FEATURE HEALTH & SAFETY


IMPORTANCE OF MAINTAINING workplace health and safety


Maintenance is crucial to ensure a safe working environment. Davina Reilly, HSEQ manager at AVT Technologies discusses how accidents can be caused by equipment failure


W


hile effective maintenance is essential in ensuring the reliability


of machinery it is crucial in minimising workplace hazards and providing a safe working environment. The consequences of equipment failure can range from inconvenient downtime to injury and loss of life as when machinery becomes unreliable or fails during service, the potential for accidents is increased. Poor maintenance practices can lead to serious injury or loss of life while accidents can be caused by equipment failure. The responsibility of a manufacturer to


ensure the safety of its employees, contractors and visitors is both moral and legal. Studies have shown that facilities that rank highly in terms of reliability have superior safety records but as maintenance can represent a significant investment for manufacturers it is often the first area where budget cuts are made. When the costs of emergency maintenance as well as compensation or fines are considered, cutting corners proves to be a false economy as implementing a properly planned reliability programme can help avert safety issues while reducing costs in the long term. Several European Commission


directives exist to identify employers’ obligations in terms of workplace safety. Council Directive 89/654/EEC in particular states that any machinery faults which pose a risk to the health and safety of employees should be rectified as quickly as possible and that where safety devices are installed to prevent injury or risk to health, they are to be regularly checked and maintained. There are specific directives covering employers’ responsibility to protect their workers from the risks associated with exposure to excessive vibration, noise dangerous substances; effective maintenance is vital to prevent pipework or machinery vibration and the release of hazardous chemicals. RIDDOR (Reporting of Injuries, Diseases


and Dangerous Occurrences Regulations) statistics reveal that in 2012/13 20 manufacturing employees were killed at work while more than 13,000 injuries were reported, accounting for one in five


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maintain equipment above head height as head injuries are likely to cause more serious consequences than injury to the foot or lower limb. Where chemicals are allowed to leak into the atmosphere due to improper sealing or faulty pumps and valves a variety of risks exist from chemical burns to the inhalation of fumes and accidential ignition of flammable liquids could be catastrophic. Poorly maintained electrical grounding


systems are liable to lead to electrocutions as are faulty electrical installations including cabling and plug sockets. Electrical equipment and connections can be negatively affected by damage to surrounding equipment including leaking lubricant or water which should be prevented. Of course, maintenance work itself can


of all reported fatalities and injuries. The main causes of major injuries in the manufacturing sector were slips and falls on the ground or from a height, accounting for 40% of reports. A common yet preventable cause of


trips in a production facility is leakage or spillage of lubricating fluid. While some spills may be human error, slips may be reduced by ensuring valves are fully functioning, blockages identified and dealt with swiftly and that autolube devices are not overfilling. Damage to any kind of moving or


rotating equipment can result in a lubricant leak and the potential dangers are not confined to slips and falls. In addition to the risk of contamination to products leaking gear oil can cause friction and overheating, leading to equipment failure or even fire. Around 15% of serious injuries in the


industry were attributed to individuals being struck by moving or falling objects. In factories where lifting equipment is necessary it is important to regularly inspect and maintain lifting mechanisms including chains which may have become corroded or dirty to prevent sudden drops. It is particularly prudent to


The responsibility of a manufacturer to ensure the safety of its


employees, contractors and visitors is both moral and legal


pose a safety risk. Often performed under time pressures, it requires workers to be in direct contact with machinery leading to risk of injury. The likelihood of accessing confined spaces and complex machinery heightens the risk and steps should always be taken to protect workers with suitable PPE and controls put in place to prevent the accidental restart of machinery during repair. Condition based, preventative


maintenance is vital in averting preventable injuries; there are several methods available to identify potentially hazardous damage or failure before they pose a risk to employees. Thermal and vibration monitoring can indicate friction, bearing failure or misalignment while ultrasound and lubrication monitoring can be used for early leak detection and contamination prevention. AVT provides consultancy, services and


training to manufacturers in all sectors; improving plant reliability, safety, cost and regulatory compliance. The company specialises in condition based maintenance; deploying techniques in maintenance management, lubrication, vibration analysis, thermal imaging, oil analysis and ultrasound.


AVT Technology T: 0161 486 3737 www.avtreliability.co.uk Enter 311


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