FHM TRAINING TOOLS This training presentation is part of FHM’s commitment to creating and keeping safe workplaces. Be sure to check out all the training programs that are specific to your industry. Power Press Operator Training Power Presses… • • • • Have a flywheel Operate by transferring energy from a rotating flywheel to the ram (or slide) by means of a clutch May be a “full-revolution” design, with a “trip” clutch engagement, or May be a “part-revolution” design, with a friction clutch and brake Power Presses… • • • Are generally defined in “size” by the force that they can generate – from under 5 ton to over 300 ton capacity Have a variety of forms and styles. The most common are straight-sided and open-backed inclinable (OBI) styles. Are addressed in detail in ANSI B11.1 and OSHA 29 CFR 1910.217 Safe Operation of a Power Press Depends Upon… • • • • • The structural integrity of the machine and it’s safeguards The reliability of the control system The condition of the tooling and feed mechanisms, and the work area Your training and awareness Strict observance of safe work practice Thirty-Eight Steps That Can Save Your Fingers, Hands or Your Life Safety is everyone’s responsibility ! The Work Area • Can the metal be moved into the work area, still leaving enough room to get out? The Work Area • What is the condition of the floor? Does it need repair? Report it! Press Integrity • • Have I checked the press completely before beginning my shift? Use your check list! Make sure that someone has not left something on the press, such as a turnover bar, blow-off hose or die block Press Integrity • • Are all the bolts tight? Are there any visible cracks? Press Integrity • Are all the service lines (electrical, air, etc.) properly connected and free of any damage. Report any deficiencies to your supervisor. Press Integrity • Have I tested the clutch and brake operation before starting the main motor? Immediately after? Press Integrity • Does the press continue to cycle when the footswitch or palm buttons remain depressed? If so, it does not have required “single-stroke capability.” – Notify your supervisor immediately. – Not required on presses when used in the continuous mode. Press Integrity • Does the press cycle with only one palm button depressed, or with one continuously held down and the other depressed to start the cycle? • If so, it does not have required “anti-tie- down circuitry.” • Notify your supervisor immediately. Press Integrity • • Are the operating controls (mode selector, palm buttons, foot switch, top stop, emergency stop) in good working condition? Is the “ground” fault detection lamp lit. • Do not operate the press if light is not. Press Integrity • Is all of the auxiliary equipment (roll feed, scrap chopper, blow off, etc.) in good working order? Press Adjustments • Have I checked all the knockout adjustments? Press Safeguarding • Does the guard or device positively prevent body access into the danger zone? POINT OF OPERATION GUARD OPENING REQUIREMENTS Dist. from PO Max Opening 1/2” to 1-1/2” 1/4” 1-1/2” to 2-1/2” 3/8” 2-1/2” to 3-1/2” 1/2” 3-1/2” to 5-1/2” 5/8” 5-1/2” to 6-1/2” 3/4” 6-1/2” to 7-1/2” 7/8” Press Safeguarding • Are the sides and back of the press guarded or placed in such a way that another person cannot be injured by any part of the machine? Press Safeguarding • • Is the safety guard sturdy and secure? Does the safety device work properly? Press Safeguarding • • If I have a foot pedal, is it guarded on the top and sides? Does it spring back when released? The Point-of-Operation • • Is the die area clean? Have all slugs and debris been removed? The Point-of-Operation • Can the parts I feed be placed into the die easily, without causing damage to the parts, or any part of my body? Understanding Risks • Do I truly understand the safe operation of the press … or do I need more training? – Don’t be afraid to admit it ! – Don’t be afraid to ask “dumb” questions ! Your life could depend on it ! Understanding Risks • • Do I know the “tonnage” of the press and the requirement of the tooling? Do I know if the press is overloaded? Understanding Risks • Do I understand the maximum thickness or “gauge” and type of metal which the tooling and press can safely run? Press In Operation • • Does the machine operate smoothly and sound O.K.? Any squealing? Shuttering? Clicking? Clanking? Excess vibration? Press In Operation • Does the die stripper work properly? Press In Operation • Does the take-up reel work properly? Press In Operation • In operation, does the die bind or jam? • If so, notify your supervisor. The problem may be the tooling, the press, or the stock/part. Press In Operation • • Does the clutch/brake work properly. In the case of a full revolution press, does the drag brake stop the press at top center? Understanding Risks • • What is the expected Noise Level? Do I need hearing protection? Read and Heed! • Never unnecessarily place your hands or any part of your body in the machine! Read and Heed! • Never operate this machine without proper eye, face and body protection! Read and Heed! • Never operate this machine without first being fully training and instructed! Read and Heed! • Never operate this machine without first reading the manufacturer’s instruction manual! Read and Heed! • Never operate this machine if it is not working properly! Stop operating and advise your supervisor immediately! Read and Heed! • Never use a foot switch to operate this machine unless a point-of-operation guard or device is provided and properly maintained! Read and Heed! • Never tamper with, rewire or bypass ANY control or component on the machine. Interlocks are provided for your safety. If they prevent proper operation, consult your supervisor immediately! Read and Heed! • Never operate this machine unless a supplied two-hand control or presencesensing device is installed at a proper safety distance. Consult your supervisor if you have any questions.