Parcels Sortation with Conveyors

Transcription

Parcels Sortation with
Conveyors
Safety compliance and supporting documentation
Ken House
Tel: 07713653072 – email: [email protected]
02/05/16
This is a synopsis of the safety documentation applicable to the deployment of conveyors to be
used with parcel sortation. Due to the size of this file I have only placed the main documents in this
synopsis. It is a requirement of the SAC1 and Risk Assessment that site assessments must be
completed prior to any new equipment being deployed, supported by local risk assessments and
consultation with local CWU representatives.
The documents within this pack are electronic copies, all master documents with
signatures are held by the originators on site. Should you need to review these please
contact Edinburgh MC – [email protected] Continuous Improvement Lead.
Mail preperation frame safety documentation within this document.
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Work Equipment Change Safety Assessment (WECSA)
……………….…………1
Safety Assessment SAC1………………………………………………………………………………….2
Safe Systems of Work………………………………………………………………………………………3
Ergonomic Screening ……………………………………………………………………………………… 4
Ergonomics Review (Edinburgh) ……………………………………………………………………..5
Ergonomics Review (Manchester) ……………………………………………………………………6
Operating Manual ……………..……………………………………………………………………………..7
Technical Drawings…………………………………………………………………………………………..8
Layout……………………………………………………………………………………………………………….9
Job Element Sheets …………………………………………………………………………………….10
ANNEX: 1…………………………………………………………………………………………………………………………….
Additional supporting document (not included in this report)
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Terms of reference (TOR)……………………………………………………………………………………..11
Joint working review……………………………………………………………………………………………..12
Industrial engineering report………………………………………………………………………………..13
1
WORK EQUIPMENT CHANGE SAFETY ASSESSMENT
Section 1
Work Equipment Title
Work Equipment Group
Work Equipment Intended Use
Explanation of change
Deployment Date
Project Manager (contact
details)
CHANGE SAFETY ASSESSMENT
CONVEYORS BY Beumer
RM 5M CONVEYOR SYSTEM
To convey mail items for sortation into
Alps and Hoods
To alleviate the manual handling
experience whilst doing the sortation
operation
Trial Begins July 2014
Martyn Dundas
NATIONAL
GEOGRAPHY
(name)
Work equipment area of use
Section 2
UNIT (name)
NORTH
Edinburgh MC
PROHIBITED CHANGE ACTIVITY
Will the change impact on any of the following:
Work Equipment Guarding (Primarily machinery guarding)
Computers or VDU’s, including all software & hardware
Electrical Systems and any power supplies
Machinery Controls
Address Interpretation Systems
Safety Systems such as interlocks, emergency stops, signs
Machines under warranty
Introducing substances to machinery hazardous to health
Lifts and lifting equipment inc mechanical handling equipment
Road vehicles
Section 3
Work Equipment Photograph
Yes/No
NO
NO
NO
NO
NO
NO
NO
NO
NO
NO
(Yes)
If ‘Yes’ STOP do not
progress. Only complete
the modification with the
authorisation of the
Subject Matter Expert
(SME) Advice on
identifying SME’s is
available in the guidance
document to this process
(No)
If ‘No’
Progress to
Step 3
CHANGE - JUSTIFICATION
Description of change activity
and improvement opportunity
To enable operators to comfortably sort flats and letters into different perstop trays.
This will remove the likelihood of any manual handling injury whilst performing this
process.
Monitoring Period used to justify the need for Change?
From:
To:
Yes/No
Target Benefit?
Achieved Y/N?
Safety?
YES
Nil injuries from manual handling
Legal?
YES
SSOW in conjunction with HASAW
Benefits from the
1974
Work Equipment
Financial?
YES
Efficiency improvement
Change Activity
Quality?
YES
Sortation process won’t have as many
errors
Performance?
YES
Modern approach to performing the
task to a high standard
Equipment Availability? NO
Other? (Describe)
NO
During a trial the benefits of any change must be monitored for 90 days. This will prove the effectiveness of the
change so it can be horizontally expanded outside the initiating unit or show if the change needs to be reversed.
Is the change reversible? (It must be possible to
YES
Explain: The conveyors can be removed from the unit
return the work equipment to its original state)
Section 4
CHANGE - ACTIVITY
What change activity is involved?
New Work Equipment, whether purchased, hired, or leased,
even on a temporary basis
Work Equipment Change Safety Assessment
Yes/No
YES
Template Owner: S. White
(Yes)
Version: 4.0
(No)
Date: Nov 2012
2
Modification to Work Equipment even on a temporary basis
(As defined in the guidance document)
Replacement of a component where the replacement isn’t
like-for-like
Change of use for the Work Equipment
NO
Significant change of workplace layout due to relocation of
fixed Work Equipment or mechanised equipment
Change of environmental in which the equipment is
designed to operate
NO
Section 5
NO
NO
If any option is
‘Yes’ progress with
the Work
Equipment Change
Safety Assessment
If all options are ‘No’
there is no need to
progress with the
Work Equipment
Change Safety
Assessment
NO
CHANGE - SIGNIFICANCE
Indicate all that apply and complete all relevant assessments
Yes?
If Yes
Which is new or the change impacts on the safety systems,
YES
Step 6 (1) Applies
controls, powered elements or it’s sufficiently close to the powered
Powered Work
elements/moving parts to constitute a significant risk.
Equipment
Which is not new and the change does not impact on the safety
NO
Step 6 (3) Applies
systems, controls, powered elements or it isn’t sufficiently close to
the powered elements/moving parts to constitute a significant risk.
Non-Powered
Which is new or the change impacts on the safety systems,
NO
Step 6 (2) Applies
Work Equipment controls, moving parts or it’s sufficiently close to the moving parts
with moving
to constitute a significant risk.
parts Exclusion,
Which is not new and the change does not impact on the safety
NO
Step 6 (4) Applies
(see Note**)
systems, controls, moving parts or it isn’t sufficiently close to the
moving parts to constitute a significant risk.
Non-Powered Work Equipment with no moving parts Inclusion (see Note**)
NO
Step 6 (5) Applies
Lifts & Lifting Work Equipment (LOLER assessments are likely for some of the above)
NO
Step 6 (6) Applies
Prohibited Changed contact SME
Ergonomic Task Activities (Ergonomic task activities are likely to apply in most cases)
YES
Step 6 (7) Applies
Note** Work equipment, where the only moving parts are wheels used to move that work equipment from one
static location to another and where those wheels are then locked in place.
Section 6
Change Significance
1
Powered Work Equipment which is new or
the change impacts on the safety systems,
controls, powered elements/moving parts or
it’s sufficiently close to the powered elements
to constitute a significant risk.
Non-Powered Work Equipment with moving
parts which is new or the change impacts on
the safety systems, controls, moving parts or
it’s sufficiently close to the moving parts to
constitute a significant risk. Exclusion, see
Note**
NOTE: PUWER Assessment:
Before making this modification is the
machine/work equipment of standard
configuration &/or up to current specification
3 Powered Work Equipment which is not new
and the change does not impact on the
safety systems, controls, powered
elements/moving parts or it isn’t sufficiently
close to the powered elements to constitute
a significant risk.
4 Non-Powered Work Equipment with moving
parts which is not new and the change does
CHANGE – ASSESSMENT TYPE
Assessment
Required
PUWER
Assessment.
2
Yes / No
YES
Screening
Assessment
To determine if a
PUWER
By Whom
Complete
Appendix
(Nationally) Head of
Engineering Safety
(Geographical/Functional/Local)
Geographical/Functional
Director Safety
Appoints an assessor
(Nationally) Head of Logistics &
Facilities Management Safety
(Geographical/Functional/Local)
Geographical/Functional
Director Safety
Appoints an assessor
If ‘No’ STOP until such time as
the machine or work
equipment has been brought
up to current specification
Project Manager or
Operational Line Manager
Version: 4.0
2
If ‘Yes’
Progress
1
Date: Nov 2012
3
5
not impact on the safety systems, controls,
moving parts or it isn’t sufficiently close to
the moving parts to constitute a significant
risk.
Exclusion, see Note **
Non-Powered Work Equipment with no
moving parts (New or existing)
Inclusion, see Note **
Section 6 cont.
6
Lifts and Lifting Work Equipment
7
Work Equipment used to manually lift, carry,
transport or hold loads or that needs to be
manually handle
assessment and/or
Ergonomic
assessment is
required
If in doubt how to proceed
seek advice from the local
Safety Team
CHANGE – ASSESSMENT TYPE
Lift Operations &
Lifting Equipment
Assessment
Ergonomic
Screening
Assessment
Section 7
Head of Logistics & Facilities
Management Safety appoints a
Technical Assessor or Safety
Advisor
Project Manager, Operational
Line Manager or Technical
Assessor or Safety Advisor
3
4
CHANGE – IMPACT
The intention is that each item of work equipment will have a Work Equipment Change Safety Assessment to assess
if it is intrinsically safe to use within Operations & Modernisation and a SAC1 (or equivalent) to determine the level of
risk that exists from hazards encountered while using the work equipment in task activities in operations.
Yes/No
(Yes)
(No)
What impact does the change have on the SAC1?
Is the Work Equipment new and will operator task activities
YES
Produce a SAC1 to
There is no need
be affected by the introduction of the work equipment?
assess task activities to produce a SAC1
If the Change is to existing Work Equipment is there the
NO
Amend the existing
There is no need
potential for the Change to impact on any task activities
SAC1 or create one
to review the
associated with the use of the work equipment?
if none exists
SAC1
List the SAC1 impacted on by the change:
We have 6 separate conveyors, all made to the same
1) SAC1 covering operational use of Work Equipment
specification, that will be used to help with the
(where equipment is introduced as a stand alone item)
smooth sortation of flats and letters and parcels into
2) Project SAC1 (when work equipment is introduced as
the correct containers.
part of a wider project related to a new procedure)
Section 8
LIST ANY INPUT RECEIVED AND FROM WHO
STAKEHOLDERS
Names and contact details
(Where applicable)
Unit Manager (Unit Level Work Equipment Change)
Safety Lead
Geographical Director Safety (GDS)
Head of Logistics & Facilities Management Safety
National Asset Team (introduction of or change to assets)
Head of Engineering Safety
Subject Matter Expert (SME)
PUWER Assessor
LOLER Assessor
Ergonomic Assessor
Other (specify)
Other (specify)
LIST STAKEHOLDERS SUPPLYING INPUT &/or
BEING CONSULTED (For National, Geographical & Unit
Paul Laidler
Kenny Mckean
Steve Greaves
Del Roffey
Scott Sutherland
NOT NEEDED
Corinne Parsons
03/07/14
Names and contact details
(Where applicable)
Date
consulted
&/or input
received
Alex Sayers
03/07/14
Level Work Equipment Change)
UNITE (National)
UNITE (Local or Geographical)
Date input
received
Version: 4.0
Date: Nov 2012
4
CWU (National)
CWU (Local of Geographical) (Ops &/or Engineering)
Mark Hugall / Ian Robson
Other (specify)
Section 9
WORK EQUIPMENT CHANGE SAFETY ASSESSMENT
I can confirm that I have the appropriate level of competency, in terms of knowledge and experience of completing
other assessments, to allow me to sign off this Work Equipment Change Safety Assessment. I can confirm that on
completion of the assessment and associated specialist assessments that provided all outstanding actions are
completed and no significant risks are identified and still outstanding that this work equipment is fit for purpose and
the intended use to which it will be put within the Business, and that the user of the work equipment or persons who
may be affected by its use have been safeguarded from any risks
Project Manager or
Operational Line Manager
Name
Martyn Dundas
Date
Signature
03/07/14
(Not valid unless signed)
Project Managers should:
• Sign the Work Equipment Change Safety Assessment in all case and retain a copy of it and all appendices
• Forward copies as appropriate:
Local Projects
- The Unit Manager
Geographical Projects - The Geographical Director Safety
National Projects
- Head of Logistics & Facilities Management Safety (Non-Powered Equipment)
- Head of Engineering Safety (Powered Equipment)
- SME (For change specific to areas of Prohibited Change)
PROCESS CONCURRENCE
NATIONAL DEPLOYMENTS & CHANGE involving PUWER & LOLER
Name
Date
Signature
Head of Logistics & FM Safety
(Non-Powered)
OR
Name
Date
Signature
Head of Engineering Safety
(Powered)
GEOGRAPHICAL or FUNCTIONAL or UNIT DEPLOYMENTS & CHANGE involving PUWER & LOLER
(Powered & Non Powered)
Name
Date
Signature
Geographical Director Safety
PROHIBITED CHANGE ACTIVITY or SME DEPLOYMENTS & CHANGE involving PUWER & LOLER
& / OR
Name
Date
Signature
Subject Matter Expert (SME)
POWERED WORK EQUIPMENT & LIFT WORK EQUIPMENT DEPLOYMENTS & CHANGE
Name
Date
Signature
Assets Supply Chain Manager
(Where it is applicable the Process Concurrence is not valid unless signed by at least one of the above)
WORK EQUIPMENT CHANGE SAFETY ASSESSMENT APPENDICIES
1. Work Equipment
Screening
Assessment
Work Equipment
Screening Assessmen
2. PUWER
Assessment (NonPowered Equipment)
For Non Powered Equipment
Technical Assessors or Safety
Advisor should use this PUWER
2. PUWER
Assessment
(Powered
Equipment)
3. LOLER
Assessment
For Powered Equipment
Technical Assessors should
use the PUWER Assessment
Tool provided by Engineering
LOLER Assessment
v1.2
Version: 4.0
Date: Nov 2012
5
Assessment
PUWER Assessment
v1.6
4. Ergonomic
Screening
Assessment
Ergonomic Screening
Assessment v1.2
(All assessments must be signed and attached where they are required )
Version: 4.0
Date: Nov 2012
SAFETY ASSESSMENT & CONCURRENCE (SAC1)
Project/Programme/Product
Title
Project/Programme/Product
Description
Proposed Schedule,
Timescales
Project Lead (Contact Details)
Cut and Tip Conveyors
Installation and use of Incline
and/or Horizontal Conveyors
Deployment Start: 22 April 2015
Deployment Finish: 26 June 2015
(est)
Additional timescales on a case by
case basis
Murray Cook (Business Case
Owner) 07702 678200
NATIONAL (SMS 8.1)
SAC1 Level
Deliver, install, use and
maintain c100 conveyor
systems into 22 mail centres.
To provide further systems on
an on-going case by case basis
REGIONAL (SMS 8.2)
UNIT (SMS 8.3)
X
LIST SAFETY INPUT(s) REQUIRED (indicate if
applies)
GROUP SAFETY RISK IMPROVEMENT MANAGER
NATIONALLY APPOINTED SAFETY LEAD
PROGRAMMES DIRECTOR/MANAGER (as applicable)
SENIOR SAFETY PROFESIONNAL
PROJECT SAFETY LEAD
PROGRAMMES MANAGER
SAFETY ADVISOR
PROJECT MANAGER (If different from Project Lead)
SUBJECT MATTER EXPERT - Conveyors
PROPERTY & FACILITIES (SAFETY TEAM)
ENGINEERING (SAFETY TEAM)
LOGISTICS (SAFETY TEAM) – (VEHICLES)
ASSETS (SAFETY TEAM)
ERGONOMIST
STAKEHOLDER CONSULTATION
Is consultation necessary with the
CWU
SAC1 Template:
Task or Work Equipment
Photograph
Y/N
Y
Y/N
CATEGORY
Y
N
Y
N
N
N
N
Y
Y
N
Y
N
N
8.1
8.1
8.1
8.1, 8.2 or 8.3
8.2 or 8.3
8.2
8.3
8.1 & 8.2 & 8.3
8.1
As appropriate
As appropriate
As appropriate
As appropriate
As appropriate
STAGE
8.1
Consultation
conducted
and agreed
with Terry
Pullinger
through
National
Steering
Group. Via
Francis
NAME & CONTACT DETAILS
Joanna Hosking
Warren Cabot
Ray Pipe 07703 404378
Craig Dowe 07587 657236
Del Roffey/Pete McGowan
NOTE: This equipment has
been ergonomically assessed
prior to national deployment
Terry Pullinger
Version: 4.3
Date: July 2013
Williams/Mur
ray Cook
Is consultation necessary with Unite
CMA
Y
Is consultation necessary with any
other stakeholder?
N
LIST ADVICE OBTAINED
Martyn Bunn
[email protected]
Y/N
STAGE
N
N
N
N
N
As appropriate
As appropriate
As appropriate
As appropriate
As appropriate
HEALTH & SAFETY EXECUTIVE
ENVIRONMENTAL HEALTH OFFICER
FIRE AUTHORITY
OTHER?
OTHER?
CONSTRUCTION, DESIGN & MANAGEMENT
Does CDM apply to the project?
If ‘Yes’ is the project notifiable to the HSE?
LIST REQUIRED SAFETY INPUT
Strategic CDM Co-ordinator
Local CDM Co-ordinator
SAC1 Template:
Version: 4.2
YES / NO
No
No
Y/N
STAGE
As appropriate
As appropriate
N/A
N/A
Date: July 2013
STEP 1
INITIAL RISK ASSESSMENT
Unit staff /
Contractors,
employees,
visitors and
customers
People
Affected
Contractors
Musculoskeletal injuries
Poor manual handling
Operating the
SAC1 Template:
Vehicle & pedestrian
collisions
Various injuries as a
result of the tasks being
undertaken for the
project.
Building & Electrical
Works.
Working with tools,
Working at height
Incorrect use of tools
Poor manual handling
Moves via FLT & Pallet
Truck
Associated Risk
Identified Hazards
Conveyor
Movement
Task or Work
Equipment
Conveyor
enabling works
and
installation.
Version: 4.2
4
Moderate
Adequately
controlled
Outcome
See Matrix
Tolerable
Date: July 2013
8
3
3
Total
4
4
Severity
Risk Assessment
Likelihood
RoMEC – Provided WELLs
1
document defining generic
procedure of undertaking works.
Site survey visits undertaken
prior to commencing any works
to ascertain local specific
considerations,
Conveyor installer (Beumer) –
Risk Assessment and Method
Statements (RAMS) provided and
issued to nominated person at
each site.
1
Only Beumer permitted to
remove conveyors from delivery
vehicles and move into final
position within each mail centre.
RAMS documents provided by
Beumer. Project team have
copies of persons trained to use
FLTs. All conveyors have wheels
to avoid use of lifting equipment
and manual handling tasks when
moving conveyors within Mail
Centre and into final position.
Wheels will be removed prior to
fixing conveyors to floor
Current manual handling
2
Existing Control(s)
List below tasks or work equipment involved & the hazards associated with them & those people affected, list all existing controls & rate the level of risk. Use separate assessment
sections for each task or work equipment & add more assessment sections and expanding as needed. If any risks are tolerable or above, move to Step 2 Risk Control.
Musculoskeletal, striking,
Defective Machine,
Maintaining the
Maintenance
Maintenance
Engineers
Employees
and
managers
Contractors/
RoMEC
Automation
drawn in and cuts
injuries
Maintenance
procedures
Maintaining the
conveyor
SAC1 Template:
drawn in and cuts
injuries
Defective Machine,
moving parts, sharp
edges or jagged metal
edges
Operating the
conveyor
conveyor – to
process bundles
of letters and
parcels.
Version: 4.2
Manual Handling SSOW
All conveyors have audited predelivery checks at factory. All
conveyors have commissioning
checks and further checks made
as part of formal handover. All
conveyors electrically tested
prior to first use, nip guard gaps
checked, all guards are checked
for security, safety and
monitoring devices are checked
(E/Stops). SME has undertaken
Machinery Directive compliance
checks as part of Regulation 10
and 11 of PUWER98. Operating
instructions have been provided
and operator training session(s)
will be provided at each
installation site. Named and
trained details will be provided.
Local PUWER assessor to
undertake and complete PUWER
assessment at each installation.
Guidance will be available from
the SME
Maintenance procedures have
been provided and contained
within the Maintenance Manual.
A technical training course will
be provided at each site
All conveyors have audited pre-
training but does not include this
conveyor.
2
1
2
4
4
4
Moderate
Tolerable
(due to
final
PUWER
assessmen
t activity)
Moderate
Date: July 2013
8
4
8
Movement of our
vehicles in the yard
where the contractors
are working to unload
the conveyors
Movement of machines
through the workplace
from the platform
Yard Safety
SAC1 Template:
Workplace
Safety
moving parts, sharp
edges or jagged metal
edges
conveyor
Contractors,
employees,
visitors and
customers
Contractors
Engineers
Crushing and striking
against injuries
Vehicle collisions with
people ME lifting
equipment
drawn in and cuts
injuries
Version: 4.2
delivery checks at factory. All
conveyors have commissioning
checks and further checks made
as part of formal handover. All
conveyors electrically tested
prior to first use, nip guard gaps
checked, all guards are checked
for security, safety and
monitoring devices are checked
(E/Stops). SME has undertaken
Machinery Directive compliance
checks as part of Regulation 10
and 11 of PUWER98. Operating
instructions have been provided
and operator training session(s)
will be provided at each
installation site. Named and
trained details will be provided.
Local PUWER assessor to
undertake and complete PUWER
assessment at each installation.
Guidance will be available from
the SME
Risk Assessment and Method
Statements will be provided by
the contractor prior to each
delivery. Enquiries will be made
for any special requirements
Conveyors are moved on casters
within each site to eliminate use
of manual handling equipment.
Workplace Risk Assessment –
WTLL to make staff aware of the
installation.
3
1
4
4
Moderate
Tolerable
Date: July 2013
12
4
(due to
final
PUWER
assessmen
t activity)
Erection of temporary
fencing in the area
where the conveyors
will be installed
Increased levels of
noise in the work area
New machines not
added to the current
Work Equipment Risk
Assessment
Fire Safety
Noise
Work
Equipment
Injuries as a result of the
use of the machine
Short or long term
hearing defects due to
the exposure to the
noise levels
Restricted access, egress
entrance and routes or
walkways to fire exits
Stepping, striking, slip,
trips, falls or
musculoskeletal injuries
Employees
and
managers
Employees
and
managers
Contractors,
employees,
visitors and
customers
Contractors
RISK CONTROL
Fire Risk Assessment.
Premises Fire Evacuation Plans
(PFEP)
Personal Emergency Evacuation
Plans (PEEP)
From the manufacturers details
the noise measured at the
operator positions on the incline
and horizontal conveyors is
44dB when in normal running,
During the start sounder and
when an emergency stop is
depressed the noise
measurement at operator
positions has been measured at
76dB. Although by design the
conveyors are relatively quiete it
is unknown if this will have a
cumulative effect in it’s final
installed location
Work Equipment Risk
Assessment
Site induction into the work area
and removal from site if
standards are breached
3
3
3
3
4
4
3
1
9
9
12
4
Moderate
Moderate
Moderate
Tolerable
SAC1 Template:
Version: 4.2
Date: July 2013
List all tasks or work equipment rated in Step 1 as tolerable or above. Identify & record the additional control measures necessary to ensure risks are removed or reduced to an
acceptable level. On the assumption these risk controls will be introduced complete the risk assessment assessing their impact on the risk rating. Where any additional controls are
proposed but cannot be immediately implemented add them at Step 5. Where necessary obtain advice from the Safety Lead to the project. Use separate assessment sections for
STEP 2
Contractors who are
unfamiliar with RMG
individual site safety
policy
Contractor
control
Moderate
Moderate
Outcome
See Step1
Moderate
SAC1 Template:
2. Maintaining
the conveyor
Task or Work
Equipment
1. Operating the
Conveyor
Initial training will be provided by the
contractor prior to first use. For on-going
training create a training package to ensure all
maintainers are competent to maintain and
use the conveyor. Provide , using operational
and technical training manuals.
27/11/2015
SSOW for operation of conveyor incorporating
the recommnedations in the Ergonomic
Assessment.
PUWER assessment to be conducted on the
machine to ensure it meets the requirements
of the Machine Directive and associated
standards
Each site to
advise date
when
completed
Each site to
advise date
when
completed
19/02/2015
Completion
Date
At date of first
use and will
be ongoing
moving
forward
Ergomic assessment of conveyors with regard
to cutting & tipping, handling and sortation of
parcels and mail items into containers such as
Yorks & Mini-Yorks.
Initial training will be provided by the
contractor prior to first use using operational
and technical manuals. For on-going training
create a training package to ensure all
employees and managers are competent to
use the conveyor. Existing documentation
could be used for this if required.
Additional Control Measures
each task or work equipment & add more assessment sections and expand as necessary.
Each site to
confirm
when
completed
Each site to
confirm
when
completed
Yes
Completed
Yes?
Each site to
confirm.
Version: 4.2
Local PUWER
assessor with
guidance from
SME Craig
Dowe if req’d
First use –
Contractor
(Beumer)
Ongoing - ETC
Ken House
Corinne
Parsons
First use Contractor
(Beumer)
Ongoing –WPC
By Whom
1
1
3
4
3
4
Total
4
Date: July 2013
Risk Assessment
Likelihood Severity
1
4
Adequately
Controlled
Tolerable
Outcome
See Matrix
Tolerable
Moderate
Moderate
Moderate
Moderate
4. Workplace
Safety
6. Fire Safety
7. Noise
8. Work
Equipment
SAC1 Template:
Moderate
3. Yard Safety
Add the new equipment to the work
equipment list and assess. Pass asset details
on to ADST
Previous site specific noise risk assessments
should be reviewed to ascertain if following the
introduction of the conveyors may tip the
balance of exceeding any noise thresholds for
that area
Review the full fire risk assessment to capture
the newly installed machines and the
associated fire emergency tests and
evacuations.
Review the Workplace Risk Assessment to
ensure the location of the machines are
considered
Unloading of the conveyors to be in an area
where there are either no or restricted vehicle
movements and preferably during the quietest
time of the operation.
Review the Yard Risk Assessment
PEM to add
date when
completed
SHE to advise
date when
completed
Each site to
advise date
when
completed
Each site to
advise when
completed
Each site to
advise date
when
completed
PEM to
advise when
done
SHE to
advise when
done
Each site to
confirm
when done
Each site to
confirm
when
completed
Each site to
confirm
when
completed
Version: 4.2
(PEM)
SME Craig
Dowe
(CWU) Safety
Rep)
(safety rep)
Regional SHE
adviser
Between,
project
manager,
nominated site
contact and
Contractor
(Beumer)
Site project
lead,
Regional SHE
adviser
(CWU Safety
Rep)
(safety rep)
Site project
lead,
Regional SHE
adviser
(CWU Safety
Rep)
(safety
rep)Rep)
1
1
1
1
1
3
3
4
4
4
Date: July 2013
3
4
4
4
Adequately
Controlled
Adequately
Controlled
Tolerable
Tolerable
Tolerable
DETAILED RISK ASSESSMENT
Outcome
See Step 2
Task or Work
Equipment
SAC1 Template:
Outcome
See Step 2
Completion
Date
Completion
Date
By Whom
By Whom
Completed
Yes?
Completed
Yes?
Version: 4.2
Severity
Likelihood
Total
Total
Outcome
See Matrix
Outcome
See Matrix
Date: July 2013
Severity
Risk Assessment
Likelihood
Risk Assessment
Detailed Redesign Assessment (Fundamental change to the project/process)
Hazard & Operability Assessment/Study (HAZOP)
Epidemiological Assessment
Health effects Assessment/Study/Surveillance
Noise Assessments
Other Assessment - specify
Use the Risk Matrix in SMS 2.1 Risk Management Standard to assess the task or work equipment.
Detailed Risk Assessments
Detailed Risk Assessments
7
8
9
10
11
12
POSSIBLE DETAILED RISK ASSESSMENTS
Work Equipment Change Safety Assessment (Mandatory for all change to work equipment)
Ergonomic Assessment
CDM Assessment
Property & Facilities Structural Assessment (Fundamental change in building structure)
Yard risk Assessment
Fire Survey and/or Fire risk Assessment
Task or Work
Equipment
1
2
3
4
5
6
List all tasks or work equipment rated as moderate or above in Step 2 in the Detailed Assessment section below, where the additional controls introduced or intended for
introduction in Step 2 cannot control the risks to at least an adequate level. It is essential at this point that the Safety Lead for the project is consulted. With their assistance identify
which of the additional detailed risk assessments are required. These assessments should be used to identify and record any specific control measures the technical safety specialist
completing the assessment feels are necessary to ensure risks are removed or reduced to an acceptable level. Where possible additional controls should be implemented straight
away. Where additional controls are proposed but not yet implemented add them at Step 5. Add more assessment sections and expand as necessary to record your findings.
STEP 3
When the additional control measures are identified progress with the risk assessment based on the new information.
All those assessed as Adequately Controlled or Tolerable
Go to Step 5
Any that are assessed as Moderate or above
Go to Step 3
Overall Assessment
Use the Risk Matrix in SMS 2.1 Risk Management Standard to assess the task or work equipment in all sections above.
STEP 4
RESIDUAL RISKS
CONCURRENCE ACTION PLAN
YES
Version: 4.2
As and when
for each
installation
Review the full fire risk assessment to capture the newly installed machines and the associated fire emergency tests and
evacuations.
SAC1 Template:
As and when
for each
installation
Completion
Date
As and when
for each
installation
Review the Workplace Risk Assessment to ensure the location of the machines are considered.
PUWER assessment to be conducted on the machine to ensure it meets the requirements of the Machine Directive and associated
standards
CONCURRENCE ACTION
NO
Completed?
Y/N
Date: July 2013
Site lead,
regional SHE
advisor, local
safety rep
Site lead,
regional SHE
advisor, local
safety rep
Local PUWER
assessor with
guidance from
Craig Dowe if
reqd
By Whom
Record from Step 2 ‘Risk Controls’ any outstanding actions that still need to be implemented and any additional risk controls from Step 3 ‘Detailed Risk Assessment’ or Step 4
‘Residual Risks’ that are outstanding. Responsibility and timescales for completion should also be determined. These are part of the conditions of concurrence. It is important to
record any actions in this section that are essential to the project but which cannot be deployed before sign off of this process, as such they will become concurrent actions.
STEP 5
b) Abort the Project - Seeking an alternative product/service solution, then start the Safety Assessment & Concurrence process again
c) Review steps 1 to 3. Include additional proposals suggested by the Group Safety Risk Improvement Manager (8.1) or the Senior Safety Professional
implementing the additional controls identified during the review of the process. Where controls cannot be implemented immediately – go to Step 5 and add to the
concurrence actions.
a) Abort the Project - Do not progress
2. Safety Lead takes appropriate course of action having escalated the issues:
1. Safety Lead to escalate all risks moderate or above for advice on a way forward to the Group Safety Risk Improvement Manager (8.1) or the most Senior Safety
Professional in the Business Unit (ex. Operations & Modernisation), Region, Logistics or Support Function (8.2/3)
RESIDUAL RISK ACTIONS FOR RISKS ABOVE MODERATE
If there are any residual risks moderate or above after step 3, take the following action:
SAFETY RECOMMENDATION
If required at
each site
Site lead,
regional SHE
advisor, local
safety rep
SAC1 Template:
3
3
N/A
N/A
Which Apply**
CATEGORY (8.1), CATEGORY (8.2) & CATEGORY (8.3)
NATIONALLY APPOINTED SAFETY LEAD
SENIOR SAFETY PROFESIONNAL (Where not final signatory)
PROJECT SAFETY LEAD
SAFETY ADVISOR (Where not final signatory
PROJECT MANAGER (If different from Project Lead)
SUBJECT MATTER EXPERT – Conveyors
PROPERTY & FACILITIES (SAFETY TEAM)
CDM CO-ORDINATOR
Ray Pipe
Craig Dowe
NAME
Version: 4.2
Ray Pipe
Craig Dowe
SIGNATURE
Date: July 2013
01/05/2015
12/05/2015
DATE
By signing below you agree that one of the below statements applies to you, therefore delete the statements that do not apply
I am satisfied in relation to the Programme, Project or Product deployment, including in relation to hazards during the operational use of work equipment where applicable that
1. There are no safety risks for my area of responsibility. I am able to recommend it for final safety concurrence.
2. The safety risks for my area of responsibility are adequately controlled or have been reduced to a tolerable risk. I am able to recommend it for final safety concurrence.
3. The safety risks for my area of responsibility have been identified and while the concurrence actions have not yet been deployed, they have been recorded for
implementation via the Safety Management Plan or the Safety Assessment Concurrence Questions & Actions document. I am able to recommend it for final concurrence
on the understanding these actions are completed before the project is deployed and the handover completed at Unit level.
STEP 6
Supporting Documents Associated with this SAC1
1) RoMEC WELL document for electrical power installation
2) Contractor Risk Assessment and Method Statement example documentation for conveyor deliveries and
installation
3) Manufacturers design residual risk assessment
4) Operator manual
5) Maintenance manual
6) Draft SSoW awaiting approval
7) Site locations, specification and number of conveyors at each type (as of 01/May/2015)
8) Standard use documents (Ken House to provide)
Undertake a Noise test of the area where the machines are located.
Review the Noise risk assessment to include the new machines
3
N/A
N/A
N/A
N/A
FINAL SAFETY CONCURRENCE
Del Roffey
SAC1 Template:
SIGNATURE
SIGNATURE
NAME
JHosking
SIGNATURE
NAME
Warren Cabot
Joanna Hosking
NAME
Version: 4.2
DATE
DATE
18/05/2015
And as
Reviewed on
19/11/2015.
DATE
Date: July 2013
NOTE: For final sign off on Unit Level (8.3) projects refer to the Safety Handover Compliance Certificate
RISK MATRIX
PROGRAMMES DIRECTOR / MANAGER (as applicable)
CATEGORY 2 SAFETY CONCURRENCE (8.2 only)
SENIOR SAFETY PROFESIONNAL
PROGRAMMES MANAGER
SAFETY ADVISOR
GROUP SAFETY RISK IMPROVEMENT MANAGER
By signing below you agree that you are satisfied the programme/project/product has received adequate safety considerations and that you are prepared to give final safety
concurrence on the understanding that any actions in this document or the Safety Management Plan or the Safety Concurrence Gateway Questions & Actions document are
completed before final deployment of and the movement of the programme/project/products and any associated work equipment to business as usual the.
STEP 7
ENGINEERING (SAFETY TEAM)
MAINTENANCE
LOGISTICS (SAFETY TEAM) – (VEHICLES)
ASSETS (SAFETY TEAM)
ERGONOMIST
SAC1 Template:
Version: 4.2
Date: July 2013
ROYAL MAIL GROUP RISK MANAGEMENT
SAFE SYSTEM OF WORK (Appendix 2)
This SSOW provides sufficient INFORMATION and INSTRUCTION to allow managers to control safety risks identified
during risk assessments. It is used by work area managers to inform and instruct operators, at induction and refresher
training events, how a task they are involved in or work equipment they are using can be completed / used safely. A
record should be retained to show that this information and instruction has been shared with those employees affected.
Task / Work Equipment Description
Generic Task / Work Equipment
(SSOW Title)
Cut & Tip Powered Conveyor
SAC1 National Cut & Tip Conveyor
V1.3
Associated Risk Assessment
SSOW Version No
WHAT RISKS ARE CONTROLLED BY THIS SAFE SYSTEM OF WORK
(As identified in the task risk assessment or SAC1 process, show the risks identified and the controls that have been introduced.
For example, pedestrian/vehicle collisions controlled by the provision of a designated & protected walkway.
Identified Risk
Operating the conveyor
Risk Rating (ref. SMS2.1 Risk Matrix)
Tolerable
Control
Following initial installation and equipment
deployment:
National project lead to ensure training is
provided on site and delivered to the workplace
coaches.
On-going training to be delivered by a
competent Workplace Coach using safe
systems detailed in this document.
INSTRUCTIONS
(How to carry out the task &/or use the work equipment safely - including the Don’t and Do written instructions)
Safe System of Work Template: Template Owner: S. White
Version: 1.3
Date: Feb 2013
Cut and Tip Conveyors
This safe system of work must be followed at all times and consolidates advice given in operator training
and operations manuals. Any problems should be reported to your line manager immediately.
It is the legal responsibility of every employee at work:
• to take reasonable care for the health and safety of themselves and others who may be affected by
their acts or omissions
• To report defective or faulty equipment immediately.
Before use
Check workstation for defects and report defects to your line manager.
The work area around any machine must be kept tidy.
Check that there are no trailing cables
All covers and/or guards must be in place and undamaged.
You must be familiar with the location and operation of all machine controls.
General
DO inform your manager of any medical condition which may affect your ability to perform
your work, or if you are pregnant.
DO follow operating instructions.
DO keep hands clear of any moving parts.
DO be aware of hypodermic needles, sharp objects and leaking or suspicious packages.
DO make sure your path is clear before you lift, carry or push a load.
WARNING:
Only authorised personnel are allowed to open and access the control panel,
power point trip switch panel and disconnect the power lead from the power
point.
DO NOT attempt to open the control panel cover.
DO NOT attempt to access the power point trip switch.
DO NOT attempt to disconnect the power lead from the power point.
DO NOT plug personal electrical equipment into the blue or red power socket
x x
Manual Handling:
To Bags
avoid repetitive actions when tipping mail bags, operators must be rotated at
pping
regular intervals.
Version: 1.3
Date: Feb 2013
Assess the weight of the bag. Inform your manager if bag is overweight. (If considered overweight, cut
seal and break down contents without lifting bag.)
Use the proper equipment to cut the bag tie (e.g. official scissors). Dispose of the string, label ties and
seals in a bin.
Use correct lifting and handling methods to lift the bag. Lift bag onto work surface in one movement.
When the bag is on the surface, feed mail out of the bag by hand before lifting to fully empty. Lifting
should be no higher than shoulder height.
Check bag is empty and place in appropriate empty bag storage container. Discard any damaged bags.
Avoid lifting and tipping bags in one movement.
DO lift full trays from the rear of the workstation using established manual handling techniques.
DO fill Yorks using the “Slide and Stack” technique.
DO manually lift empty grey Totes.
DO NOT over stretch or overstrain arm muscles while tipping a bag.
DO NOT leave bags loose on the floor.
Incline Conveyor
DO operate an emergency stop button in case of emergency
DO operate an emergency stop button when attempting to retrieve jammed mail, even if the
machine has already stopped.
DO secure, completely cover or remove all loose jewellery and loose clothing, and tie back long
hair before operating any machine.
DO NOT use this equipment unless you have been fully trained.
DO NOT attempt to start or interfere in any way with any machine which is under maintenance
control or displaying a “machine under maintenance” sign.
DO NOT tamper with electrical or mechanical equipment/remove safety covers/guards.
DO NOT attempt to insert, extract, touch any component, or attempt to remove any jammed
item of mail from a moving part of a machine.
DO NOT start the machine until you are sure no one is working on it.
DO NOT reset an emergency stop until the fault has been cleared.
DO NOT use personal stereos when operating this machine.
DO NOT lean, touch, stand, walk, or lie on any conveyor belt.
DO NOT make unauthorised or unsafe repairs to the conveyor
DO NOT overload conveyor belt or load above side height of conveyor.
DO NOT throw strings, label ties, or seals on the floor.
Flat Bed Conveyor
DO operate an emergency stop button in case of emergency
DO operate an emergency stop button when attempting to retrieve jammed mail, even if the
machine has already stopped.
DO secure, completely cover or remove all loose jewellery and loose clothing, and tie back long
hair before operating any machine.
DO NOT use this equipment unless you have been fully trained.
DO NOT attempt to start or interfere in any way with any machine which is under maintenance
control or displaying a “machine under maintenance” sign.
DO NOT tamper with electrical or mechanical equipment/remove safety covers/guards.
DO NOT attempt to insert, extract, touch any component, or attempt to remove any jammed
item of mail from a moving part of a machine.
Version: 1.3
Date: Feb 2013
DO
DO
DO
DO
DO
DO
DO
NOT start the machine until you are sure no one is working on it.
NOT reset an emergency stop until the fault has been cleared.
NOT use personal stereos when operating this machine.
NOT lean, touch, stand, walk, or lie on any conveyor belt.
NOT make unauthorised or unsafe repairs to the conveyor
NOT overload conveyor belt or load above side height of conveyor.
NOT throw strings, label ties, or seals on the floor.
Conveyor Safety Phrase Label
DO make sure you are aware of the Safety Phrase label which is has been affixed to the side of
the incline conveyor above the main control panel
Before use:
Mandatory Pre-use Checks
Version: 1.3
Date: Feb 2013
P1. Before Use:
P1.1 Carry out a visual check of
the conveyors general condition.
 Are there any protruding,
sharp, jagged edges?
 Has the conveyor received
any impact damage i.e. are
the covers damaged?
 Is the belt free from
damaged and visible wear?
 Is there visible damage to
the emergency stop
buttons?
P1.1
The equipment must not be used if
faults or damage are identified.
Report all defects to your line
manager immediately.
P2. (Machine not running)
Emergency Stop button check:
P2.1 There are up to eight
emergency stop buttons located
on the conveyor
Head Strike hazard
Be aware of the protruding
emergency stop buttons when
accessing the control panel or
picking up mail items from the floor.
P2.2 Engage the emergency
stops by depressing the buttons.
P2.3 Release the emergency
stop by turning the button anticlockwise.
P2.1
P2.2
P2.3
Machine Operation:
P3. Machine Start-up procedure:
Control Panel
P3.1
Check to ensure the people are
clear of the conveyor prior and
during the completion of the
machine start-up procedure.
P3.1 (On the control panel) Turn
the control power switch
clockwise into the vertical
position.
Version: 1.3
Date: Feb 2013
P4. Machine Start-up procedure:
P4.1 With the red light now
illuminated:
P4.2 Press the reset button and
hold for 5 seconds.
P4.3 Amber light now
illuminates.
P4.4 Press the start button.
P4.5 The first Warning sounds
with a single beep and Amber
light illuminates.
P4.6 Continuing to keep start
button pressed, second warning
alarm sounds, the green light
illuminates and the conveyor belt
starts.
P4.1
P4.2
P4.3
P4.4
P4.5
P4.6
Emergency stop & start-up procedure:
P5. Emergency Stop:
P5.1
Immediately press the nearest
emergency stop button.
The conveyor will now stop.
P5.1
P6. Emergency stop restart
procedure:
P6.2
P6.1
P6.3
Before starting this process ensure
the reason for the emergency stop
has been safely resolved and if
needed checked by an engineer or
other competent person.
P6.1 Release the emergency
stop button. Continual alarm
sounds.
P6.2 Press the reset button and
hold for 5 seconds
P6.3 Amber light now illuminates
P6.4 Press the start button,
alarm sounds once. Keeping the
start button pressed the alarm
sounds twice.
P6.5 The green light now
illuminates and the conveyor belt
starts.
P6.4
P6.5
Bag tipping to the conveyor:
Version: 1.3
Date: Feb 2013
P7. Loading the Hopper:
P7.1 Use correct lifting and
handling methods to remove the
bag from the York container.
Rest the bag on the front of the
Hopper
When the bag is on the surface,
empty or feed mail out of the
bag by hand before lifting to fully
empty. Lifting should be no
higher than shoulder height.
Store the empty bag in a suitable
receptacle.
P7.1
Bag tipping must only be
carried out at the front of the
incline conveyor.
DO NOT tip bags over the sides
of the conveyor
Warning!
Watch out for sharps!
DO NOT overload the conveyor
belt
Flat Bed Conveyor
P8. Working with the Conveyor:
Position 2.
P8.1. Extract the appropriate
mail items as they pass on the
conveyor and sort to the
associated container.
P8.1
Warning!
watch out for sharps
Version: 1.3
Date: Feb 2013
P9. Conveyor Sensor:
P9.1. Sensors are located at the
end of the conveyor to prevent
mail items falling form the belt.
As mail items pass the sensors,
the belt will automatically stop.
The belt will again re-start once
the mail item blocking the sensor
is removed.
P9.1
P9.2. Through local management
procedures the sensor can be
disabled on the control panel by
use of a key switch
P9.2
Warning!
If sensor is disabled items
will travel off the end of the
belt. Ensure a suitable mini
sleeved York container is in
place.
P9.3. Where the end of the
conveyor has a no “Bump Bar”
under no circumstances must a
container be placed at the end of
the conveyor and the sensor
“MUST “be enabled and the key
switched to the “ON” position.
NO container allowed at end of
conveyor!
P9.4. Where the end of the
conveyor has a “Bump Bar” the
sensor can be enabled or
disabled through the local
management procedure.
Container allowed at end of
conveyor!
GENERAL INFORMATION
(Anything specific to the task &/or work equipment)
All operators must have received suitable and sufficient manual handling lifting and handling
training.
Link to 2:15 Manual Handling:
Version: 1.3
Date: Feb 2013
https://portal.royalmailgroup.com/sites/A402/Risk/Forms/Manual.aspx
COMPETENCY
(Beyond the training received from this SSOW list any other training that is required)
Training
Format (Course/Certificated/Qualification)
Following initial installation and equipment deployment:
Theory and practical with the equipment.
National project lead to ensure training is provided on
site and delivered to the workplace coaches.
Manual Handling training
WTLL based with practical demonstration.
PERSONAL PROTECTIVE EQUIPMENT
(This PPE is to be provided & used, as specified, by people undertaking this task &/or using this work equipment)
Item
Ordering details
Comments
N/A
SAFETY SIGNAGE
(The below Safety Signage is to be displayed, as specified, in the workplace where this SSOW applies)
Item
Ordering details
Comments
N/A
All of the above controls will, if implemented effectively, reduce the safety risks associated with this task &/or work
equipment to an ACCEPTABLE level and as such will be ‘Adequately Controlled’.
SSOW AUTHORISATION
Name
Signed
Ray Pipe
Author
Date
07/09/2015
Safety Support
(where applicable)
I have authorised this SSOW for deployment
11/09/2015
Safety Authorisation:
(As defined in Levels of
Authority Appendix 4)
Peter McGowan
On deployment in the Work Area a copy of the SSOW should be retained for reference
SSOW LOCAL ARRANGEMENTS
SSOW Title
Region
Unit
(Where applicable to individual Unit)
Version: 1.3
Date: Feb 2013
(For use where a Unit Manager wants to add local arrangements to a Group or Business Unit SSOW)
While the SSOW provides sufficient INFORMATION and INSTRUCTION to allow managers to control safety risks for a
specific task &/or item of work equipment it is possible that local circumstances within a Unit could introduce
additional risks. Where local risk assessment indicates this to be the case LOCAL ARRANGEMENTS could be prepared
help to remove or reduce the additional risks to an acceptable level. This additional INFORMATION and INSTRUCTION
must be used within the Unit(s) affected to inform and instruct those employees affected. It should also be used at
induction and refresher training events to inform employees how a task they are involved in can be completed safely
&/or how work equipment they are using can be used safely. Any training or briefing using the SSOW should be
recorded to show where the additional information and instruction has been given.
NOTE: Local amendments to a SSOW cannot be less stringent than the national version.
LOCALISATION
Locally Identified Risk
LOCAL SIGN OFF
Risk Rating
(ref. SMS2.1
Risk Matrix)
Control
Signature
Date
Local Author
Safety Authorisation:
(As defined in Levels of Authority set out in
the Standard)
11/09/2015
Peter McGowan
Version: 1.3
Date: Feb 2013
1
Ergonomic Screening Assessment
Serial Number/identification
mark
Work Equipment Group
Work Equipment Details
Incline conveyors
Project Manager (contact
details)
Martyn Dundas
(Appendix 4)
Work equipment photograph
Conveyors
NOTE: This is a preliminary assessment which may lead to a more detailed ergonomic assessment depending upon
the answers to the following questions. If any of the answers to the questions below are No remedial action or a
more detailed assessment will be required. Contact Jane Dillon or Corinne Parsons if you need help to complete the
assessment. Reference should be made to the illustrations Fig 1, Fig 2, Fig 3 when answering these questions
1
1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
2.3
2.4
2.5
2.6
For this equipment …….
Is the equipment less than 16kg
total weight? If yes go to Question
1.2, if no go to Question 1.3
Will suitable handles be provided
for lifting and carrying the
equipment?
If the equipment exceeds 16kg
total weight will alternative means
of transporting be provided?
(wheels for example)
Are all visual aids/instructions that
form part of the equipment clear
and easy to understand?
Is the working space where this
equipment is likely to be used
adequate i.e. unlikely to be
congested or cramped?
For this equipments intended use (so
far as can be ascertained) …….
Will all the lifting tasks be within the
HSE guideline figures, (see Fig 1)?
Will all the lifting tasks be repeated 7
times/min or less frequently?
Will all the forces required to keep a
load in motion require little effort
(e.g. be less than 7kg)?
Will all the forces required to initiate
movement easy to exert (e.g less
than 15kg)?
Will all the pushing forces required be
exerted with hands between knuckle
and shoulder height?
Will all forces or items lifted whilst
seated be less than 5kg?
Yes
No
N/A
If No state what remedial action
required
Detailed assessment
required Y/N
required
Detailed assessment
required Y/N
No
N/A
Yes
Yes
Yes
No
N/A
Yes
No
No remedial required as it is
parcels being lifted (not large
parcels)
Yes
Yes
Yes
N/A
Version: 2.0
Date: May 2013
2
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
Will any items to be carried in the
hands weigh less than 10kg and need
carrying for less than 1 minute at
time?
Can all lifting and handling tasks be
carried out without twisting or
bending?
Are all tasks completed within the
Golden Zone, (AA or A on Fig 3)?
Yes
Will shorter or taller people find
reaching or seeing to complete task
elements involving this equipment
easy?
Are work surface heights
appropriate? (e.g. around 700mm
for seated work, 950 – 1000mm for
standing work; reduced to
accommodate items placed on work
surface or use of tools. Bag tipping
heights below 500 mm)
Are all movements likely as part of
using this equipment Low or Medium
risk 2 on the Muri chart, (see Fig 2,
ignore walking)
Are all postures on the Muri chart
scoring Medium or High held for less
than 1 minute at a time or repeated
less than 7 times/min, (see Fig 2,
Ignore walking)?
Can suitable time be allowed in any
task using this equipment for rest
and recovery?
Can suitable seats be provided for all
tasks that can be done seated?
Where this equipment is used for
tasks lasting longer than one hour
and cannot be done seated will
provision been made to allow sitting
down during breaks?
Yes
Yes
No
There are two low volume
selections which are situated
beside and slightly behind
the operators. There is no
remedy required
N
Yes
Yes
Yes
Yes
N/A
Yes
ERGONOMIC ASSESSMENT
I can confirm that I have the appropriate level of competency, in terms of knowledge and experience of completing
other assessments, to allow me to sign off this preliminary Ergonomic assessment. I can confirm that on completion
of the assessment and any remedial actions that are identified as necessary and no significant risks are identified
and still outstanding then this work equipment is fit for purpose and the intended use to which it will be put within
the Business as far as its ergonomic impact is concerned, and that the user of the work equipment or persons who
may be affected by its use have been safeguarded from any risks.
NOTE: If remedial actions highlighted in the remedial action column indicate that a more detailed Ergonomic
assessment report is required then the ergonomists Jane Dillon or Corinne Parsons should be contacted for advice.
(as per page one)
Assessor name
(Not valid unless signed)
Incline Conveyors
Assessment date:
10/11/2015
Martyn Dundas
Assessor signature
(not valid unless signed)
Martyn Dundas
The assessors must retain a copy of this Ergonomic assessment and forward a copy to the Project Manager if the
assessor and the project manager aren’t one and the same person.
Version: 2.0
Date: May 2013
3
End of ERGONOMIC Assessment
Fig 1: HSE Lifting and Handling Guideline Figures
Fig 2: Muri Chart
Version: 2.0
Date: May 2013
4
Version: 2.0
Date: May 2013
5
Fig 3: Golden Zone
C
1700
1400
1150
900
Version: 2.0
Date: May 2013
WCM Parcel conveyors
ergonomics assessment
19th February 2015
Corinne Parsons
Lead Ergonomist
SHE Technical Support, Ergonomics
[email protected]
07738 311368
Motorola Finger Scanner Initial Ergonomics Assessment – Version Creation Date: 19/06/14
Royal Mail is a trading name of Royal Mail Group Ltd. Registered number 4138203. Registered in England and Wales. Registered office: 100 Victoria Embankment, London, EC4Y 0HQ
Contents
1.0 Introduction .......................................................................................................................................... 3
Assessment .................................................................................................................................................. 4
Home Counties North .......................................................................................................................... 4
Edinburgh ................................................................................................................................................ 5
Assessment of Repetative Work ......................................................................................................... 7
Conclusions .................................................................................................................................................. 8
Motorola Finger Scanner Initial Ergonomics Assessment – Version Creation Date: 19/06/14 – Page 2 of 9
1.0 Introduction
An ergonomics assessment of the parcel conveyors in use at Home Counties North (HCN)
and Edinburgh was carried out at the request of Ken House, National Workplace
Organisation Deployment Lead, as part of the evaluation of the national WCM parcel
conveyor trial.
This assessment should be read in conjunction with the Ergonomics Screening assessment
which was carried out at the start of the conveyor project.
WCM conveyor Ergo
Screening Assessmen
Three points on the screening assessment were identified as requiring a more detailed
ergonomics assessment during the trials:2
2.2
For this equipments intended use (so
far as can be ascertained) …….
Will all the lifting tasks be repeated 7
times/min or less frequently?
Yes
No
N
N/A
required
Parcel sorting activities for small
parcels. Manual handling risk will
be low provided throwing distances
are minimised and provision is
made to walk round with any heavy
or difficult parcels
Detailed assessment
required Y/N
Assessment
during trial
2.9
Are all tasks completed within the
Golden Zone, (AA or A on Fig 3)?
N
Parcels will be thrown into miniyorks, layouts may vary at different
centres but should not exceed 1
deep if across a conveyor or 2 deep
elsewhere. Space should be allowed
to walk round to place any items
that are too flimsy, heavy or
awkward to throw easily.
Review during
trial
2.13
Are all postures on the Muri chart
scoring Medium or High held for less
than 1 minute at a time or repeated
less than 7 times/min, (see Fig 2,
Ignore walking)?
N
Depends on sorting layout. Parcel
sorting frequency will be greater
than 7times/min, parcels thrown
over a distance or difficult parcels
to throw will result in arm posture
at or above shoulder height
Review during
trial
A visit was made to Edinburgh and HCN Mail Centres to observe the operation during the
trials and to discuss the working methods with the operators.
Assessment
The conveyors in use at the two mail centres are similar. Both have the benefit of a low
level tipping hopper, rising conveyor and working belt at a good working height for standing
work. The belts differ in that the one at HCN is 60cm wide and the one at Edinburgh is
50cm wide.
The layouts of containers and working methods differ at the two mail centres. Both have
one person tipping into the hopper and two people sorting from the conveyor into miniyorks or full sized Yorks with ALP sleeves. At HCN the staff work on both sides of the
conveyor and at Edinburgh the staff work on one side and the containers are positioned on
the other.
Home Counties North
The conveyors are used for all primary parcel traffic except for the large parcels which are
sorted in a separate bullring. Both parcel bags and parcels in ALP sleeves are tipped into
the hopper.
Home Counties North set up
There are 8 selections around the end of the conveyor in mini-Yorks which are shared
between the two staff working on the belt. In addition there are 3 full sizes Yorks for
foreign, second class and a local selection. There is an additional mini-York on each side for
mis-sorts
Three of the selections on each side and the mis-sorts are within easy reach of the
individual on that side. The majority of selections are well outside the golden zone and it is
necessary to throw the parcels. For the furthest containers the throwing distance is in
excess of 2m causing the arms to be raised above the shoulder height to throw at times.
This arrangement exceeds the recommendation in the ergonomics screening assessment
for mini-yorks to be only one deep if on the opposite side of the conveyor or two deep if on
the same side. As there are two people, one on each side of the conveyor, anything that
would be difficult to throw, or for the furthest selections could be sorted by the person on
the same side of the conveyor. All selections can readily be walked to with items that are
particularly difficult to handle. During the observations occasional parcels missed and
landed on the floor.
Sorting to closer selections
Sorting to more distant selections
Edinburgh
The conveyor at Edinburgh was 500mm wide and the containers were arranged on the far
side of the conveyor. The conveyor was used for Horizon and PPI parcels. Collection parcels
were processed separately due to the need to cancel the stamps. There were 11 containers
altogether including 5 roads, local selections, Glasgow and foreign selections. For First Class
parcels mini-Yorks were used for the roads and the local parcels and full sized Yorks were
used for the other selections. For Second Class parcels full sized Yorks were used for all
selections.
First class set up
Second class set up
The conveyor was easy to sort across due to being relatively narrow. Although the reach is
slightly outside the golden zone it was a comfortable distance to sort parcels without the
need to throw them. The working method was for two people to work on the belt and for
parcels for the selections at the far end of the belt to be left on the conveyor for the second
person to sort.
It was easy to sort parcels into the full sized sleeves with the front open but it was harder to
sort over the top of the closed sleeves as this requires sorting items above shoulder height,
increasing the strain on the shoulders and arms. It was easy to reach across the conveyor
to sequentially close the containers. This should be the normal practice rather than
unnecessarily sorting all parcels over the top of the sleeve as was observed during the visit.
The operators using the conveyor at the time of the visit preferred this to their previous
method of working. The low level tipping hopper was seen as a particular benefit. The main
concern raised was the tendency for parcels to fall off the side, particularly if there was a
big batch of slippery poly-wrapped items coming up the conveyor together. The main point
at which the parcels fell off was the interface between the rising conveyor and the flat
sorting conveyor. A slightly higher side rail at this point may help but should not extend onto
the working area as this will get in the way of elbows when sorting. In addition it may be
necessary for the individual working at the first position to move parcels that may fall first.
Using a wider conveyor may reduce the number of parcels which fall off but this would have
the disadvantage of increasing the risk of sorting across the conveyor by placing all
selections further outside the golden zone and so is not recommended.
Parcels surge
Parcels fallen off conveyor
Several concerns were raised about the conveyor itself:•
•
•
Temperamental to start
Tearing of the uplift conveyor belt which was not considered strong enough material
Vulnerability of the sensor to damage from parcels and it was suggested that this
should have a cage to protect it from damage.
Sensor
Assessment of Repetative Work
The actions carried out for both the HCN and Edinburgh layout were analysed and an
assessment of the risk from repetative work was carried out using the Health & Safety
Excecutive ART tool. The tool takes into consideration the postures of the hands, wrists,
arms, trunk and neck; the repetativeness, task duration and forces. The results are given in
the table below for the two layouts.
HSE ART tool .pdf
Risk factor
A1 Arm movements
A2 Repetition
B Force
C1 Head/Neck posture
C2 Back posture
C3 Arm posture
C4 Wrist posture
C5 Hand/finger grip
D1 Breaks (between 1 and 2
hours between breaks)
D2 Work pace
D3 Other factors
Task score
D4 Duration multiplier
Exposure score full shift
Psychosocial and other risk
indicators
HCN
Edinburgh
Score
3
3
1
2
0
2
1
1
2
Score
3
3
0
1
0
1
0
1
2
0
0
15
1 (all shift)
0.75 (up to 4 hours)
15
11.25
Not identified, site
dependant
0
0
11
1 (all shift)
11
8.25
Not identified, site
dependant
The results show that the risk from repetitive work is higher for the HCN layout than for the
Edinburgh layout for First Class mail. If carried out for a whole shift the HCN layout would
pose a medium risk of injury for repetitive work, Edinburgh would pose a low risk. For the
Second Class layout at Edinburgh, with full sized York sleeves, the risk would increase to
medium if the sleeves were closed during the whole sorting process.
Conclusions
•
The introduction of a parcel conveyor with a low level tipping hopper, rising conveyor
and good working height sorting belt reduces the risk from manual handling
compared to tipping parcel bags into a mini-York/ALT or onto a table.
•
The Edinburgh layout has shorter sorting distances and so poses a lower risk of
injury from repetitive work than the HCN layout.
•
Both layouts are designed for two sorters to work together and so risks can be
minimised by the individual closest to the selection sorting the parcels rather than
throwing them over long distances.
•
Where full sized Yorks are used the sleeves should be closed as the container fills
rather than closing them at the start of the sorting process. This prevents
unnecessarily sorting above shoulder height and which increases the risk of injury.
Tipping from York Sleeve to Parcel
Conveyor
Ergonomics Assessment
17th April 2016
David Annett
Chartered Ergonomist
Ergotherapy
[email protected]
www.ergotherapy.co.uk
07957 542341
1
Introduction
An ergonomic review of tipping parcels from York Sleeves into an ascending conveyor was
requested by Ken House, National Workplace Organisation Deployment Lead. The
operation was observed on the early shift at Manchester Mail Centre and took place on 5th
April 2016. Operators and managers were interviewed and video was taken for postural
analysis. Mark Connolly (Shift Manager) and Mathew Bullen (WCM Champion) were
present during the visit.
Loading the belt with Parcels from the York Sleeve
Background
Manual parcel processing is now a large part of the Royal Mail Operation. Many parcels are
sorted from York Sleeves into other York Sleeves in a Bullring. The hopper and ascending
belt were originally designed for bag tipping, but has been used with York Sleeves for the
last 6 months at Manchester. This provides sorters with a continuous stream of parcels
presented at a good working height. This work area was assessed by Dr Corinne Parsons in
February 2015 at Edinburgh and Home Counties North (HCN) but focussed on the sorting
operation, with alternative layouts of containers. In these offices one person was tipping and
two people were sorting from the belt.
2
Assessment
The operation observed in Manchester was different from the offices in the previous report;
as there were four operators sorting from the belt rather than two. This appeared to put
more pressure on the person tipping the parcels onto the belt, as they were expected by the
managers to get through 15 Yorks an hour in order to cost-in the manpower of the operation.
Some of the operators felt they were being put under pressure to work faster than their
natural pace in order to meet these goals. The CWU representative Graham Booth felt that
staff were being put under undue pressure to achieve these goals.
Several operators were observed loading the belts and they were generally able to keep a
good posture, minimising bending and twisting. The York Sleeve self-levelling system
generally works well to minimise bending, but there will always be times when a heavier item
is in the bottom so the base does not raise sufficiently. Operators were generally good at
positioning the York close to the hopper and angled such to minimise twisting.
The type/size of parcel made a significant difference to the speed of the operation – larger
parcels tended to be lifted with 2 hands and can be sorted quite quickly, so it was harder to
keep up. With small items, many could be grabbed at a time and they took longer to sort, so
it was easier to keep up. A new working method introduced by the WCM champion is to
have a second York available with small items, so that they can alternate with a few handfuls
of these to slow down the sorters so it is easier to keep up. This appeared to work well with
the limited amount of time it was observed.
The tipper role was rotated every hour with other tasks in the work area, although some staff
liked the task and were not always rotated. Taking the empty York away and fetching a full
York gives the tipper a break from the repetitive work, but if they are away from the belt for
too long the belt empties and the sorters may be standing waiting for work which can put
more stress on the tipper and manager. This can vary depending on the quality of portering.
Risks were increased when:
•
•
•
•
•
Operators did not apply the brake of the York so it moved away from them if they
leant into the York.
Items were thrown longer distances to fill in gaps higher up the belt. (Some operators
walked down the side of the belt to do this, but this took up time).
The York was not placed close to the belt which could introduce more twisting when
loading.
Pressure on manager/tipper if the belt was seen to be empty or the closest sorters
were standing waiting for work.
Staff are not rotated to another task after an hour.
3
Assessment of Repetitive work
The actions carried out were analysed and an assessment of the risk from repetative work
was carried out using the Health & Safety Excecutive ART tool. The tool takes into
consideration the postures of the hands, wrists, arms, trunk and neck; the repetativeness,
task duration and forces. The results are given in the table below for Manchester where
there are four people sorting. An estimate has also been given for the risk when only 2
people are sorting assuming they will not be required to load the belt as quickly. Hence
lower figures for the frequency of arm movements, repetitions and work pace.
Risk factor
A1 Arm movements
A2 Repetition
B Force
C1 Head/Neck posture
C2 Back posture
C3 Arm posture
C4 Wrist posture
C5 Hand/finger grip
D1 Breaks (between 1 and 2
hours between breaks)
D2 Work pace
D3 Other factors
Task score
D4 Duration multiplier
Exposure score half shift
Psychosocial and other risk
indicators
4 people sorting
Estimate for 2 people
sorting
Score
5
6
1
1
1
2
1
1
2
Score
3
3
1
1
1
2
1
1
2
1
0
21
1 (all shift)
21
15.75
Under pressure, but
site dependant
0
0
15
1 (all shift)
15
11.25
Less time pressure?
Risk Levels
Exposure score
Proposed exposure level
Action
0–11
Low
12–21
Medium
22 or more
High
Consider individual
circumstances
Further investigation
required
Further investigation
required urgently
4
Conclusion
If the task of loading the belt from a York Sleeve is undertaken at a steady rate (less than 20
lifts per minute) then it is considered a low risk if undertaken for half shift or (low)medium risk
if undertaken for a full shift. This assumes that the York is placed close to the belt to
minimise twisting and the York brake is applied.
If the task is undertaken at a faster pace – over 20 lifts per minute then it is rated as a
medium risk for a half shift and full shift, although the full shift is very close to the high risk
category. Psychosocial indicators at Manchester suggested there was pressure on
managers and operators to maintain a high work rate to achieve emptying 15 Yorks per
hour.
Handling rates at Manchester varied between 16-30 lifts per minute, so further investigation
is recommended. This could include the following:
i.
ii.
iii.
Review other offices using this system to check perceived pressure and handling
rates.
Consider using fewer sorters to reduce the pressure on the tipper (2 or 3).
Review in more detail if having a second York with smaller items, to top up the belt,
reduces the handling rates.
5
Pictures
Increased risk when throwing items to empty gaps higher up the belt (left). Walking along
the belt to drop them higher up takes more time (right).
Placing the York too far from the Belt can
lead to more twisting of the torso.
The conveyor sides are relatively low, so if
sometimes items may fall over the side they
have to be picked off the floor.
Layout for when two Yorks are used, so the
operator can alternate between left and right
handed.
This operator preferred to work from one
side.
6
Operator Instructions
Operating Instructions
for Cut and Tip conveyors
Incline Conveyor and 4m Horizontal Conveyor
for
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
NAME
DRAWN
1
DEBUR AND
BREAK SHARP
EDGES
FINISH:
SIGNATURE
DATE
DO NOT SCALE DRAWIN
TITLE:
Table of contents
About this document
Information about this document
Warning signs in this document
3
4
Safety
Basic safety instructions
Intended use
Incorrect use
Specialists
Dangers
Malfunctioning during operation
Interfaces to other devices
Operating modes
5
5
5
5
6
6
6
7
Position of Key Components
8
Start up and operation
Initial start-up
Operation
Procedure for accidents or malfunctioning
9
9
9
Operational Procedures
10
Troubleshooting
Daily Checks
12
14
Risk assessment
Certificate of Conformity
15
16
APPENDIX
A – Print out procedures
17
2
Information about the operating instructions
Contents
- These operating instructions contain important details and information about the
various operating phases of the conveyor:
• Transport, assembly and start-up
• Safe operation, required maintenance, remedy of possible faults
• Spare parts, supplementary accessories
Product affiliation - The operating instructions describe the finished conveyor at the time of initial delivery.
Supplementary to these operating instructions, special contractual agreements and
technical documents apply for special conveyor versions and additional appliances.
- These operating instructions are an integral part of the conveyor
- To ensure trouble-free and safe operation as well as the settlement of any warranty claims,
always read these operating instructions first and observe all the information contained herein.
- Keep these operating instructions close to the conveyor.
- Always give the operating instructions to each subsequent owner or user.
Beumer Group UK shall not accept liability for any damages or malfunctioning caused by non-adherence to
these operating instructions.
- Please contact Beumer Group UK if you have any further questions after reading these operating instructions.
BEUMER House, 9 Cartwright Court, Cartwright Way, Bardon Hill
LE67 1UE Leicestershire
United Kingdom
Phone: 01530 4412 97
Fax: 01530 8157 17
E-Mail: [email protected]
CONVEYOR IDENTIFICATION
Electrical Pass:
RM Office:
Y/N
System:
Belt width
Horiz. Length
LHS
RHS
Serial no Inc
Serial no Horiz
Date of Install:
Engineer:
3
Warning signs in this document
The warning signs in this document provide information about dangers which may
arise during conveyor operation. The relevant warning signs are displayed in the
"safety" section.
There are three types of warning signs:
• DANGER
• WARNING
• CAUTION
Signal word
DANGER
WARNING
CAUTION
Meaning
Consequences of non-adherence
warns of an imminent
danger
warns of a possible
danger
warns of a possibly
dangerous situation
death or serious injuries.
death or serious injuries are
possible.
slight injuries are possible.
4
Safety
Basic safety instructions
The conveyor was state of the art and generally safe to operate at the time of
delivery; however dangers may still arise during utilization:
• Danger of death or personal injury to operators and others
• Adverse effects on the conveyor and other areas
Non-adherence to the information in these operating instructions can result in life
threatening injuries!
- Read these operating instructions carefully and adhere to the information
contained herein to ensure safe conveyor operation.
Intended use
The conveyor is intended for use in mail sort environments and should only be
applied to transport goods, such as, parcels or letters.
The conveyor is intended for certain application areas only and its defined capacity limits must not be exceeded
during operation. Maximum loading is 50kg/m, over loading may cause product to fall off the conveyors
Any other use without prior consultation with Beumer Group UK is not recommended. Operating conditions which deviate from those specified require
Beumer Group UK to agree that the changes are safe.
Users should not carry out alterations or modifications without agreeing such
changes with Beumer Group UK.
Incorrect use
The conveyor is not intended for transporting people. Beumer Group UK or Conveyortek take no responsibility if
the conveyor is not used as originally intended.
Specialists
Specialists are personnel who have the knowledge to read and understand the
operating instructions and the ability to carry out work professionally while observing
national regulations.
5
Safety
Dangers
This section provides information about various dangers and damages which
may occur when operating the conveyor.
- Do not climb on the conveyor during operation.
- Only carry out maintenance and repair work once the machine has been de-energized and
measures have been taken to ensure that it cannot be started accidentally.
- Organise additional safety measures for passageways and to stop people
reaching into the moving conveyor.
- Protective covers and housings should only be removed by a competent person carry out maintenance
work. All covers and housing must be refitted before the system can be handed back for operational use.
- Regularly inspect safety equipment.
- No unauthorised access into electrical enclosures or guarding.
- Loose clothing could get caught in the conveyor.
- Jewelry, such as necklaces or bracelets may get caught in the conveyor.
- Long hair could also get caught in the conveyor..
- Always remove materials and objects which are not required from the work environment area to avoid trip
hazards.
Malfunctioning during operation
- Regularly inspect the conveyor for visible damage.
- Stop the device immediately and ensure that it cannot be started accidentally
in the event of: Smoke, unusual noises, trapped or broken goods, defective
support stands, side guides or accessory appliances.
- A specialist must locate the source and remedy the fault before the conveyor can be used again.
Interfaces to other devices
Danger zones can arise when integrating the conveyor into a system. These
zones will not be described in these operating instructions and must be analyzed
during installation and initial start-up of the respective system.
After connecting the conveyor to other conveyors or machines, always check
for new danger zones prior to initial start-up. Especially at the drive roller
where cuts, nips and crushing can occur.
6
Safety
Operating modes
Normal mode. Operation when installed at the end customer's site as an individual
conveyor or as a conveyor in a system.
Special mode. All operating modes which are required to guarantee and
maintain safe and normal operation and listed below.
SPECIAL OPERATING
MODEmode
Special operating
Transport/Storage
TRANSPORT/STORAGE
Assembly/Initial start-up
ASSEMBLY/INITIAL
START-UP
Cleaning
CLEANING
Maintenance/Repairs
Troubleshooting
Fault elimination
MAINTENANCE
REPAIRS
Shut-down
TROUBLESHOOTING
Disposal
FAULT ELIMINATION
EXPLANATION
Explanation
Comment COMMENT
Loading and unloading, transport and
correct storage
LOADING & UNLOADING,
TRANSPORT & CORRECT STORAGE
Installation at the end customer's and
execution
of a test runAND EXECUTION OF A TEST
INSTALLATION
AT END CUSTOMERS
Cleaning the outside RUN
without removing
When de-energized
safety equipment
CLEANING THE OUTSIDE WITHOUT REMOVING SAFETY
WHEN DE-ENERGISED
Maintenance and inspection tasks
When de-energized
Trouble shooting EQUIPMENT
during normal operation
Eliminating
theINSPECTION
fault
When de-energized
MAINTENANCE
AND
TASKS
WHEN DE-ENERGISED
Removal from the system
When de-energized
TROUBLE SHOOTING
WHEN DE-ENERGISED
Removal from the system and disassembly
When de-energiz
ELIMINATING THE FAULT
WHEN DE-ENERGISED
SHUT DOWN
REMOVAL OF THE SYSTEM
WHEN DE-ENERGISED
DISPOSAL
REMOVAL FROM THE SYSTEM AND DISSASSEMBLY
WHEN DE-ENERGISED
The conveyors are fitted with Emergency Stop devices which are monitored to ensure the system
comes to a safe stop when activated or if the safety circuit has a fault
7
SENSOR
EMERGENCY
STOPS
BEACON
INCLINE
MOTORISED
DRUM
NON OPERATOR SIDE
CONTROL
CABINET
EMERGENCY STOP
HORIZONTAL BELT
DRIVE MOTOR
SENSOR
POSITION OF KEY COMPONENTS
OPERATOR SIDE
EMERGENCY STOPS
CONVEYOR SHOWN IS LEFT HAND SIDE OPERATOR
WORKING
CONTROL CABINET AND BEACON ARE NORMALLY
LOCATED ON OPERATOR SIDE
8
Start-up and operation
Initial start-up
Wear correct PPE
The conveyor has been factory tested. The belt adjustment or the belt tension is factory set and
does not usually have to be altered.
- If goods become trapped isolate the conveyor and only if easy and safe to do so remove the item
If not easy to do so then call Engineering
Procedure for accidents or malfunctioning
- Stop the conveyor system and ensure that the isolator is switched off.
- In case of an accident: Use the site accident procedure.
- Inform your supervisor.
- Only restart the conveyor after it has been deemed safe and released by your supervisor
9
NORMAL OPERATIONAL PROCEEDURE
CONTROL
CABINET
CONTROL
CABINET
LIGHT
BEACON
RESET
BUTTON
START
BUTTON
RED
STOP
BUTTON
AMBER
GREEN
SENSOR
ON/OFF
POWER ON
INDICATOR
MAIN ISOLATOR
Normal Working
a)
b)
c)
d)
Ensure the main isolator is switched on on the control cabinet.
If red lamp with buzzer sounds continuously an emergency stop is depressed
Check that the sensor is clear
On the control panel press the blue reset button for 5 seconds until a constant amber light shows on
the beacon
e) Press and hold the start button for 3 seconds, this will show a flashing amber light on the beacon and
sound an intermittent buzzer for 3
f) During the sounding of the buzzer and flashing beacon the operator should check that colleagues are
clear of the conveyor. Releasing the button will prevent the conveyor from starting
g) When the signal ends the conveyor will start automatically and is ready for operational us
h) The conveyors will continue to run with a constant green light until the sensor beam is broken, upon
which an intermittent amber light will be displayed
i)
To stop the conveyor press the stop button, the green light will flash to indicate
"operator stop". To start again press start button and the conveyor will start again without warning
10
The system will fall into sleep mode if:a) On a green flashing light it is left idle for more than 5 mins and require starting again
b) On an amber flashing light or constant green light with no activity for more than 2 hours and will
require starting again
EMERGENCY STOP
In the case of an emergency one of the 4 E stop buttons on the four corners of the incline conveyor or
2 on the horizontal conveyor operator side must be pressed.
Doing this will initiate a continuous buzzer as well as a constant red light on the beacon.
To re-start use the following procedure:a) Reset the E stop
b) On the control panel press the blue reset button until amber light shows
c) Press and hold the start button for 3 seconds, this will sound an intermittent buzzer and flashing
amber light on the beacon for 3 seconds
d) During the sounding of the buzzer and flashing beacon the operator should check that colleagues
are clear of the conveyor. Releasing the button will prevent the conveyor from starting
e) When the signal ends the conveyor will start automatically and is ready for operational use
f) The conveyors will continue to run with a constant green light until the sensor beam is broken,
upon which an intermittent amber light will be displayed
g) To stop the conveyor press the stop button, the green light will flash to indicate
"operator stop". To start again press start button and the conveyor will start again without warning
This conveyor should only be used by trained operatives
CONVEYORS SHOULD NOT BE OVER LOADED
MAXIMUM LOAD 50Kg/M
11
Troubleshooting
In case of malfunctioning
Operators are only allowed to eliminate faults which are clearly related to an
operator error! The danger zones at the conveyor are covered by guards and
protective equipment.
- Stop the device immediately and ensure that it cannot be started
accidentally.
- Remove the conveyed material.
- Always make sure that nobody can be injured before restarting the conveyor.
- Dispose of any leaked gear oil correctly. If necessary, a specialist must
replace the geared motor.
12
DAILY CHECKS
TROUBLESHOOTING WARNINGS
LIGHT
BEACON LIGHT
Interval
STATUS
SOUNDER
Part
Entire conveyor YES
CONSTANT
CONSTANT
CONSTANT
Belts
YES
FLASHING
Visible cables
NO
FLASHING
NO
3 PULSES
E Stops
8 PULSES
RESET ESTOP AND FOLLOW START
Report
if necessary
PROCEEDURE
Report if necessary
General
inspection
ESTOPvisual
DEPRESSED
Check screwed connections
Monthly
Listen for noise
SYSTEM IS RUNNING
development
Report if necessary
Daily
Check the straight running
FAILURE IN SAFETY SYSTEM
Check for damage
Report if necessary
CALL AN ENGINEER
Report if necessary
Daily
SENSOR HAS BEEN COVERED
SYSTEM HAS BEEN RESET
NO
FLASHING
ACTION
Required work
Weekly
Monthly
YES
Rollers
CAUSE
Task/
Inspection
Check for damage
General Visual Inspection
PRESS AND HOLD START BUTTON
NONE REQUIRED
REMOVE ITEM BLOCKING SENSOR,
WILL START
Report ifCONVEYOR
necessary
STOP BUTTON PRESSED
Report if PRESS
necessary
START BUTTON
AFTER PULSES
INTERNAL OR SUPPLY FAILURE
AFTER PULSES
Check for damage
Check that they work
MOTOR OVERHEAT
CALL AN ENGINEER
Report if necessary
Report if necessary
CALL AN ENGINEER
Remove if safe to do so
Report if necessary
Daily
Trapped items
Daily
13
troubleshooting table
DAILY CHECKS
Part
Interval
Task/ Inspection
Required work
Entire conveyor
Weekly
Monthly
General visual inspection
Check screwed connections
Report if necessary
Report if necessary
Rollers
Monthly
Listen for noise
development
Report if necessary
Belts
Daily
Check the straight running
Check for damage
Report if necessary
Report if necessary
Visible cables
Daily
Check for damage
General Visual Inspection
Report if necessary
Report if necessary
E Stops
Daily
Check for damage
Check that they work
Report if necessary
Report if necessary
Trapped items
Daily
Remove if safe to do so
Report if necessary
14
OPERATOR
OPERATOR
OPERATOR
GENERAL RUNNING
GENERAL RUNNING
GENERAL RUNNING
ENGINEER
OPERATOR
TIPPING MAIL BAGS
GENERAL
OPERATOR
TIPPING MAIL BAGS
CAUGHT IN BELT
ACCIDENTAL START UP
STATIC SHOCK
ELECTRIC SHOCK
MOTOR OVERHEATING
4
MANUAL HANDLING INJURIES
TAIL DRUM INRUNNING NIP POINT
HEAD DRUM INRUNNING NIP POINT
OPERATOR
OPERATOR
CAUGHT IN BELT
OPERATOR
TIPPING MAIL BAGS
CLEARING MAIL
PARTS LOOSENING
TRANSPORTATION
OPERATION
TIPPING OVER
TRANSPORTATION
HAZARD
GENERAL
PERSON AT RISK
PROCESS
AREA
1
1
2
2
2
2
4
3
3
4
2
2
3
3
2
3
2
4
2
2
3
3
2
4
1. IMPROBABLE
3. POSSIBLE
4. PROBABLE
RISK RATING: LOW: 1 -10 MEDIUM: 11-15 HIGH:15-25
2.REMOTE RISK
RISK = SEVERITY X PROBABILITY
PROBABILITY
5. LIKELY
BEFORE MOVING FROM SITE TO SITE A GENERAL CHECK OF ALL BOLTS
SHOULD BE CARRIED OUT
ALL BOLTS USED WITH SPRING WASHERS TO PREVENT
LOOSENING
MOTOR RATED TO DO MORE BUT HAVE BUILT IN A SAFETY FACTOR
CONTROL CABINET CANNOT BE OPENED UNLESS ISOLATED FIRST. SHOULD
ONLY BE OPENED BY TRAINED ENGINEERS
WHEN TOP SHELF IS REMOVED IT REVEALS A LOWER
SHELF THAT STILL COVERS THE TAIL DRUM
CONVEYOR LOADED AND RAN WITH 150KGS LOAD
BEFORE DISPATCH
ONLY EXTERNAL CABLES ARE TO FOOT PEDAL (IF FITTED)
AND MAINS FEED
INCLINE CONVEYOR IS FULLY EARTHED
CONVEYOR IS FITTED WITH TWO LEVELS FOR EMPTYING MAIL
BAGS
PLC IS PROGRAMMED TO CUT POWER AND SEND WARNING
MESSAGES IF MOTOR OVERLOADED
INCLINE CONVEYOR IS FULLY EARTHED
ALL EXTRANEOUS CONDUCTIVE PARTS ARE ELECTRICALLY
BONDED BY NATURE OF THE BUILD TO ENSURE THERE IS NO
POTENTIAL DIFFERENCE BETWEEN PARTS
IF LEFT RUNNING THE PLC WILL SWITCH THE CONVEYOR
OFF AFTER A SET TIME
PUSH BUTTON VERSION - ONCE STARTED CONVEYOR RUNS
CONTINUOUSLY
WHEN RUNNING OR READY TO RUN THE GREEN LIGHT IS LIT ON THE
LIGHTING STACK
Please note this is a design Risk Assessment and should be used in conjunction with a site
specific risk assessment
COVERS MADE OF CLEAR POLYCARBONATE TO
ISOLATE POWER AND LOCK OUT WITH PERSONAL LOCK BEFORE STAR
ALLOW A VISUAL INSPECTION BEFORE REMOVING
IF LEFT IDLE FOR GREATER THAN 5 MINS THE CONVEYOR
NEEDS TO BE RESET AND RESTARTED
FOOT PEDAL VERSION - OPERATOR CONTROLS START UP
PVC BELT IS ANTISTATIC FABRIC BACKED GRIP FACE BELT
EXISTING PROCESS WITHIN ROYAL MAILIS OF A SIMILAR NATURE VIEWED
AND REPLICATED
THE TAIL DRUM SITS INSIDE CONVEYOR STRUCTURE COMPLETE WITH
INTERNAL BEARINGS
BELT COMPLETELY COVERS THE TAIL DRUM WHICH IS
LOCATED BEHIND TWO COVERS
TAIL DRUM IS COMPLETELY ENCLOSED
HEAD DRUM IS COMPLETELY ENCLOSED
HEAD DRUM IS COMPLETELY ENCLOSED WITH INTERNAL MOTOR AND
BEARINGS
BELT IS SET AT BOTTOM OF 150MM WELL AND OUT OF GENERAL ACCESS FOR
BELT IS COMPLETELY COVERED IN APART FROM PHYSICAL
THE MOST PART. THERE IS A VISUAL AND ACOUSTIC WARNING ON START UP
WORKING AREA
COMPLETE WITH 10 SEC DELAY
GENERAL COMMENTS
CONVEYOR CAN BE MOVED AROUND BY MEANS OF PALLET PLACED UNDER
HORIZONTAL FRAMEWORK
ADDITIONAL CONTROL MEASURES
CAN BE MOVED BY FORK TRUCK OR PALLET TRUCK
AROUND SITE
BELT COMPLETELY COVERS THE HEAD DRUM WITH
FINGER GUARDS AT EACH SIDE
ALL IN RUNNING NIPS ARE BUILT TO EN619
ALL BOLTS & FIXINGS FACTORYCHECKED BEFORE DISPATCH
SUPPLIED STRAPPED ON PURPOSE BUILT PALLETS
CONTROL MEASURES
RISK ASSESMENT
DIRT COVERS CAN BE REMOVED FROM UNDERSIDE
WITHOUT REVEALLING ANY HAZARDS
6
6
6
8
2
6
6
6
8
6
8
SEV PROB RISK
RISK ANALYSIS
RISK
SEVERITY
1. NO RISK
2. LOW
RISK ANALYSIS
3. MEDIUM RISK 4. MAJOR IN JURY 5. HIGH RISK
PROBABILITY
1. IMPROBABALE
2. REMOTE RISK 3. POSSIBLE
4. PROBABLE
5. LIKELY
SEVERITY
1. MINOR INJURY 2. LOST TIME INCIDENT 3. +3 DAYS OFF
4. MAJOR INJURY
FATALITY
RISK = SEVERITY X PROBABILITY: RISK RATING LOW 1-10 MEDIUM 11-15 HIGH 15-25
15
CERT. of CONFORMITY
16
START UP PROCEEDURE
ONLY NAMED AND TRAINED OPERATORS SHOULD USE THESE CONVEYORS
OPERATORS SHOULD FAMILIARISE THEMSELVES WITH THE RM HEALTH AND SAFETY LABEL
BEFORE USING
1) TURN ON MAIN ISOLATOR
2) THERE WILL BE AN INITIAL START UP SOUND AND THE POWER INDICATOR LIGHT
WILL LIGHT UP
3) ENSURE THAT ALL OPERATORS ARE CLEAR OF MOVING PARTS
4) PRESS AND HOLD THE BLUE RESET BUTTON FOR 5 SECONDS UNTIL THE AMBER LIGHT STAYS
ON
5) PRESS AND HOLD THE START BUTTON FOR 3 SECONDS – THE AMBER LIGHT WILL FLASH AND
THE SIREN WILL SOUND
6) T HE CONVEYORS WILL START TO MOVE
7) SENSOR –
A. IF THE PEC IS SWITCHED OFF THE CONVEYORS WILL RUN CONTINUOUSLY
B. IF THE PEC IS SWITCHED ON THE CONVEYORS WILL RUN UNTIL THE SENSOR BEAM IS
BLOCKED
LIGHT BEACON
CONTROL CABINET
17
CONVEYOR START UP TROUBLE SHOOTING
LIGHT
1) Power indicator not lit
TROUBLESHOOTING WARNINGS
- Check isolator on panel is on
BEACON LIGHT
CAUSE
ACTION
STATUS
SOUNDER
- Check
that the main supply isolator is on
RESET ESTOP AND FOLLOW START
ESTOP DEPRESSED
CONSTANT
YES
PROCEEDURE
- If both on and no power indicator light call an engineer
CONSTANT
YES
SYSTEM HAS BEEN RESET
SYSTEM IS RUNNING
2) Red light NO
stays lit and steady
audible warning
-FLASHING
An EstopYES
is depressed FAILURE IN SAFETY SYSTEM
SENSOR HAS BEEN COVERED
NO and start again
-FLASHING
Reset Estop
PRESS AND HOLD START BUTTON
NONE REQUIRED
CONSTANT
FLASHING
NO
CALL AN ENGINEER
REMOVE ITEM BLOCKING SENSOR,
CONVEYOR WILL START
STOP BUTTON PRESSED
PRESS START BUTTON
OR SUPPLY
3 PULSES
PULSES
3)
AmberAFTER
light
continuesINTERNAL
to flash
andFAILURE
audible warning
MOTOR
OVERHEAT
-8 PULSES
SensorAFTER
at PULSES
end of horizontal
is covered
- Unblock sensor and start again
REFER TO MANUAL FOR ADDITIONAL DETAILS
18
CALL AN ENGINEER
CALL AN ENGINEER
900
759
8619
Q.A
MFG
APPV'D
CHK'D
DRAWN
NAME
FINISH:
SIGNATURE
UNLESS OTHERWISE SPECIFIED:
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH:
TOLERANCES:
LINEAR:
ANGULAR:
8619
DATE
WEIGHT:
MATERIAL:
DEBUR AND
BREAK SHARP
EDGES
SCALE:1:25
DWG NO.
TITLE:
REVISION
SHEET 1 OF 1
600x 6000 horiz
DO NOT SCALE DRAWING
A3
Date: 10/11/2015
Maximum No of operators: 4
Issued by: Ken House
Belt length: 5 Meters
Tip
Minimum No of operators: 2
Issues No: 3
Duplicate
2.6m
Defects / Incorrect Stream
Op 2
Operator 1 zone to sort.
Items not to be sorted to Op 2 zone.
Op 1
5m
15.55m
Ensure that motor are not covered by sleeves
Open/ aside
Maximum No of selections: 13
Sheet 1 of 1: Not to scale
1C Parcels Layout with use of Conveyor 5 Meter Belt (Bag Tip)
6.52m
Sort
2.6m
Tip
Date: 10/11/2015
Issues No: 3
Duplicate
Sort
5m
15.55m
Open/ aside
2C Parcels Layout with use of Conveyor 5 Meter Belt (Bag Tip)
6.52m
Sort
2.6m
Tip
= Duplicate
Date: 25/04/2016
Issues No: 1
If storing to work plan sortation is into full sleeves.
If work is moving directly to secondary roads when sorted,
Sortation should be into mini sleeves.
Sort
5m
15.55m
Primary Parcels Layout with use of Conveyor 5 Meter Belt (from full Sleeves)
6.52m
JOB ELEMENT SHEET
INCLINE CONVEYOR CUT AND TIP
= CRITICAL STEP
SAFETY WARNING =
Process Step
Key Point
Be aware of
overweight bags.
Max bag weight 11
kg. Report over
weight bags to your
line manager.
Test weight by
moving the bag.
Remember to
use both hands
and bend your
knees, not your
back.
Lift the bag onto
the hopper ledge.
Check the label to
ensure you have
the correct
stream.
Re distribute
missorted bags.
Cut the tie.
Place discarded
tie and label in
correct bin.
Tip the bag
contents into the
hopper.
Do not bend
down to retrieve
debris from
hopper.
Check bag is
empty of all mail.
Fold and place
bag onto the
correct york.
Issued by:
Compliance…
Manning Levels
Verified by:
JES Ref:
Incline
Cut
and Tip
Maximum
Minimum
1
1
Version 1:0
Date 21/04/2105
Ken House
JOB ELEMENT SHEET
CONVEYOR - PARCEL SORTING
= CRITICAL STEP
SAFETY WARNING =
Process Step
Key Point
Pick up one parcel
from the belt. If the
item has a bar code
scan the item.
Ensure that the
scanner has registered
the item.
If the parcels has
stamps on them check
that they are canceled.
Cancel all stamps
before sorting to
selection.
Now look for the
onward post code.
If no post code place to
one side, so post code
can be found. DO not
guess destination.
If the selection is not
on your side of the
belt, pass to the
operator next to you.
DO NOT throw across
each other
Sort the item to the
correct selection. Mini
sleeve or full sleeve
only.
If the belt is over
500mm wide, then the
Logistics operator
should fasten the
sleeve.
If the red sleeves needs
to be fastened this can
be done if the belt if it
is 500mm wide.
Logistics team
will then replace
with an empty
container
Allow logistics team to
move all full
containers.
Issued by:
Compliance…
Manning Levels
Verified by:
JES Ref:
Conveyor
Sorting
Maximum
Minimum
2
1
Version 1:0
Date 18/01/2106
Ken House

Parcels Sortation with Conveyors

Transcription

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