Instruction on labor protection for the adjuster of cold forging equipment and dies on presses

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Instructions on labor protection for the adjuster of cold forging equipment and dies on presses. Full Document

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General safety requirements

1.1. This instruction was developed on the basis of GOST 12.3.026-81 (SSBT. Forging and pressing works. Safety requirement.) and GOST 12.2.109-89 (SSBT. Sheet stamping dies. General safety requirement). It contains requirements that ensure the safety of work during the installation, adjustment of dies and safety devices on cold stamping presses in the main mechanical and stamping shops of the plant, and also sets out the rules of conduct for a worker in the shop and on the territory of the plant.

1.2. Persons not younger than 18 years of age who have passed a medical examination, special training and knowledge testing by a qualification commission are allowed to work independently as an adjuster.

1.3. All newcomers to work are allowed to perform their duties only after passing an introductory briefing on labor protection and a briefing on safety at the workplace.

1.4. All workers, regardless of qualifications and length of service, are re-instructed at least every 3 months.

1.5. Unscheduled briefing is carried out when changing the rules for labor protection, the technological process, replacing or upgrading equipment, fixtures and tools, raw materials, materials, violations by workers of labor safety requirements that have led or may lead to injury, accident, fire, explosion.

1.6. Work only on those presses that you have studied well and for which you are allowed to work independently. Persons who are not directly involved in the work are not allowed to enter the workplace.

1.7. Do only the work that is assigned to you by the master, and on the condition that you know the safe ways to do it.

1.8. If you notice safety violations by other workers, warn them about the need to comply with safety requirements.

1.9. Do not work near open live parts (trolleys, electrical panels, cables, etc.) until you make sure that there is no voltage on them and will not be applied before the end of work.

1.10. Do not work on faulty equipment and in the absence or malfunction of protective guards, interlocks, grounding.

1.11. Do not turn on the press until you have ensured that all moving parts that present a entrapment hazard are securely guarded.

1.12. Work only in serviceable, neatly tucked overalls and protective devices provided for by the Model Industry Standards for this profession:

a) cotton suit GOST 12.4.108-82;

b) leather boots GOST 12.4.137-84;

c) combined gloves GOST 12.4.013-86.

1.13. Make sure that the floor around the press is level and non-slip, that all hatches, trenches and openings are closed. If the floor is covered with oil, emulsion, demand that it be sprinkled with sawdust or do it yourself.

1.14. Dangerous and harmful production factors during the installation and adjustment of dies on presses are:

sharp edges, burrs and irregularities on the surfaces of tools and equipment;
moving machines and mechanisms, moving parts of equipment;
work with lifting mechanisms;
the possibility of getting under the influence of electric current;
noise.

1.15. On the territory of the plant and in the workshops, follow these rules:

internal labor regulations, work and rest regime;
walk on sidewalks and paths specially designed for pedestrian traffic, and where there are none, on the carriageway, keeping to the left;
be attentive to the signals of moving vehicles and do not run across the path in front of it;
do not walk on railroad tracks;
do not crawl under standing platforms and wagons;
do not accelerate workshop transport carts and do not ride on them;
use only the established passages, do not climb over conveyors, conveyors, etc.;
if people work at a height, pass this place at a safe distance, as any object may fall from a height;
do not stand or walk under a lifted load or in its immediate vicinity;
do not look at electric welding with unprotected eyes; remember that eye pain may not appear immediately, but after a few hours;
beware of gas poisoning, do not be idle near gas pipelines, gas generators, acetylene apparatus and other devices where gas can be released;
do not touch electrical wires or other current-carrying parts, do not try to fix the malfunction of electrical wires or electrical equipment yourself, call an electrician for this purpose;
do not turn on or stop (except in emergency cases) machines, machines and mechanisms, work on which is not entrusted to you by the administration;
ride electric cars, tractor trailers, sit on the sides of cars, car steps, etc. prohibited;
do not open the doors of electrical panels and other equipment;
do not make an open fire without the permission of the administration, smoke in specially designated areas;
do not lift the load beyond the permissible norm.

Remember that it is allowed to lift a load weighing no more than:

men - 50 kg;

women aged 18 and over:

lifting and moving weights when alternating with other work (up to 2 times per hour) - 10 kg,
lifting and moving weights constantly during a work shift - 7 kg;

the amount of dynamic work performed during each hour of a work shift should not exceed:

from the working surface - 1750 kgm,
from the floor - 875 kgm;
lifting weights to a height of more than 1,5 m - 10 kg;
when moving goods on trolleys or in containers, the applied force should not exceed 10 kg.

1.16. Report every accident with you or other workers immediately to the foreman or foreman, provide first aid in accordance with IOT-149 and contact the health center.

1.17. You should not follow the order of the foreman (foreman), if it contradicts the rules of labor protection and can lead to an accident, inform the senior foreman or the head of the workshop about this.

1.18. For failure to comply with the requirements of the instructions, you are responsible in accordance with the Internal Labor Regulations and labor legislation.

1.19 Harmful and dangerous production factors when setting up cold forging equipment and dies on presses:

electricity;
moving parts of the machine;
noise - remote control 80dB;
illumination - not less than 300 lux;
temperature regime: 17-23°C in the cold season, 18-27°C in the warm season.

2. Safety requirements before starting work

2.1. Tidy up your work clothes: fasten or tie up your cuffs, put on a headdress, women should put their hair under a scarf tied without hanging ends. It is forbidden to work in light open shoes and without stockings, as well as with rolled up sleeves.

2.2. Check all necessary tools.

2.3. Check the status of the workplace:

the condition of the floor, which must be clean and dry;
whether the workplace, passages and driveways near it, as well as passages to electrical appliances are cluttered;
availability, serviceability of equipment for laying workpieces (bedside tables, tables, stands, folding tables on presses, etc.) and special tools (tweezers, tongs, etc.).

2.4. Check the presence and serviceability of guards, local lighting, grounding and fastening of the ground wire.

2.5. Check the correctness and reliability of fastening the stamps on the presses of the site, from the previous shift, accept the work in combination with the means of protection and mechanization, receive from the master the task of installing stamps on the presses.

2.6. Before installing the stamps, check the press in all modes of operation and make sure that the start-stop devices (levers, buttons, pedals), brakes and clutches, protective devices, etc. are in good condition. to work on this press until it is eliminated.

2.7. Install stamps on the press in accordance with the technological process, this manual and the press passport.

2.8. Inspect the stamp for fitness for work.

2.9. Before installing the stamp on the press:

check the presence of protective guards on it and lubricate its guide columns;
check with a special hook, and a large-sized die with mechanization: smoothness and correctness of the movement of the upper die block along the columns and guide bushings (the columns must enter the holes of the guide bushings of the plate without shocks and distortions), as well as the correct installation of the matrix and punch (the punch must shocks and distortions to enter the matrix hole).

2.10. The dies must be fastened to the press tables with the help of special bolts and measuring pads. The use of random fasteners or underlays is not allowed.

2.11. Check with the stamper:

serviceability of control mechanisms in all operating modes of the press (buttons, pedals, consoles, control knobs, etc.);
smoothness and correctness of the movement of the slider in the guides and the absence of pushes and jerks of the press;
correct installation of the matrix and punch: the punch must enter the matrix hole without shocks and distortions;
the absence of double impacts of the press and spontaneous lowering in the single stroke mode;
serviceability and availability of protective devices on the press and stamp;
specify which special tools and press controls should be used for this operation, according to the technical process.

2.12. When using hoisting mechanisms, work in accordance with the OHS Instruction for Persons Associated with Work on Small Floor Operated Lifting Machinery, OHS Instructions for the Stacker Crane Operator.

2.13. Keep the workplace clean, do not clutter up the aisles and driveways with stamps and parts.

3. Safety requirements during work

3.1 Be attentive, do not be distracted by extraneous matters and conversations, do not distract others.

3.2. Before installing and adjusting the stamps on the starting devices of the press, post a poster "Do not turn on - adjustment work is underway" and remove it only after completing the installation, adjustment and adjustment of protective devices.

3.3. Fasten the stamp firmly and securely; installation on the press of dies with guide columns coming out of the bushings is prohibited.

3.4. When handing over the press to the worker after adjustment, instruct him about safe working methods.

3.5. When transporting stamps from the warehouse, strictly observe the following conditions:

dies with provided transport pins or with lugs for transportation should be hooked with a cable, and the pins should be inserted to the entire depth of the hole. The use of random pins or bolts is prohibited;
when transporting dies on trolleys with a lifting table, monitor the serviceability of the table lifting mechanisms, the presence of boards on the table, and the serviceability of the floor in the workshop;
transport and install the stamp on the press in the closed state;
install the stamp only using serviceable carts, folding press tables, lifting tables.

3.6. When installing the stamp, remove the die cuts and foreign objects from the press plate, close the openings for buffer devices with plugs if they are not needed for the operation of the installed stamp.

3.7. Install the stamp in the following order:

release the slider to the lower position in the "adjustment" mode, turn off the press and measure the actual closed height from the table plate to the slider, and when using the provided spacers, the height from the slider to their upper surface.
check the stop bolts of the upper rigid ejector so that they do not interfere with the free rise of the press slider;
check the marking on the stamp and measure its height in the closed position;
install the dies on the press only when the distance between the slider, which is in the lower position, and the upper die plate in the closed state is no more than 5-10 mm (this requirement must also be met when using during the installation of the die on the provided spacers);
on presses, perform the entire process of installing and fixing the stamp with the electric motor turned off;
to set the slider to the desired closed height of the die, unscrew the locking bolts of the ball screw with the electric motor turned off and adjust the height of the slider with the ball screw (using a wrench manually) until it touches the top plate of the die, and then fix the ball screw with the locking bolts;
when fixing the stamp on the plate and the slider, use special spacers and brackets, make sure that the height of the spacer is equal to the height of the fixing lug of the die plate. Do not use excessively long bolts, placing them closer to the stamp plate (the height of the bolts, special gaskets and brackets should ensure the reliability of fastening and the safety of its operation);
turning on the electric motor of the press, in the "adjustment" mode, carefully raise the slider to the upper position;
lubricate the columns and guide bushings with a thick lubricant before starting work and check the coincidence of the upper and lower halves of the stamp, then lower the press slider down and carefully tighten the die fastening bolts, check the tightness by hitting the gaskets under the stamp plate fastening brackets with a hammer, then check the fastening at least 2 times per shift;
when installing cutting and punching dies, check whether the cutouts fall into the failure hole of the press plate and die;
when installing cutting, cutting and punching dies, adjust the slider so that the depth of entry of the punch into the matrix is minimally sufficient to separate the material, adjust the height of the protective grid depending on the height of the lower part of the stamp (the surface of the matrix or punch).

3.9. Check the smoothness of the movement of the slider and the operation of the pedal, the serviceability of the brake device; the correct operation of safety devices, the reliability of fastening the stamp on the press table; make sure that the guide bushings do not go beyond the guide columns when the slider is in the upper position; if this is not possible, install a telescoping column and spigot guard or an additional mount for the top of the die.

3.10. Check at idle using wooden plates with a long handle that the protective grids are correctly adjusted in accordance with the height of the plane of the matrix or punch on the press table (if adjusted correctly, the grid should take the wooden plate out of the danger zone of stamping).

3.11. Whenever turning the press motor on and off, be especially careful and carefully watch which button to press, while it is necessary to distinguish between the buttons for turning on the electric motor of the press drive and turning on the slider.

3.12. When installing dies with shanks, secure the top first and then the bottom; when attaching the upper part of the stamp with a shank, its dimensions must correspond to the hole in the press slider; use of additional fastening by means of bolts and brackets is allowed. It is allowed to use additional adapter bushings on the shanks of the dies if the dies are additionally fastened with bolts and brackets to the press slider.

3.13. Before stamping, check:

are there tools, bolts, nuts, etc. left on the press;
whether all moving parts of the press are covered with protective guards;
correct installation and operation of the stamp at idle speed of the slider;
compliance with the dimensions of the workpiece products according to the technology and the drawing; stamp 10 - 15 test parts, following the requirements of the labor protection instructions for punchers;
together with the foreman, the correspondence of the details according to the drawing and the technological process and present it to the inspector of the BTK (BKSK).

3.14. After stamping:

before removing the stamps from the press, remove the remaining waste and cuttings, wipe the stamp;
when removing the stamp from the press, setting the "adjustment" mode, remove the protective devices;
then lower the slider to its lowest position and turn off the press;
then remove the fastening of the upper part and after that, turning on the press, carefully raise the slider;
after that, turn off the press, making sure that the slider is in the upper position and the market pins do not hold the die, and only then unfasten the lower part of the die to remove it from the press;
when removing or installing a stamp on the press plate, use special stands, lift tables, folding press tables.

3.15. When installing draw dies on double acting presses, inspect the dies, press and work station as above. If the drawing dies work on impact, then the last part left after stamping when removing the stamp from the press should be in the die before it is installed on the press, which provides the necessary clearance when installing and adjusting the dies.

3.16. Lower the outer and inner sliders to the bottom position and measure the actual closed height from the press platen to the outer and inner sliders.

3.17. Release the locking bolts from the connecting rods and the nuts from the outer slider.

3.18. Install the die on the press only if the closed height of the die is less than the closed height to the inner and outer sliders of the press by 5-10 mm.

3.19. When installing the stamp, follow the installation diagram. It is allowed to use additional plates and gaskets only in accordance with the specified scheme.

3.20. When installing the die on the bottom plate of the press, use special plates or stands.

3.21. Align the die with mounting holes in the inner and outer sliders. At the time of alignment and fastening, ensure safe working practices

3.22. Make a preliminary adjustment of the press and secure the die with a wrench without a lever.

3.23. Adjust the inner slider with the punch to the drawing depth and the clamping ring with the outer slider to the thickness of the metal; do a test run.

3.24. When adjusting the slider until a good product is obtained, do not allow a hard blow. In all cases, adjust the lower position of the slider with great care.

3.25. Finally secure the lower part of the die to the press platen. On the screws of the outer slider, fix the adjusting rings and the locking bolts at the connecting rods of the inner slider.

3.26. Before installing drawing dies on double acting presses, clean the air passages in the punches, do not use compressed air.

3.27. It is obligatory to test the stamp in the adjustment mode when turning on the press with two hands.

3.28. If the noise level in the work area is above 80 dB, use personal protective equipment (anti-noise headphones, earplugs).

3.29. Turn on the press for the working stroke only after the workpiece is correctly placed in the die, and the hands are removed from the danger zone. When moving the press slide, do not correct the workpiece, even if it is incorrectly laid - in this case, quickly turn off the press.

3.30. In case of a stamp malfunction, turn off the press and inform the master.

3.31. It is forbidden:

work with malfunctions of the press, protective fences, grounding and stamps;
use boxes and other random objects for sitting;
blow yourself or a friend with compressed air; wash hands in oil, emulsion and kerosene;
allow unauthorized persons who are not related to the assigned work to their workplace;
eat at work.

3.32. Be sure to turn off the press:

when leaving the press, even for a short time;
during power outages;
when repairing, cleaning, lubricating, cleaning the press;
when replacing a stamp;
to remove a part stuck in the matrix;
in the event of a stamp failure.

4. Safety requirements upon completion of work:

4.1. Turn off the motor. Disconnect the press from the mains.

4.2. Wipe and lubricate the rubbing parts. Clean the table of scale and oil.

4.3. Tidy up your workspace. Put the rest of the material in even piles, put the waste in a container or designated place. Hand over the finished product to the warehouse.

4.4. Put the used rags in a metal box with a lid.

4.5. Inform the shifter and foreman about any malfunctions noticed during operation.

4.6. Observe the rules of personal hygiene (both after finishing work and after a break before eating):

wash your hands with soap and water or other prescribed detergents, use wash basins;
dry your hands with an electric towel or dry them with a towel allocated for this purpose;
it is forbidden to wash hands in oil, emulsion, kerosene and other substances, wipe hands with rags contaminated with dust, sawdust, sand;
clean overalls in the place designated for this purpose and store them in a wardrobe closet separately from home clothes.

4.7. Wash your hands with soap, take a shower, change clothes and get a good rest until the next shift.

5. Safety requirements in emergency situations

5.1. In case of emergencies on the presses, immediately turn off the press and report this to the foreman or shop manager.

5.2. If the machine suddenly stops, turn it off.

5.3. The most common causes of press injuries are:

lack of safety devices;
malfunction of control mechanisms;
violation of the requirements of this instruction;
negligence and negligence in the performance of work;
non-use of personal protective equipment.

5.4. In the event of a fire being discovered, everyone who discovers it must:

de-energize electrical equipment;
immediately report the fire to all those working in the room and to the fire department: call tel. _______;
start extinguishing the source of fire with the available fire extinguishing equipment. When extinguishing electrical equipment with carbon dioxide, powder fire extinguishers or sand, keep a safe distance (at least 1 m) from the spray nozzle and the fire extinguisher body to live parts;
take measures to call the direct manager of the workshop, section or other officials to the fire site.

5.5. In the event of a power outage, turn off machines, equipment and tools.

5.6. In the event of an accident, first release the victim from the traumatic factor.

Attention: when releasing the victim from the action of electric current, make sure that you yourself do not come into contact with the current-carrying part and are energized.

5.7. Provide first aid to the injured.

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