposure to these hazards. Hazardous Substances 5. “Safe Working Zones” around all shaping machines are clearly defined by yellow Is it likely that the plant safety lines – (or similar) operator or others nearby in the workspace could be 6. All appropriate and approved personal exposed to hazardous or toxic protective equipment (PPE) is used where chemicals such as oils, required. hydraulic fluids, greases, coolants, volatile vapours, fumes or airborne toxic wood dust particulates?
1. Where possible, shaping machines & work Ergonomics & Manual Handling: adjacent benches are planned & adjusted to a comfortable work height thus minimizing any unsafe or excessively Can the plant be safely strenuous manual tasks. operated, in a suitable location, providing clear & 2. Sufficient workspace is provided in all unobstructed access? practical classrooms to help ensure Poorly designed work stations unobstructed, safe operation. often necessitate teachers & 3. “Safe Working Zones” are clearly defined students performing manual around all fixed plant including shaping tasks involving heavy lifting & machines. Floors are free of excessive lowering, pushing, pulling or waste materials & other extraneous carrying, etc. Such tasks then objects. contribute to a range of musculoskeletal sprains & 4. Staff training is provided with regard to strains for workers. manual handling techniques & procedures to minimise exposure to these hazards.
Explosion & Fire: 1. Fire extinguishers of the correct type are readily available in all workspaces & As a consequence of using positioned near exit doorways. this particular item of plant & Staff training is provided regarding equipment, could anyone be 2. injured by the release of procedures for the correct & appropriate stored energy triggered by use of fire safety equipment. volatile, explosive substances 3. Exits from buildings & other work areas are such as stored gasses, defined & access to them kept clear of vapours or liquids? obstructions.
4. Safety signage is posted clearly denoting the location of all fire safety items and emergence exits.
DETE - Organisational Health Unit Issued: November, 2013. V3 Page 5 of 8 Uncontrolled when printed Additional Control Measures Other Hazards/Risks These would relate to the specific student needs, locations and conditions in which you are conducting your activity.
Approval
Submitted by: Date:
Approved as submitted. Approved with the following condition(s):
Not Approved for the following reason(s):
By: Designation:
Signed: Date:
ITD staff members involved in the use of this risk assessment & the associated plant & equipment:
Signature: ……………………………….. Date:
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Signature: ……………………………….. Date:
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DETE - Organisational Health Unit Issued: November, 2013. V3 Page 6 of 8 Uncontrolled when printed DETE - Organisational Health Unit Issued: November, 2013. V3 Page 7 of 8 Uncontrolled when printed Monitoring and Review This Plant & Equipment Risk Assessment is to be monitored and reviewed annually for a further four (4) years
Review 1: Yes No
Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?
Are Minimum Standards and Recommended Control Measures unchanged over 12 months ? ITD staffing details at this school have remained unchanged over the past 12 months ?
If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)
Reviewed by: Designation: Signed: Review Date :
Review 2: Yes No
Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?
Are Minimum Standards and Recommended Control Measures unchanged over 12 months ? ITD staffing details at this school have remained unchanged over the past 12 months ?
If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)
Reviewed by: Designation: Signed: Review Date :
Review 3: Yes No
Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?
Are Minimum Standards and Recommended Control Measures unchanged over 12 months ? ITD staffing details at this school have remained unchanged over the past 12 months ?
If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)
Reviewed by: Designation: Signed: Review Date :
Review 4: Yes No
Are allocated risk levels and “Actions Required” unchanged over the past 12 months ?
Are Minimum Standards and Recommended Control Measures unchanged over 12 months ? ITD staffing details at this school have remained unchanged over the past 12 months ?
If the responses are “NO” for any question, record current details here, and list all staff changes (with signatures)
Reviewed by: Designation: Signed: Review Date :
DETE - Organisational Health Unit Issued: June, 2013. V3 Page 8 of 8 Uncontrolled when printed