Safe use of machinery factsheets : Information, Installation, Operation and Maintenance
Numerous accidents, including amputations, have occurred during the cleaning and maintenance of inadequately maintained and/or guarded machines.
Machinery that has not been properly installed, maintained or used correctly can result in machinery operators and bystanders being seriously harmed or killed.
Employers have a legal responsibility under the Health and Safety in Employment Act 1992 (HSE Act) to provide a safe working environment and this includes the safe use of machinery. Under Regulation 17 of the HSE Act’s 1995 Regulations, provision has to be made for machine lockout for the safe cleaning, maintenance and repair of machinery.
This includes guarding, lockout mechanisms, and a training programme for safe work procedures. A requirement is to install and operate machinery according to the manufacturer’s instructions.
Significant Hazards
Suppliers of second-hand machinery should provide an instruction handbook to the new owner. If this does not occur the new owner must attempt to get a replacement handbook from the supplier or the original manufacturer. Without the instruction handbook, the new owner may be unaware of safe maintenance procedures and guarding standards.
Hazard Controls
Designers, manufacturers, and suppliers of new and second-hand machinery have legal obligations to ensure the equipment is designed, made and maintained so it is safe for its intended use. Comprehensive information and instructions must be supplied for the safe use, adjustment, installation, maintenance, dismantling, repair and any other relevant matters for the machinery.
Machinery owners (employers) also have similar obligations to ensure that their machines are properly designed, maintained and operated safely, in accordance with the manufacturer's original instructions.
Current best practice based on AS 4024.1-2006 (Series) Safety of Machinery uses machinery markings and comprehensive, up-to-date instruction handbooks to ensure machinery safety information is readily available to owners and operators.
Other machine-specific safety standards require additional machine marking and more detailed handbook contents which can be checked with the manufacturer.
Hazard Assessment
- Consider the ergonomic set-up of the new machine for safety and comfort of operation.
- Assess the need for additional guarding systems, especially where product blockages may occur.
- Provide tag/lockout systems for maintenance and cleaning and repairs.
- Ensure staff are adequately trained on how to safely use the machine and supervision is effective.
Machinery markings
All machinery should have a marking/maker’s plate or a label with at least the following information:
- Name and address of the manufacturer and supplier
- Year of construction
- Machine type or model number
- Serial number
- Indication of compliance with mandatory requirements and standards.
If significant hazards are present then the following markings may include:
- Markings related to mechanical, fluid power and electrical hazards, mandatory and hazardous atmospheres
- Maximum speeds, loads or other operating limitations
- Mass of the machine itself or any removable parts
- Warning signs and pictograms
All machinery markings should be permanently fixed or printed directly onto the machine. They must be replaced when damaged or become unreadable.
Instruction handbook
The employer must obtain a machinery instruction handbook or provide other written instructions that include the following information:
- A publication date and revision details (if the information has been redrafted or updated)
- Information about any transport, handling or storage requirements, including details of the machine's dimensions, mass and lifting points
- Information about installation and commissioning, including details of any assembly information and power supply requirements.
Specific information about the machine itself should include:
- A detailed description of the machine (including any fittings, guards or protective safety devices)
- Reference to any machinery safety standards used in its design, including any mandatory requirements (for example a conformance declaration or a verification of design)
- Details of any emissions (noise, fumes or dust) the machine produces while operating.
Specific user information should include:
- The machine’s intended use
- A description of the machine’s controls (especially emergency stops)
- Details of operating instructions, including start-up preparations, process change-over and shutting down
- A description of common faults and any reset instructions to be undertaken by the operator
- Details of any guards or protective safety devices which must be used for particular hazards
- Safety sign descriptions and details
- Details of any prohibited or foreseeable misuse
- Details of any hazards which the manufacturer could not eliminate
- Details of any personal protective equipment which needs to be used, and any training that is required.
Maintenance information which should include:
- Details of routine inspection and maintenance, including any timings
- Detailed maintenance and inspection instructions (for example adjustment, cleaning and routine lubrication) which can be undertaken by a machine operator
- Detailed maintenance and inspection instructions (for example, replacement of damaged parts) which MUST be undertaken by a competent person (for example, an electrician, fitter or technician)
- Machinery drawings and circuit diagrams for use by a competent maintenance person to enable them to carry out their tasks
- Information to enable a competent person to safely decommission, dismantle and dispose of the machine
- Emergency information, including details of any specific fire fighting or containment equipment required.
All markings and written instructions must be provided in English or accompanied by an English translation.
Instruction manuals can be provided and stored in electronic format, but MUST be backed up in a printed form that is readily available in the event of an emergency.
Machinery owners should ensure that instruction handbooks for machinery that is refurbished or modified beyond its original intended use are updated or revised, and include references to any new or revised machinery safety standards.
Machinery markings should identify both the machine and its manufacturer and any specific hazards or safety precautions.
Instruction handbooks (manuals) should be supplied with all machinery, which owners should maintain and update (as necessary) and make accessible to their employees.
For further information Contact the Department of Labour
Free phone 0800 20 900 20 during business hours
Email info@dol.govt.nz
www.dol.govt.nz
Current Standards – Available www.standards.com.au
AS 4024.1 - 2006 (series) Safety of machinery
It may also be available for loan or reference from some Crown Research Institutes, Universities or Central Libraries.
The Department of Labour would like to acknowledge the Victorian WorkCover Authority (WorkSafe Victoria) for allowing the reproduction of their material in this Guidance Sheet. Further information can be obtained at www.worksafe.vic.gov.au.
Note: This material is also only intended to provide general advice and does not constitute legal advice. You should make your own judgement about action you may need to take to ensure you have complied with your workplace health and safety obligations under the law.
