1. Shipping and Receiving
Background
The shipping and receiving area is where raw material, such as raw steel bar and metal plate to make bumpers. It receives all materials used by different departments in the manufacturing processes, as well as plant supplies and equipment. The personnel in the shipping and receiving area send accept and record the movement of raw materials and other supplies to and from the company.
Findings
The shipping and receiving area is manned by a number of personnel that are responsible for:
- Determining method of shipment and preparing shipping documents
- Assembling containers and crates, packaging and preparing identifying information and instructions for shipping
- Overseeing loading and unloading of raw materials and other supplies
- Inspecting incoming materials and supplies
- Operating forklift, hand truck or other equipments in loading and unloading of raw materials and other supplies
- Implementing safety in storage and shipping
The health and safety hazards that are associated with shipping and receiving are also identified. These hazards are as follows:
Chemical
The danger of being exposed to chemicals and other hazardous materials cannot be discounted in this line of work. Shippers and receivers may be exposed to toxic materials. Usage of equipments can also expose the workers to hazards. For example, battery powered equipments can produce battery acids that is dangerous to the skin and the eyes. Fuel powered vehicles exposes workers to gases that have health effects.
Ergonomic
The shippers and receivers may also experience ergonomic-related health and safety hazards that are caused by prolong standing, lifting, working in awkward positions, repetitive manual operations, and pushing and pulling objects.
Physical
The shippers and receivers work long hours outdoors where they can be exposed to extreme temperatures. There is a danger that workers may be exposed to ultraviolet radiation.
Safety
One of the safety concerns is the use of equipments such as carts, hand trucks, trolleys, forklifts and others. When these equipments are not used properly and are not in good condition, it can lead to accidents.
Recommendations
Make sure that each equipment has safe work procedures and precautions. It is also important the employees have personal protective equipment such as eye protection and gloves. In order to prevent accidents and other health hazards it is important to:
- Make sure that every employee knows the correct procedures in handling materials and equipments
- Be aware of awkward positions or repetition that the job may entail and make sure that workers take frequent breaks in order to avoid health and safety hazards
- Always use correct personal protective equipment
- Keep the work areas clean
- Have a safety procedure in handling and storing chemicals and materials
- Make sure that the equipments and tools are in good working condition before using
2. Warehouse
Background
The warehouse stores bulk bumper assembly materials for bumper manufacturing. Materials are stored on concrete floors and three levels of shelving. The warehouse receives manufacturing materials from the shipping and receiving department. The warehouse also distributes manufacturing materials from its bulk stock directly to the rest of the plant, as well as ancillary materials.
Findings
The warehouse is important in sending, receiving, storing and circulation of bulk bumper assembly materials and other manufacturing materials throughout the facility. With so much activities in the warehouse, it becomes a place where accidents occur most of the time.
Hazards in the Warehouse
One of the most common hazard groups in the warehouse is slips, trips and falls. When workers carry and move materials on different levels, and on different types of floor surfaces, they might lose their balance and stumble. Another worry is that workers mat get hit by falling objects. Items that are not carefully stacked on floors, shelves, and other surfaces can fall on a worker’s head, body or foot. Warehouse equipments can also cause hazards. If not properly used and not in good working condition, conveyors, forklift trucks and hand trucks can cause accidents. Workers can also experience ergonomic-related hazards such as back injuries from improper lifting and carrying of materials. Equipments in loading, packing and packing must also be used properly.
Material Handling Hazards
Housekeeping is very important in the warehouse. Material handling is a major source of hazard. The material handling hazards are the following:
- Forklift trucks can tip over if not driven slowly and carefully. Materials can slip if they are not placed properly on the forks.
- Hand trucks, dollies and other material equipment can be hazardous if used by untrained workers.
- Manual lifting is a major potential source of back pains. If the workers do not lift materials easily they may have back injuries or they may trip or bump into things.
Recommendations
Below are some recommendations that may help in the prevention of health and safety hazards in the warehouse.
Material Handling
The first thing to do in safe material handling is checking the load and deciding on how to move it. It is also important that the workers are well trained in operating the equipments in materials handling.
Safe Lifting
The best way to prevent injuries in manually handling and carrying materials is by doing it properly. Safe lifting is the key. To ensure safety in manual lifting one must:
- Stand close to the load and squat down to it
- Grip the load firmly with hands and bring it close to the body
- Lift the head and shoulders first, then let the legs push up the body up
- Be sure that one can see over the load
- Take small steps and do not twist
- In unloading, face the spot and lower the load slowly, bending the knees
- Place the load on the edge of the surface then slide the load back
Housekeeping
Good housekeeping allows the workers to function much more effectively and productively in a warehouse. It also helps the workers identify and remove hazards that can lead to slips, trips, falls, and a variety of other accidents.
3. Assembly
Background
The assembly area is where the actual construction of the truck bumpers takes place. Mild steel is used in the form of metal blank and metal bar and pressed into the main bumper section, or cut and formed into metal brackets, and then assembled into a completed bumper.
Findings
Steel planks are placed into a metal press machine under high hydraulic pressure. This is pressed and shaped into a final bumper form. Finished bumpers move along a conveyor belt to a different area of the shop where a welding area is in operation. Welding involves the use of oxy-fuel gas systems to generate high temperatures. Using the oxy-fuel gas also enriches the atmosphere with oxygen and emits fumes. Welding processes may result in the following injuries or harm to health:
o Electric shock through contact with electrically live parts
o Radiation burns to the eyes or body due to welding arc
o Body burns to unprotected skin from hot metal surfaces, metal fragments and sparks
o Illness following inhalation of fumes
o Fire and explosion caused by the arc, flame, sparks or spatter, or by electrical faults in combination with flammable materials, gases or liquids
Hazards and Possible Harmful Effect
- Mechanical Equipments – hands and fingers may be cut, sprained, dislocated, broken, crushed, or severed. Eyes injuries can occur.
- Welding – electric shock, burns to eyes or body from the welding arc or hot metal surfaces. Inhalation of fumes can result in nausea or serious illness.
- Hazardous Substances – irritation or burning of skin, or if fumes are breathed in; Some chemicals, metal fumes and gases are flammable and exposure to flame can result in a fire or explosion.
- Noise – permanent hearing loss
- Manual Handling – musculoskeletal disorders including sprains and strains
Recommendations
Eye Protection
Using eye protection in the assembly area is the most important safety rule of all. Metal chips and shavings can fly at great speeds and distances and cause serious eye injury.
Safety Rules for Machine Tools
- Do not operate any machine tool without proper lighting
- Never attempt to operate any machine tool until you fully understand how it works and know how to stop it quickly
- Always stop the machine before cleaning it or taking measurements of the workpiece
- Always wear safety glasses or goggles while operating machine tools
4. Grinding and Inspection
Background
The assembled bumpers next transferred into the grinding and inspection shop. Two teams of two employees take one bumper at a time and place it on a flat metal table. The bumper is placed in metal clamps, which hold it securely to the table. The finished bumper is then placed on a steel roll conveyor and moved to another table where it will be inspected.
Common Equipments: Angle Grinders
These are hand held tools with a rotating disc used for grinding metal. They are designed for grinding and not as a cutting tool. They can be dangerous if not kept in good order and if not used safely. If the disk is damaged or over tightened it can shatter or explode, sending pieces flying across the workshop.
Common Injuries and Hazards
The most common injuries from mechanical equipment are to hands and fingers, which may be cut, sprained, dislocated, broken, crushed or severed by machinery or tools. These injuries can cause lengthy periods of time off work and sometimes they can result in permanent disability. Eye injuries caused by mechanical equipment accidents include being hit by an object, small particles such as metal shavings; heat, radiation; falls; trips and slips. Most angel grinder injures are from metal particles lodging in the operator’s eye. The most serious injuries are from kickback where the disc is thrust violently away from the object it is grinding and back towards the operator.
Credit:ivythesis.typepad.com
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