Machine Safety for Injection Molding Machines

OccupationalSafety and HealthAdministration

The Societyof the PlasticsIndustry, Inc.

A Presentation of the OSHA-SPI Alliance

OccupationalSafety and HealthAdministration

The Society of the PlasticsIndustry, Inc.

Course Objectives• Identify the types of injuries that can

occur while operating injection molding machines

• Describe the possible causes of these injuries

• Identify ways to safely operate injection molding machines

• Recognize the importance of a total safety and health approach

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Reasons to Focus on Injuries in the Injection Molding

Process

• High injury/illness rates

• OSHA citations

• National Emphasis Program

• Site-Specific Targeting

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Types of Injuries

• Fatalities

• Amputations

• Avulsions

• Fractures

• Cuts and bruises

• Sprains and strains

• Burns

• Electric shock

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Some Causes of Injuries

• Reaching around, under, over or through guards into hazardous areas

• Removing or bypassing guards

• Reaching into equipment to remove stuck parts

• Not using LOTO procedures

• Machine/equipment malfunctions

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Causes of Injuries (cont’d)

• Lack of recognition of hazards of the job

• Lack of familiarity with the equipment

• Inadequate training, comprehension, or both

• Operating machines with missing or inoperable guards and improper or inadequate machine maintenance

OccupationalSafety and HealthAdministration

The Society of the PlasticsIndustry, Inc.

Injection Molding Machinery

• Horizontal injection molding machine (HIMM)

• Vertical injection molding machine (VIMM)

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Vertical Injection Molding Machines - VIMMs

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VIMMs

• Combinations of vertical and horizontal clamp and injection configurations of machines

• Regardless of the configuration of the machine, basic machine guarding and good safe work practices must be applied– Point of operation– Other moving machine parts

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VIMMs: Unique Hazards and Issues

• Gravity

• Plastic splatter/missing insert

• Flying inserts

• Unexpected bystander interventions

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Horizontal Injection Molding Machines - HIMMs

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HIMMs: Mechanical Hazards

• Point of operation

• Pinch points

• Nip points

• Rotating parts

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Potential Injuries from Mechanical Hazards

• Fatalities• Amputations• Avulsions• Crushing injuries• Fractures

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Safety Guards and Devices

• Types of guards and devices • Movable guards with interlocks• Fixed barrier guards• Presence-sensing devices

• Mechanical safety bars • Locations of guards

– Over moving equipment – Around electrical hazards– Around thermal hazards

OccupationalSafety and HealthAdministration

The Society of the PlasticsIndustry, Inc.

Operator’s Gate

• Equipped with redundant interlocks– Electrical– Hydraulic– Mechanical safety bar

• Allows the machine to operate only when the gate is closed

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Electrical Interlock

• Allows the electrical system to operate and close the clamp

• Actuated when the operator’s gate is opened or closed

• Prevents clamp from closing when the operator’s gate is open

OccupationalSafety and HealthAdministration

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OccupationalSafety and HealthAdministration

The Society of the PlasticsIndustry, Inc.

Hydraulic Interlock

• Actuated by opening or closing the operator’s gate

• Each hydraulic IMM requires at least one

• Prevents clamp from closing when the operator’s gate is open

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OccupationalSafety and HealthAdministration

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• Prevents clamp from closing when the operator’s gate is open

• Must have at least one mechanical device on all IMM’s

Mechanical Safety Device

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OccupationalSafety and HealthAdministration

The Society of the PlasticsIndustry, Inc.

Other Guarding

• Rear guard• Top guard• Parts discharge

guard• Feed opening guard

• Electrical system guards

• Purge guard• Injection barrel

cover

OccupationalSafety and HealthAdministration

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Rear Guard

• Prevents clamp from closing when interlocked rear guard is opened

• Should have at least two interlocks

• Prevents access to mold areas

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Top Guard

• Required if operator can reach over the top of the machine and into hazardous areas

• Should be interlocked if movable

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Top Guards (cont’d)

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Parts Discharge Guard

• Keeps employees from reaching under operator’s gate and into the danger zone

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Purge Protection

• Covers the nozzle and purging area

• In combination with PPE, minimizes exposure to molten plastic during purging

• Window allows observation through purge guard, if equipped

• Should be equipped with an interlock

Purge guard

Safety window

Barrel cover

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Injection Barrel Cover

• Protects from exposure to high voltage and high temperatures

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How to Protect Yourself

• Recognize the hazards in the job you are doing

• Understand the requirements for guarding machines

• Implement guarding solutions

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Virtual Safety Tour

                                                               

       

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Emergency Stop

Know:

• Where it is located

• What it controls

• When to use it

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Signs and Warnings

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Colors used with Safety Signs have meaning!

DANGER

White Lettering/Red Background

WARNING

Black Lettering/Orange Background

CAUTIONBlack Lettering/Yellow

Background

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High Voltage

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Rotating Screw

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High Temperature

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High Pressure

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Robots

• Used to automate repetitive or hazardous tasks

• Must be guarded to prevent workers from entering or reaching into hazardous areas

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The Robot

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Our sincere thanks to:

• United Southern Industries, Inc.

• OSHA Region V

• The OSHA Training Institute

• OSHA’s Salt Lake Technical Center

• Paulson Training Programs, Inc.

• The Society of the Plastics Industry, Inc.

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Questions?