0.Mail Prep Station Jubilee - Communication Workers Union · Jubilee - Mail Prep Station Safety...

Jubilee - Mail Prep Station

Safety compliance and supporting documentation

Ken House

Tel: 07713653073 – email: [email protected]

12/05/16

This is a synopsis of the safety documentation applicable to the deployment of mail preparation stations . 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 local sites suitability assessment must be completed prior to any new equipment deployments, 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 the originators on site. Should you need to review these please contact Jubilee – [email protected] Operation and WO lead.

Mail preparation frame (Jubilee Model) safety documentation within this document.

§ Work Equipment Change Safety Assessment (WESCA) ……………….…………1

§ Safety Assessment SAC1………………………………………………………………………………….2 § Safe Systems of Work………………………………………………………………………………………3 § Safe Working Instructions……

……………………………………………..................................4 § Ergonomic Screening……………………………………………………………………………………… 5 § Job element sheet…………………………………………………………………………………………….6 § One Point Lessons (Visual Aids)

…………………………………………………………………….. 7 § Manning Levels…………………………………………………………………………………………………8 § Technical Drawings…………………………………………………………………………………………. 9 § Operating Manual …………………………………………………………………………………… ……10 § Ergonomics Review………………………………………………………………………………………. 11

ANNEX: 1…………………………………………………………………………………………………………………………….

Additional supporting document (not included in this report)

§ Terms of reference (TOR)……………………………………………………………………………………..12

§ Joint working review……………………………………………………………………………………………..13

§ Industrial engineering report………………………………………………………………………………..14

§ Maintenance schedules………………………………………………………………………………………… 15

Work Equipment Change Safety Assessment Template Owner: S. White Version: 2.8 Date: Sep 2012

WORK EQUIPMENT CHANGE SAFETY ASSESSMENT

Section 1 CHANGE SAFETY ASSESSMENT Work Equipment Title DSA mech cell transfer chute Work Equipment Photograph Work Equipment Group DSA

Work Equipment Intended Use

Preparation of mail

Explanation of change Deflector required to eliminate mail blockages/stoppages

Deployment Date Apr 2014 Project Manager (contact details)

Steve Stapleton

NATIONAL REGIONAL (name) UNIT (name) Work equipment area of use

Jubilee MC

Section 2 PROHIBITED CHANGE ACTIVITY Does the change impact on any of the following: Yes/No (Yes) (No) Work Equipment Guarding (Primarily machinery guarding) No 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

If ‘No’ Progress to Step 3

Computers or VDU’s, including all software & hardware No Electrical Systems and any power supplies No Machinery Controls No Address Interpretation Systems No Safety Systems such as interlocks, emergency stops, signs No Machines under warranty No Introducing substances to machinery hazardous to health No Road vehicles No

Section 3 CHANGE - JUSTIFICATION Reason for the Work Equipment Change Activity

Safety Ergonomics and Performance

Monitoring Period used to justify the need for Change? From: June 2012 To: Aug 2012 Yes/No Target Benefit Benefits from the Work Equipment Change Activity

Safety? Yes Eliminates need to manually “drag” mail from conveyor

Legal? N/A N/A Financial? Yes Quality? no Performance? Yes Improved cycle time due to less mail jams Equipment Availability? Yes Increase in operational availability to process mail Other? (Describe) no

During a trial the benefits of a change must be monitored for 90 days. This proves the effectiveness of the change so that it can be horizontally expanded outside the initiating unit. It will also show if the change needs to be reversed. Is the change reversible? (It must be possible to return the work equipment to its original state)

Yes Explain: Can revert to old process if necessary

Section 4 CHANGE - ACTIVITY What change activity is involved? Yes/No (Yes) (No) New Work Equipment, whether purchased, hired, or leased, even on a temporary basis

no

If any option is ‘Yes’ progress with the Work Equipment

If all options are ‘No’ there is no need to

progress with the Work

Any Modification to Work Equipment even on a temporary basis

yes

Replacement of a component where the replacement is not like-for-like

No


Change of use for the Work Equipment

No Change Safety Assessment

Equipment Change Safety Assessment

Significant change of workplace layout due to relocation of fixed Work Equipment or mechanised equipment

no

Change of the environmental conditions within which the equipment is designed to operate

No

Section 5 CHANGE - SIGNIFICANCE Indicate all that apply and complete all relevant assessments Yes? If Yes

Powered Work Equipment

Which is new or the change impacts on the safety systems, controls, powered elements or it’s sufficiently close to the powered elements/moving parts to constitute a significant risk.

No Step 6 (1) Applies

Which is not new and the change does not impact on the safety systems, controls, powered elements or it isn’t sufficiently close to the powered elements/moving parts to constitute a significant risk.

No Step 6 (3) Applies

Non-Powered Work Equipment with moving parts Exclusion, see Note**

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.

Yes Step 6 (2) Applies

Which is not new and the change does not impact on the safety systems, controls, moving parts or it isn’t sufficiently close to the moving parts to constitute a significant risk.

N/A Step 6 (4) Applies

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 Ergonomic Task Activities (Ergonomic task activities are likely to apply in most cases) no 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 – ASSESSMENT TYPE Change Significance Assessment

Required By Whom Complete

Appendix 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.

PUWER Assessment.

(Nationally) Head of Engineering Safety (Geographical/Functional/Local) Geographical/Functional Director Safety appoints an assessor

2

2 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**

(Nationally) Head of Logistics & Facilities Management Safety (Geographical/Functional/Local) Geographical/Functional Director Safety appoints an assessor

NOTE: PUWER Assessment: Before making this modification is the machine/work equipment of standard configuration &/or up to current specification

Yes / No If ‘No’ STOP until such time as the machine or work

equipment has been brought up to current specification

If ‘Yes’ Progress

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.

Screening Assessment

To determine if a

PUWER assessment

and/or Ergonomic assessment is

required

Project Manager or Operational Line Manager

If in doubt how to proceed seek advice from the local

Safety Team

1

4 Non-Powered Work Equipment with moving parts which is not new and the change does 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 **


5 Non-Powered Work Equipment with no moving parts (New or existing) Inclusion, see Note **

Section 6 cont. CHANGE – ASSESSMENT TYPE 6 Lifts and Lifting Work Equipment

Lift Operations & Lifting Equipment

Assessment

Head of Logistics & Facilities Management Safety appoints a Technical Assessor or Safety

Advisor

3

7 Work Equipment used to manually lift, carry, transport or hold loads or that needs to be manually handle

Ergonomic Screening

Assessment

Project Manager or Operational Line Manager or Technical Assessor or Safety

Advisor

4

Section 7 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. What impact does the change have on the SAC1? Yes/No (Yes) (No) Is the Work Equipment new and will operator task activities be affected by the introduction of the work equipment?

no Produce a SAC1 to assess task activities

There is no need to produce a SAC1

If the Change is to existing Work Equipment is there the potential for the Change to impact on any task activities associated with the use of the work equipment?

No Amend the existing SAC1 or create one if

none exists

There is no need to review the SAC1

List the SAC1 impacted on by the change: 1) SAC1 covering operational use of Work Equipment (where equipment is introduced as a stand alone item) 2) Project SAC1 (when work equipment is introduced as part of a wider project related to a new procedure)

Section 8 STAKEHOLDERS LIST ANY INPUT RECEIVED AND FROM WHO Names and contact details

(Where applicable) Date input received

Unit Manager (Unit Level Work Equipment Change) Steve Stapleton Safety Lead Peter Ingram Geographical Director Safety (GDS) Head of Logistics & Facilities Management Safety Head of Engineering Safety Subject Matter Expert (SME) PUWER Assessor Peter Ingram LOLER Assessor Ergonomic Assessor Other (specify) Other (specify) LIST STAKEHOLDERS SUPPLYING INPUT &/or BEING CONSULTED (For National, Geographical & Unit Level Work Equipment Change)

Names and contact details (Where applicable)

Date consulted &/or input received

UNITE (National) UNITE (Local or Geographical)


CWU (National) CWU (Local of Geographical) (Ops &/or Engineering) Steve Wyatt Other (specify) 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 then 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 Name Date Signature Project Manager or Operational Line Manager (Not valid unless signed)

Steve Stapleton

Project Managers should: • Sign the Work Equipment Change Safety Assessment in all case and retain a copy of it and all appendices • Forward copies to the appropriate people

Local Projects - The Unit Manager Regional Projects - The Geographical Director Safety National Projects - Head of Logistics & Facilities Management Safety (Non-Powered Equipment) - Head of Engineering Safety (Powered Equipment)

PROCESS CONCURRENCE NATIONAL DEPLOYMENTS Only on completion of a PUWER &/or LOLER Assessment

Name Date Signature Head of Logistics & Facilities Management Safety

OR Name Date Signature Head of Engineering Safety PROHIBITED CHANGE ONLY Name Date Signature

Subject Matter Expert (SME)

Geographical/Functional & Unit Deployments

Only on completion of a PUWER or LOLER Assessment Name Date Signature

Geographical Director Safety (The Process Concurrence is not valid unless signed by one of the above where a PUWER Assessment

&/or LOLER Assessment has been completed at a national / regional level) NOTE: All assessments must be signed and attached where they are required

WORK EQUIPMENT CHANGE SAFETY ASSESSMENT APPENDICIES 1. Work Equipment Screening Assessment

Work Equipment Screening Assessmen

2. PUWER Assessment (Powered Equipment)

For Powered Equipment Technical Assessors

should use the PUWER Assessment Tool

provided by Engineering 2. PUWER Assessment (Non-Powered Equipment)

For Non Powered Equipment Technical Assessors or Safety

Advisor should use this PUWER Assessment

PUWER Assessment v1.5

3. LOLER Assessment

LOLER Assessment v1.2

4. Ergonomic Screening Assessment

Ergonomic Screening Assessment v1.2

SAC1 Template: Template Owner: S. White Version: 4.3 Date: July 2013

SAFETY ASSESSMENT & CONCURRENCE (SAC1)

Project/Programme/Product Title

Cut and Tip Conveyors Task or Work Equipment Photograph

Project/Programme/Product Description

Installation and use of Incline and/or Horizontal Conveyors

Deliver, install, use and maintain c100 conveyor systems into 22 mail centres. To provide further systems on an on-going case by case basis

Proposed Schedule, Timescales

Deployment Start: 22 April 2015 Deployment Finish: 26 June 2015 (est) Additional timescales on a case by case basis

Project Lead (Contact Details)

Murray Cook (Business Case Owner) 07702 678200

NATIONAL (SMS 8.1) REGIONAL (SMS 8.2) UNIT (SMS 8.3)

SAC1 Level X

LIST SAFETY INPUT(s) REQUIRED (indicate if applies)

Y/N CATEGORY NAME & CONTACT DETAILS

GROUP SAFETY RISK IMPROVEMENT MANAGER Y 8.1 Joanna Hosking NATIONALLY APPOINTED SAFETY LEAD N 8.1 PROGRAMMES DIRECTOR/MANAGER (as applicable) Y 8.1 Warren Cabot SENIOR SAFETY PROFESIONNAL N 8.1, 8.2 or 8.3 PROJECT SAFETY LEAD N 8.2 or 8.3 PROGRAMMES MANAGER N 8.2 SAFETY ADVISOR N 8.3 PROJECT MANAGER (If different from Project Lead) Y 8.1 & 8.2 & 8.3 Ray Pipe 07703 404378 SUBJECT MATTER EXPERT - Conveyors Y 8.1 Craig Dowe 07587 657236 PROPERTY & FACILITIES (SAFETY TEAM) N As appropriate ENGINEERING (SAFETY TEAM) Y As appropriate Del Roffey/Pete McGowan LOGISTICS (SAFETY TEAM) – (VEHICLES) N As appropriate ASSETS (SAFETY TEAM) N As appropriate ERGONOMIST As appropriate NOTE: This equipment has

been ergonomically assessed prior to national deployment

STAKEHOLDER CONSULTATION Y/N STAGE NAME & CONTACT DETAILS Is consultation necessary with the CWU

Y 8.1 Consultation conducted and agreed with Terry Pullinger through National Steering

Group. Via Francis

Terry Pullinger


Williams/Murray Cook

Is consultation necessary with Unite CMA

Y Martyn Bunn [email protected]

Is consultation necessary with any other stakeholder?

N

LIST ADVICE OBTAINED Y/N STAGE NAME & CONTACT DETAILS HEALTH & SAFETY EXECUTIVE N As appropriate ENVIRONMENTAL HEALTH OFFICER N As appropriate FIRE AUTHORITY N As appropriate OTHER? N As appropriate OTHER? N As appropriate

CONSTRUCTION, DESIGN & MANAGEMENT YES / NO

Does CDM apply to the project? No If ‘Yes’ is the project notifiable to the HSE? No LIST REQUIRED SAFETY INPUT Y/N STAGE NAME & CONTACT DETAILS Strategic CDM Co-ordinator As appropriate N/A Local CDM Co-ordinator As appropriate N/A

mailto:[email protected]


STEP 1 INITIAL RISK ASSESSMENT 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.

Task or Work Equipment

Identified Hazards Associated Risk People Affected

Existing Control(s) Risk Assessment Outcome See Matrix Likelihood Severity Total

Conveyor enabling works and installation.

Building & Electrical Works. Working with tools, Working at height Incorrect use of tools Poor manual handling

Various injuries as a result of the tasks being undertaken for the project.

Contractors RoMEC – Provided WELLs 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 4 4 Tolerable

Conveyor Movement

Moves via FLT & Pallet Truck

Vehicle & pedestrian collisions

Contractors, employees, visitors and customers

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

1 3

3 Adequately controlled

Operating the Poor manual handling Musculoskeletal injuries Unit staff / Current manual handling 2 4 8 Moderate


conveyor Contractors/ RoMEC Automation

training but does not include this conveyor

Operating the conveyor

Defective Machine, moving parts, sharp edges or jagged metal edges

Musculoskeletal, striking, drawn in and cuts injuries

Employees and managers

All conveyors have audited pre-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

2 4 8 Moderate (due to final PUWER assessment activity)

Maintaining the conveyor

Maintenance procedures

Musculoskeletal, striking, drawn in and cuts injuries

Maintenance Engineers

Maintenance procedures have been provided and contained within the Maintenance Manual. A technical training course will be provided at each site

1 4 4 Tolerable

Maintaining the conveyor

Defective Machine, moving parts, sharp

Musculoskeletal, striking, drawn in and cuts

Maintenance Engineers

All conveyors have audited pre-delivery checks at factory. All

2 4 8 Moderate


edges or jagged metal edges

injuries 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

(due to final PUWER assessment activity)

Yard Safety Movement of our vehicles in the yard where the contractors are working to unload the conveyors

Vehicle collisions with people ME lifting equipment

Contractors Risk Assessment and Method Statements will be provided by the contractor prior to each delivery. Enquiries will be made for any special requirements

1 4 4 Tolerable

Workplace Safety

Movement of machines through the workplace from the platform

Crushing and striking against injuries


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 4 12 Moderate

Contractor Contractors who are Stepping, striking, slip, Contractors Site induction into the work area 1 4 4 Tolerable


control unfamiliar with RMG individual site safety policy

trips, falls or musculoskeletal injuries

and removal from site if standards are breached

Fire Safety Erection of temporary fencing in the area where the conveyors will be installed

Restricted access, egress entrance and routes or walkways to fire exits


Fire Risk Assessment. Premises Fire Evacuation Plans (PFEP) Personal Emergency Evacuation Plans (PEEP)

3 4 12 Moderate

Noise Increased levels of noise in the work area

Short or long term hearing defects due to the exposure to the noise levels


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 quiet it is unknown if this will have a cumulative effect in its final installed location

3 3 9 Moderate

Work Equipment

New machines not added to the current Work Equipment Risk Assessment

Injuries as a result of the use of the machine


Work Equipment Risk Assessment

3 3 9 Moderate

STEP 2 RISK CONTROL

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 each task or work equipment & add more assessment sections and expand as necessary.



Outcome See Step1

Additional Control Measures Completion Date

By Whom Completed Yes?

Risk Assessment Outcome See Matrix Likelihood Severity Total

1. Operating the Conveyor

Moderate 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.

At date of first use and will be ongoing moving forward

First use - Contractor (Beumer) Ongoing -WPC

Each site to confirm.

1 4 4 Tolerable

Moderate 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

Local PUWER assessor with guidance from SME Craig Dowe if req’d

Each site to confirm when completed

1 4 4 Tolerable

2. Maintaining the conveyor

Moderate 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.


First use – Contractor (Beumer) Ongoing - ETC


1 3 3 Adequately Controlled

3. Yard Safety Moderate 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


Between, project manager, nominated site contact and Contractor (Beumer)


1 4 4 Tolerable

4. Workplace Safety

Moderate Review the Workplace Risk Assessment to ensure the location of the machines are considered

Each site to advise when completed

Site project lead, Regional SHE adviser (CWU Safety Rep) (safety rep)


1 4 4 Tolerable


6. Fire Safety Moderate Review the full fire risk assessment to capture the newly installed machines and the associated fire emergency tests and evacuations.


Site project lead, Regional SHE adviser (CWU Safety Rep) (safety rep)Rep) (safety rep)

Each site to confirm when done

1 4 4 Tolerable

7. Noise Moderate 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

SHE to advise date when completed

Regional SHE adviser (CWU) Safety Rep)

SHE to advise when done

1 3 Adequately Controlled

8. Work Equipment

Moderate Add the new equipment to the work equipment list and assess. Pass asset details on to ADST

PEM to add date when completed

(PEM) SME Craig Dowe

PEM to advise when done

1 3 3 Adequately Controlled

Use the Risk Matrix in SMS 2.1 Risk Management Standard to assess the task or work equipment in all sections above.

Overall Assessment 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

STEP 3 DETAILED RISK ASSESSMENT

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. POSSIBLE DETAILED RISK ASSESSMENTS

1 Work Equipment Change Safety Assessment (Mandatory for all change to work equipment) 7 Detailed Redesign Assessment (Fundamental change to the project/process) 2 Ergonomic Assessment 8 Hazard & Operability Assessment/Study (HAZOP) 3 CDM Assessment 9 Epidemiological Assessment 4 Property & Facilities Structural Assessment (Fundamental change in building structure) 10 Health effects Assessment/Study/Surveillance 5 Yard risk Assessment 11 Noise Assessments 6 Fire Survey and/or Fire risk Assessment 12 Other Assessment - specify


Outcome See Step 2

Detailed Risk Assessments Completion Date




Outcome See Step 2

Detailed Risk Assessments Completion Date



Use the Risk Matrix in SMS 2.1 Risk Management Standard to assess the task or work equipment.

STEP 4 RESIDUAL RISKS If there are any residual risks moderate or above after step 3, take the following action:

RESIDUAL RISK ACTIONS FOR RISKS ABOVE MODERATE YES NO

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)

2. Safety Lead takes appropriate course of action having escalated the issues:

a) Abort the Project - Do not progress

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.

STEP 5 CONCURRENCE ACTION PLAN

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.

CONCURRENCE ACTION Completion Date

By Whom Completed? Y/N

PUWER assessment to be conducted on the machine to ensure it meets the requirements of the Machine Directive and associated standards

As and when for each

installation

Local PUWER assessor with guidance from Craig Dowe if reqd

Review the Workplace Risk Assessment to ensure the location of the machines are considered. As and when for each

installation

Site lead, regional SHE advisor, local safety rep

Review the full fire risk assessment to capture the newly installed machines and the associated fire emergency tests and evacuations.

As and when for each

installation


Undertake a Noise test of the area where the machines are located. Review the Noise risk assessment to include the new machines

If required at each site


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)

STEP 6 SAFETY RECOMMENDATION 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.

CATEGORY (8.1), CATEGORY (8.2) & CATEGORY (8.3) Which Apply** NAME SIGNATURE DATE 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) 3 Ray Pipe Ray Pipe 01/05/2015 SUBJECT MATTER EXPERT – Conveyors 3 Craig Dowe Craig Dowe 12/05/2015 PROPERTY & FACILITIES (SAFETY TEAM) N/A CDM CO-ORDINATOR N/A ENGINEERING (SAFETY TEAM) 3 Del Roffey MAINTENANCE N/A LOGISTICS (SAFETY TEAM) – (VEHICLES) N/A ASSETS (SAFETY TEAM) N/A ERGONOMIST N/A

STEP 7 FINAL SAFETY CONCURRENCE 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.

CATEGORY 1 SAFETY CONCURRENCE (8.1 only) NAME SIGNATURE DATE GROUP SAFETY RISK IMPROVEMENT MANAGER Joanna Hosking JHosking 18/05/2015 PROGRAMMES DIRECTOR / MANAGER (as applicable) Warren Cabot


CATEGORY 2 SAFETY CONCURRENCE (8.2 only) NAME SIGNATURE DATE SENIOR SAFETY PROFESIONNAL PROGRAMMES MANAGER

CATEGORY 3 SAFETY CONCURRENCE (8.3 only) NAME SIGNATURE DATE SAFETY ADVISOR

NOTE: For final sign off on Unit Level (8.3) projects refer to the Safety Handover Compliance Certificate RISK MATRIX

Safe System of Work Template: Template Owner: S. White Version: 1.3 Date: Feb 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

Associated Risk Assessment SAC1 National Cut & Tip Conveyor SSOW Version No V1.3

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 Risk Rating (ref. SMS2.1 Risk Matrix) Control

Operating the conveyor

Tolerable 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)


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.

Manual Handling:

pping Bags

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

To avoid repetitive actions when tipping mail bags, operators must be rotated at regular intervals.

x


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.


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.

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


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?

P2. (Machine not running) Emergency Stop button check: P2.1 There are up to eight emergency stop buttons located on the conveyor

P2.2 Engage the emergency stops by depressing the buttons. P2.3 Release the emergency stop by turning the button anti-clockwise.

Machine Operation: P3. Machine Start-up procedure:

P3.1 (On the control panel) Turn the control power switch clockwise into the vertical position.

P1.1

The equipment must not be used if faults or damage are identified. Report all defects to your line

manager immediately.

P2.1

P2.2 P2.3

Head Strike hazard Be aware of the protruding

emergency stop buttons when accessing the control panel or

picking up mail items from the floor.

P3.1 Control Panel

Check to ensure the people are clear of the conveyor prior and during the completion of the machine start-up procedure.


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.

Emergency stop & start-up procedure:

P5. Emergency Stop: P5.1 Immediately press the nearest emergency stop button. The conveyor will now stop.

P6. Emergency stop restart procedure:

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.

Bag tipping to the conveyor:

P4.1 P4.2 P4.3

P4.4 P4.5 P4.6

P5.1

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 P6.2 P6.3

P6.4 P6.5


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.

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.

P7.1

DO NOT overload the conveyor belt

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!

Warning! watch out for sharps

P8.1


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.

P9.2. Through local management procedures the sensor can be disabled on the control panel by use of a key switch

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.

P9.4. Where the end of the conveyor has a “Bump Bar” the sensor can be enabled or disabled through the local management procedure.

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:

P9.1

Warning! If sensor is disabled items

will travel off the end of the belt. Ensure a suitable mini sleeved York container is in

place.

P9.2

NO container allowed at end of conveyor!

Container allowed at end of conveyor!


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: National project lead to ensure training is provided on site and delivered to the workplace coaches. Manual Handling training

Theory and practical with the equipment. 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 Date Author Ray Pipe

07/09/2015

Safety Support (where applicable)

I have authorised this SSOW for deployment Safety Authorisation: (As defined in Levels of Authority Appendix 4)

Peter McGowan

11/09/2015

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)

https://portal.royalmailgroup.com/sites/A402/Risk/Forms/Manual.aspx


(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

Risk Rating (ref. SMS2.1 Risk Matrix)

Control

LOCAL SIGN OFF

Signature

Date

Local Author

Safety Authorisation: (As defined in Levels of Authority set out in

the Standard) Peter McGowan

11/09/2015

4.SWI Mail Prep Stations SWI (v1 ) .doc

ROYAL MAIL GROUP RISK MANAGEMENT

SAFE WORKING INSTRUCTIONS (Appendix 2)

Task or Work Equipment Title: Two Dimensional Mail Preparations Station

Figure 1: Prep Frame Figure 2 Powered Rollers The purpose of these safe working instructions is to highlight appropriate safe work practices to minimise exposure to hazards and prevent harm to people. These safety instructions must be followed at all times. Your manager (in conjunction with your Workplace Safety Representative) will regularly review the implementation of the safety instructions to ensure they remain effective in your work area. If you want to comment on these safety instructions at any time, you should speak to your line manager.

Warning (e.g. check for damage/defects) Undertake pre and post visual checks of the equipment and report ALL damage to your line manager and ensure any damage is repaired or corrected before operating the equipment. Ensure operational footprint is clear and tidy and free from any debris or obstructions.

Prohibition (Do Not) Do Not stand or climb on any part of the equipment. Do Not attempt to adjust or modify any part of the equipment. Do Not move the equipment when loaded with full or empty trays. Do Not attempt to move the frame on your own (2 person move). Do Not use with any other container other than a Perstop tray. Do Not crawl under the frame to retrieve any fallen items, use a grabber or wheel the frame to one side. Do Not allow any wheeled containers to come into contact with the equipment. Do Not hang any personal items on the frame, such as coats or bags. Do Not leave cable ties, elastic bands or strapex on the belt, rollers or on the floor.

4.SWI Mail Prep Stations SWI (v1 ) .doc

Do Not eat or drink whilst using this equipment. Do Not cover the equipment with any unauthorised labels. Do Not stack full or empty trays on the equipment. Do Not connect any other equipment to any part of the frame. Do Not operate if you have not been given instruction use. Do Not overfill the trays. The maximum weight is 10kg. Do Not put any part of your body in the frame whilst in operation. Do Not overstretch to reach – if you cannot reach the rear of the tray without stretching only part-fill the tray.

Mandatory (Do)

Do check workstation for defects and report defects to your line manager. Do inform your manager of any physical condition which may affect your ability to perform your work ,e.g. (medical condition or if you are pregnant).

Do ensure brakes are applied to the wheels that have them. Do report any improper use of the equipment, to your line manager. Do follow instructions for safe use, Do ensure any loose clothing, lanyards, long hair etc. that could become entangled with moving parts of the equipment are removed, secured, tied back etc. whilst operating the equipment. Do ensure you rotate to other tasks (e.g. cutting & tipping) frequently (no less than every 2 hours in any continuous period). Do take ‘comfortable’ rather than large handfuls of mail. Do when loading empty trays grip the tray from the bottom corners and rest on the frame before pushing it onto the rollers to reduce the strain on the neck and shoulders”

Safety Actions Gloves may be worn if required by individual but are not a mandatory PPE requirement. Author: Ken House Signed: K House Date: 22/01/2016 Safety Support: Joanna Hosking Signed: JHosking Date: Safety Authorisation: James Cannon

Signed: J Cannon Date:

Local hazards (List any hazards (and any instructions additional to those above) specific to your workplace) Ensure that the logistics route is separate from the preparation area to reduce the risk of collisions with wheeled containers and staff.

Ergonomic Assessment Template Owner: S. White Version: 2.0 Date: May 2013

Ergonomic Screening Assessment (Appendix 4) Work Equipment Title DSA Mech Cells Work equipment photograph Serial Number/identification mark

Work Equipment Group LCA Work Equipment Details

Gravity feed transfer of mail from powered conveyor to operators

Project Manager (contact details)

Steve Stapleton

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 For this equipment ……. Yes No N/A If No state what remedial action required

Detailed assessment required Y/N

1.1 Is the equipment less than 16kg total weight? If yes go to Question 1.2, if no go to Question 1.3

x

1.2 Will suitable handles be provided for lifting and carrying the equipment?

x

1.3 If the equipment exceeds 16kg total weight will alternative means of transporting be provided? (wheels for example)

x

1.4 Are all visual aids/instructions that form part of the equipment clear and easy to understand?

x

1.5 Is the working space where this equipment is likely to be used adequate i.e. unlikely to be congested or cramped?

X

2 For this equipments intended use (so

far as can be ascertained) ……. Yes No N/A If No state what remedial action

required Detailed assessment

required Y/N 2.1 Will all the lifting tasks be within the

HSE guideline figures, (see Fig 1)? X

2.2 Will all the lifting tasks be repeated 7 times/min or less frequently?

X

2.3 Will all the forces required to keep a load in motion require little effort (e.g. be less than 7kg)?

x

2.4 Will all the forces required to initiate movement easy to exert (e.g less than 15kg)?

X

2.5 Will all the pushing forces required be exerted with hands between knuckle and shoulder height?

x

2.6 Will all forces or items lifted whilst seated be less than 5kg?

X

2.7 Will any items to be carried in the hands weigh less than 10kg and need carrying for less than 1 minute at

X


time? 2.8 Can all lifting and handling tasks be

carried out without twisting or bending?

x

2.9 Are all tasks completed within the Golden Zone, (AA or A on Fig 3)?

X

2.10 Will shorter or taller people find reaching or seeing to complete task elements involving this equipment easy?

x Shorter people will have to reach to clear mail jams

2.11 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)

x

2.12 Do all movements likely as part of using this equipment score 2 or more on the Muri chart, (see Fig 2 ignore walking)?

X

2.13 Are all movements on Muri chart scoring 2 or less held for less than 1 minute at a time or repeated less than 7 times/min, (see fig 2 ignore walking)?

X

2.14 Can suitable time be allowed in any task using this equipment for rest and recovery?

X No less than every 2 hours in any continuous period. Operators should rotate between tasks (cut and tip, prep, tray off load)

2.15 Can suitable seats be provided for all tasks that can be done seated?

N/A

2.16 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?

X

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. Work Equipment Title (as per page one)

DSA Mech Cells Assessment date:

Assessor name (Not valid unless signed)

Steve Stapleton Assessor signature (not valid unless signed)

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.


End of ERGONOMIC Assessment

Fig 1: HSE Lifting and Handling Guideline Figures

Fig 2: Muri Chart


Fig 3: Golden Zone

90

115

1400

1700 C

Test the weight by moving the bag.

Be aware of overweight bags.

Max bag weight 11 kg. Report over

weight bags to your line manager.

Lift the bag onto the hopper ledge.

Remember to use both hands and

bend your knees, not your back.

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.

Ensure that you have a smooth flow of mail, and use the mirror at the top to see mail is

moving.

Over loading will cause items to get stuck in the NIP

guard, and damage the mail.

Check bag is empty of all mail.

Fold and place bag onto the correct

York.

Issued by: Verified by: JES Ref:

Maximum Minimum1 1

Manning Levels Version 1:0 Date 21/04/2105

JOB ELEMENT SHEET

INCLINE CONVEYOR CUT AND TIP

Process Step Key Point

Compliance… Incline Cut and Tip

= CRITICAL STEP SAFETY WARNING =

Mail should flow over the rollers freely and

be guided to you.

Over loading will cause items to get stuck in the NIP

guard, and damaged the mail.

Use the stop start button to control the flow of mail into the

hopper.

DO NOT use the emergency stop

button to control the flow of mail.

Pick up one bundle of mail at a time from

the rollers in front of you.

You can slide mail to the operator next to

you if required.

Remove any strapex or elastic band from

the bundle.

Ensure that scissor are placed in a safe

area when not using, not on the

rollers.

Dispose of all waste in the correct recycling

bin.

Ensure that full bins are emptied and do allow to over flow

onto the floor.

Letters should be placed in the trays

with indicia face down.

If you unable to reach the rear of the tray, despatch

3/4 full. (This should only

effect shorter OPG'S)

Issued by: Verified by: JES Ref:Ken House

Maximum Minimum2 1


JOB ELEMENT SHEET

INCLINE CONVEYOR MAIL PREP


Compliance… Incline Mail Prep


Letters should be placed the trays with

indicia face down.

If you unable to reach the rear of the tray despatch

3/4 full. (This should only effect shorter

OPG'S)

Large letters should be place in the tray with

indicia face up.

DO NOT over fill the trays 10kg

maximum weight, and use the fill line

as the gauge.

When trays are full push the tray onto the

gravity rollers.

DO NOT push hard, allow gravity to take the tray down the

rollers.

Replace the full tray with an empty one

from under the frame.

Remember to check the amount of mail on

the rollers.OVER LOADED

Use the stop start button as required to

control the flow.


Maximum Minimum2 1


JOB ELEMENT SHEET

INCLINE CONVEYOR MAIL PREP


Compliance… Incline Mail Prep


Ensure all brakes are applied to York's

within the work area.

Don’t place the trays on the floor, keep them in the York

until you need them.

Pick up one tray at a time from the York, using both hands.

Don't use damaged trays. Remove old

labels.

Load empty trays to the bottom shelf of

the frame.

Don't use excessive force allow gravity to move the trays.

To remove full trays from the top shelf,

first lift the tray and pull toward you.

Ensure you have control of the tray

at all times, by using both hands.

Place full tray on the correctly stacked on

the York.

Ensure you keep letters and large letter separate

Yorks.

When the York is full, ensure all straps are tightened before

moving the York.

Move York to next work area.


Maximum Minimum1 1


JOB ELEMENT SHEET

MAIL PREP - REMOVING FULL TRAYS


Compliance…Tray Unload


Overloading the belt with mail may cause jams.

DO NOT OVER LOAD

Should any items become stuck in the nip guard. STOP

THE CONVEYOR

Do Not attempt to remove whilst

running. Can cause injury to you.

When the unit has been turned off, you need to

see if items can be removed without force.

REMEMBER If the unit is not off Your

fingers may get pulled in.

IT WILL HURT.

If you are unable to remove using finger and thumb and gently pulling,

you need to call an engineer.

Engineering will ensure the nip

guard is set to the required gap.

Only when all items are removed can you restart

the belt.

IF in doubt stop the belt and call your Line

Manager, and report all concerns.

Use the emergency stop if you need too.

Do Not attempt to free any jams if you

have not been trained.


Maximum Minimum2 1


JOB ELEMENT SHEET

INCLINE CONVEYOR HOW TO REMOVE ITEMS JAMMED


Compliance… Removal of Jammed Items


20/06/2016 Page 1 Incline

Mail Centre: Work Area:

X

Title:

Problem: Improvement:

Results

Trainer:

Form number:

BEFORE AFTER

If the incline conveyor is over filled it will cause a jam at the next set of rollers, This will then cause mail to get damaged and dragged back into the conveyor.

Ensure that the conveyor is not over loaded, if the belt has been stopped do not add any more mail until restarted, unless the belt is empty, then only tip 2 bags and wait until restarted.

OPL-Incline

Improved quality by not damaging customer mail and reduce the risk of damage to the equipment. This will also improve the flow of the mail to the operators.Training Date:

Trainees:

Review Date: Approved by: Ken House

WCM Pillar: WO

OPL: ONE POINT LESSON

Mail PreparationContact: Date:

Basic Knowledge Point of Attention Improvement Area / Item Ref. :

Ken House 2nd Feb 2016Croydon

20/06/2016 Page 1 Powered Roll

Mail Centre: Work Area:

X

Title:

Problem: Improvement:

Results

Trainer:

Form number:

Croydon

WCM Pillar: WO

OPL: ONE POINT LESSON

Mail PreparationContact: Date:

Basic Knowledge Point of Attention Improvement Area / Item Ref. :

2nd Feb 2016Ken House

BEFORE AFTER

Allowing the mail to build up at this point will cause the mail to get stuck and dragged back into the conveyor. When this happens customer mail gets damaged.

Using the stop start button will improve and controlling the flow and will ensure that mail is not dragged back into the conveyor.

OPL-Prep Frame

Ken House

Improved quality by not damaging customer mail and reduce the risk of damage to the equipment. This will also improve the flow of the mail to the operators.Training Date:

Trainees:

Review Date: Approved by:

Date 29/12/2015 Version No: 2 Issued by: Ken House

Appendix 1

Powered Rollers

Prep Frame Manning Levels by Product

Cut and Tip Mail Prep Tray Load & Unload

Stream Operation Manning levels Minimum Maximum

Down Stream Access Cut & Tip 1 per unit 1 per unit Mail Prep 1 per unit 2 per unit Load Unload 1 per unit 1 per unit

Stream Operation Manning levels Minimum Maximum

Meter Mail Cut & Tip 1 between 4 units 1 per unit Mail Prep 1 per unit 2 per unit Load Unload 1 between 4 units 1 per unit

Flexibility is required by the work area manger supported by the production control manager, to adjust the manning levels of the equipment to align with the incoming work load.

Rivit

Bolt Though

145

0

200

50 50

59

PROPRIETARY AND CONFIDENTIALTHE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE

PROPERTY OF THE TUBE AND BRACKET COMPANY. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE

WRITTEN PERMISSION OF THE TUBE AND BRACKET COMPANY IS PROHIBITED. Last Edit by

DWG. NO.

UNLESS OTHERWISE SPECIFIED: DIMENSIONS ARE IN MILLIMETERS

A

SHEET 2 OF 2DO NOT TO SCALE

Royal Mail Metal Side Slide Mock 2Head Office Unit 8, Canada Close, Banbury, Oxon OX16 2RT

T +44 (0)1295 277791 F +44 (0)1295 268654

www.tubeandbracket.com

26/04/2016Mark

1430 763

121

0

711

N

Royal Mail-DSA ConveyorSHEET 1 OF 5

DWG NO.DO NOT SCALE DRAWING

DIMENSIONS ARE IN MILLIMETERSTOLERANCES: 50MM

THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF THE TUBE AND BRACKET COMPANY. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN

PERMISSION OF THE TUBE AND BRACKET COMPANY IS PROHIBITED.

Head Office Unit 8, Canada Close,

Banbury, Oxon OX16 2RTT +44 (0)1295 277791 F +44 (0)1295 268654


Last Edit By

Design Approval

Name______________________________________

Signature___________________________________

Dated ____/____/____

Please Note that once the design approval has been signed, any subsequent changes after delivery will be chargeable

23/02/2016Mark

1430

745 6

00

711

9

20

121

0

711

350

845

400

980

100 100

763

140

360

150

40




DWG. NO.


N


Royal Mail-DSA ConveyorHead Office Unit 8, Canada Close, Banbury, Oxon OX16 2RT

T +44 (0)1295 277791 F +44 (0)1295 268654


23/02/2016Mark

Rivits

145

0

Rivit

360

100

50 50

90

1

410




DWG. NO.


A


Royal Mail Metal Side Slide Mock 1Head Office Unit 8, Canada Close, Banbury, Oxon OX16 2RT

T +44 (0)1295 277791 F +44 (0)1295 268654


26/04/2016Mark

181

0

540

120

0

825

940

2550 1680

400 A4 Load CapacityLabel Holder

All Graphit Brackets to be fitted with Nyloc Nuts

G

Royal Mail-DSA Jubilee RHSHEET 1 OF 3

DWG NO.DO NOT SCALE DRAWING

DIMENSIONS ARE IN MILLIMETERSTOLERANCES: 50MM

THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF THE TUBE AND BRACKET COMPANY. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN

PERMISSION OF THE TUBE AND BRACKET COMPANY IS PROHIBITED.

Head Office Unit 8, Canada Close,

Banbury, Oxon OX16 2RTT +44 (0)1295 277791 F +44 (0)1295 268654


Last Edit By

Design Approval

Name______________________________________

Signature___________________________________

Dated ____/____/____

Please Note that once the design approval has been signed, any subsequent changes after delivery will be chargeable

07/04/2015mark

1

Operating Instructions

Incline Conveyor and 2.8m Horizontal Conveyor for

Beumer Group Royal Mail Bristol Royal Mail Bristol

Table of contents

About this document Information about this document 4 Warning signs in this document 5

Safety Basic safety instructions 6 Intended use 6 Incorrect use 6 Specialists 6 Dangers 7 Malfunctioning during operation 7 Maintenance intervals 7 Interfaces to other devices 7 Operating modes 8

Product Identification Conveyors schematic 9 Product information Incline 10 Product information Horizontal 11

Assembly 12 Electrical installation 12

Start up and operation Initial start-up 13 Operation 13 Procedure for accidents or malfunctioning 13

Operational Procedures 14

Cleaning, maintenance & repairs Cleaning 15 Maintenance and repair information 15 Conveyor Electrical Safety Testing 16

Incline Conveyor Adjusting tension & tracking 19 Replacing the belt 20 Replacing the end idlers 21 Horizontal Conveyor Adjusting tension & tracking 22 Replacing the belt 22 Replacing the end idlers 23

Maintenance intervals 24 Troubleshooting 25 Exploded Schematic – Incline 27 Exploded Schematic – Horizontal 28 Spare parts list 29

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30 Essential health and safety requirements 31 Risk assessment 35 Wiring Diagrams 36 Motor calculations 39 Belt calculations 41 Predelivery electrical test certificate 43 Certificate of Conformity 44

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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 instruc-tions.

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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, see "Safety", page 5 and at the beginning of each chapter.

There are three types of warning signs: • DANGER • WARNING • CAUTION

Signal word Meaning Consequences of non-adherence

DANGER warns of an imminent death or serious injuries. danger WARNING warns of a possible death or serious injuries are danger possible. CAUTION warns of a possibly

dangerous situation slight injuries are possible.

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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.

Any other use without prior consultation with Beumer Group UK is not recom-mended. 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 ob-serving national regulations.

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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. - Never reach into a live machine. - 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. - Wearing of safety shoes is advised.

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 of the fault before the conveyor can be used again.

Maintenance intervals - Carry out maintenance and inspections as per the recommended frequency. - Only use genuine replacement spare parts.

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.

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Safety

Operating modes

Normal mode. Operation when installed at the end customer's site as an indi-vidual 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 mode Explanation Comment Transport/Storage Loading and unloading, transport and

correct storage Assembly/Initial start-up Installation at the end customer's and

execution of a test run Cleaning Cleaning the outside without removing When de-energized

safety equipment Maintenance/Repairs Maintenance and inspection tasks When de-energized Troubleshooting Trouble shooting during normal operation Fault elimination Eliminating the fault When de-energized Shut-down Removal from the system When de-energized Disposal Removal from the system and disassembly When de-energized

The safety systems on the incline conveyor and extending conveyor are additionally monitored at start-up

Safety Circuit/Relay Crosscheck To ensure correct operation of the safety relay the programmable logic controller will crosscheck or power down the signal from the safety relay system until the re-set button has been pressed. This is to ensure the system cannot be inadvertently ran with a known fault on the safety system. The specific fault this is designed to detect is jammed contacts on the safety relay. In this event the system will give the following alarm:- Red flashing lamp with pulsing buzzer. The machine will not start. To clear this alarm use the reset procedure 'cold reset'

Prevention of accidental restart after a fault condition

The motors on both incline and extender are monitored for thermal over tem-perature and if detected will trip the system run mode and indicate and alarm condition. The motors on both incline and extender are also monitored for variable speed drive fault detection (for example over current) if detected this will also trip the system to cold start mode and indicate an alarm condition.

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2035 mm

490 mm

Incline Conveyor - Product Identification

Area Technical data

Load area 3mm steel bed

Conveying speed 8m/min (variable)

Belt widths

Conveyor length

615mm

2567mm

Drive 3-phase motorized drum, max. 8 N/mm

Conveyor belt 2 ply polyester belt with high friction cover

Belt return Return Idler enclosed in clear polycarbonate cover

Drums 138mm diameter

Frame Aluminium profile

Sides 150 mm deep powder coated mild steel plate

Temperature range -5 °C to +50 °C ambient temperature Humidi-

ty Max. 90%, non-condensing

Ambient conditions Not suitable for application in areas with chemically aggressive media, e.g. acids or alkali's.

Accessories Speed control inverter

Light bea-con stack Siren

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Horizontal Conveyor - Product Identification

Area Technical data

Load area 3mm steel bed Convey-

ing speed 8m/min (variable)

Belt widths 490mm

Conveyor length 4800 mm

Drive 3-phase gear box motor

Conveyor belt 2 ply polyurethane belt with low friction cover

Belt return Return Idler enclosed in clear polycarbonate cover

Drums 50 mm diameter

Frame Aluminium profile

Body Coated mild steel on both sides Temperature range -5 °C to +50 °C ambient temperature

Humidity Max. 90%, non-condensing

Ambient conditions Not suitable for application in areas with

chemically aggressive media, e.g. acids or alkali's.

Accessories Speed control inverter Photo electric

Sensor

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2800mm

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Assembly

The conveyor is supplied partially assembled and requires further assembly and connection on site

Ensure that drivers attached to the belt do not rub on adjacent conveyors! During

alignment, ensure that a minimum distance of 5 mm is observed for all operating conditions.

After conveyor installation, make sure passageways are clear of obstacles. If necessary, assemble walkways. When integrating the conveyor in a system, always consider possible danger zones, especially where cuts and crushing can occur.

Electrical installation

Power is supplied to the conveyor either via a CEE plug or direct installation in a control panel.

- Always check cables and assemblies for damages prior to installation.

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Start-up and operation Initial start-up

The conveyor has been factory tested. The belt adjustment or the belt tension is factory set and does not usually have to be altered.

Operation

- Check the conveyors for visible damage. Pay special attention to the belts - Ensure that all safety equipment is functioning correctly. - Make sure that only authorized persons are in the conveyor's work area. - Always remove materials and objects which are not required from the work

area. - Provide instructions about and monitor correct loading of the conveyor.

- If goods become trapped in the side guides, switch off the conveyor and ensure that it cannot be started accidentally, then remove the trapped item.

Procedure for accidents or malfunctioning

- Stop the device and ensure that it cannot be started accidentally. - In case of an accident: Use the site accident procedure. - Inform a specialist. - A specialist must investigate and eliminate the fault. The system should then only be used after the site procedures have been completed - Only restart the conveyor after it has been deemed safe and released by

a specialist.

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Operational Procedure

Normal Working

a) Ensure the machine isolator is switched on. b) On the control panel press the blue reset button for 5 seconds until the amber light shows - If amber light flashes, something is blocking the sensor. This must be removed and the

reset pressed again - If red lamp with buzzer sounds continuously an emergency stop is depressed c) Press and hold the start button for 3 seconds, this

will sound an alternate start up buzzer and flashing amber light for 3 seconds d) During the sounding of the buzzer and flashing light the operator should check that colleagues

are clear of the conveyor. Releasing the button will prevent the process from continuing should this be deemed necessary.

e) When the signal ends the conveyor will start automatically. f) Both conveyors will continue to run until the beam is broken at the end of the sorting conveyor. When the beam is broken the amber light will flash, when the beam is cleared the green light will become lit and the belt will run automatically g)To stop the conveyor press the stop button, the green light will flash to indicate

"user stop". To start again press start button and the conveyor will start again without warning

The system will fall into sleep mode if left idle for more than 5 mins and require starting again.

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 must be pressed. Doing this will initiate a continuous buzzer to sound along with a red light. To restart use the following procedure:-

a) Reset the E stop b) On the control panel press the blue reset button until amber light shows c) Follow steps as laid out above

This conveyor should only be used by trained operatives

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Cleaning, maintenance and repairs

Cleaning

- Only dry clean the belts. - Only use suitable cleaning agents. - Clean panels on the underside with a vacuum cleaner.

Maintenance and repair work information

- Work on electrical equipment should only be carried out by authorized and qualified persons. - Display signs warning of maintenance and repair work when carrying out tasks. - Cordon off the area around the conveyor. - Inform people entering the cordoned off area of the risks.

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Conveyor Electrical Safety Testing

Visual Inspections

A visual inspection should be carried out periodically to ensure safe operation

Important notice the extraneous aluminum parts are anodized, this will mean it may appear to the inspecting engineer that the aluminum is not earthed therefore it is important only to test at the designated earth points!

Mains cable should be fully inspected for damage or excessive wear

Mains cable entry point to control gear should be inspected for firm and tight connection and outer earth sheath should be firmly connected to gland

Earth points should be inspected to ensure firm and tight connection

Control panel should be opened and inspected to ensure all connections are firm and tight

Flexible conduit and complex glands should be inspected to ensure they are correctly connected with no exposed wiring

A further visual inspection should be carried out on all parts of the conveyor including the internal wiring of control gear

Earth Continuity Test

Using appropriate equipment test all earth connections within the control panel and tested independently to ensure continuity

All extraneous conductive parts of the exterior should be tested to ensure connection to earth

Installation Resistance Test

Installation resistance testing should only be carried out on the following circuits

Mains lead

Phase 1+2 2+3 3+1

Phase to neutral

Phase to earth

Neutral to earth

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Notes on motor wiring testing

We recommend installation resistance testing only be carried out between :-

U and Earth

V and Earth

Y and Earth

to prevent misreading and possible damage to the motor.

Polarity Test

Polarity test should be carried out on the mains lead to ensure the correct orientation of neutral to control,

L1 to Control

L2 to Control

L3 to Control

The internal wiring of the control cabinet should be tested in the following manner to ensure correct polarity

L4 to connect with MCB 1 to connect with transformer L1

L5 to connect with MCB 2 to connect with L7 connection 33 on top of safety relay

L6 to connect with MCB 3 to connect with L8 connection 23 on top of safety relay

Connection 24 from the bottom of safety relay should connect L1 of motor VSD

Connection 34 from bottom of safety relay should connect to pin seven of external slave plug

Neutral should connect to VSD L2 and external pin N on external slave plug and T2 transformer.

Low voltage polarity testing is not recommended

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Part Entire conveyor

Interval

Weekly Monthly

Task/ Inspection

General visual inspection Check screwed connections

Required work

Re-tighten, if required

Rollers

Monthly

Listen for noise development

Replace, if necessary

Belts

Daily

Check the straight running

Adjust if necessary

Visible cables

Daily

Check for damage General Visual Inspection

Clean if necessary

Replace if necessary

Earth Loop Impedance Test

Earth loop impedance of this conveyor to be carried out as per the initial tests with test results very similar or exact to the pre-delivery test certificate.

RCD testing is not applicable for this conveyor.

Full electrical testing should be carried out annually

Cleaning, maintenance and repairs

Maintenance intervals

Refer to the manufacturer's documentation for information about lubricating intervals and maintenance tasks at the motor.

All the conveyor's bearings have lifetime lubrication and are maintenance free at operating temperatures of between -5 °C and +50 °C in a low dust and low moisture environment.

Formatted: Indent: Left: 2.47 cm,Right: 3.34 cm, Tab stops: 14.29 cm,Left

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Incline Conveyor - Cleaning, maintenance and repairs

Adjusting tension and straight running of the belt

1. Tag and lock out all energy to the conveyor 2. Ensure only qualified Engineers carry out these procedures in a safe manner. Ensure the proper tools are used. 3. Remove the side covers from the conveyor, this will expose the tensioning blocks for the drums.

4. On the idle end loosen these bolts x4 on both sides and slacken the tension bolt to remove pressure from the belt

5. Unwind the tracking screws to there home position (for tracking, these need to be indi-vidually set so as to align the belt centrally on the rollers These allow fine adjustment to the drive rollers )

6. With all tracking screws in the home position start the belt. If it doesn't run, tension back the drum using the tension bolt, lock in place using the tension plate bolts. The belt should be tightened back until it runs with a full load.

7. Run the belt and ensure running straight. If running slightly to one side adjust tracking screws accordingly between runs 8.Test the conveyor and allow it to run supervised to ensure that the belt is tracked and running correctly 9. When belt has been tracked, re-assemble the conveyor and ensure that all the covers are refitted 10. Inspect the machine and ensure everything is 100% before returning to operations

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Cleaning, maintenance and repairs Replacing the belt

1. Tag and lock out all energy to the conveyor 2. Ensure only qualified Engineers carry out these procedures in a safe manner.

Ensure the proper tools and equipment are used. 3. Remove the side covers from the conveyor

This will expose the tensioning blocks for the drums. 4. Unwind the tracking screws to their home position on both drums 5. At the idle end loosen the 4 bolts on each of the tensioning plates and slacken the tension bolt to remove pressure from the belt . 6. On the control panel side, while supporting the drum, remove the 4 bolts followed by the tensioning plate. 7. Remove the idler drum and set to one side 8. Remove the first section of polycarbonate cover underneath the drive drum 9. While supporting the drive drum loosen the 4 bolts in the fixing plate and then remove the plate letting it slide along the drive cable

10. Remove the drive drum 11. Remove the line of bolts along each side of the belt slider bed 12. Making sure the slider bed is supported remove the last 2 bolts and lift the bed clear complete with belt 13. Fit new belt over slider bed, ensuring direction arrow is followed. 14. Retrace steps ensuring all bolts are tightened securely 15. The belt should be tensioned back manually, using the plates on the idle drum end to lock the drum in position. 16. Track the belt using the tracking bolts and replace the side cover 17. Test the conveyor and allow it to run supervised to ensure that the belt is tracked and running correctly 18. Inspect the machine and ensure everything is 100% before returning to operation

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Cleaning, maintenance and repairs Replacing the Drive roller


Ensure the proper tools and equipment are used. 3. Remove the side covers from the conveyor

This will expose the tensioning blocks for the drive drum. 4. Unwind the tracking screws to their home position on all drums 5. Remove the first section of polycarbonate cover underneath 6. While supporting the drive drum loosen the 4 bolts in the fixing plate and then remove the plate letting it slide along the drive cable 7. Remove the drive drum and disconnect from the control panel 8. Connect the new drum to the control panel. 9. Retrace steps ensuring all bolts are tightened securely 10. The belt should be tensioned back manually, using the plates on the idle drum to lock it in position 11. Track the belt using the tracking bolts and replace the side cover 12. Test the conveyor and allow it to run supervised to ensure that the belt is tracked and running correctly 13. Inspect the machine and ensure everything is 100% before returning to operation

Replacing the idle roller


Ensure the proper tools and equipment are use 3. Remove the side covers from t

This will expose the tensioning blocks for the drive drum. 4. Unwind the tracking screws to their home position on all drums 5. While supporting the drum loosen the 4 bolts in the fixing plate and the tension bolt then remove the plate.

6. Remove the idle drum and replace with new drum 7. Retrace steps ensuring all bolts are tightened securely 8. The belt should be tensioned back manually, using the plates on the idle drum to lock

it in position 9. Track the belt using the tracking bolts and replace the side cover 10. Test the conveyor and allow it to run supervised to ensure that the belt is

tracked and running correctly 11. Inspect the machine and ensure everything is 100% before returning to operation

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Horizontal Conveyor - Cleaning, maintenance and repairs

Adjusting tension and straight running of the belt

1. Tag and lock out all energy to the conveyor 2. Ensure only qualified Engineers carry out these procedures in a safe manner. Ensure the proper tools are used. 3. On the idle end loosen the two bolts in each of the bearing blocks. 4. On the drive end, remove the gearbox guard on the drive side and repeat item 3 5. Unwind the tracking screws to their home position (for tracking, these need to be individually set so as to align the belt centrally on the rollers These allow fine adjustment to the drive rollers) 6. With all tracking screws in the home position start the belt. If it doesn't run, tension back the bearings

slightly and retry. These should be tightened back until belt runs. 7. Run the belt and ensure running straight. If running slightly to one side adjust tracking screws accordingly between runs 8.Test the conveyor and allow it to run supervised to ensure that the belt is tracked and running correctly 9. When belt has been tracked ensure that all the safety guards are fitted 10. Inspect the machine and ensure everything is 100% before returning to operations.

Replacing the belt

1. Tag and lock out all energy to the conveyor 2. Ensure only qualified Engineers carry out these procedures in a safe manner. Ensure the proper tools and equipment are used. 3. Unwind the tracking screws to their home position on both drums 4. At the idle end loosen the 2 bolts on each of the bearings to remove pressure from the belt . 5. Remove one bearing block and then slide the idler drum and the other bearing out and set to one side 6. At the drive end remove the gearbox and carefully set on something of adequate height. 7. Remove the bearing block on the opposite side and then slide the drive drum out and set to one side 8. Remove the bolts along the side covers on both sides and lift the slider bed clear 9. Remove the old belt and slide the new endless belt over the slider bed and its aluminium frame 10. Retrace steps to reassemble the conveyor again 11. The belt should be tensioned back using the plates on the idle drum end until it runs 12. Track the belt using the tracking bolts and lock in place with the locking bolts 13. Test the conveyor and allow it to run supervised to ensure that the belt is tracked and running correctly 14. Inspect the machine and ensure everything is 100% before returning to service

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Cleaning, maintenance and repairs Replacing the End Idlers

1. Tag and lock out all energy to the conveyor 2. Ensure only qualified Engineers carry out these procedures in a safe manner. Ensure the proper tools and equipment are used. 3. Unwind the tracking screws to their home position on both drums 4. At the idle end loosen the 2 bolts on each of the bearings to remove pressure from the belt . 5. Remove one bearing block and then slide the idler drum and the other bearing out and set to one side 6. At the drive end remove the gearbox motor. 7. Remove the bearing block on the opposite side and then slide the drive drum out and set to one side 8. Fit new idler. 9. Retrace steps ensuring all bolts are tightened securely 10. The belt should be tensioned back using the plates on the idle drum end until it runs. 11. Track the belt using the tracking bolts and replace the side cover 12. Test the conveyor and allow it to run supervised to ensure that the belt is tracked and running correctly 13. Inspect the machine and ensure everything is 100% before

Connector Plate Tensioning/Tracking Bolt

Locking Bolts

Bearing Housing

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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.

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Troubleshooting

Warnings & Alarms

Alarm

Cause

Action

Buzzer & red light continuous

Estop activated

Reset Estop and follow start up procedure

Amber flashing

Sensor blocked

Clear and follow

start up procedure

8 Pulses of light & buzzer

Motor Overheat

Thermal Cutout activated Disconnect from mains Check for any jammed material Allow motor to cool and follow start up procedure

3 Pulses of light

Internal/supply

Contact engineering dept. & buzzer failure

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B

C

D

1 2

A

321 4

B

A

5 6

DO NOT SCALE DRAWING ALL DIMENSIONS IN mm UNLESS OTHERWISE STATED

SCALE:1:1 SHEET 1 OF 1

A4

C

WEIGHT: Kg Approx.Customer:

Date: 16/02/2013

ALL DRAWINGS ARE PROPERTY OF CONVEYORTEK LTD AND SHOULD NOT BE REPRODUCED OR DISTRIBUTED WITHOUT PERMISSION

COPYRIGHT © CONVEYORTEK LTD

Drawn by: MMG

DWG NO.

RM.DSAINCLINE-EXPLODE

TITLE:

Incline-Conveyor

REVISIONSNo. By DATE

1

2

3

4

5

6

1 - LIGHT STACK2 - ESTOPS3 - ALUMINIUM FRAME4 - RETURN IDLER5 - MOTORISED DRUM6 - TAIL DRUM7 - BELT SLIDER BED

7

B

C

D

1 2

A

321 4

B

A

5 6

DO NOT SCALE DRAWING ALL DIMENSIONS IN mm UNLESS OTHERWISE STATED

SCALE:1:1 SHEET 1 OF 1

A4

C

WEIGHT: Kg Approx.Customer:

Date: 16/02/2013

ALL DRAWINGS ARE PROPERTY OF CONVEYORTEK LTD AND SHOULD NOT BE REPRODUCED OR DISTRIBUTED WITHOUT PERMISSION

COPYRIGHT © CONVEYORTEK LTD

Drawn by: MMG

DWG NO.

RM.DSA4800-EXPLODE

TITLE:

4800 Horiz-Conveyor

REVISIONSNo. By DATE

1

2

3

4

5

6

7

1- BELT SLIDER BED2- MOTORISED GEARBOX3 - DRIVE DRUM4 - TAIL DRUM5 - BEARINGS6 - POLYCARBONATE7 - ALUMINIUM FRAME

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2800 Horizontal Conveyor

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RM.DSA2800 Explode

Part Part Number Used Qty Stock Qty

ELECTRICAL 0.37KW 230v VSD ATV312H037M2 2

1 1

5AMP POWER SUPPLY BAE0006 1 1 SMART RELAY (ZELIO) SR2E201BD 1 1 TRIPLE POLE ISOLATOR + EXT KIT SIRCO M32 1 1 SAFETY RELAY XPSAC5121P 1 1 PEC XUFN12301 1 1 LENS XUFZ01 1 1 SINGLE POLE BREAKER 6AMP PLSMC6 3 1 EMERGENCY STOPS (SIEMENS) 3SB3801-0EF3 5 1 LIGHT STACK 24V XVMB1RAGS 1 1 PUSH BUTTON M22-D-X 3 1 PUSH BUTTON INSERT (WHITE) M22-XD-W 1 1 PUSH BUTTON INSERT (BLACK) M22-XD-S 1 1 RESET BUTTON INSERT (Blue marked "Reset") M22-XD-B-GB14 1 1 AFP946S AMPLIFIER FOR PLASTIC FI XUYAFP946S 1 1

MECHANICAL MOTORISED HEAD DRUM 138mm MOTORISED DRUM 1 1 TAIL DRUM 138mm IDLER DRUM 1 1 RETURN IDLER 50mm DIA RETURN ROLLER 1 1 610MM WIDE GRIP FACE PVC ENDLESS BELT PVC-610GF 1 1 80MM DIA. RUBBER GRIP FOOT FOOT 80 4 2 HOLLOWSHAFT MOTORISED GEARBOX BONFIG 18 1 1 DRIVE IDLER HD50 1 1 FREE IDLER TD50 1 1 CLOSED BEARING CONBEAR45 3 1 DRIVE BEARING CONBEAR20 1 1 610MM WIDE SMOOTH PU ENDLESS BELT PU-490 1 1 80MM DIA. RUBBER GRIP FOOT FOOT 80 6 4

SPARES LIST FOR CONVEYORS

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Shut-down and disposal

Shut-down and disposal

- Adhere to the manufacturer's disposal documents when disposing of the motor oil. - To protect the environment, recycle the packaging.

Environmental regulations

When working on and at the conveyor, always observe legal rules and regulations as regards waste avoidance, correct disposal and material recycling.

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Essential Health & Safety Requirements As stated in The supply of Machinery (Safety) Regulations 2008

1.1 General Remarks

1.1.2 Principles of safety integration conveyor has been constructed from a painted 3mm mild steel frame mounted on an aluminium profile stand. The only exposed area is the working surface of the PVC belt 1.1.3.Materials and Products The materials used in its construction are all standard materials which will not

endanger any persons health or safety 1.1.4.Lighting N/A

1.1.5.Handling Conveyor is shipped wrapped and strapped to a purpose built pallet that is fit

for purpose. This enables the conveyor to be unloaded and moved into posi-tion by either fork truck or pallet truck. The conveyor can be lifted off the pallet by fork truck and placed in its working position by either pallet truck or fork truck 1.1.6.Ergonomics Loading height is designed in accordance with a similar existing process with-

in the Royal Mail. Operation is controlled by the operator and operational pro-cedures put in place by the Royal Mail 1.1.7.Operating Positions Conveyor is driven by motorised drum so there are no exhaust gases 1.1.8. Seating N/A

1.2 Control Systems 1.2.1.Safety and reliability The control system is designed in such a way that it self regulates before

starting to ensure that all safety features are in place and working before pro-ceeding. Any discrepancies will prevent the machine from starting and give a warning signal. If the drive drum becomes inhibited leading to overheating the machine will not start and if left in a ready state it will switch to standby after a set time. 1.2.2. Control Devices The control panel buttons are all labeled as to their function as are the 4 Estops situated at each corner of the inclined conveyor and the 2 Estops situated on the operator side of the horizontal conveyor allowing all opera-tors access without impeding their duties. Before initial start-up there is both a visual and an acoustic warning from the light stack and a delayed start 1.2.3. Starting The conveyor can only be started by following the procedures as laid out in the manual. Any deviation from this will not facilitate a start-up. If foot pedal fitted then running of the conveyor is operator controlled by means of the foot pedal If push button control the conveyor when started will run until stopped on the control panel or in case of necessity by the Estop. The photo cell will pause the belt periodically but not stop it permanently.

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1.2.4. Stopping 1.2.4.1. Normal Stop If foot pedal fitted removal of the operators foot stops the conveyor On push button version pushing the clearly marked stop button will cease. operation. The photo cell will pause the belt periodically but not stop it permanently. 1.2.4.2 Operational Stop Once the machine has been stopped the start button or the foot pedal if fitted must be pushed to restart. If paused by the photo cell the, removing the ob-struction will allow the belt to resume running 1.2.4.3 Emergency Stop The machine is fitted with 4 Estops, one at each corner of the machine If an Estop has been activated it must be reset and the whole machine reset before starting again. Failure to reset the Estop will prevent the machine from being reset and started 1.2.4.4 Assembly of Machine When connected the horizontal conveyor and the incline conveyor act as one machine. The controls and Estops on either conveyor stop both 1.2.5 Selection of Control The machine has only 2 modes of operation run and stop. Once selected each of these overrides the other 1.2.6 Failure of Power Supply Upon failure or interruption to the power supply the machine must be reset before it can be restarted

1.3 Protection against Mechanical Hazards 1.3.1. Risk of loss of Stability Conveyors are stand-alone mild steel conveyors fitted to an aluminium profile stand mounted on 80mm dia. feet 1.3.2. Risk of break-up during Operation All construction materials are adequate for the nature of the environment and the operation designed for. The operational instructions include a full parts list and maintenance schedule 1.3.3. Risks due to ejected or falling objects N/A 1.3.4. Risks due to surfaces, edges or angles During construction, where possible, all edges have been rounded to prevent cause of injury 1.3.5 Risks related to combined machinery N/A 1.3.6. Risks related to variable operating conditions N/A 1.3.7. Risks related to moving parts The only moving part readily accessible to the operator is the belt itself. The potential in running nip point at the drive drum is created by the mail retention cover and is fixed with a max. 5mm gap in accordance with EN619 1.3.8. Choice of Protection 1.3.8.1 Moving Transmission points N/A 1.3.8.2 Moving parts involved in the process The only moving part is the belt as discussed in 1.3.7. above 1.3.9. Risk of uncontrolled movements When the conveyor is stopped there is no run back of belt

1

32

1.4 Required Characteristics of Guards and Protective Devices 1.4.1. General Requirements All covers are retained by means of bolt, spring washer and washer retained in a rivenut. Where applicable these have been fitted with domed heads to pre-vent injury to operators. 1.4.2. Special Requirements for Guards N/A 1.4.3. Special requirements for Protective devices N/A

1.5 Risks due to Other hazards 1.5.1. Electricity Supply Constructed to comply with Directive 2006/95/EC 1.5.2 Static Electricity All extraneous conductive parts are electrically bonded by nature of the build to ensure there is no potential difference between parts 1.5.3. Energy supply other than Electricity N/A 1.5.4. Errors of fitting Full parts list of original parts contained in manual along with fitting instructions and diagrams both mechanical and electrical 1.5.5. Extreme temperatures N/A 1.5.6. Fire N/A 1.5.7. Explosion N/A 1.5.8. Noise Machine emits negligible noise from running belt 1.5.9. Vibration Minimal vibration caused by turning drum 1.5.10 Radiation N/A 1.5.11 External Radiation N/A 1.5.12 Laser Radiation N/A 1.5.13. Emissions N/A 1.5.14. Trapped N/A 1.5.15. Slips, Trips and Falls Machines are supplied with an external cable approx. 3m for power supply, when installed these need to be routed to avoid creating a hazard by the customer to suit installation The conveyors with the foot pedal option will have an extra cable, the foot pedal should be attached to the floor where possible to ensure a tidy workplace 1.5.16 Lighting N/A

1

33

1.6 Maintenance 1.6.1 Machinery maintenance All tracking and belt tensioning areas are contained within the side covers to avoid unnecessary tampering. When the covers are removed the areas are easily accessible and outside of any danger areas 1.6.2 Access to operating positions and servicing points N/A 1.6.3 Isolation of Energy sources A lockable isolator is positioned on the control cabinet and the cabinet cannot be opened unless the isolator is turned to the off position. 1.6.4 Operator Intervention Operator intervention is not required. 1.6.5 Cleaning of Internal parts Only cleaning required is underneath to remove any dust build up or caught mail. Access to this is via quarter turn fittings in the polycarbonate cover. Removal of this cover does not put the operator in any immediate risk alt-hough isolating first should be done and the cover replaced before putting the machine back into operation.

1.7 Information 1.7.1. Information and Warnings on the machine 1.7.1.1. Information The machine has clear and legible warning stickers in all appropriate places. The operating instructions also contain warnings as appropriate 1.7.1.2. Warning Devices Machine has both visual and acoustic warnings. These warn of both potential start up and give an indication of why the conveyor will not operate 1.7.2 Warning of Residual Risks Program sends both a visual and acoustic warning to notify operator of any fault in system 1.7.3 marking of Machinery Machines are all CE marked on the control cabinet 1.7.4 Instructions Operating constructions have been compiled in accordance with The Supply of Machinery (Safety) Regulations 2008#

1

RISK ANALYSIS

SEVERITY 1. NO RISK 2. LOW RISK 3. MEDIUM RISK 4. MAJOR IN JURY 5. HIGH RISK

PROBABILITY 1. IMPROBABALE 2. REMOTE RISK 3. POSSIBLE 4. PROBABLE 5. LIKELY

RISK = SEVERITY X PROBABILITY: RISK RATING LOW 1-10 MEDIUM 11-15 HIGH 15-25

RISK ASSESMENT

AREA

PROCESS

PERSON AT RISK

HAZARD

SEV

PROB

RISK

CONTROL MEASURES

ADDITIONAL CONTROL MEASURES

GENERAL COMMENTS

GENERAL

TRANSPORTATION

TIPPING OVER

4

2

8

SUPPLIED STRAPPED ON PURPOSE BUILT PALLETS CAN BE MOVED BY FORK TRUCK OR PALLET TRUCK

AROUND SITE

CONVEYOR CAN BE MOVED AROUND BY MEANS OF PALLET PLACED

UNDER HORIZONTAL FRAMEWORK

TRANSPORTATION

PARTS LOOSENING

3

2

6 ALL BOLTS & FIXINGS FACTORYCHECKED BEFORE

DISPATCH

ALL BOLTS USED WITH SPRING WASHERS TO

PREVENT LOOSENING

BEFORE MOVING FROM SITE TO SITE A GENERAL CHECK OF ALL BOLTS

SHOULD BE CARRIED OUT

OPERATION

CLEARING MAIL

OPERATOR

CAUGHT IN BELT

4

2

8

ALL INRUNNING NIPS ARE BUILT TO EN619

BELT IS COMPLETELY COVERED IN APRT FROM

PHYSICAL WORKING AREA

BELT IS SET AT BOTTOM OF 150MM WELL AND OUT OF GENERAL ACCESS

FOR THE MOST PART. THERE IS A VISUAL AND ACOUSTIC WARNING ON

START UP COMPLETE WITH 10 SEC DELAY

CLEARING MAIL

OPERATOR HEAD DRUM INRUNNING NIP

POINT

3

2

6

HEAD DRUM IS COMPLETELY ENCLOSED BELT COMPLETELY COVERS THE HEAD DRUM WITH

FINGER GUARDS AT EACH SIDE

HEAD DRUM IS COMPLETELY ENCLOSED WITH INTERNAL MOTOR AND

BEARINGS

TIPPING MAIL BAGS

OPERATOR TAIL DRUM INRUNNING NIP

POINT

3

2

6

TAIL DRUM IS COMPLETELY ENCLOSED BELT COMPLETELY COVERS THE TAIL DRUM WHICH

IS LOCATED BEHIND TWO COVERS

THE TAIL DRUM SITS INSIDE CONVEYOR STRUCTURE COMPLETE WITH

INTERNAL BEARINGS

TIPPING MAIL BAGS

OPERATOR

MANUAL HANDLING INJURIES

3

2

6

CONVEYOR IS FITTED WITH TWO LEVELS FOR EMPTYING

MAIL BAGS

WHEN TOP SHELF IS REMOVED IT REVEALS A

LOWER SHELF THAT STILL COVERS THE TAIL DRUM

EXISTING PROCESS WITHIN ROYAL MAILIS OF A SIMILAR NATURE VIEWED

AND REPLICATED

TIPPING MAIL BAGS

OPERATOR

MOTOR OVERHEATING

2

1

2 PLC IS PROGRAMMED TO CUT POWER AND SEND

WARNING MESSAGES IF MOTOR OVERLOADED

CONVEYOR LOADED AND RAN WITH 150KGS LOAD

BEFORE DISPATCH

MOTOR RATED TO DO MORE BUT HAVE BUILT IN A SAFETY FACTOR

GENERAL RUNNING

OPERATOR

ELECTRIC SHOCK

4

2

8

INCLINE CONVEYOR IS FULLY EARTHED ONLY EXTERNAL CABLES ARE TO FOOT PEDAL (IF

FITTED) AND MAINS FEED

CONTROL CABINET CANNOT BE OPENED UNLESS ISOLATED FIRST. SHOULD

ONLY BE OPENED BY TRAINED ENGINEERS

GENERAL RUNNING

OPERATOR

STATIC SHOCK

3

2

6

ALL EXTRANEOUS CONDUCTIVE PARTS ARE

ELECTRICALLY BONDED BY NATURE OF THE BUILD TO

ENSURE THERE IS NO POTENTIAL DIFFERENCE BETWEEN

PARTS

INCLINE CONVEYOR IS FULLY EARTHED

PVC BELT IS ANTISTATIC FABRIC BACKED GRIP FACE BELT

GENERAL RUNNING

OPERATOR

ACCIDENTAL START UP

3 2

6 FOOT PEDAL VERSION - OPERATOR CONTROLS START

UP

IF LEFT IDLE FOR GREATER THAN 5 MINS THE CONVEYOR NEEDS TO BE RESET AND RESTARTED

WHEN RUNNING OR READY TO RUN THE GREEN LIGHT IS LIT ON THE

LIGHTING STACK 3 2

6 PUSH BUTTON VERSION - ONCE STARTED CONVEYOR

RUNS CONTINUOUSLY

IF LEFT RUNNING THE PLC WILL SWITCH THE CONVEYOR OFF AFTER A SET TIME

MAINTENANCE

CHANGING DRUM

ENGINEER


3

1

3

COVERS CAN BE EASILY REMOVED TO GIVE AS MUCH

ACCESS AS POSSIBLE

FULL INSTRUCTIONS IN MANUAL IN THE MAINTE-

NANCE CHAPTER BUT SHOULD BE CARRIED OUT BY

TRAINED PERSONNEL ONLY

2 PERSON OPERATION, DRUMS ARE HEAVY (25KG) DUE TO THEIR

CONSTRUCTION WITH INTERNAL WORKINGS

CHANGING DRUM

ENGINEER

ELECTRIC SHOCK

4

1

4 BEFORE DISCONNECTING FRON CONTROL PANEL IT

MUST BE ISOLATED FIRST BEFORE OPENING

THE CONTROL CABINET SHOULD BE OPENED BY


CHANGING BELT

ENGINEER


4

2

8 PANELS AND COVERS ARE ALL MANUFACTURED IN SIZES

THAT ARE PERSON MANAGEABLE

2 PERSON OPERATION DUE TO NECESSITY OF

LOCATING BOLTS

FULL INSTRUCTIONS ARE IN THE OPERATING MANUAL

CHANGING BUILT IN

LIGHT STACK

ENGINEER

ELECTRIC SHOCK 3 1

3 EACH LIGHT COLOUR IS REMOVABLE WITH A SIMPLE

TWIST ACTION

NO TRAILING WIRES, CONNECTION MADE WHEN

REFITTING WITH TWIST CONNECTION

ISOLATE POWER AND LOCK OUT WITH PERSONAL LOCK BEFORE STARTING

CHANGING CABLES

ENGINEER

ELECTRIC SHOCK 3 1

3

CABLES ARE SY CABLES THAT ARE FIT FOR PURPOSE CONTROL CABINET CANNOT BE OPENED WITHOUT

ISOLATING


TENSIONING BELT

ENGINEER

CAUGHT IN BELT

3

1

3

BELT CAN BE TENSIONED WITHOUT ACCESS TO THE

DRUMS, ACCESS TO THE TENSIONING PLATES IS

AVAILABLE BY REMOVING THE SIDE COVERS

FULL INSTRUCTIONS IN MANUAL IN THE

MAINTENANCE CHAPTER BUT SHOULD BE CARRIED

OUT BY TRAINED PERSONNEL ONLY


TRACKING BELT

ENGINEER

CAUGHT IN BELT

3

2

6

BELT IS TRACKED BY MEANS OF 4 TENSIONING BOLTS, 2 ON EACH DRUM. BELT CAN BE TENSIONED WITHOUT

ACCESS TO THE DRUMS, ACCESS TO THE TENSIONING

PLATES IS AVAILABLE BY REMOVING THE SIDE COVERS

FULL INSTRUCTIONS IN MANUAL IN THE MAINTE-

NANCE CHAPTER BUT SHOULD BE CARRIED OUT BY



CLEANING

GENERAL

ENGINEER

SHOCK 4 1

4 ONLY EXTERNAL CABLES ARE TO FOOT PEDAL (IF FITTED)

AND MAINS FEED

ALL WIRING IS HOUSED INTERNALLY WERE POSSIBLE


GENERAL

ENGINEER

CAUGHT IN BELT

4

1

4 DIRT COVERS CAN BE REMOVED FROM UNDERSIDE

WITHOUT REVEALLING ANY HAZARDS

COVERS MADE OF CLEAR POLYCARBONATE TO

ALLOW A VISUAL INSPECTION BEFORE REMOVING


Please note this is a design Risk Assessment and should be used in conjunction with a site specific risk assessment

34

SEVERITY 1. MINOR INJURY 2. LOST TIME INCIDENT 3. +3 DAYS OFF 4. MAJOR INJURY FATALITY

PROBABILITY 1. IMPROBABLE 2.REMOTE RISK 3. POSSIBLE 4. PROBABLE 5. LIKELY

RISK = SEVERITY X PROBABILITY RISK RATING: LOW: 1 -10 MEDIUM: 11-15 HIGH:15-25

RISK ANALYSIS

1

Drawing No.

Drawn By:

CLIENT

PROJECT

DRAWING No.

Drawing Title:

Scale: Date:

ROYAL MAIL - CHELMSFORD

Incline Conveyor and Extender

Panel 1LAYOUT

DF NTS 15 May 2013RMCIC_001

1

1 of 10

1 of 10 RMCIC_001

PSU

24V5A

MCB

1

6A

MCB

2

6A

MCB

3

6A

FIELD TERMINALS

SafetyRelay

SR1

SafetyCont.

SC1

Zelio 1

Smart Relay

Inverter 1

InclineConveyor

ATV

Drive 1

Neu

tral

Neu

tral

Earth

Earth

Earth

Earth

SupplyOn

Start

Panel ID Plate

Stop

RESET

Stuart

Snapshot

Drawing No.

Drawn By:

CLIENT

PROJECT

DRAWING No.

Drawing Title:

Scale: Date:



Panel 2LAYOUT


1

2 of 10

2 of 10 RMCIC_002

FIELD TERMINALS

Inverter 2

InclineConveyor

Extender Drive

Stuart

Snapshot

Drawing No.

Drawn By:

CLIENT

PROJECT

DRAWING No.

Drawing Title:

Scale: Date:



Power Supply


1

3 of 10

3 of 10 RMCIC_003

Stuart

Snapshot

Drawing No.

Drawn By:

CLIENT

PROJECT

DRAWING No.

Drawing Title:

Scale: Date:



Incline ConveyorATV Drive 1


1

4 of 10

4 of 10 RMCIC_004

Incline ConveyorATV Drive 1

26

W

W

U V L1L1

1L2

N

Comm

0V

L1

54

L2

107

R1 C

54Ze

lio 1

Rel

ay

107

Zelio

1 R

elay

Supp

ly fr

om c

onta

ctor

SC

1N

Supp

ly fr

om c

onta

ctor

SC

1L1

1

U V

Delta ConnectMOTOR

Dw

g: R

MC

IC_0

07

Dw

g: R

MC

IC_0

07

104

22

162

Dw

g: R

MC

IC_0

0510

4D

rive

2

Mot

or O

verh

eat

Stuart

Snapshot

Drawing No.

Drawn By:

CLIENT

PROJECT

DRAWING No.

Drawing Title:

Scale: Date:



Extender ConveyorDrive 2


1

5 of 10

5 of 10 RMCIC_005

Extender ConveyorATV Drive 2

26

W

W

U V L1L1

0L2

N

Comm

0V

L1

105

L2

106

R1 C

105

Zelio

1 R

elay

106

Zelio

1 R

elay

Supp

ly fr

om c

onta

ctor

SC

1N

Supp

ly fr

om c

onta

ctor

SC

1L1

0

U V

Delta ConnectMOTOR

Dw

g: R

MC

IC_0

07

Dw

g: R

MC

IC_0

07

33 34 27 28

104

+24V

Stuart

Snapshot

Drawing No.

Drawn By:

CLIENT

PROJECT

DRAWING No.

Drawing Title:

Scale: Date:

+ - I1 I2 I3 I4 I5 I6 IB IC ID IE IF IG - -

Zelio Smart Relay

SR2 B201BD

1 2Q1

1 2Q2

1 2Q3

1 2Q4

1 2Q5

1 2Q6

1 2Q7

1 2Q8

OutputsQ1 to Q8 Relay 8A

24V DC I1 to I6 24V DC IB to IG Analog or 24V DC Inputs

+ 24

V D

C

0V 156

157

158

159

161

103

20 21 25

Dw

g: R

MC

IC_0

08

Pane

l 1 D

oor

- R

ES

ET

0V

156

FED FROMTransformer T1

0V

Safe

ty R

elay

OK



Smart Relay INPUTS


1

6 of 10

6 of 10 RMCIC_006

TB1

Mot

or F

ault

PEC

Sen

sor

Not

Use

d

Not

Use

d

Futu

re U

se

Foot

Sw

itch

- (if

fitte

d)

Pane

l 1 D

oor

- S

TAR

T

Pane

l 1 D

oor

- S

TOP

Futu

re U

se

Futu

re U

se

Stuart

Snapshot

Drawing No.

Drawn By:

CLIENT

PROJECT

DRAWING No.

Drawing Title:

Scale: Date:



Smart Relay OUTPUTS


1

7 of 10

7 of 10 RMCIC_007

+ - I1 I2 I3 I4 I5 I6 IB IC ID IE IF IG - -

Zelio Smart Relay

SR2 B201BD

1 2Q1

1 2Q2

1 2Q3

1 2Q4

1 2Q5

1 2Q6

1 2Q7

1 2Q8

OutputsQ1 to Q8 Relay 8A

24V DC I1 to I6 24V DC IB to IG Analog or 24V DC Inputs

Q1-

1 Q1-

2

Spee

d 2

Inve

rter 2

Q2-

1 Q2-

2

15

Q3-

1 Q3-

2

16

Q4-

1 Q4-

2

17

Q5-

1 Q5-

2

27

Q6-

1 Q6-

2

18

Q7-

1 Q7-

2

28

Q8-

1 Q8-

2

24V DC

54 115

116

117

105

118

106

107

Spee

d 1

Inve

rter 1

TB1

Spee

d 2

Inve

rter 1

Spee

d 1

Inve

rter 2

Ambe

r Lam

p

Gre

en L

amp

Soun

der

Red

Lam

p

Amb Grn Red

0V0V0V 0V

Stuart

Snapshot

Drawing No.

Drawn By:

CLIENT

PROJECT

DRAWING No.

Drawing Title:

Scale: Date:



Safety RelaySR1


1

8 of 10

8 of 10 RMCIC_008

Stuart

Snapshot

Drawing No.

Drawn By:

CLIENT

PROJECT

DRAWING No.

Drawing Title:

Scale: Date:



Incline ConveyorE-STOPS


1

9 of 10

9 of 10 RMCIC_009

E-stops locatedwithin the Incline Conveyor System

along the work station

Stuart

Snapshot

Drawing No.

Drawn By:

CLIENT

PROJECT

DRAWING No.

Drawing Title:

Scale: Date:



Extender ConveyorE-STOPS


1

10 of 10

10 of 10 RMCIC_010

31 32

E-stops locatedwithin the Incline Conveyor Systemalong the EXTENDER work station

Stuart

Snapshot

Drum Motor Calculation 26/05/2013

Company ConveyorTekContact Stuart McElhinneyApplication Horizontal 2.8m

Application data's

Conveyor type flat belt Frequent start/stop YesShock load NoNose bar/fixed knife edge NoCarrying belt support slider bed 0.2Return belt support none 0Conveyor length 2.8 mBelt width 600 mmInclination 0.0 DegreeBelt specific weight 1.4 Kg/m2Angle angle of wrap around Drum Motor 180.0 degBelt tensile force (SD value or K1%) 8.0 N/mmTotal load on belt 100 KgSafety margin 10 %Belt speed 0.13 m/sAccumulated and/or diverted load 0 KgExternal forces : scrappers, brush etc. 0 NThickness of lagging on Drum motor 0 mm

Calculation results

Belt pull (including safety factors) 316 NMinimum required drum motor range 80iRequired drum motor power 0.04 kWRequired drum motor speed 0.13 m/sRequired drum motor torque 13 NmInitial belt elongation 0.30 %Required belt take up 8 mmBelt tension T1+T2 2880 N

Date

belt friction factor on slide bed belt friction factor on return

Belt-goods friction factor

http://www.interroll.com/

Stuart

Text Box

Stuart

Snapshot

Stuart

Snapshot

Drum Motor Calculation 15/02/2013

Company ConveyorTekContact Stuart McElhinneyApplication Incline

Application data's

Conveyor type flat belt Frequent start/stop YesShock load NoNose bar/fixed knife edge NoCarrying belt support slider bed 0.2Return belt support none 0Conveyor length 2.6 mBelt width 615 mmInclination 20.0 DegreeBelt specific weight 4.4 Kg/m2Angle angle of wrap around Drum Motor 180.0 degBelt tensile force (SD value or K1%) 8.0 N/mmTotal load on belt 150 KgSafety margin 10 %Belt speed 0.13 m/sAccumulated and/or diverted load 0 KgExternal forces : scrappers, brush etc. 0 NThickness of lagging on Drum motor 0 mm

Calculation results

Belt pull (including safety factors) 1267 NMinimum required drum motor range 113iRequired drum motor power 0.18 kWRequired drum motor speed 0.13 m/sRequired drum motor torque 72 NmInitial belt elongation 0.30 %Required belt take up 8 mmBelt tension T1+T2 2952 N

Date

belt friction factor on slide bed belt friction factor on return

Belt-goods friction factor

http://www.interroll.com/

Stuart

Text Box

Stuart

Snapshot

Stuart

Snapshot

ConveyorTek Conveyor Belt Power and Tension Calculation

CUSTOMER

CONVEYOR REFERENCE

Table Value

B= Belt width 1 600.00D= Material Density in Kgs per cubic Metre. 17 431.00S= Speed in Metres per Second. 2 0.13m=*Drive factor 11 2.16 *GTU (FOR STU ADD 20%)

Q= Theoretical Tonnes per Hour 3,4 26.68F= Friction 9 0.02C= Centre Distance in Metres 2.80G= Inertia Factor for Idlers. 7 30.87S= Belt Speed in Metres per Second. 2 0.13H= Height in Metres 0.00Motor Efficiency Factor 0.85I= resistance allowance length 8 0.00Belt discharge plough or tripper 10 0.00No. of belt cleaners/ploughs 0.00Total length of skirting 0.00

Power Calculation Effective Tension P(N)P= Nnx1000/s

(a). Power to move Empty Belt 55

Max TensionT1(N)Kilowatt's Required T1=Pxm

120

0.00 Working Tension p(N/mm)p=T1/b

(b). Power to move Load Horizontally 0.20

Kilowatt's Required1. TYPE EP

0.00 2. BELT STRENGTH # 8

3. NUMBER OF PLIES 2

(c). Power to Lift Load 4. TOP COVER 0.3

5. BOTTOM COVER 0

Kilowatt's Required 6. COVER LF

# SAFETY FACTOR 40

0.00 # Recommended safety factor 10:1

CONVEYOR BELT POWER AND TENSION CALCULATION

Royal MailHORIZONTAL

Input Data.

Approved by M.Buchanan

Stuart

Snapshot

Stuart

Snapshot

Stuart

Text Box

ConveyorTek Conveyor Belt Power and Tension Calculation

CUSTOMER

CONVEYOR REFERENCE

Table Value

B= Belt width 1 615.00D= Material Density in Kgs per cubic Metre. 17 431.00S= Speed in Metres per Second. 2 0.13m=*Drive factor 11 2.16 *GTU (FOR STU ADD 20%)

Q= Theoretical Tonnes per Hour 3,4 26.68F= Friction 9 0.02C= Centre Distance in Metres 2.60G= Inertia Factor for Idlers. 7 30.87S= Belt Speed in Metres per Second. 2 0.13H= Height in Metres 1.00Motor Efficiency Factor 0.90I= resistance allowance length 8 0.00Belt discharge plough or tripper 10 0.00No. of belt cleaners/ploughs 0.00Total length of skirting 0.00

Power Calculation Effective Tension P(N)P= Nnx1000/s

(a). Power to move Empty Belt 611

Max TensionT1(N)Kilowatt's Required T1=Pxm

1319

0.00 Working Tension p(N/mm)p=T1/b

(b). Power to move Load Horizontally 2.14

Kilowatt's Required1. TYPE EP

0.00 2. BELT STRENGTH # 8

3. NUMBER OF PLIES 2

(c). Power to Lift Load 4. TOP COVER 3.7

5. BOTTOM COVER 0

Kilowatt's Required 6. COVER HF

# SAFETY FACTOR 4

0.07 # Recommended safety factor 10:1

CONVEYOR BELT POWER AND TENSION CALCULATION

Royal MailIncline

Input Data.

Approved by M.Buchanan

Stuart

Snapshot

Stuart

Snapshot

Stuart

Text Box

MACHINE SERIAL NUMBER

MANUFACTURE DATE

TEST DATE

PASS/FAIL

Pass

Pass

Pass

Pass

Pass

Pass

Pass

Pass

TEST AREA MIN Mohm TEST RESULT PASS/FAIL

Main Isolator (Control Panel) B-E 2 2 Pass

Main Isolator (Control Panel) Bl-E 2 2 Pass

Main Isolator (Control Panel) G-E 2 2 Pass

Main Isolator (Control Panel) N-E 2 2 Pass

Supply to Motor 1 B-E 2 2 Pass

Supply to Motor 1 Bl-E 2 2 Pass

Supply to Motor 1 G-E 2 2 Pass

TEST AREA POLARITY MAX TEST Ohms TRUE TEST Ohms

Control Pannel Ph 1 Pass 3.2 1.31

Control Pannel Ph 2 N/A


TEST AREA TEST TEST RESULT PASS/FAIL

Control Panel Backplane Continuity 0 OHM Pass

Control Panel Door Continuity 0 OHM Pass

Footpedal Continuity N/A N/A

Trunking Continuity 0 OHM Pass

Bonding Connection 1 Machine Front Continuity 0 OHM Pass

Bonding Connection 2 machine middle Continuity 0 OHM Pass

Bonding Connection 3 machine a to machine B Continuity 0 OHM Pass

Bonding Point Control Panel Incline Continuity 0 OHM Pass

Bonding Point Control Panel Horizontal Continuity 0 OHM Pass

Earth Connection Motor Rear Continuity 0 OHM Pass

Manufacturer

Serial Number

Date Of Last Calibration

DATE:-

CONVEYOR PREDELIVERY ELECTRICAL SAFETY TEST

266

5th June

5th June

TEST EQUIPMENT DETAIL

VISUAL INSPECTION

INSTALLATION RESISTANCE TESTING

EARTH LOOP IMPEDANCE & POLARITY TESTS

EARTH CONTINUITY TEST

E stop Connections

Internal Board Connections

Light Stack Connections

External Controls and Labels

External Flexible Cables

Mains 3 Pin Plug Top

Cable Glands

External Earthing Points

COMMENTS

At point of test removed for transport

Testing use only may be removed on site

All bonds made internally

INSPECTION AREA INITIALS

RM

RM

RM

RM

RM

RM

RM

RM

INITIALS

RM

RM

COMMENTS

RM

RM

RM

RM

RM

INITIALS

RM

RM

RM

COMMENTS

To be Retested after install

single phase config

single phase config

COMMENTS INITIALS

NOT FITTED

RM

RM

RM

RM

RM

RM

RM

RM

RM

RM

I certify this equipment has been tested and inspected by :- Roy Millar

Fluke 1652B

9222048


MANUFACTURE DATE

TEST DATE

PASS/FAIL

Pass

Pass

Pass

Pass

Pass

Pass

Pass

Pass
























Manufacturer

Serial Number


DATE:-


271

5th June

5th June


VISUAL INSPECTION




E stop Connections






Cable Glands


COMMENTS





RM

RM

RM

RM

RM

RM

RM

RM

INITIALS

RM

RM

COMMENTS

RM

RM

RM

RM

RM

INITIALS

RM

RM

RM

COMMENTS


single phase config

single phase config

COMMENTS INITIALS

NOT FITTED

RM

RM

RM

RM

RM

RM

RM

RM

RM

RM


Fluke 1652B

9222048


MANUFACTURE DATE

TEST DATE

PASS/FAIL

Pass

Pass

Pass

Pass

Pass

Pass

Pass

Pass
























Manufacturer

Serial Number


DATE:-


267

5th June

5th June


VISUAL INSPECTION




E stop Connections






Cable Glands


COMMENTS





RM

RM

RM

RM

RM

RM

RM

RM

INITIALS

RM

RM

COMMENTS

RM

RM

RM

RM

RM

INITIALS

RM

RM

RM

COMMENTS


single phase config

single phase config

COMMENTS INITIALS

NOT FITTED

RM

RM

RM

RM

RM

RM

RM

RM

RM

RM


Fluke 1652B

9222048


MANUFACTURE DATE

TEST DATE

PASS/FAIL

Pass

Pass

Pass

Pass

Pass

Pass

Pass

Pass
























Manufacturer

Serial Number


DATE:-


268

5th June

5th June


VISUAL INSPECTION




E stop Connections






Cable Glands


COMMENTS





RM

RM

RM

RM

RM

RM

RM

RM

INITIALS

RM

RM

COMMENTS

RM

RM

RM

RM

RM

INITIALS

RM

RM

RM

COMMENTS


single phase config

single phase config

COMMENTS INITIALS

NOT FITTED

RM

RM

RM

RM

RM

RM

RM

RM

RM

RM


Fluke 1652B

9222048


MANUFACTURE DATE

TEST DATE

PASS/FAIL

Pass

Pass

Pass

Pass

Pass

Pass

Pass

Pass
























Manufacturer

Serial Number


DATE:-


269

5th June

5th June


VISUAL INSPECTION




E stop Connections






Cable Glands


COMMENTS





RM

RM

RM

RM

RM

RM

RM

RM

INITIALS

RM

RM

COMMENTS

RM

RM

RM

RM

RM

INITIALS

RM

RM

RM

COMMENTS


single phase config

single phase config

COMMENTS INITIALS

NOT FITTED

RM

RM

RM

RM

RM

RM

RM

RM

RM

RM


Fluke 1652B

9222048


MANUFACTURE DATE

TEST DATE

PASS/FAIL

Pass

Pass

Pass

Pass

Pass

Pass

Pass

Pass
























Manufacturer

Serial Number


DATE:-


270

5th June

5th June


VISUAL INSPECTION




E stop Connections






Cable Glands


COMMENTS





RM

RM

RM

RM

RM

RM

RM

RM

INITIALS

RM

RM

COMMENTS

RM

RM

RM

RM

RM

INITIALS

RM

RM

RM

COMMENTS


single phase config

single phase config

COMMENTS INITIALS

NOT FITTED

RM

RM

RM

RM

RM

RM

RM

RM

RM

RM


Fluke 1652B

9222048

Powered Roller Mail Prep Frame - Ergonomics Assessment Creation Date: 15/01/2016

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

Ergonomics Assessment of Powered Roller Mail Preparation Frame at Croydon Mail Centre

Version: 2.0

21st January 2016

David Annett

Chartered Ergonomist

www.ergotherapy.co.uk

[email protected]

07957 542341

mailto:[email protected]

Powered Roller Mail Prep Frame - Ergonomics Assessment Creation Date: 15/01/2016 – Page 2 of 10


Contents

Introduction ................................................................................................................................................. 4

Overview ...................................................................................................................................................... 5

Findings ........................................................................................................................................................ 8

Conclusions .................................................................................................................................................. 9


Introduction

The Mail Preparation Frame (MPF) facilitates bag tipping and splitting of bundled mail and transfers the contents into standard Royal Mail trays for onward processing. The equipment can be used for Down Stream Access mail, Mailsort, Meter mail, PPI and residue mail and accommodates letters and large letters.

Versions of the frame have been developed in Bristol with an inline rising belt and a mechanical pedal to push the trays when full and at Jubilee Mail centre with a similar setup to Croydon. They have had ergonomic reviews by Jane Dillon in 2013, Corinne Parsons in 2014 and David Annett in 2015, as modifications were made. The frame in this is located at Croydon Mail Centre and originally the mail came off the rising belt onto gravity fed rollers. There were some issues with mail getting jammed on the rising belt roller and becoming damaged. The frame has now been modified to try to reduce this occurrence by using powered rollers instead of gravity fed rollers. One version had angled rollers and the second version had flat powered rollers.

An ergonomics review of these new versions was requested by Ken House, National Workplace Organisation Deployment Lead, to ensure the equipment was suitable for use. The visit to Croydon Mail Centre was made on 5th January 2016. Local managers present during the assessment included Nigel Coleman, Peter Kane and Spencer Benedict. Operational staff were observed using the equipment and then interviewed.


Overview

Powered Roller Mail Preparation Frame, Croydon

The MPF has been in use at Croydon since about May 2015. An issue was identified where mail was being caught in the in-running nip of the rising belt. This caused jams and damaged mail. The frequency was so great that they often had to have an operator standing over the area to clear the mail and prevent jams.

Apparently this happened when heavy bundles got stuck on the gravity fed rollers and caused a back-up of mail at the drop off point. Initial solutions included raising the whole tipping conveyor to create more space under the drop off. In July 2015 this was superseded with the gravity rollers being replaced by powered rollers. According to the managers, this significantly reduced the problem. The latest version, which was installed in the second week of December 2015, featured flat rollers rather than angled ones to create more space under the drop off.


Original gravity-fed rollers

Mod 1 – angled powered rollers Mod 2 – flat powered rollers

Apparently this further improved the reliability of the system and minimised the number of jams and mail damage. The operator tasks for bag tipping, tray filling and tray removal have been assessed previously, so the focus of this assessment is on the task of jam clearance and avoiding jams and mail damage.


Findings

Observations were made of staff using both the angled and flat powered roller frames. Both staff and managers stated that both types of powered roller had significantly reduced the amount of jams and mail damage compared to the gravity fed rollers.

If mail gets caught and damaged in the top of the rising belt it can be awkward to retrieve. The nearest operator is the tray loader, who has to reach and twist from their location (see picture below). This area is best accessed from the back of the frame, so the operator who removes the full trays and loads the empty trays would be best placed to deal with the jams. However, they still have to reach over the rollers. Reducing the jams will reduce the risk of injury from reaching over to clear the jams.

Operator reaching to clear mail from belt drop off area

The managers felt that the flat rollers performed better than the angled rollers in terms of reducing the number of jams and mail damage. The operators were less aware of the difference, although they had not used the different frames very often. The frames were observed for around 2.5 hours and no mail items were caught or damaged on either frame.

There can still be some build up of mail at the drop off of the rising belt, which is out of sight of the bag tipper. The installation of a mirror so the bag tipper can see this area has been well received by the operators. They are planning on increasing the size of the mirror to improve the ease of viewing.


Mirror (in centre of image) for bag tipper to view belt drop-off area.

From an ergonomics perspective there is little to choose between the angled and flat rollers in terms of reach distances. Their performance in terms of avoiding jams is the most important factor.

With regard to comments made in the previous report by Corinne Parsons at Jubilee Mail Centre in May 2015, there were some concerns about space issues for two operators to work at the tray filling area. This was not a concern for any of the operators observed at Croydon and they had no issues with part of the frame causing knocking hazards for their arms or elbows.

Corinne’s report also recommended that staff rotate between tasks. At the time of the visit the staff regularly rotated on an informal basis about once an hour which reduces the injury risks of repetitive working. It should be ensured that rotation to other tasks (e.g. cutting & tipping, prep, clearing and portering) occurs frequently and no less than every 2 hours in any continuous period).

Conclusions The Mechanised Mail Preparation Frame with conveyor is a significant improvement over the previously used tipping tables. The main operator interactions have been assessed before in terms of bag tipping, tray loading and tray removal. These tasks were operating well with no problems reported from the operators or managers.


The focus of this review was to look at the modification of changing gravity fed rollers to powered rollers to feed the tray loading workstations. This had been initiated due to the high levels of jams and mail damage at the top of the rising conveyor when mail backs up.

Both staff and managers reported that the both versions of the powered rollers reduced the incidence of jams and mail damage significantly. On the visit, there were no mail damage incidents.

From an ergonomics perspective the modifications reduce the amount of reaching and awkward postures adopted to clear the jams. It is reported that the flat version of the rollers reduces the amount of jams and damage the most, so this would be the recommended way forward.

Acknowledgements

Thanks to the staff at the Croydon Mail Centre for their cooperation during the visit, in particular Nigel Coleman and Spencer Benedict.

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