PART 11 - HOW YOU CONTROL PROCESS RISKS WHICH APPLY LARGELY TO THE WOOL TEXTILES INDUSTRIES

1. Carding

1.1 Carding machinery

a. Are interlocked guards in use with a time limit arrangement to prevent access until movement of dangerous parts has ceased?

b. Where access is available under machines, via pits etc, are interlocked gates fitted?

c. Is a limited inch system available and used only by named personnel with specific training?

d. Can all routine operations be carried out with the machine stopped and isolated?

e. If spare keys are available is there use strictly restricted to non-routine operations, and a register kept for these occasions?

f. Is access to scotch feed rollers and nearby moving parts guarded or safe by design?

g. Are Peralta rollers guarded to prevent easy access and are nip bars fitted?

h. On manually fed machines is access to spiked feed sheets restricted at the hopper?

Condenser Equipment

i. Are condensers guarded to the standard contained in the reference?

j. Are emergency stop wires fitted above the calendar rollers and in dog holes?

k. Where web feeding or other operations need to be carried out with the machines in motion are limited inching devices fitted/

l. Is a limited inching device and is its use restricted to specific named and trained employees.

m. On large and other fast moving cards are full height guards in use to prevent access to all moving parts including condensers, tapes and rubbers?

n. Are such guards fitted with walkways, hand rails and handholds etc?

o. On fast moving machines is there a start up warning signal?

p. Are all cleaning and lap removal operations carried out with the machine stopped or on limited inching?

q. Are radioactive sources monitored and inspected on a regular basis?

1.2 Carding Procedures

a. Is a written permit system in use for cleaning, fettling and repairs with guards open?

b. Do Safe Systems cover the hazards of climbing onto machines?

c. Do Safe Systems include lifting rollers and other heavy objects from machines?

d. When using limited inching mechanisms are documented Safe Systems of Work followed?

e. Whilst the inching mechanism is in use, can operators see all danger points and other operators?

f. Where hazardous operations still need to be carried out e.g. feeding Peralta rollers or getting web to the condenser, is the job limited to specific, designated, trained employees?

g. Are they using a permit system for these operations and have all other alternatives been considered?

2. Garnetting

2.1 Garnetting Machinery

a. Is the machine totally guarded with interlocking timed devices, which prevent any access until all dangerous movement has ceased?

b. Are spare keys available to enable the systems to be by-passed?

c. Is effective Local Exhaust Ventilation provided to remove respirable dust?

d. Is a vacuum cleaning method provided and used for cleaning up dust?

2.2 Garnetting Procedures

a. Is a system in force for checking the function of all isolation, emergency stop and control buttons prior to daily start up?

b. Is a documented system in force for lifting and handling material at all areas?

c. Is a safe system or work permit in force for removing, fitting and maintaining components?

d. Where permits are in use for maintaining are named trained competent persons listed?

e. Are fettling and cleaning operations subject to a documented safe system?

f. When dust bags require emptying do employees wear suitable RPE?

g. Where employees need to climb onto machines or use steps and ladders to get access to equipment are hazard permits in use and are specific employees named and trained for the task?

h. Is there a safe system of work for dealing with fires?

3. Non-woven Felting

3.1 Non-Woven Felting Machinery

a. Are isolation controls, inching buttons and emergency stops all fitted and within easy reach of all sizes of operatives?

b. Are spare keys available that enable access to be made with machinery running?

c. Are cross-lappers correctly guarded or fenced to prevent easy access?

d. Where large rolls of materials are doffed automatically, are warning signals in operation and retaining barriers in place to prevent contact with employees?

e. Are material cutting and trimming devices guarded?

f. Are conveyor systems guarded at access and nip points and do other hazards arise when movement is in reverse?

g. Where employees need to climb onto machines are steps, ladders, platforms substantial and of a safe design?

h. Are spare and replacement cutting and trimming blades stored safely?

i. Are all in-running nips properly guarded to prevent access?

j. Are dust and fume extractor units in operation and recorded inspections made at weekly intervals?

3.2 Non-Woven Felting Procedures

a. Is a system in force for checking the function of all isolation, emergency stop and control buttons prior to daily start up?

b. Is a documented system in force for lifting and handling material at both feed and doff areas?

c. Is a safe system or work permit in force for removing, fitting and sharpening blades?

d. Where permits are in use for blade handling are named trained competent persons listed?

e. Are cleaning operations subject to a documented safe system?

f. Where hot parts, steam, presses are used do all employees follow a documented Safe System for adjustments and valve controls?

g. Where dust and fumes have been measured as a hazard, are documented Safe Systems followed e.g. PPE, vacuum cleaning, extraction units etc?

h. When dust bags requires emptying is a written Safe Systems followed and are employees regularly supervised on this task?

i. Where employees need to climb onto machines or use steps and ladders to get access to equipment (e.g. dust bag collars) safe systems of work followed?

4. Opening

4.2 Opening Machinery

a. Are guards fitted to prevent access moving parts on sides of feed sheets?

b. If manually fed, is a tunnel guard fitted over the feed sheet to prevent access to the feed rollers?

c. Are all other moving/working parts of the machine fully guarded?

d. Is the fan doffer mechanism locked or bolted to prevent access to the fan and motor drive belts?

e. Are adequate interlocking mechanisms fitted?

f. Is it possible to by-pass the interlock with a spare key?

g. On rag pulling machines are swifts, intake rollers and other moving parts guarded to a high
standard?

h. On fleece breakers, are interlock and trip guards used to prevent access or contact with spiked feed sheets and moving parts?

 

4.3 Opening Procedures

a. Where 'Samson' or other fleece opening machines are in use is a documented Safe Systems followed for operating and cleaning?

b. Are isolators and padlocks used when employees have to climb inside chambers/confined spaces to clean or maintain?

c. Is a daily system of checking safety devices in place?

d. Is there a safe system of work for fighting fires inside machinery?

5. Spinning

5.1 Spinning Machines

a. Are all drive parts and shafts guarded or secure by position?

b. Where regular access is required are interlock systems in use?

c. Are rear areas of single sided frames blocked off or fully guarded?

d. Are all brakes working?

e. Are there safe systems of work for cleaning machines?

f. On mule frames are all carriage wheel guards in place?

g. Are isolation devised in use when employees are working inside the carriage?

h. Are all drive mechanisms on mules guarded at the rear to prevent access?

i. On older machines are emergency stop buttons easily accessible to employees at any point on the machine?

j. On high speed rubbing frames are interlocks fitted to prevent access to rubbing aprons?

k. Are limited inch controls fitted to high-speed machines?

5.2 Spinning Procedures

a. Is access to headstock for adjustments and minor repairs limited to trained specific employees who follow a documented Safe System?

b. Are keys for locks kept in the control of a responsible person?

c. Where operators are still picking/piecing ends manually are documented safe systems in use?

d. Are employees complying with instructions prohibiting loose clothing, jewellery and unsecured hair?

e. Are automatic loading and doffing systems operated by a two handed control from a safe position?

f. Are safe systems of work used for removing laps which include the use of safety knives?

g. Are procedures in place for inspecting brakes and reporting defective brakes?

6. Topmaking

6.1 Synthetic fibre and topmaking plant

a. Are moving parts, rollers and coiler heads guarded or safe by position from the feed area?

b. Are interlocks in use on all fallers, squeeze rollers, shear areas and in running nips?

c. Where interlocked hoods need to be opened is an inching system fitted or hold to run control?

d. Is the noil box removable and does this allow access to moving parts?

e. Are two handed controls fitted to bump top presses, alternatively interlocked sliding doors or trip guarded system and are bump top machines guarded at the side and rear?

f. On tow conversion machines are interlocked guards fitted?

g. Is a trip device available to stop the machine if someone becomes entangled in the tow?

h. On stretch breakers does the guarding protect and prevent access from intake through all stages to the final roller set?

i. With automatic can doffers is access to crush or shear points prevented?

6.2 Topmaking Procedures

a. Do documented Safe Systems detail procedure for cleaning, lap removal and minor adjustment?

b. On bump top presses are employees using needles in a safe manner with other employees kept
clear?

c. On tow conversion and stretching machinery are employees aware of entanglement hazards. Do records and procedures identify information and training given to employees?

7. Weaving and Warping

7.1 Weaving Machinery

a. Are drive mechanisms, belts etc fully guarded?

b. Are spoked handwheels, gearwheel, let off motions etc blanked off or provided with emergency stop controls?

c. Are start control buttons and system distinguishable by touch and designed to prevent inadvertent start up?

d. Are dangerous moving parts of the shedding mechanism (tappets, dobbies, jacquard) fully enclosed or safe by position?

e. Are weft insertion mechanism adequately guarded?

f. On shuttle looms, are shuttle guards provided?

g. Are trap areas guarded, reed, temple and other fixed parts?

h. Is there a safe access to upper jacquard mechanism e.g. steps, walkways, platforms?

i. Are guard-rails, handholds and openings all clearly marked and maintained?

j. Can the machine be isolated from the jacquard platform?

k. Are ear defenders being correctly worn and are ear protection zones marked?

7.2 Warping Machinery

a. Are trip wires and bars fitted on beaming off, to prevent access to danger zones?

b. Are revolving shafts, conveyors and gears fully guarded and will they operate if someone is entangled?

c. Are safety brakes fully effective?

d. When safety devices are inactive is hand rotation or crawl speed motors the only method of movement?

e. Are pressure sensors or safety valves fitted in the power circuit to stop the machine in the event of pressure loss?

f. Are beam flanges and associated shafts free from damage and projections

g. Is an inspection system in operation to ensure safety requirements are being met?

h. Are moveable interlocked guards fitted at drawing in points, pressure rollers, beam flanges etc?

i. On warp beam storage, are the stands designed, fitted and marked with maximum load weight
limits?

j. Are they totally enclosed or otherwise guarded to prevent beams falling out?

k. Are drawing in points on drive chains and sprockets guarded?

l. Are arrangements in force for the lifting mechanism to be checked by a competent engineer under LOLER?

7.3 Weaving and Warping Procedures

a. Where climbing onto the machine to carry out repairs is unavoidable are isolation controls and safe procedures in operation?

b. Where tuning operations require the machine to be operated without guards are Safe Systems used (lock out) etc?

c. On warp creels are employees given a variety of tasks in order to limit WRULDs?

d. Where employees are required to climb steps to reach the creel are they aware of correct climbing and balancing techniques?

e. Where high-speed beaming operations take place do the Safe Systems cover inching and starting up procedures?

8. Blending, Scouring and Packing

8.1 Blending, Scouring and Packing Plant

Feed Sheets and Conveyors

a. Are spiked feed sheets guarded or fenced at all access points?

b. Are access panels interlocked where there is a need for frequent cleaning?

Blending

c. Are traps and floor openings guarded or fenced?

d. Where access is required to the tops of bins, are suitable ladders or stairs provided?

e. Where access is required to bin tops and walkways, are they safe, clearly marked and fenced?

f. Is a safety harness fitted where work is required on an unfenced bin top?

g. Are bin tops and access ways well illuminated?

h. Is access to heights restricted to named employees by permit systems?

i. Where moving bin emptiers are used is there an emergency escape door with a rim cylinder latch at the closed end of each bin?

j. Are traps between moving bin emptiers and fixed structures guarded or fenced?

k. Is a warning system in operation prior to machines starting up?

l. Where pneumatic transfer ducting is in use, are special structures available to gain access to ducting areas prone to fibre blockage?

m. Are ducting fans safe by distance or interlock guarded?

Scouring Equipment and Machinery

n. Are fixed or distance guards fitted to prevent access to squeeze rolls at all areas in scouring and
drying?

o. Are all spiked feed sheets guarded at access points?

p. If ducking rollers are fitted is there adequate clearance allowed between the vanes and any other
parts of the machine?

q. Where R F dryers are used is a warning indicator fitted?

8.2 Blending, Scouring and Packing Procedures

a. Are all cleaning maintenance operations carried out with the machine stopped and isolated?

b. Is a daily system of checking safety devices in place?