Safety Measures For Power Press

KOMORI

Safety Measures for Power Press

Mark (Masahiro) [email protected]

Komori Safety Device Lab. Co. Ltd.

1, Overview of press accident and measures in Japan

2, How to prevent press accident

3, Proposal to Malaysia

KOMORI

Masahiro Komori ( Nickname MARK), born 1950

Working for Komori Safety Device Laboratory Co., Ltd. As a Chairman

Public Service :

Chairman of Press Inspectors Association (JISHA)

Executive of Japan Forming Machinery Association

Executive of Press Safety Device Association

Lecturer for JISHA Press education and Others

Overseas experience

Short term Expert to Singapore National Productivity Board

Short term Expert to Singapore Ministry of Labor

Seminar at Singapore, Korea, Taiwan, and others

Technical corporation with Italy, Germany and U.S.A.

SELF INTRODUCTION

KOMORI

KOMORI SAFETY DEVICE LAB. CO., LTD.Company Established 1955, Apr. Started as Metal Stamping Factory Changed to Safety Device Manufacturer from 1951

COMPANY OUTLINE

Supported in 3 basic business

1, Safety DeviceLight Curtain, Barrier Guard,Pull-out, Area Sensor etc.Other Machinery Safety productsAnd Consulting Machine Safety System

2, Compulsory Inspection Safety Education

3, Other Accessories Brake Stop Timer,Tonnage monitor, Forming Analysis,Production Engineering

URL : http://www.komorisafety.co.jpe-mail : [email protected]

Singapore agent : J V Engineering +65-6267-8901

KOMORI1, Overview of press accident and measures in Japan

13000

12000

11000

10000

9000

8000

7000

6000

5000

4000

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042 43 44 45 45 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 H1 2 3 4 5 6 7 8

Phase 1: 1955 to 1971Phase 2: 1972 to 1990 Phase 3; 1991 to Present situation

①

②

③

2010： 559

12,000→7,000

7,000→4,000

3,000→559

7000

4000

12000

1972 1990

KOMORI

Phase 1 : 1955 to 1971　　 After WW2, Every Press Machine must install Safety Device

Phase 2 : 1972 to 1990 　　 Safety and Health Law established Inherent Safety Measure ①Top Priority :No Hand in the Die ②Construction Code Press Machine and Safety Device ③Compulsory Inspection System established

Phase 3 : 1991 to 2010　　 ①Adopt ISO standards ②Risk Assessment and OSHMS ③New regulation and construction code

Preventive 　 measures by Phase

12,000→7,000

7,000→4,000

3,000→559

2010 :559

KOMORI

1, Size of Company : Below 30 workers (70%)

2, Numbers of Presses : Below 30 Machines (90%)3, Foot pedal or switch operation (80% of Full Revolution)

4, Size of Press Machine : Below 100 tons (80%) 5, Type of Clutch : Part Revolution 45%, Full Revolution 33% Hydraulic 7%, Press Brake 7%5, Increasing Fatal Accidents at Big scale Press Machine6, Still insufficient Safety Device, Small Protective Height7, Many Human Error Reasons8, Standard Operation 80%, Tool and Die Operation 20%　

Trend of Press Accident

Remark : Many Press Accidents Happens , following Small and Medium size factory, Below 30 presses equipped, Below 1000kN

KOMORIPrevention of Dangers Due to a Press MachinePrevention of Dangers Due to a Press MachineOrdinance Article 131Ordinance Article 131

TOP Priority : No Hand in the Die

All the operation must use Safety Enclosure,Guard

Safety Die (Die equipped with safety Guard)

Small stroke Press (Below 6 mm stroke length)

Automatic Feeding Press (with Safety Guard)

Second Priority : Hand in the Die with Safety System Press Machine

Safety Power Press Authorized M.H.L.W

Interlock Guard , Two Hand Push button, Light Curtain, PSDI,

Third Priority : Hand in the Die and Use Proper Safety Device

Interlock Guard, Two hand push switch, Light curtain, Pullout

KOMORIComprehensive Measures for Press Machine Accident Prevention (Guideline 1998)

Main Points

(1) Promoting the safety of press machinery

(2) Full implementation of press machine safety devices etc.

(3) Effective measures in accordance with the situation at workplaces where press machine is installed

Promoting Press Machine Safety• Steps to secure the safety of press machine• Appropriate selection and management of safety device• Switching from foot-pedal to both-hand push button operation• Improving the safety of press machine operation• Using proper metal dies• Securing safety at the manufacturing and installation stages

KOMORI2, How to prevent press accident

• HardwareHardware

1,Danger of the Press machine

2,Compulsorily Inspection

• SoftwareSoftware

1, Operation Chief system

2, Operator Safety education

3, From the Top Management

KOMORIHardwareHardware1,Danger of the Press machine

• Two types of Stopping MechanismNo stopping Mechanism Full revolution Positive Clutch⇒

Most Dangerous but simple and cheap MachineEmergency stop Mechanism Part revolution and Hydraulic⇒

Possible to use sensor device

Full revolution Positive clutch Part revolution Friction clutch

KOMORI• Operate with Safety Measure 1,No Hand in the Die

Safety Enclosure, Automatic Feeding, Hand tool e.t.c. 2,Hand in the Die Select proper Safety Device

Safety Enclosure, Automatic Feeding, Hand tool e.t.c

Machine Guarding

KOMORI

• Interlock Guard

• Two Hand Control

• Light Curtain• PSDI 　 (Presence Sensing Device Initiation)

• Laser Beam (for Pressbrake)

• Pull Out

Kinds　 of Safety Device

KOMORI2, Compulsorily Inspection

• Annual Inspection by Qualified Expert Inspection Agency Inside company Inspector

• Monthly and Daily InspectionOperatorMaintenance by Operation Chief

• Use ChecklistAnnual InspectionMonthly and Daily Inspection

KOMORI

SoftwareSoftware

1, Operation Chief system Every 5 Presses

2, Operator Safety educationNew Operator’s

education

3, From the Top Management

KOMORINew Regulative Approach in Japan

Japanese MHDL released New regulation and construction code at 2011.

As follows:1, To protect all operator from Machine with stroke edge

Automatic feeding requires new protective way.Many accidents happens and some fatal accidents.Tarret Puch press ,Moving bolster,

2, Pressbrake Safety DevicesIntroduced from EU way

3, Guard Area must be considered not only opeator, but die setter and some other members4, New Construction code for Press machine and Safety device

KOMORI3, Proposal to Malaysia

• Case Study

• Proper Timing Inspection

• Safety Operation

• Safety Training

• Legal Enforcement

• Risk Assessment ⇒ 　 OSHMS