FACULTY OF ENGINEERING AND THE BUILT ENVIRONMENT (FEBE)

Department of Mechanical and Mechatronic Engineering

Subjects:
MECHANICAL MANUFACTURING ENGINEERING (MEM150S)
Manufacturing Engineering 1(MMG150S)

Lecture one

Topic: Safety
Safety doesn’t happen by accident ~Author Unknown

Presented by: V Moni

Topics to be covered on lecture 1

1. Safety

1.1 Safety legislation (OHS Act and Regulations)

1.2 General workshop safety
1.3 Safety measures when using machines and hand tools
1.4 Colour coding
1.5 Fire control and prevention
1.6 Risk control
1.7 First Aid

2. Learning outcomes

Apply the OHS Act broadly to describe health and safety in a workplace.

2.1 Understanding of the act and related regulations

2.2 Cultivate safe working principles
2.3 Promote the use Personal Protective Equipment
Occupational Health
Safety Act
(OHS Act)
of 85 of 1993
Occupational Health Safety Act (OHS ACT) of 85 of 1993: Overview
The purpose of the OHS Act is to provide for the safety and health of persons at work and in connection
with the use of plant and machinery. It further provides for the protection of people other than people at
work from hazards arising out of or in connection with the activities from people at work [ SA Labour
Guide].
Occupation is the profession that you are doing, and currently you are a Mechanical/Mechatronic
Engineering student. As you are in field, you MAY BE affected by injuries and diseases associated with
this occupation, hence we are dealing with OHS Act.

OHS Act contains 50 sections in total

Employer/ Employees/
Institution students
Definitions (±60)
OHS sec 17 Health and
OHS sec 16.1 CEO/VC &
Duty to inform Safety Representatives
Deans are 16.2
employees:

Work safely

Training
OHS sec 18 Functions
OHS sec 7 Health & Health and Safety Reps
Policies
Safety Policy
Procedures, etc

OHS sec 8.1 Duties of OHS sec 19 Health and

employer (HOD) to employees Safety Committees
OHS ACT
85 of 1993

OHS sec 24 OHS sec 20 Health and

Reporting of incidents Safety Committees duties
Duty to report
to employer:

Hazards

Injuries OHS sec 14 Duties of

OHS sec 37 Acts/ omissions
employees/students
by employees/mandataries
Procedures

Policies, etc.

OHS sec 13 Duties

OHS sec 38 Offences, inform/report
penalties & special orders OHS sec 43 Regulations (21)
Significance of definitions
Definitions of an act help the reader (employer, employees/students, contractors, unions, health and
safety representatives, health, and safety committees) to interpret that part of legislation clearly,
correctly, and accurately.

Term Definition
INCIDENT when a person dies or becomes unconscious or suffers the loss of a limb or
part of a limb or becomes ill or is likely to die or suffer permanent physical
defect.
Accident* This term is not defined in OHS Act definitions but defined in elaborating the
term “incident”.
BIOLOGICAL is a scheduled collection and analysis of body fluid, tissues, exhaled air to
MONITORING detect and quantify the exposure to or absorption of any substance or
organism by a person.
BUILDING is any structure attached to the soil; part thereof which is in the process of
being built and structure not attached to the soil.
PREMISES includes any building, vehicle, vessel, train or aircraft.

WORK PLACE means any premises or place where a person performs work in the course of
his employment
SAFE free from any hazard
HAZARD is a source of or exposure to danger
DANGER is anything which may cause injury or damage to persons or property.
RISK is the probability that injury or damage will occur;
HEALTHY is being free from illness or injury related work
ORGANISM is any biological entity which is capable of causing illness to persons.
HEALTH AND is any equipment designed or its component, made available or installed in the
SAFETY interest of the health or safety of any person.
EQUIPMENT
HEALTH AND is a person designated to maintain and monitor health and safety standard in
SAFETY the work place.
REPRESENTATIVE
MACHINERY means any article or combination of components assembled and which is used
for converting any form of energy to perform work.

MAJOR HAZARD is permanent or temporary installation where a stored/processed

INSTALLATION substance has a potential to cause major incident.
MAJOR an occurrence of catastrophic proportions, resulting from the use of
INCIDENT plant or machinery.
PLANT includes fixtures, fittings, implements, equipment, tools and appliances, and
anything which is used for any purpose in connection with such plant
MANDATARY Refers to an agent, a contractor, or a sub-contractor for work (people working
where they are not permanently employed).
PROPERLY USED means used with reasonable care, and with due regard to any information and
instruction supplied by the manufacturer.
 USER means any person who uses plant or machinery for his own benefit or who
has the right of control over the use of plant or machinery but does not
include a lessor.
identify hazards associated with your actions.
REASONABLY evaluate the risk and eliminate or mitigate
PRACTICABLE available knowledge in dealing with risk
weigh the costs of risk with mitigating actions
REGULATION means rules that are the extension of the legislation to give a meaningful
As in OHS sec 43 interpretation of the law and offenders are penalized.

OHS Act section 13: Duty to inform

Without derogating from any specific duty imposed on an employer by this Act, every employer shall–
(a) every employee to be made conversant with the hazards to his health and safety attached to
any work which he must perform.
(b) inform the health and safety representatives concerned of inspections, investigations or formal
inquiries.
(c) inform a health and safety representative as soon as reasonably practicable of the occurrence
of an incident in the workplace or section of the workplace for which such representative has
been designated.
OHS Act section 14: Duties of employees (students included)
OHS Act section 14(1) states that every employee shall-

(a) Take reasonable care for his own health and safety as well as those who may be affected by his
actions.
(b) Carry out any lawful order given to him and shall obey the safety rules and procedures laid down
by his employer or by anyone authorized thereto by his employer, in accordance with or for the
proper observance of the provisions of the Act or the regulations or in the interest of safety.
(c) Where a situation that is unsafe at or near his workplace comes to his attention, as soon as
possible report such situation to a safety representative or to his employer.
(d) Report any incident, which has affected his health or safety or has caused injury to himself, to his
employer or H & S not later than the end of the shift in which the incident occurred

OHS Act section 15: Duty not to interfere with, damage or misuse things
No person shall intentionally or recklessly interfere with,
damage or misuse anything which is provided in the
interest of health or safety.
OHS Act section 17: Health and Safety Representatives
Employees are empowered to nominate from their
colleagues who are willing to stand for H & S role
and only then the employer can appoint in writing.

If the parties do not

agree within 14 days on an arbitrator, the employer shall give on an
arbitrator, the employer shall give written notice to the Industrial Court
whose decision shall be final.
Appointment of H & S representative are done when there are more
than 20 employees,
In workplaces with fewer than 20 employees, the inspector may direct
the employer in writing to designate as many H & S as he deems necessary.
For shops and offices be at least one representative for every 100 employees or part thereof; employees
In case of other workplaces at least one representative for every 50 employees or part thereof
employees or part thereof.
Requirements to be a H&S rep: -
✓ persons employed in a full-time employed
✓ must be acquainted with conditions and activities of the workplace
✓ Trained in health and safety
OHS Act section 18: Functions Health and Safety Representatives (H & S rep)
A health and safety representative may perform the following functions in respect of the
workplace or section of the workplace for which he has been designated, namely –
(a) review the effectiveness of health and safety measures;
(b) identify potential hazards and potential major incidents at the workplace;
(c) in collaboration with his employer, examine the causes of incidents at the workplace;
(d) investigate complaints by any employee relating to that employee’s health or safety at work;
(e) make representations to the employer or a health and safety committee.
(f) make representations to the employer on general matters affecting the health or safety of the
employees at the workplace;
(g) inspect the workplace, health and safety equipment at that workplace with a view to the health
and safety of employees.
(h) participate in consultations with inspectors at the workplace and accompany inspectors on
inspections of the workplace;
(i) receive information from inspectors as contemplated in section 36; and
(j) in his capacity as a health and safety representative attend meetings of the health and safety
committee of which he is a member, in connection with any of the above functions.
OHS Act section 19: Health and Safety Committees

An employer shall in respect of each workplace where two or more health and safety
representatives have been designated, establish one or more health and safety committees

1) persons must be designated in writing

2) the committee shall hold meetings as often as may be necessary, but at least once every three
months
3) A health and safety committee may co-opt one or more persons by reason of his or their particular
knowledge of health or safety matters as an advisory member of the committee.
OHS Act section 20: Functions of health and safety committees

A health and safety committee –

1) make recommendations to the employer

2) shall discuss any incident at the workplace

3) shall keep record of each recommendation made to any employer

4) or a member thereof shall not incur any civil liability by reason if he failed to do anything
which is required to do in terms of this Act.

OHS Act section 24: Reporting of incidents

OHS Act section 24(1) states that every employer shall report to the inspector regarding certain
incidents occurring at work or use of plant or machinery in which:

(a) Reportable incidents to the inspector

i. any person dies,
ii. becomes unconscious,
iii. suffers the loss of a limb or part of a limb or
iv. injured or becomes ill to such a degree to be unable to
work for at least 14 days;

(b) A major incident occurred; or the health or safety of any person was endangered and where
i. a dangerous substance was spilled;
ii. the uncontrolled release of any substance;
iii. machinery failed resulting in uncontrolled moving objects; or
iv. machinery ran out of control.

OHS Act Section 37: Acts/ omissions by employees/mandataries

OHS Act Section 37 explains that employer can be held liable should any of the mandataries act
carelessly within the employer’s premises unless the employer has taken all necessary steps to
prevent such act.
OHS section 43: Regulations (21 in total)
OHS Act Section 43 states that the Minister may make regulations as to any matter which in terms of the
OHS Act shall or may be prescribed.

Regulation’s overview:

1. Health related regulations (4): Asbestos Regulations; Hazardous Biological Agent Regulations;
Regulations for Hazardous Chemical Agents; Lead Regulations & Noise Induced Hearing Loss
Regulations)

2. General regulations (5): Environmental Regulations for Workplaces; Facilities Regulations;

General Administrative Regulations; General Administrative Regulations & General Safety
Regulations

3. Electrical regulations (2): Electrical Installation Regulations & Electrical Machinery

Regulations

4. Machinery regulations (4): Driven Machinery Regulations; General Machinery Regulations;

Lift, Escalator and Passenger Conveyor Regulations & Pressure Equipment Regulations

5. Specific regulations (6): Regulations concerning the Certificate of Competency; Construction

Regulations; Diving Regulations Explosives Regulations; Major Hazard Installation Regulations;
Regulations on Hazardous Work by Children in SA & Ergonomics Regulations

Regulations, scopes of application and covered topics in the regulation

Health related Scope of application Regulations

regulations
Asbestos (1) Subject to subregulation 3. Identification of asbestos in place
Regulations, (2), these Regulations apply to
2021 every employer and self- 4. Inventory of asbestos in place
employed person who may 5. Asbestos risk assessment
expose any person to asbestos
dust at the workplace. 6. Asbestos management
(2) Regulations 5(2), 8(1), 7. Information, instruction and training
9(4), 12(3)(d), 16(4), 17 and
8. Duties of persons who might be exposed
23 do not apply to self-
employed persons. 9. Control of exposure to asbestos
10. Notification of asbestos work
11. Duties of asbestos client for asbestos work
12. Duties of registered asbestos contractor for asbestos
work
 13. Duties of approved inspection authority for asbestos
work
14. Disputes
15. Plan of work
16. Air monitoring
17. Medical surveillance
18. Regulated asbestos area
19. Personal protective equipment and facilities
20. Labeling and signage
21. Disposal of asbestos
22. Asbestos clearance certificate
23. Records
24. Prohibition
Hazardous These regulations shall apply 3. Classification of biological agents
Biological Agent to every employer and self-
Regulations,2001 employed person at a 4. Information and training
workplace where: 5. Duties of persons who might be exposed to HBA
a) HBA is deliberately 6. Risk assessment by employer or self-employed
produced, processed, used, person
handled, stored or transported;
or 7. Monitoring exposure at workplace
b) an incident, for which an 8. Medical surveillance
indicative list is given in
9. Records
Annexure A to this
Regulation occurs that does 10. Control of exposure to HBA
not involve a deliberate
intention to work with a HBA 11. Personal protective equipment and facilities
but may result in persons 12. Maintenance of control measures, equipment and
being exposed to HBA in the facilities
performance of his or her
work. 13. Prohibitions
14. Labeling, packaging, transporting and storage
15. Special measures for health and veterinary isolation
facilities
16. Special measures for laboratories, animal rooms
and industrial processes
17. Disposal of HBA
Regulations for These regulations apply to an 3. Information, instruction and training
Hazardous employer or a self-employed
Chemical person who carries out work 4. Duties of persons who may be exposed to hazardous
Agents, 2021 at a chemical agents

workplace which may expose 5. Assessment of exposure

any person to an HCA at the 6. Air monitoring
workplace; and a 7. Medical surveillance
manufacturer, importer,
supplier or retailer of an HCA 8. Respirator zone
that is intended for use at a
9. Records
workplace.
10. Control of exposure to hazardous chemical agents
11. Personal protective equipment and facilities
12. Maintenance of control measures
13. Prohibitions
14. Classification of hazardous chemical agents
14A. Safety data sheet
14B. Labelling of hazardous chemical agents
14C. Packaging of hazardous chemical agents
14D. Disclosure of ingredient identity
15. Disposal of hazardous chemical agents
16. Offences and penalties
Lead These regulations shall apply 3. Exposure to airborne lead
Regulations, to every employer and self-
2001 employed person at a 4. Information and training
workplace where lead is 5. Duties of persons who may be exposed
produced, processed, used,
handled or stored in a form in 6. Assessment of potential exposure
which it can be inhaled,
7. Air monitoring
ingested or absorbed by any
person in that workplace. 8. Medical surveillance
9. Respirator zone
10. Records
11. Control of exposure to lead
12. Personal protective equipment and facilities
13. Cleanliness of premises and plant
14. Maintenance of control measures
 15. Prohibitions
16. Labeling, packaging, transportation and storage
17. Disposal of lead waste
Noise Induced These regulations shall apply 3. Exposure to noise
Hearing Loss to an employer or self-
Regulations, employed person who, at any 4. Information and training
2003 workplace under his or her 5. Duties of persons who may be exposed to noise
control, carries out work that
may expose any person at that 6. Assessment of potential noise exposure
workplace to noise at or above
7. Noise monitoring
the noise-rating limit.
8. Medical surveillance
9. Noise zone
10. Control of noise exposure
11. Record
12. Hearing protective equipment
13. Maintenance of control measures
General Scope of application Regulations
regulations
Environmental These regulations in general 2. Thermal requirements
Regulations for refers to the physical
Workplaces, conditions of the work 3. Lighting
1987 environment 4. Windows
5. Ventilation
6. Housekeeping
8. Precautions against flooding
9. Fire precautions and means of egress
Facilities These regulations in general 2. Sanitation
Regulations, refers to sanitary facilities,
1990 toilets, bathrooms, showers, 3. Facilities for safekeeping
dining facilities, drinking 4. Change-rooms
water, certain prohibitions as
well as the conditions of these 5. Dining-rooms
facilities that forms part of the
6. Prohibition
work environment
7. Drinking water
8. Seats
9. Condition of room and facilities
General These regulations in general 2. Access to premises
Administrative refers to sanitary facilities,
Regulations, toilets, bathrooms, showers, 3. Exemption
2003 dining facilities, drinking 4. Copy of the Act
water, certain prohibitions as
well as the conditions of these 5. Health and safety committee
facilities that forms part of the
6. Negotiations and consultations before designation of
work environment
health and safety representatives
7. Designation of health and safety representatives
8. Reporting of incidents and occupational diseases
9. Recording and investigation of incidents
10. Witness at inquiry
11. Returns
General Safety These regulations refer to 2. Personal protective equipment and facilities
Regulations, general health and safety
1986 matters or requirements set 2A. Intoxication
for the work environment 2B. Display of substituted notices and signs
2C. Admittance of persons
3. First aid, emergency equipment, and procedures
4. Use and storage of flammable liquids
5. Work in confined spaces
6. Work in elevated positions
7. Working in danger of engulfment
8. Stacking of articles
9. Welding, flame cutting, soldering and similar
operations
10. Operating trains
13A. Ladders
13B. Ramps
Electrical Scope of application Regulations
regulations
Electrical These Regulations shall apply 2. Responsibility for electrical installations
Installation to every user or lesser of an
Regulations, electrical installation as well 3. Approved inspection authorities for electrical
2009 as Approved inspection installations
authorities. 4. Functions of approved inspection authorities for
electrical installations
 5. Design and construction
6. Electrical contractor
7. Certificate of compliance
8. Commencement and permission to connect
installation work
9. Issuing of certificate of compliance
10. Disputes
11. Application for registration as a registered person
12. Withdrawal of registration and approval
13. Substitution of lost, damaged or destroyed
certificate
14. Fees payable
Electrical These Regulations shall apply 2. Safety equipment
Machinery to every employer, employee
Regulations, and self-employed person 3. Work on disconnected electrical machinery
who carries out work whilst 4. Notices
1988 using electrical machinery at a
workplace. 5. Switch and transformer premises
6. Electrical control gear
7. Switchboards
8. Electrical machinery in hazardous locations
9. Portable electric tools
10. Portable electric lights
11. Electric fences
12. Inspection Authorities
13. Earthing
14. Supports
15. Clearances of power lines
16. Protective Supports
17. Insulators and Fittings
18. Conductors
19. Overhead service connections and overhead service
conductors
20. Crossings
 21. Bare conductors on premises
22. Schemes to be submitted to the Postmaster General
Machinery Scope of application Regulations
regulations
Driven These Regulations shall apply 2. Scope of Application
Machinery to every employer, employee
Regulations, and self-employed person 3.Revolving Machinery
2015 who carries out work whilst 4. Circular Saws
using driven machinery at a
workplace 5. Band Saws and Band Knives
6. Wood Planing Machines
7. Wood Moulding and Mortising Machines
8. Sanding Machines
9. Grinding Machines
10. Shears, Guillotines, Presses
11. Slitting Machines
12. Mixing, Agitating and Similar Machines
13. Rolls and Calenders
14. Washing Machines, Centrifugal Extractors, Etc.
15. Air Compressors
16. Refrigeration and Air Conditioning Installations
17. Transportation Plants
18. Lifting machines, hand powered lifting devices and
lifting tackle
19. Approval and registration of lifting machinery
entity
20. Approval and registration of training providers
General These Regulations shall apply 2. Supervision of machinery
Machinery to every employer, employee
Regulations, and self-employed person 3. Safeguarding of machinery
1988 who carries out work whilst 4. Operation of machinery
using machinery at a
workplace. 5. Working on moving or electrically alive machinery
6. Devices to start and stop machinery
7. Reporting of incidents in connection with machinery
8. Notifiable substances
 9. Information regarding regulations
Lift, Escalator These Regulations shall apply 2. Permission to install and use
and Passenger to every employer and self-
Conveyor employed who installs, uses 3. Design and Construction
Regulations, and have lifts, escalators and 4. Particulars of lifts, escalators or passenger conveyors
1994 passenger conveyors in their
workplace. 5. Inspections and Tests
6. Maintenance
7. Record keeping
Pressure These regulations shall apply 3. General Requirements
Equipment to the design, manufacture,
Regulations, operation, repair, 4. Duties of manufactures
2009 modification, maintenance, 5. Duties of importers and sellers
inspection and testing of
pressure equipment with a 6. Duties of users
design pressure equal to or
7. Approved and duties of approved inspections
greater than 50 kPa, in terms
authorities.
of the relevant health and
safety standard incorporated 8. Registration of steam generator
into these Regulations.
9. Pressure equipment marking
10. Pressure safety accessories
11. Inspection and test
12. Risk based inspection
13. Repairs and modifications
14. Records
15. Access
16. Door interlocks
17. Gas reticulation equipment and systems
18. Transportable gas containers
19. Fire extinguishers
Specific Scope of application Regulations
regulations
Regulations Certificate of Competency: A 2. Issue of Certificates
concerning the certificate of competency as a
Certificate of mechanical or electrical 3. Suspension or cancellation of Certificates
Competency, engineer. Certificate will be 4. Substitution of lost, damaged or destroyed
1990 issued by Chief Inspector with Certificates
the recommendations of the
Commission of Examiners 5. Commission of Examiners
 6. Qualifying examination
7. Acceptance as candidate
Construction These regulations apply to all 3. Application for Construction Work Permit
Regulations, persons involved in
2014 construction work. 4. Application for a permit to perform construction
Regulations 3 and 5 are not work.
applicable where the 5. Duties of client
construction work carried out
is in relation to a single storey 6. Duties of Designer
dwelling for a client who
7. Duties of Principal Contractor and Contractor
intends to reside in such
dwelling upon completion 8. Management and Supervision of Construction Work
thereof.
9. Risk Assessment for Construction Work
10. Fall Protection
11. Structures
12. Temporary works
13. Excavation
14. Demolition work
15. Tunneling
16. Scaffolding
17. Suspended platforms
18. Rope Access Work
19. Material hoists
20. Bulk mixing plant
21. Explosive Actuated Fastening Device
22. Cranes
23. Construction vehicles and mobile plant
24. Electrical installations and machinery on
construction sites
25. Use and temporary storage of flammable liquids on
construction sites
26. Water environments
27. Housekeeping and general safeguarding on
construction sites
28. Stacking and storage on construction sites
 29. Fire precautions on construction sites
30. Construction employees’ facilities
31. Construction health and safety technical committees
32. Approved Inspection Authorities
Diving These regulations basically 3. Training of divers
Regulations, shall apply to all diving
2001 operations and all persons 4. Designated medical practitioners, medical
engaged in diving operations examinations and medical certificates of fitness
in the Republic of South 5. Diving supervisor
Africa or the territorial waters
thereof. 6. Operations manual
7. Control of diving operations
8. Decompression
9. Compression chambers and bells
10. Plant and equipment
11. Council for Diving
12. Rules, syllabi and examinations
13. Registration as learner diver
14. Registration as a diver
15. Registration as a diving supervisor
16. Applications
17. Withdrawal of certificate of registration
18. Fees payable
Explosives These regulations shall apply 3. Classification of explosives for manufacturing
Regulations, to any employer, self-
2003 employed person or user who 4. Licensing of explosives workplaces
operates an explosives 5. Non-detonatable and non-sensitised explosives
workplace for the purpose of
manufacturing, testing, 6. Danger area
storing or using explosives.
7. Danger buildings
8. Safeguarding of explosives workplace
9. Design, construction and manufacture
10. Importation of explosives
11. Safety distances
12. Supervision of explosives workplace
 13. Safe handling of explosives
14. Emergencies
15. Incidents
16. Closure of explosives workplaces
17. National Explosives Council
18. Approved inspection authorities
19. Standards of training
Major Hazard These regulations shall apply 3. Notification of Installation
Installation to employers, self employed
Regulations, persons and users, who have 4. Temporary Installations
1993 on their premises, either 5. Risk assessment
permanently or temporarily, a
major hazard installation or a 6. On-site Emergency Plan
quantity of a substance which
7. Reporting of risk and emergency occurrences
may pose a risk that could
affect the health and safety of 8. General Duties of Suppliers
employees and the public.
9. General duties of local government
10. Closure
Regulations on These regulations is there to 3. Risk assessment
Hazardous prohibit or place conditions
Work by upon the work that may be 4. Respiratory hazards
Children in SA, required, expected or 5. Work in elevated position
2010 permitted to be performed by
child workers, and which is 6. Lifting of heavy weights
not prohibited in terms of any
7. Work in cold environment
law.
8. Work in hot environment
9. Work in noisy environment
10. Power tools and cutting or grinding equipment
11. Report to department of social development
Ergonomics These Regulations will focus 3. Information and Training
Regulations, on a programme approach to
2019 manage physical and 4. Duties of those who may be at Risk of Exposure to
cognitive ergonomics in the Ergonomic Risk Factors
workplace. 5. Duties of Designers, Manufacturers and Suppliers
6. Ergonomic Risk Assessment
These regulations shall apply 7. Risk Control
to:
8. Medical Surveillance
(a) an employer or a self- 9. Maintenance of Controls
employed person who carries
out work at a workplace 10. Record
which may expose any person 11. Ergonomics' Health and Safety Technical
to physical or cognitive Committee
ergonomic risk factors in that
workplace; and 12. Offensives and Penalties

(b) a person, who designs,

manufactures, erects, installs
or supplies machinery,
equipment or articles for use
at work
 General
Workshop
Safety
General workshop safety
Accidents do not just happen, but they are caused because of failure to follow the needed safety
precautions and safety rules.

Five types of common accidents

1. Near Accident -An accident with no damage or injury is called near accident.

2. Trivial - An accident with very less damage is called trivial.

3. Minor Accident -It is an accident with damage and injury more than trivial.

4. Serious Accident -An accident with heavy damage and lot of injury

5. Fatal -It is an accident with very heavy damage with loss of lives.

All accidents should be reported and investigated irrespective of the type.

Effect of Accidents

(A) Effect on the owner of the factory

(i) Direct cost of an accident

1. Cost of the compensation paid to the workers.

2. Cost of the money paid for treatment.
3. Cost of the monetary value of damaged tools, equipment and materials.

(ii) Indirect cost of an accident

1. Cost of the lost time of injured worker.

2. Cost of the time lost by other employees.
3. Cost of the delays in production.
4. Cost of the time lost by supervisors, safety engineers etc.
5. Cost of the lowered production due to substitute worker.

(B) Effect on worker

1. The workers may get temporary or permanent disability.

2. If the worker dies, his family loses the earner and family member and the compensation
never equals to his/her life.
3. Accident also affects the morale of the employees .

(C) Effect on society

Work connected with injuries put a considerable burden on the society as shown below:

1) Cost of accidents is included in the products, so the society must pay more prices.
2) If workers do not come under compensation act, the need for help from society is huge.
3) Loss of production hours may cause fewer products in market.
CAUSES OF ACCIDENTS

The accidents may take place due to human, environmental and mechanical causes.

Accidents due human causes

1. When working unsafe or dangerously

equipment

2. While operating machines without

proper knowledge,

3. While operating or working at unsafe

speed.

4. While working for long duration of

work, shift duty etc.

5. Occur during use of improper tools.

6. While working with ignorance,

nervousness, absent minded

7. Not using personal protective

devices.

8. Poor housekeeping

SABS approved goggles: (Clear, anti-mist, scratch resistant, integral side shield for improved and
greater protection & impact resistant)
SABS approved safety boots:

Cotton overall: (100% cotton

overall is preferred as it retards the
flames than polyester material)
Accidents due to environmental causes

1. Working in abnormal temperature and humidity.

2. Dust fumes and smoke in the working area

3. Inadequate illumination.

4. Improper ventilation in the plant

Accidents due to mechanical causes

1. use of old, poor maintained or unsafe equipment

2. Use of unguarded or improper guarded machines

3. Unsafe processes, unsafe design

4. Improper material handling system plant layout.

5. Not using of safety devices (pins, PPE, etc.)

Other general causes of accidents in workshops are:

1. Because of ignorance to work with equipment, hand tools, cutting tools and machine tools.
2. Extra curiosity to work without knowledge.
3. Due to poor working conditions.
4. Because of speedy work.
5. Improper method to work.
6. Because of lack of discipline.
7. Uninterested in work.
8. Due to over confidence.
9. Bad working environment.
10. Dangerous materials with which to work.
11. Lack of cleanliness.
12. Due to poor planning.

COMMON SOURCES OF ACCIDENTS

1. Revolving parts, e.g., pulley, flywheels, worms, worm wheel, fan, gears, gear trains,
gear wheels etc.
2. Projecting fasteners of revolving parts; like bolts, screws, nuts, key heads, cotters
and pins etc.
 3. Intermittent feed mechanisms, e.g., tool feed of planer; table feed of a shaper, ram
feed of power presses and similar other applications.
4. Revolving shafts, spindles, bars, mandrels, chucks, and tools like drills,
taps, reamers, milling cutters, and boring tool etc.
5. Rotating worms and spirals enclosed in
casings, such as in conveyors and revolving
cutting tool, like milling cutters, circular
saw blade, saw band, circular shears and
grinding wheels, etc.
6. Reciprocating tools and dies of power
presses, spring hammer, drop hammers, and
reciprocating presses, reciprocating knives
and saw blade such bow saw, shearing
and perforating machines and the cutting
and trimming machine and power hacksaws
etc.

7. Moving parts of various machines, like those of printing machines, paper-cutters

and trimmers, etc.
8. Revolving drums and cylinders without casing, such as concrete and other mixers,
tumblers and tumbling barrels, etc.
9. High speed rotating cages such as in hydro-extractors.
10. Revolving weights, such as in hydraulic accumulator or in slotting machines for
counterbalance.

Common safety methods are safety by:

1) construction or design.
2) position.
3) using fixed guards.
4) using interlock guards.
5) using automatic guards.
6) using trip guards.
7) using distance guards.
8) workplace layout and proper working conditions.
9) proper material handling.
10) using personal protective devices.

Types of Safety

The following general types of safety are considered in the workshop

a) Safety of self and others.

 b) Safety of the job.
c) Safety of machines tools.

General safety precautions when working in a workshop

1) Do not leave the machine ON even after the power is OFF and until it has
stopped running completely.
2) Do not oil, clean, adjust or repair any machine while it is running. Stop the
machine and lock the power switch in the OFF position.
3) Do not operate any machine unless authorized to do
so by the authorize
person in the shop.
4) Always check that work and cutting tools on any
machine are clamped securely
before starting.
5) The floor should be kept clean and clear of metal
chips or curls and waste pieces.
6) Scraps and chips or curls may cut through a shoe and
injure the foot put them in a container
7) Defective guards must be replaced or repaired
immediately.
8) Do not operate any machinery when the supervisor or
instructor is not in the shop.
9) All set screws should be of flush or recessed type.
10) Do not try to stop the machine with hands or body.
11) Only trained person should operate machine or switches as far as possible.
12) Always take help for handling long or heavy pieces of material.
13) Always follow safe lifting practices
14) No one should run in the shop.
15) Always keep your body and clothes away from moving machine parts. Get first aid
immediately for any injury.
16) Never talk to anyone while operating the machine, nor allow anyone to come near
you or the machine.
17) Stop the machine before making measurements or adjustments.
18) Never wear necktie, loose sweater, wristwatch, bangles, rings, and loose fitting
clothing while working in workshop.
19) Be thoroughly familiar with the ‘stop’ button and any emergency stop buttons
provided on the machines.
20) Remove burrs, chips, and other unwanted materials as soon as possible. They can
cause serious cuts.
21) Do not leave loose rags on machines.
22) Wash your hands thoroughly after working to remove oils, abrasive particles, cutting
fluid, etc.
23) Report all injuries to the supervisor, howsoever small. Cuts and burns should be
treated immediately.
24) Keep the work area clean.
25) Keep your mind on the job, be alert, and be ready for any emergency.
26) Always work in proper lighting.
27) Do not lean against the machines.
Safety measures when

using machines and

hand tools
Safety measures when using machines and hand tools

Screw Drivers*
1. When working on electrical equipment use only a
screwdriver with an approved handle.
2. Wear goggles when re-sharpening screw-driver tips.
3. Screws with burred heads are dangerous and must be
replaced or the burrs removed with file or an abrasive cloth.
4. Use the correct tip of screw drivers while screwing. Too narrow or too wide tip will damage the work.

Wrenches/Spanners*
1. Do not hammer a wrench to loosen a stubborn fastener unless the tool has been specially designed for
such treatment.
2. Always pull on a wrench. One can have more control
over the tool if pulling instead of pushing and there is less
chance of injury.
3. It is dangerous practice to lengthen the wrench handle
for, additional leverage. Use a larger wrench.
4. Choose a wrench that fit properly. A loose-fitting wrench may slip and round off the corners of the bolt
head and nut.
5. When using wrenches clean grease or oil from the floor in the work area. This will reduce the
possibility of slipping and losing balance.

Hammers*
1) Do not use a hammer unless its head is tightly fixed to the handle.

2) Place the hammer on the bench carefully. A falling

hammer can cause serious foot injuries.

3) Never strike two hammers together. The faces are very

hard, and the blow might cause a chip to break off.

4) Never hold the hammer too far on the handle when striking a blow.

5) Unless the blow is struck squarely, the hammer may glance of the work.
Safety Precautions while Working with Different Cutting Tools

Files*
1. Always use a file card to clean the file. Never use your hand. The chips may penetrate in your hand and
cause a painful infection.
2. Do not use a file without a handle.
3. Short burns formed in filling may cause serious cuts. Always use a
piece of cloth to wipe the surface being field.
4. Files are highly brittle and should never be used as a hammer
otherwise the file will break.
5. Never hammer on a file. It may shatter and chips fly in all directions.

Chisels
1. Always hold the chisel in such a manner that the hammer blow may not miss the chisel to injure your
hand.
2. Edges of metal cut with the chisel are often sharp and cause bad cuts.
3. Flying chips are dangerous. Wear transparent plastic safety goggles
and use a shield, when using a chisel, to protect yourself and those
working near you.
4. Sharp edges of chisels are removed by grinding or filing.
5. Mushroomed head of the chisel should be removed by grinding.

Saw blades*
1. Do not test the sharpness of the blade by a running a finger across the teeth.
2. Do not brush away the chips with your hand.

3. All hard blades can shatter and produce

flying chips. Wear your goggles.
4. Do not be sure that the blade is properly tensioned.
5. Store the saw so that you will not accidentally reach into the teeth when you pick it up.
6. If the blade breaks while you are on cutting stroke, your hand may strike the work/vice and cause an
injury. Therefore, when cutting your pushing stroke should be away from the vice or work.
Reamers

1. Remove all burrs from the reamed holes.

2. Never use your hands to remove chips and cutting fluids from the
reamer and work. Use a piece of cotton waste.

Taps and Dies*

1. Use a brush to clean away chips formed by hand threading. Never use your hand.
2. Always wear goggles if the tap, die or threaded
piece is to be cleaned with compressed air.
3. Tap operator should also be careful that other
person working in the area also wearing goggles.
4. Handle broken taps as you would handle broken
glass. They are sharp edges and are dangerous to
handle.
5. Wash your hands after using cutting fluid. Skin-
rashes caused by some cutting fluids can develop into
a serious skin disorder if they are left on the skin for a
long period.
6. Take care of any cuts immediately. Infection may occur when injuries are not properly treated.
Abrasives*
1. If the lathe is used for polishing make sure that the machine is protected from the abrasive grains that
fall from the polishing wheels during polishing. They can cause rapid wear
of the precision parts.
2. Do not rub fingers or hand across a piece that has just been polished by
abrasive.
3. Cuts and burns should always be treated immediately by using first aid
equipment.
4. Remove all abrasive particles by washing them thoroughly after the polishing operation.
General Safety Precautions while Working in Machine Shop
Safety precautions or guidelines are generally adopted for every metal cutting or machining shop.
Specific safety guidelines for some of the machine process like lathe, drilling, shaping, planning slotting,
grinding, milling, and finishing operations are also described.

1. Use the correct tools and work holding devices recommended for the process.
2. Hold the work piece and tool securely on the machine.
3. Clamp the tool correctly. An overhanging tool may cause catastrophic failure
4. Do not try to remove chips from the machine with your hands.
5. Never use compressed air for cleaning, use a brush.
6. Do not touch a job-piece with bare hands while doing
inspection or removing it from the machine.
7. Operate the machine at recommended operating conditions
based on work material and tool material combination and
other cutting conditions specified.
8. Use recommended coolant depending upon work-tool
material combination.
9. During machining ductile materials, use chip breakers and
chip guards.
10. Re-sharp the tools immediately when it starts producing
rough surfaces on the job-piece or produces chatter.
11. Do not run the machines at speed higher than
recommended. It may produce vibrations and chatter and
damage job-piece, tool, or both.
12. Provide sufficient approach and over travel distances wherever necessary.
13. In case of power failures, switch off the machine and retrieve tool from the workpiece.
14. Wear goggles to protect eyes from flying chips.
15. Machines are governed by the old saying “garbage input, garbage output”. The skill of the operator is
often the limiting factor for the machining operation.
16. Stop machine before attempting to clean, removing tool or workpiece.
General Safety Guidelines while Working on Grinding Machines*
1. Grinding wheels badly worn or cracked should be replaced
2. The grinding wheel should be properly balanced while mounting.
3. Ensure that no combustible or
flammable materials are nearby
that could be ignited by sparks
generated by grinding wheels during grinding operations.
4. Allow the grinding wheel to reach full speed before
stepping it into the grinding position. Faulty wheels usually
break at the start of an operation.
5. Always use the face of the grinding wheel that is meant for
grinding.
6. Slowly move job-pieces across the face of wheel in a uniform manner. This will keep the wheel sound.
7. Grinding wheels should be checked properly timeously for
soundness. Suspend the wheel on a string and tap it. If the wheel
rings, it is probably sound.
8. Do not use a grinding wheel that has been dropped or dealt
with a heavy blow, even if there is no apparent damage.
9. Before using a new grinding wheel, let it run for a few seconds
at the full speed to check and make sure that it is perfectly
balanced.
10. One should not operate the grinding wheel beyond its bursting speed.
11. Follow the manufacturer’s instructions for the correct use of the grinding wheels.
12. Always wear goggles during grinding or allied processes.

Safety Precautions while Working on Lathe Machine*

1. Always be sure that all guards are in place before running the
machine.
2. Always clamp the work and tool properly with correct size of
work and tool holding device.
3. Always keep the machine clear of tools.
4. Machine should be stopped before making measurements or
adjustments.
5. Wear an apron or a properly fitted shop coat. Goggles should also be used.
6. Remove necktie, wristwatch and jewelry while working.
7. Do not operate the lathe until you know the proper operating procedure.
8. Check the work frequently when it is being machined.
9. Check the faceplate or chuck by hand to be sure that there is no danger of the work striking any part of
the lathe.
10. Stop the machine and remove chips with pliers. One should not remove the chips by hand.

Safety Precautions while Working in Casting shop

Similar to other manufacturing processes, the following safety precautions need to be taken
in the casting shop also.

1. Use mask to avoid excessive inhalation

of the dust, which may cause serious
problem to health.
2. Always wear protective clothes to keep
safe from the heat radiating from the
melting process.
3. All foundry men should wear protective
clothes, glasses, shoes, and gloves while
handling molten metal for casting process.
4. Be alert as severe burn injury can result from spillage of the molten metal.
5. Always use proper ventilation to protect from molten metal fumes and gases that evolve from the
mould during pouring.
6. Do not touch hot moulds and castings.
7. Always use earplugs to safeguard against the heavy noise.
8. Always keep clean the work area.

Safety Precautions while Working in Welding shop

Gas welding*
1. Do not use a leaking gas cylinder.
2. Do not handle oxygen cylinders, valves, regulators, hoses, or fittings with oily hands.
 3. Welder should not mix the gases in one cylinder.
4. No one should transfer the gas from one cylinder to another.
5. Clearly label on the cylinders the type of gas in it (i.e., oxygen, acetylene,
etc.).
6. Use welding respirator where the local exhaust
ventilation is not practicable. Insist the safety officer
to provide proper ventilation system.
7. Always avoid skin contact with fluxes, which contain fluorides. If they will
penetrate the skin, they produce severe irritation.
8. No one should weld the parts, which are coated with toxic material such as lead,
cadmium, zinc, mercury, or paint containing toxic before materials. Any such
coatings must be removed prior to welding.
9. Acetylene gas should not be brought in contact with the unalloyed copper
directly (except in torch) which may result in an explosion.

Arc welding*
1. Use protective clothing and eye protection devices while performing arc welding operation, otherwise
radiation from electric arc will damage the retina of eyes. Ensure that other people standing nearby also
uses eye-protection devices from ultraviolet rays.
2. Always use ear protection devices such as muffler because excessive noise caused during the process
of arc welding may cause temporary or permanent hearing loss.
3. Welder should keep clothing and gloves dry.
4. Always keep welding cables free of grease and
oil.
5. Prevent the non-insulated portion of the
electrode holder from touching the welding ground
or job-piece when the current is on.
6. Always keep the body insulated from both the
work and the metal electrode holder.
7. Carry out the welding process by standing on the insulating material like dry wood rather than on a
grounded metal structure.
8. It is easier and safer to establish an arc on a clean surface than on a dirty or rusty one.
9. Always turn the welding machine off when it is not in use.
10. Do not change the polarity switch when the machine is under use. This will burn the surface of the
switch and the resulting arc can cause injury to the welder.
11. Always avoid using electrode holders with defective jaws or poor insulation.
COLOUR CODING
IN HEALTH AND
SAFETY SYSTEM
COLOUR CODING IN HEALTH AND SAFETY SYSTEM
COLOUR CODING

Colour coding is a visual method in health and safety system to caution, notify and guide employees

Colour codes identify:

Dangerous parts of machines

Electrical energized
equipment (Orange)

Safe walk/work areas

(Yelllow)

Danger zones(Red and

white tape)

Contents of pipeline and other features colour codes

Air (Light Blue)

Acids (Dark violet)

Alkalis (Grey)

Oils (Brown)

Gases other than air (Yellow)

Steam (Silver or Aluminium)

Cooling water (Brilliant green)

Portable water (Brown copper)

Fire-fighting (Red)
Different categories of signs
There are five different categories of signs, easily disguished from one another and easily identified by
their shapes and color.

Signage Identification
Warning sign (Triangular and could any
color)

Prohibitory sign (Circle Red & White)

Mandatory/do (Circle Blue & White )

Information General (Square Green &

White)

Information Fire (Square Red and White)

 FIRE
CONTROL
AND
PREVENTION
Fire control and prevention

Steps to be taken for fire prevention

1. Enough fire marshals must be trained in firefighting.
2. Keep all flammable liquids in closed containers or in safe
cylinders.
3. Effective fire warning signals.
4. Emergency doors should be opened towards outside the
building as means of escape in case of fire.
5. Emergence windows used as exit in case of fire should be
easily located marked with red letters.
6. The least flammable liquid that will serve the purpose should be preferred.
7. Provide ventilation to prevent any accumulation of vapors.
8. Provide suitable and adequate means of
fire extinguishment.
9. Fire marshals be familiar with the
location of fire extinguishers and their use.
10. Proper clearance must be there in
between the heating device and any
combustible material.
11. Electrical wiring should be proper
installed.
12. Always prohibit smoking, open flames
and sparks near the flammable materials.
13. A free passageways and easily open-able windows should be always provided.
14. Provide always suitable means for the safe storage and handling of all fuel and acids.
15. Use of flammable liquids should be minimized
16. Safe disposal for the flammable liquid wastes must be provided.
17 . No one is permitted to accumulate fuels or other combustibles near the source of open fire or spark.
ESSENTIAL ELEMENTS OF A FIRE
There are 3 essential elements needed to start a fire or keep it going.

Removing one of these elements will

extinguish the fire.
Once a fire has started, it produces
sufficient heat to maintain its own
combustion reaction and sufficient heat
to spread itself.

MAIN CLASSES OF FIRE AND COMMONLY USED EXTINGUISHERS

A fire extinguisher is a piece of equipment used for putting out fires. Different types of fires need to be
dealt with in different ways.
There are various types of fire extinguishers namely:-
1) Fire hoses with pressurised water
2) Fire hydrants
3) Foam extinguishers for fighting oil and chemical fires
4) Carbon Dioxide extinguishers used on burning gasses and vapours
5) Dry Powder extinguishers used for small fires involving flammable liquids.

Class Fire Type of extinguisher

A Burning of ordinary combustible Water, foam, dry powder,

materials such as wood, cloth, Halotron
paper, grass, tobacco and other
organic materials
B Burning of flammable liquids Ordinary foam, Halotron, CO2,
such as oils, petrol, grease and dry powder, blanket thus
fat, alcohol, benzene, paraffin, excluding oxygen, water must
etc. never be used
C Electrical fires Halotron, carbon dioxide, dry
powder, non-conducting of
electricity and water must not be
used
During fire outbreak given the situation try the following RACE method to help others:
Rescue -try to rescue anyone that might be in danger
Alarm -sound the alarm to notify others
Contain -contain the affected area to prevent the fire from
spreading
Extinguish -use the correct fire-fighting equipment to put out the
fire

In using the fire extinguisher, one may remember the PASS method:
P- Pull. Pull the pin. Hold the fire extinguisher and
release the locking pin.
A- Aim. Aim the nozzle towards the base of the fire.
Spraying the flames will not put out the fire.
S- Squeeze. Squeeze the lever slowly and evenly.
Pushing the lever too fast may shoot the stream from
your and waste the firefighting agent.
S- Sweep. Sweep the nozzle side to side to combat
the fire.
Risk Control
Risk Control
Risk is the probability that injury or damage will occur while hazard is a source of or exposure to
danger.
Risk control is the identification, assessment, and prioritization of risks followed by coordinated and
economical application of resources to minimize, monitor and control the probability and/or impact of
unfortunate events.
Types of common risk
➢ Chemical: This includes but not limited dusts, gases, vapors, fluids which may cause harm
by inhalation, ingestion, absorption through skin
➢ Physical: This includes but not limited noise, vibration, extremes temperatures, heights, and
different pressure zones than normal
➢ Ergonomic: Inadequate working height, body positions; confined areas and repeated motions
➢ Biological: Include insects, moulds, fungi, and bacterial contamination encountered in
workplace.
➢ Psychological: Long hours of work, unenjoyable work atmosphere, fatigue, and high danger
working conditions
Hierarchy of Risk control

Elimination: includes removing the hazard or hazardous work practice from the workplace. (most
effective control measure)

Substitution:
includes substituting
or replacing a hazard
or hazardous work
practice with a less
hazardous one

Engineering
Control: include the
use of engineering
skills to reduce
hazards and may
include modifications
to tools or equipment
e.g. providing
guarding to
machinery/equipment

Administrative Control: includes reducing hazards through written instructions/rules e.g.

introducing improved work practices and may include limiting the amount of time a person is
exposed to a particular hazard

Personal protective equipment: should only be considered when other control measures are not
practicable or to increase protection.
First Aid
When should first aid be provided at the workplace?
OHS section 43: Regulations, paragraph 2(ii) & (iii) states that an employer shall take all reasonable
steps that are necessary under the circumstances, to ensure that persons at work receive prompt first
aid treatment in case of injury or emergency.

The appointment of first aiders

Where more than 5 employees are employed at a workplace, the employer needs to appoint a first
aider.
It is a compulsory for first aiders to be legal appointed by the employer to be readily available during
normal working hours.
The first aider should be in possession of a valid first aid certificate to be appointed.
Shops and offices - one first aider for every 100 employees.
Other workplaces - one first aider for every 20 employees.

What medications can be kept in the First Aid Kits?

No form of oral (pain killers, aspirin, Ibuprofen, decongestants, sinus relief) medications are allowed
to be kept in your First Aid boxes.
Employees are only allowed to bring their medication to work if it is safe to use it in the premises.

How do we control the items used in the kits, and can they be locked?
First aid kits are not allowed to be locked for easy access during emergency.
Soft plastic locking devices can be used for
controlling first aid boxes
An incident report book can be used to not
only monitor injuries on the premises but also
to do stock taking of first box items.

The First aider can monitor any injuries and administer the correct procedure for the incident.
By making a First Aider responsible for their First Aid Kits, this will minimizes the abuse of contents.
First Aid kits should be checked on regular on monthly bases to ensure that items are not expired
finished.
Safety/first aid equipment

Combination of Deluge showers and eye wash

Evacuation stair wheelchair

Stretcher

Medical waste disposal boxes