Instructions for labor protection when working on the processing of book blocks on the KOLBUS line

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OCCUPATIONAL SAFETY AND HEALTH
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Instructions on labor protection when working on the processing of book blocks on the KOLBUS line. Full document

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General requirements for labor protection

1.1. Persons who have passed a medical examination and have no contraindications to work in this profession (specialty), introductory briefing and briefing at the workplace are allowed to work. Workers are allowed to work independently after an internship, verification of theoretical knowledge and acquired skills in safe ways of working. In the future, at the workplace, briefings on labor protection are held at least once every 3 months.

1.2. When transferring to a new job, from temporary to permanent, from one operation to another with a change in the technological process or equipment, employees must be instructed in labor protection at the workplace.

1.3. Conducting all types of briefings must be recorded in the Briefing Log with the obligatory signatures of the person who received and conducted the briefing.

1.4. Each employee is obliged to comply with the requirements of this instruction, labor and production discipline, work and rest regime, all requirements for labor protection, safe work performance, industrial sanitation, fire safety, electrical safety.

1.5. Smoking is allowed only in specially designated areas. The use of alcoholic beverages at work, as well as going to work in a state of alcoholic or drug intoxication, is prohibited.

1.6. When performing work, it is necessary to be attentive, not to be distracted by extraneous affairs and conversations, and not to distract others from work. It is forbidden to sit down and lean on random objects and fences.

1.7. It is forbidden to approach operating machines, installations, machines on which other workers work, and distract them with extraneous conversations, turn on or off (except in emergency cases) equipment, transport and lifting mechanisms, work on which is not assigned, go beyond the fences of hazardous areas, in zones of technological passages.

1.8. The employer is obliged to provide workers with overalls, safety shoes, as well as personal protective equipment in accordance with the work they perform and in accordance with applicable standards. It is forbidden to work without overalls, safety shoes and other personal protective equipment laid down in accordance with the standards.

1.9. Each employee needs:

know the place of storage of the workshop first-aid kit;
be able to provide first aid for work-related injuries.

1.10. It is allowed to store and eat food only in established and equipped places.

1.11. It is forbidden to be in production premises in outerwear, undress or hang clothes, hats, bags on equipment.

1.12. Do not clutter up passages, driveways, workplaces, approaches to shields with fire fighting equipment, fire hydrants and a general switch.

1.13. Spilled cleaners, lubricants, water, etc. on the floor. wipe off immediately.

1.14. Cleaning materials impregnated with oil, paint, solvent, put in tightly closed metal boxes. Do not scatter these materials, at the end of the shift they should be removed from the premises.

1.15. Store fuels, lubricants and flammable liquids only in a tightly closed metal container (box) or cabinet in an amount not exceeding the replacement rate. It is forbidden to leave combustible liquids and flammable liquids in the aisles, driveways and the working area of the equipment.

1.16. It is forbidden to repair equipment, fix electrical equipment and the electrical network to personnel who do not have access to these works, work near unshielded current-carrying parts, touch electrical wires, general lighting fittings, open doors of electrical cabinets, fencing of knife switches, switchboards and control panels.

1.17. Do not use lubricants for washing hands.

1.18. Finished products should be stacked carefully, on racks with a height of no more than 1,6 m from the floor (including the height of the rack).

1.19. It is forbidden to use faulty racks (pallets): with a faulty coating, with broken legs, etc., lean racks (pallets) against the machine frame or wall, as well as put them on the end, transfer, stack and disassemble the racks from a stack by one employee.

1.20. It is forbidden to use defective hand tools, as well as tools of inappropriate sizes, to scatter them around the equipment, in aisles, in driveways (keep tools and tools in specially designated places).

1.21. Perform only the work assigned by the head. It is forbidden to entrust the equipment to another person and to allow persons who are not related to the assigned work to the workplace.

1.22. It is forbidden to be in the production room after the end of work.

1.23. The employee is responsible in accordance with applicable law for compliance with the requirements of instructions, industrial injuries and accidents that occurred through his fault.

1.24. The control of the implementation of this instruction is assigned to the head of the department.

2. Safety requirements before starting work

2.1. Put on your uniform, put it in order.

2.2. Familiarize yourself with the entries in the Journal of the technical condition of the equipment. In case of any comments, do not start work until the troubleshooting and a note in the journal (adjuster, electrician) about the health of the equipment.

2.3. Inspect equipment and work area. Prepare the necessary devices and tools for work, check their serviceability.

2.4. Check the serviceability of the equipment, including, switching off and braking devices, the presence and strength of the fastening of fences, the reliability of the functioning of safety devices, interlocks, the presence of protective grounding, cleanliness and order at the workplace. Remove unnecessary items from the equipment (oil cans, rags, etc.).

2.5. Additional labor safety requirements for certain sections of the line:

Book block feeder and glue-drying machine:

set the switches on the machine control panel to the "flow" position;
check the presence of glue in the glue bath and the installation of the bath itself.

Crimp press:

make sure that there are no foreign objects between the moving blocks;
check the operation of the on and off devices, set the switch to the "flow" position.

Stacker:

set the switch to position "1";
check the setting of the feed finger counter;
check the operation of the feed finger;
check the operation of the photocell and the conveyor belt.

Three-knife cutting machine (type "MM55", etc.):

test the operation of the machine manually or in the "push" mode, make sure that it is in good working order;
check the serviceability of the switching, disconnecting and braking devices, especially the automatic stop of the knives in any position when the machine is turned on manually;
check the presence, serviceability and strength of fastening of safety devices and fences;
before starting, make sure that no one is in the danger zone of the machine.

Unit "VG-40":

pour glue into the section for gluing gauze, captal paper and book insert section;
set the desired heating temperature by turning on the regulator on the control panel;
put the switch in the "jog" position and test the operation of the machine.

Stroke Crimping Machine:

set the temperature regime;
check the presence of oil in the hydraulic system;
turn on the "pressure" button.

2.6. Check and adjust workplace lighting.

2.7. Check whether the local exhaust and general supply and exhaust ventilation systems are turned on (ventilation should be turned on 10 - 15 minutes before starting work).

2.8. Immediately inform the supervisor of the noticed shortcomings and malfunctions at the workplace and do not start work until the troubleshooting and permission of the master.

3. Safety requirements during work

3.1. When repairing equipment, carrying out preventive maintenance, it is necessary to make an entry in the Journal of the technical condition of the equipment. Persons who carried out repairs and preventive maintenance are required to make an entry in the Journal allowing them to work.

3.2. Fasten the knives in the knife holder with all bolts. When fixing the knives, be careful and use only serviceable (without knocked down jaws) keys of the appropriate size.

3.3. Carry knives only in special wooden cases.

3.4. When changing knives, take them out of the case one at a time and immediately place them in the knife holder. Place the removed knives and fix them in a case, do not lean against the machine bed, wall, etc.

3.5. It is forbidden:

use faulty wooden shields and stands, chairs and benches;
work with guards removed and safety devices disabled, as well as in case of their malfunction or absence;
put foreign objects on the beds and other parts of running machines;
leave the machine turned on when leaving the workplace (the equipment must be stopped and de-energized);
work without proper lighting of the workplace;
independently fix something in machines and units, especially in electrical equipment;
remove scraps, remove fallen or stuck book blocks without turning off the equipment;
repair, lubricate, clean and adjust the machine without disconnecting it from the network;
work sitting;
transfer any items through the operating equipment;
touch moving parts of the equipment and electrical wires.

3.6. It is prohibited while working on certain sections of the line:

Book block feeder and glue-drying machine:

straighten or remove jammed book blocks from the loading chute or conveyor;
carry out adjustment between the guide walls of the conveyor;
wash off the brush and clean the glue roller;
apply an excess amount of glue to the spine of the block (glue drops can cause damage to the heating elements and short circuit the system);
remove the protective system above the lamps for drying blocks;
tension the belts.

Crimp press:

clean the pads and the table from glue;
release stuck blocks;
compress blocks with "raw", tack-free roots.

Stacker in front of the three-knife cutting machine:

release stuck blocks;
correct the pusher;
allow overloading of the cutting machine conveyor.

Three blade cutting machine:

to rule knives with a bar that does not have a special frame;
lean knives against the car, tables, walls, etc.;
work with open guards, faulty locks;
adjust friction clutch and braking device;
during lubrication, allow oil to enter the brake mechanism of the brake;
leave your foot on the start pedal of the machine while laying and leveling the screw-in;
take knives with your hands from the side of the sharpened edge;
upload blocks manually;
adjust the fittings on the introductory conveyor;
remove scraps, remove fallen or stuck book blocks.

Unit "VG-40":

correct or remove stuck blocks from the guide chute;
remove or remove scraps of paper, endpaper;
refill or change rolls of gauze, paper, captal;
change the format, replace profile tables and pads, rollers and slats;
clean the glue from the vice of the laminating section, the conveyor, the table of the captal and book-inserting sections;
carry out adjustment of the conveyor;
process book blocks with "raw", sticky spines;
adjust or remove stuck lids in the calender;
remove scraps of paper, flyleaf, captal, gauze, etc. from the glue rollers;
change rollers in adhesive sections.

Stroke Crimping Machine:

straighten books on the loading chute near the pusher;
straighten books in the way of clamping jaws;
change the distance between clamps and knives.

3.7. When the machine stops automatically, it is necessary to identify the cause of the stop, eliminate it, and only after that turn on the machine to the working stroke by pressing the "start" button.

3.8. Rags and paper impregnated with detergents and lubricants should be placed in tightly closed metal boxes.

4. Safety requirements in emergency situations

4.1. In the event of a fire or a fire, employees must immediately call the fire brigade, inform the work manager and proceed to extinguish the fire using the available fire extinguishers.

4.2. If voltage (sensation of current) is detected on the metal parts of the equipment, the electric motor is buzzing, the ground wire is broken, immediately turn off the equipment, report to the foreman about the malfunction of the electrical equipment and do not start work without his instructions.

4.3. Disconnect the equipment from the network, stop working and notify the workshop administration in case of equipment malfunction, if there is a smell of burning and smoke in electrical equipment, if foreign objects get into it.

4.4. In the event of a power outage, vibration or excessive noise, turn off the equipment.

4.5. In case of injury, first of all, release the victim from the traumatic factor, call for medical assistance, provide first aid to the victim, notify the work manager and save the traumatic situation until the causes of the incident are investigated.

5. Safety requirements at the end of work

5.1. Remove workplace. Turn off equipment.

5.2. Take off your overalls, put them in the closet.

5.3. Wash hands and face with warm soapy water.

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