PART 10 - HOW YOU CONTROL PROCESS RISKS WHICH APPLY ACROSS THE TEXTILES INDUSTRIES

1. Autoclaves

1.1 Autoclave Apparatus

a. Are safety devices, valves, gauges, controls, alarms etc simple to read and understand?

b. Are they easily accessible to operatives of all sizes?

c. Where machines have automatic door opening are alarms and trip devices fitted?

d. Is there a suitable safety valve fitted?

e. Is there a correct steam pressure gauge?

f. Is the maximum safe working pressure clearly marked?

g. Is a suitable reducing valve or similar automatic device fitted?

h. Is there an isolating valve in the inlet line for each machine?

i. For multi and single bolted door machines is a device fitted to break the seal?

j. For quick opening type doors are the required devices provided?

1.2 Autoclave Procedures

a. Has the autoclave been examined according to a scheme of examination in the last 14 months?

b. Is a permit system available and used for entering vessels for any reason?

c. Are records kept of weekly checks on locks, guards, gauges and safety devices?

d. Is the autoclave checked by a competent person at specified intervals and do the managers see the report?

e. Are operators fully instructed and properly trained in correct operating procedures, purpose and function of the controls and safety devices?

2 Baling Machines

a. Is mechanical equipment used to handle bales?

b. Is all bale handling equipment (including bale elevating systems) adequately guarded and regularly maintained?

c. Are horizontal bale presses fitted with door interlocks of a suitable design and integrity?

d. On other bale packing machines are all conveyor nip points guarded and trap entanglement areas guarded or safe by design?

e. Is access to the ram or other moving parts, guarded by fixed guards or interlocked to a suitable standard?

f. Are shearing points guarded or safe by distance?

g. Where swivel boxes are in use is the control a "hold to run" type?

h. Where automatic swivel boxes are in use are trip guards and warning signals in operation?

i. Is working at height accessible by adequate steps and platforms?

j. Are these interlocked where moving parts are accessible?

k. Is there a safe system of work, including isolation, for use when working inside guards, for example during cleaning and maintenance?

l. Are bales stored in a stable manner?

m. Is the storage space reserved for bales of adequate space to allow safe movement of equipment and bales within the area with clear gangways maintained?

n. Is a safe system of work employed for bale handling?

o. Are timber pallets used and are they in good condition?

p. Does the area show evidence of good housekeeping?

q. Is adequate personal protective equipment worn during handling, packing and unpacking of bales?

r. Are there any procedures for stacking and de-stacking of bales?

s. Has training in bale handling and handling equipment been provided?

3. Cloth Finishing and Fabric Coating

3.1 Cloth Finishing and Fabric Coating Machinery

a. Are all drive points, belts and shafts correctly guarded?

b. Are roller intakes on all types of finishing machinery correctly guarded with modern interlocks or trip devices on fast moving equipment?

c. Are braking systems checked on a regular basis?

d. Are suitable safety devices (e.g. rubber needles) provided for feed scouring machines?

e. Are all hot parts/pipes etc guarded or insulated to prevent accidental burns?

f. Are hydro-extractors:

i) Fitted with functioning interlocked lids which lock the lid to prevent access when drum is moving?
ii) Fitted with out of balance detectors and properly anchored to the floor?

g. On stenters:

i) Are traps between chains and sprocket wheels guarded?
ii) Are guards fitted to prevent access to nips between rollers and fabric and rollers?
iii) Are fabric pins guarded in areas of easy employee access?
iv) Are employees prevented from climbing up machines to re-fix fabric back into pins?
v) Are slitting knives provided with effective guarding?
vi) Is explosion relief fitted on direct gas fired stenters?

h. On brushing, raising and cropping machines:

i) Are in-running nips guarded?
ii) are interlocked cover guards incorporating guard locking fitted to all cutter blades?
iii) Where blade sharpening or wire dressing takes place "in situ" are temporary guards and safe systems of work used?
iv) Is LEV fitted to remove dust and are safe cleaning methods used to remove any build up?

i. Are dry cleaning machines and tumble dryers interlocked to prevent entry to clean or remove items whilst they are running?

j. Are operators of dry-cleaning machines trained in operation and routine maintenance such as cleaning traps and the still?

k. Are dry cleaning machines properly maintained and checked for solvent leaks,

l. Are there emergency procedures in place to deal with spillages of drycleaning solvent?

m. Where 'A' Frames are used is a suitable safety device provided for batching units?

n. Where heavy weights are loaded to 'A' Frames are these still moved manually?

o. Where 'A' frames are moved by motorised systems, are brakes and steering devices adequate?

p. Are fixed or interlock guards used in pressurised finishing machines?

3.2 Cloth Finishing and Fabric Coating Procedures

a. Are specific named employees appointed to carry out sharpening work on the blades of cropping and cutting machines?

b. Where operatives need to climb onto machines to make adjustments, feed material or check controls are they trained in correct techniques, use of ladders and steps etc?

c. Are pressure vessels subject to regular inspection by the company maintenance and schemes of examination by an external competent person?

d. Are fault reporting procedures in operation for leaks of steam, solvents and other substance?

e. Where batch carts, 'A' frames etc are moved by manual labour, have measurements been made of the effort required?

f. Are there procedures for maintenance of carts so that they run freely?

g. Are employees involved in lifting, pushing and pulling been trained in these skills and has such training been recorded?

h. Are special permits in use for entering enclosed or confined spaces?

i. On pressurised finishing machines are safety devices checked each day?

4. Dyeing

4.1 Atmospheric Dyeing Machinery

a. On open vessels are valves and other controls located in a safe position (no risks from overflowing or boiling liquor)?

b. Are steam injection nozzles of a noise-reduced design?

c. Are hot parts guarded or lagged?

d. Are buckets with lids in use to prevent spillages?

e. Is adequate drainage provided?

f. Are pits and gullies guarded, fenced and clearly marked?

g. Where liquor preparation plants are in separate rooms are arrangements made for lone worker emergency contact?

h. Where winding on or batching of operations takes place at speed, is access limited?

i. Where 'A' Frames are in use are precautions in place to stop them falling over?

4.2 Screen Printing

a. Are all traps and shearing areas guarded or safe by design?

b. On wide rotary or flat printing machines are platforms or walkways available?

c. During screen preparation where lasers, ultra violet or other special light sources are used, are systems in use to prevent access whilst operations are taking place?

4.3 High Pressure Dyeing Machines

a. Are the recommendations in HSE guidance note PM 4 followed?

b. Is a suitable safety valve fitted?

c. Is there a correct pressure gauge fitted?

d. Is the safe working pressure and corresponding temperature clearly marked?

e. Is the supply pipe fitted with a suitable reducing valve or similar automatic device?

f. Are thermal locks fitted and maintained regularly both on main and sample machine?

g. If hydrogen peroxide is in use have extra precautions been taken?

h. Are safety devices and gauges simple to read and understand, and easily accessible?

i. Where machines are inter-connected is a non-return valve fitted in each line?

j. For multi-bolted door machines is a device fitted to break the seal?

k. For quick opening doors are the necessary safety devices fitted?

l. Are hot parts guarded or lagged?

m. Is ventilation sufficient to remove steam quickly and effectively?

n. Where winching, winding or automatic feeds are in operation, is an emergency stop button fitted to allow instant access for employees?

o. Is access to equipment and machinery well maintained and regularly cleaned e.g. steps, platforms, rails, gantries?

4.4 Dyeing Procedures

a. Where employees are handling hazardous chemicals and dyestuffs are they training and competent and is such training documented?

b. Are special permits used where employee's need to enter enclosed or confined spaces?

c. Where employees are lifting or pulling heavy wet weights have measurements of effort been made?

d. Are employees trained in good lifting and handling techniques and is this recorded?

e. Where hazardous substances are pumped into tanks from delivery vehicles are Safe Systems of Work in operation?

f. When such operations are taking place is a competent person overseeing the delivery?

g. Has a major spillage emergency plan been prepared and are all employees trained and aware?

h. Where hazardous substances are moved in buckets, are colour-coded systems in operations to assist in preventing mistakes?

i. Is there a safe sampling procedure?

j. Is a documented Safe System available and used for clearing blockages?

k. Is a permit system available and used for entering vessels to clean and carry out maintenance duties?

l. Are formal fault reporting systems in use to cover leaks of steam or other substances?

m. Where batching, winding and automatic feeds are in use, is a documented Safe System followed which reduces the likelihood of entanglement?

n. Are emergency showers available and tested weekly?

o. Are safe systems of work in place to protect employees from trapped pockets of superheated water?

p. Are high pressure dyeing machines subject to a written scheme of examination?

q. Are operators trained and instructed in correct operating procedures and the purpose and function of controls and safety devices?

4.5 Dyestuff handling

General principles

a. Has consideration been given to the feasibility of handling dyes in dust-free reduced-dust forms?

b. Is handling of dry powder dyes reduced by for example the use of pre-weighed quantities, dissolving under local exhaust ventilation (lev) directly after weighing, or using water soluble bags?

c. Is effective lev used for handling dyestuffs?

d. Is good housekeeping applied to keep areas free from contamination?

e. Is suitable personal protective equipment such as coveralls, gloves, aprons, and respirators provided and worn where necessary?

Reactive dyes

a. Are all reactive dyes treated as potential respiratory sensitisors?

b. Does anyone using or working near reactive dyes have symptoms of respiratory sensitisation, e.g. itchy/swollen eyes, runny nose or wheeziness/breathlessness?

b. Does anyone using or working near reactive dyes have symptoms of skin sensitisation, e.g. red rash on body but particularly on hands?

c. Are workers trained to recognise and report symptoms?

d. Do reactive dyes have to be used - could a less hazardous dye be used?

e. If use of a reactive dye is essential, is the least hazardous form used, e.g. in liquid or low-dust pellet form?

f. Is the whole of the process involving reactive dyes, not just weighing out, covered by local exhaust ventilation?

g. If PPE is worn as an additional protection, do you have arrangements for cleaning it and changing filters?

h. Do you have a health surveillance programme in place for people exposed to reactive dyes? Does it include maintenance workers who may also be exposed?

j. Do you keep health records for employees who work with reactive dyes?

5. Fabric Cutting

5.1 Fabric Cutting Machinery

a. Are danger areas clearly marked, and access restricted by barriers, especially at cutting tables?

b. On motorised and automatic cutting tables are warning signals fitted to indicate when blade is in motion?

c. Where lay up machines are in use, are trip guards or other devices in operation to prevent access?

d. Is the machine fitted with automatic adjustable guards to fully cover the exposed part of the cutting blade?

e. Are electrical conductors in good condition?

f. Are 5 finger chain mail gloves available for use which fit all operators?

5.2 Fabric Cutting Procedures

a. Is there a regular check on the condition of the light, guard, and table fittings?

b. Has a formal PPE assessment been carried out for all operations?

c. Are 5 finger chain mail gloves worn at all times during cutting work?

d. Are only fully trained operatives allowed to work band knives?

e. Are trainees fully supervised by experienced cutters at all times when under training?

f. Are operators' standards checked against the published operating practice on a regular basis?

g. Are breaches of standard operating practice and working rules identified and corrected by the use of disciplinary procedures?

h. Do operators know the fault reporting procedures?

i. Where band knives are in use, are specific named and trained competent persons listed?

j. Is an effective cleaning system in operation that prevents build up of fluff, fly and off cuts, thus reducing fire, health & trip hazards?

k. Is a documented Safe System available for changing and disposing of cutter blades?

l. Are such operations restricted to named and trained and competent employees?

m. Do maintenance personnel wear chain mail gloves when handling blades?

n. Are old blades disposed of in a safe manner which precludes their use as DIY handknives etc.?

o. Where awkward or heavy items have to be manually lifted onto cutting tables have alternative methods been investigated?

p. Are employees involved in lifting awkward or heavy items, e.g. piece of cloth, band knives been trained in correct lifting and handling techniques?

6. Sewing

6.1 Sewing Machines

a. Are robust needle guards fitted and used?

b. Has a risk assessment been carried out on the provision of eye guards?

c. Is the lighting adequate and does the light remain on when the motor is switched off e.g. for safe threading?

d. Are vee belt and pulley drives guarded?

e. Does seating allow for good posture and ease of movement?

f. Is electrical wiring supplied from overhead or otherwise to avoid cables on floors?

g. Where automated making up machines are in use, has special consideration been given to additional guarding requirements?

6.2 Sewing Procedures

a. Is a monitoring system in force to inspect guards, needles and work areas on a weekly basis?

b. Have new employees been instructed on the reasons for guards and the importance of correct fitting?

c. Are guards adjusted for each individual operator's finger size?

d. Have employees been given information on good posture and correct seating/table adjustment?

e. Does the safe systems specifically mention removing feet from treadle when threading and changing needles?

f. Are employees following a system of switching off power when carrying out adjustments and needle changing?