Work Equipment and Machinery

In this blog article, Mike Ellerby deals with some of the questions concerning employers about vast subject of Work Equipment and Machinery. Consideration is given to the issues of machinery guarding, operator checks, worker training and maintenance of the work equipment.

Q – What is Work Equipment?

The term ‘Work equipment’ applies to almost any equipment used by a worker at work including (but not limited to):

• workplace machinery (such as drilling machines, circular saws, lathes, photocopiers, mowing machines, power presses, etc.)
• vehicles (including cars, dumpers trucks, lorries, fork lift and reach trucks, etc.)
• hand tools (such as: chisels, files, screwdrivers, knives, hand saws and meat cleavers
• lifting equipment (such as hoists, lift trucks, (mobile) elevating work platforms, vehicle hoists (Hiab, etc.), lifts, stair lifts, etc.
• other equipment (such as: access equipment, ladders pressure cleaners, etc.)

Q – What is meant by the hierarchy of machinery guarding?

Suitable measures must be taken to prevent access to the dangerous moving parts of machinery. The Provision and Use of Work Equipment Regulations 1998 create a hierarchy that must be considered when deciding on machinery guarding.

The hierarchy of control measures is:

• Fixed guards
• Other guards or protection devices
• Protection appliances, such as jigs, holders, and supervision
• Information, instruction, training and supervision

Each measure must be supplied to the extent that it is practicable (i.e. technically feasible) before relying on a protection measure that is lower in the hierarchy.

This means that we should use fixed guards wherever possible. These fixed guards must be properly fastened in place with screws or nuts and bolts that need tools to remove them (not wing nuts). If employees need regular access to certain parts of the machine and a fixed guard is not possible, then an interlocked guard may be used for those parts. This must be designed to ensure that the machine cannot start before the guard is closed and that the equipment will stop if the guard is opened whilst it is in operation.

Alternatively:

• light guards
• photoelectric systems
• automatic guards

may be used instead of fixed or interlocked guards.

Such guards must be checked and designed to ensure that they are convenient to use and are not easy to defeat.

Consideration needs to be given to the materials of construction for any guards – solid metal guards are easy to make, but do not allow operators to see through them, while plastic guards allow vision, but may not be robust enough and will scratch and become opaque with time.

Mesh guards must not allow access to the dangerous parts of the equipment and consideration must be given to stopping the release of materials, including dusts and (for example) metal working fluids. In cases where guards cannot give full protection, the use of jigs, holders, push sticks, etc. should be considered to move the work piece.

Q – Are there any special considerations for maintenance of work equipment?

Work equipment must be maintained in a safe and efficient condition. This means that to control the risk you should carry out regular maintenance and preventive checks, as well as inspections where there is a significant risk.

It should be noted, however, that many accidents occur during maintenance operations. This means that suitable control measures (or precautions) need to be introduced to ensure safety during maintenance.

Several issues need to be considered:

• Isolation of power. Where possible, carry out maintenance with the power to the equipment switched off and isolated. Consideration should be given to stored power, such as pneumatics, hydraulics and stored electrical power (capacitors, etc.). Where appropriate, remove keys and/or fuses from equipment.
• Bring the equipment to a stop before maintenance work commences.
• Lock off isolation points. Isolate equipment and pipelines containing pressurised fluid, gas, steam or hazardous material. Isolation valves should be locked off and the system depressurised where possible, particularly if access to dangerous parts will be needed;
• Access. Ensure that a safe and secure means of access (and egress) is provided that is suitable for the nature, duration and frequency of the maintenance work to be undertaken.
• Falling parts. Give consideration to falling parts and objects on the equipment.
• Mobile Plant and Equipment. Ensure that the engine of is switched off and made safe and, where appropriate, put the gearbox in neutral, apply the brake and/or chock the wheels;
• Fire/explosion. Consider the need to clean or purge vessels that (may) have contained flammable solids, liquids, gases or dusts. Ensure that these vessels are checked thoroughly before any hot work is carried out.
• Procedures. Maintenance tasks may need to have suitable procedures devised to ensure the safety of those carrying out the work. This could involve a written safe system of work or the use of a Permit to Work System.

Q – What sort of checks can operators be expected to carry out on work equipment?

The use of work equipment should be restricted to competent persons. As a consequence of this, there are many checks that the operator should be able to carry out to ensure that a piece of equipment is, and remains, safe in use.

Operator checks may include:

• Checks on the operation of the emergency stop controls
• Checks on the machinery guards (to ensure that they are available, in position and correctly adjusted.
• Checks on the operation of safety devices, such as interlocks or light guards.
• Checks on the safety features of mobile work equipment (including brakes, horn, warning devices, lights, etc.)
• Checks on the functioning of ancillary equipment, such as dust extraction equipment. This may involve ensuring that the extraction is on and appears to be working correctly (such as a manometer check).

It is recommended that such checks are carried out regularly (the frequency to be determined by risk assessment) and that records are maintained.

Q – What sort of training should workers be given and who needs to be trained?

The use of work equipment should be restricted to competent persons. Training should ensure that workers can use and maintain work equipment safely.

This will mean providing them with:

• the information that they need (such as: manufacturer’s instructions or operating manuals) and
• appropriate training courses.

Having provided training, it is essential to check that the training has been assimilated and that it has been understood.

Training should include

• detail of the risks that the use of the equipment may present (to the user and to others) and
• the control measures to be used to ensure that the risks are avoided (where reasonably practicable to do so) or controlled adequately.

Training may be needed for:

• existing workers
• inexperienced workers
• new workers
• temporary staff, particularly if they have to use powered machinery.

The greater the level of danger, the greater the need for training and the better training needs to be. It is recommended that for some high-risk work (such as driving fork-lift trucks, using a chainsaw or operating a crane) that training is carried out by specialist instructors.