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Version 1.3a (18/02/2013)
Outline the criterion for the selection of suitable work equipment for particular tasks
and processes to eliminate or reduce risks.
Explain how risks to health and safety arising from the use of work equipment are
controlled.
Explain safe working procedures for the maintenance, inspection and testing of work
equipment according to the risks posed.
Explain the role of competence, training, information and supervision in the control of
risks arising from the installation, operation, maintenance and use of work equipment.
Relevant Standards:
International Labour Standards, Guarding of Machinery Convention, C119, International Labour Organisation, Geneva, 1963.
NB ILO Draft code of practice on safety in the use of machinery - Draft Meeting of Experts
on the Code of Practice on Safety in the use of Machinery (Geneva, 29 November - 7 December 2011).
1.0 - Selection.
The main pieces of UK legislation concerning the suitability of the task and environment are:
1.1 - The Provision and Use of Work Equipment Regulations 1998 (PUWER).
In general terms, PUWER requires that equipment provided for use at work is:
including manufacturers, importers and others in the supply chain. They set out the essential
requirements which must be met before machinery or safety components may be supplied in
the UK.
There are basically three steps to dealing with the requirements:
The responsible person should ensure that machinery and safety components satisfy
the relevant essential health and safety requirements of the Supply of Machinery
(Safety) Regulations and that, where appropriate, relevant conformity assessment
procedures have been carried out.
The responsible person must issue a declaration of conformity (or a declaration of
incorporation) which is issued with the finished product so that it is available to the
user. This will contain various details such as the manufacturer's address, the machinery type and serial number, and the harmonised European, or other, standards
used in design.
When the first two steps have been satisfactorily completed, the responsible person
or person supplying or assembling the final product should affix the CE marking if
they are satisfied it is safe.
The HSE is responsible for enforcing these Regulations in relation to machinery supplied for
use at work.
the Supply of Machinery (Safety) Regulations 1992, which implement the European
Machinery Directive, and which contain detailed requirements for manufacturing safe
new machinery;
the Health and Safety at Work etc Act 1974, which contains general requirements for
the manufacture and supply of safe workplace machinery (including second-hand
machinery);
other regulations which implement other European Directives, such as those on the
supply of electrical equipment or on gas appliances, which are important for many
suppliers of machinery.
machinery meets relevant essential health and safety requirements (these are listed
in detail in the Regulations), which include the provision of sufficient instructions;
a technical file for the machinery has been drawn up, and in certain cases, the machinery has been type-examined by a notified body;
there is a 'declaration of conformity' (or in some cases a 'declaration of incorporation') for the machinery, which should be issued with it (see questions 18-20);
there is a CE marking affixed to the machinery (unless it comes with a declaration of
incorporation).
'C E Marking'
Does the same law apply in other European countries?
The Machinery Directive has now been implemented as national law in all countries in the
EEA. This means that the same legal requirements now apply to all new machinery
wherever it is supplied within the EEA.
What if I am directly importing machinery manufactured outside the EEA?
This machinery must still meet the Supply of Machinery (Safety) Regulations 1992 and
because you are importing it directly from outside the EEA, you take on the legal
responsibilities of the manufacturer. So you need to make sure either that the manufacturer
has met the relevant requirements or that you meet them yourself.
What law applies to the sale of second-hand machinery?
The Supply of Machinery (Safety) Regulations 1992 only applies to the first supply of
machinery into the EEA, and only if this takes place after 1 January 1993. Therefore, if you
are supplying second-hand machinery which was first in use before 1993, without
substantially refurbishing it, the machinery does not need to comply with these Regulations.
Also, if you are re-supplying used CE-marked machinery, these Regulations do not apply.
However, all machinery should be maintained in a safe state, and Section 6 of the Health
and Safety at Work etc Act 1974 will apply to the re-sale (in Great Britain) of all second-hand
workplace machinery, however old it is.
What if the old machinery I am supplying is substantially refurbished?
If machinery has been refurbished to such an extent that almost all the replaceable parts are
new, it would be considered to be new machinery and so you will need to comply with the
Supply of Machinery (Safety) Regulations 1992. For example, where CNC controls are
retrofitted to an older manual lathe, these Regulations apply. But if old machinery has simply
been given new guards or some improved controls or just repainted, this would not make it
'new' and the Regulations will not apply when it is re-sold. However, Section 6 of the Health
and Safety at Work etc Act 1974 will apply.
identify the health and safety hazards (trapping, crushing, electrical shock, dust or
fumes, noise, vibration, etc) that are likely to be present when the machinery is used;
assess the likely risks;
eliminate the risks, or if that is not possible:
provide safeguards (e.g. guarding dangerous parts of the machinery, providing noise
enclosures) or, if that is not possible:
provide information about any residual risks and place signs on the machinery to
warn of risks that cannot be reduced in other ways (e.g. 'noisy machine' signs).
still make sure as far as you can that the machinery is safe.
What if the machinery is manufactured by someone else either in the UK or elsewhere
in the EEA and I (as a supplier) consider that the safeguards or other protective devices are inadequate?
There could be several reasons why this might happen. For example, the harmonised European Standard for that machinery may not yet have been agreed, and different interpretations of the level of protection that is required may exist in different countries. Alternatively, it
may be that the machinery does not meet agreed levels of protection and the law is clearly
not being met. If you are not satisfied with the levels of protection for the machinery you are
supplying, discuss the matter with the manufacturer or your UK Trade Association.
CHECKLIST: DO NOT SUPPLY OR USE MACHINERY WHICH YOU CONSIDER UNSAFE.
Before supplying new machinery:
Look for obvious defects, such as missing guards or other safety devices, or inadequately protected electric wiring.
Check that known risks (including risks from fumes or dust, noise or vibration) from
the machinery when it is in use will be properly controlled or that there is information
on how they can be controlled.
Make sure the manufacturer has provided instructions for safe installation, use, adjustment and maintenance, and that these are in English if the machinery is for use
in the UK (some maintenance instructions may be in another language if staff from
the manufacturer is to carry out specialised maintenance).
Check that data about noise and vibration emissions have been provided, where appropriate.
Make sure that any warning signs are visible and easy to understand.
Check that you have a properly-completed declaration of conformity, or a declaration
of incorporation if appropriate.
Check for CE marking.
Check with the manufacturer if you have concerns about any of the above matters.
state the name and address of the manufacturer or (in the case of machinery made
outside the EEA) of the importer;
contain a description of the machinery, its make, type and serial number;
indicate all relevant European laws (directives) with which the machinery complies;
state details of any notified body that has been involved;
specify which standards have been used in the manufacture (if any); and
be signed by a person with authority to do so.
For machinery supplied in the UK, the declaration of conformity must be in English. For
machinery exported to other countries in the EEA, instructions must be in the recognised
language of the country where it is to be used.
When is a declaration of incorporation appropriate rather than a declaration of
conformity?
If the machinery is intended for:
In practice, this means that the machinery should not be used until the final product has
been manufactured, all relevant essential health and safety requirements met, and a
declaration of conformity issued - by the final installer or assembler.
The machinery should not be CE marked if it has a declaration of incorporation; CE marking
should only take place at the end of incorporation or assembly.
Every employer shall ensure that work equipment is maintained in an efficient state,
in efficient working order and in good repair.
Every employer shall ensure that where any machinery has a maintenance log, the
log is kept up to date.
The extent and complexity of maintenance can vary substantially from simple checks on
basic equipment to integrated programmes for complex plant. In all circumstances, for
maintenance to be effective it needs to be targeted at the parts of work equipment where
failure or deterioration could lead to health and safety risks. Maintenance should address
those parts which have failed or are likely to deteriorate and lead to health and safety risks.
A number of maintenance management techniques could be used:
Maintenance log.
There is no requirement for you to keep a maintenance log. However, it is recommended
that you keep a record of maintenance for high-risk equipment. A detailed maintenance log
can provide information for future planning of maintenance activities and inform
maintenance personnel and others of previous action taken. If you have a maintenance log,
you should keep it up to date. Maintenance procedures should be carried out in accordance
with any manufacturer's recommendations which relate to the equipment, for example
periodic lubrication, replacement and adjustment of parts.
'5 Steps'
The PUWER approved code of practice, however, does give some advice on control
measures:
Action to eliminate/control any risk might include, for example, during maintenance:
or in conjunction with the structure of the equipment, they enclose the dangerous parts, fixed
guards meet the requirements of the first level of the hierarchy. Note that fixed enclosing
guards - and other types of guard - can have openings provided that they comply with appropriate safe reach distances.
Other guards include movable guards which can be opened without the use of tools, and
fixed guards that are not fully enclosing. These allow limited access through openings,
gates, etc for feeding materials, making adjustments, cleaning, etc.
Moveable guards may be power-operated, self-closing, adjustable, etc and are likely
to require an interlocking device so that:
the hazardous machine functions covered by the guard cannot operate until the
guard is closed;
if the guard is opened while hazardous machine functions are operating, a stop instruction is given;
when the guard is closed, the hazardous machine functions covered by the guard
can operate, but the closure of the guard does not by itself initiate their operation.
Interlocking guards may be fitted with a locking device so that the guard remains closed and
locked until any risk of injury from the hazardous machine functions has passed. A control
guard (interlocking guard with a start function) is a particular type of interlocking guard which
should be used only in certain situations where frequent access is required. It should also
fulfil specific conditions in particular, where there is no possibility of an operator or part of
their body remaining in the danger zone or between the danger zone and the guard while
the guard is closed.
Protection devices are devices which do not prevent access to the danger zone but stop the
movement of the dangerous part before contact is made. They will normally be used in
conjunction with a guard. Typical examples are mechanical trip devices, active optoelectronic devices such as light curtains, pressure mats and two-hand controls.
Protection appliances are used to hold or manipulate in a way which allows operators to
control and feed a loose work piece at a machine while keeping their body clear of the
danger zone. They are commonly used in conjunction with manually-fed woodworking
machines and some other machines such as band saws for cutting meat, where it is not
possible to fully guard the cutting tool. These appliances will normally be used in addition to
guards.
Adequate information, instruction, training and supervision are always important, even if the
hazard is protected by hardware measures; however, they are especially important when the
risk cannot be adequately eliminated by the hardware measures mentioned above. It may
be necessary to lay down procedures to define what information, instruction, training and
supervision must be given, and to restrict use of equipment to those who have received
such instructions etc.
evaluate the existing competence of employees to operate the full range of work
equipment that they will use;
evaluate the competence they need to manage or supervise the use of work equipment; and
train the employee to make up any shortfall between their competence and that required to carry out the work with due regard to health and safety.
Account should be taken of the circumstances in which the employee works. For example,
do they work alone or under close supervision of a competent person?
Training needs are likely to be greatest on recruitment. However, training needs are
also required:
if the risks to which people are exposed change due to a change in their working
tasks; or
because new technology or equipment is introduced; or
if the system of work changes.
Also, you should provide refresher training if necessary. Skills decline if they are not used
regularly. Pay particular attention to people who deputise for others on occasions, as they
may need more frequent refresher training than those who do the work regularly.
Training for young people.
Training and proper supervision of young people is particularly important because of their
relative immaturity and unfamiliarity with the working environment. Induction training is of
particular importance. There are no general age restrictions in legislation relating to the use
of work equipment, although there is some ACOP material in the relevant publications
dealing with lifting, power presses and woodworking. All employees should be competent to
use work equipment with due regard to health and safety, regardless of their age.
The Management Regulations contain specific requirements relating to the employment of
young people under the age of 18. These require employers to assess risks to young people
before they start work, taking into account their inexperience, lack of awareness of potential
risks and their immaturity. Employers must provide information to parents of school-age
children (for example when they are on work experience) about the risks and the control
measures introduced, and take account of the risk assessment in determining whether the
young person should undertake certain work activities.
These requirements may seem obvious, but it is surprising how many designers are quite
remote from the workplace and, if left by themselves, may have little idea of the realities of
the environment in which their machines are to be used.
The accident history for machines in the same product area or for similar machines is an
essential element in this process. Some accident data are published by the Health and
Safety Executive (HSE) in their annual reports but in most cases, it is not detailed enough to
give anything but generalised trends. Some manufacturing associations may give more
information but the best source is from the HSE who record and investigate accidents as
part of their enforcement duties.
Inspectors have a wealth of information on accidents and remedial measures and
information can be obtained from:
HSE, Field Operations Directorate (FOD) Safety Unit on 0161 952 8222.
HSE "Infoline" on 0845 345 0055
In addition, HSE publish a series of guides dealing with machines that have given specific
problems. The guides are very comprehensive and give details of recommended protective
measures.
Eliminate or reduce risks as far as possible (inherently safe machinery design and
construction).
Take the necessary protection measures in relation to risks that cannot be eliminated.
Inform users of the residual risks due to any shortcomings of the protection measures adopted.
Indicate whether any particular training is required.
Specify any need to provide personal protection equipment.
When designing and constructing machinery, and when drafting the instructions, the
manufacturer must envisage not only the normal use of the machinery but also uses which
could reasonably be expected. The machinery must be designed to prevent abnormal use if
such use would engender a risk. In other cases, the instructions must draw the user's
attention to ways -which experience has shown might occur -in which the machinery should
not be used.
Under the intended conditions of use, the discomfort, fatigue and psychological stress faced
by the operator must be reduced to the minimum possible taking ergonomic principles into
account.
When designing and constructing machinery, the manufacturer must take account of the
constraints to which the operator is subject as a result of the necessary or foreseeable use
of personal protection equipment (such as footwear, gloves, etc).
Machinery must be supplied with all the essential special equipment and accessories to
enable it to be adjusted, maintained and used without risk.
Where the weight, size or shape of machinery or its various component parts
prevents them from being moved by hand, the machinery or each component part
must:
Special arrangements must be made for the handling of tools and/or machinery parts, even
if lightweight, which could be dangerous (shape, material, etc).
2.8 - Controls.
Safety and reliability of control systems.
Control systems must be designed and constructed so that they are safe and reliable,
in a way that will prevent a dangerous situation arising. Above all, they must be designed and constructed in such a way that:
they can withstand the rigours of normal use and external factors;
errors in logic do not lead to dangerous situations.
Control devices.
Where a control is designed and constructed to perform several different actions, namely
where there is no one-to-one correspondence (e.g. keyboards, etc), the action to be
performed must be clearly displayed and subject to confirmation where necessary. Controls
must be so arranged that their layout, travel and resistance to operation are compatible with
the action to be performed, taking account of ergonomic principles. Constraints due to the
necessary or foreseeable use of personal protection equipment (such as footwear, gloves,
etc) must be taken into account. Machinery must be fitted with indicators (dials, signals, etc)
as required for safe operation. The operator must be able to read them from the control
position.
From the main control position, the operator must be able to ensure that there are no
exposed persons in the danger zones. If this is impossible, the control system must be
designed and constructed so that an acoustic and/or visual warning signal is given
whenever the machinery is about to start. The exposed person must have the time and the
means to take rapid action to prevent the machinery starting up.
Starting.
It must be possible to start machinery only by voluntary actuation of a control provided for
the purpose.
The same requirement applies:
This essential requirement does not apply to the restarting of the machinery or to the change
in operating conditions resulting from the normal sequence of an automatic cycle. Where
machinery has several starting controls and the operators can therefore put each other in
danger, additional devices (e.g. enabling devices or selectors allowing only one part of the
starting mechanism to be actuated at any one time) must be fitted to rule out such risks. It
must be possible for automated plant functioning in automatic mode to be restarted easily
after a stoppage, once the safety conditions have been fulfilled.
dered safe. The machinery's stop control must have priority over the start controls. Once the
machinery or its dangerous parts have stopped, the energy supply to the actuators concerned must be cut off.
Emergency stop.
Each machine must be fitted with one or more emergency stop devices to enable actual or impending danger to be averted. The following exceptions apply:
Machines in which an emergency stop device would not lessen the risk, either because it would not reduce the stopping time or because it would not enable the special measures required to deal with the risk to be taken.
Hand-held portable machines and hand-guided machines.
The emergency stop control must remain engaged; it must be possible to disengage it only
by an appropriate operation; disengaging the control must not restart the machinery, but only
permit restarting; the stop control must not trigger the stopping function before being in the
engaged position.
Complex installations.
In the case of machinery or parts of machinery designed to work together, the manufacturer
must so design and construct the machinery that the stop controls, including the emergency
stop, can stop not only the machinery itself but also all equipment upstream and/or
downstream if its continued operation can be dangerous.
Mode selection.
The control mode selected must override all other control systems with the exception of the
emergency stop. If machinery has been designed and built to allow for its use in several
control or operating modes presenting different safety levels (e.g. to allow for adjustment,
maintenance, inspection etc), it must be fitted with a mode selector which can be locked in
each position. Each position of the selector must correspond to a single operating or control
mode. The selector may be replaced by another selection method which restricts the use of
certain functions of the machinery to certain categories of operator (e.g. access codes for
certain numerically controlled functions, etc).
If, for certain operations, the machinery must be able to operate with its protection
devices neutralized, the mode selector must simultaneously:
In addition, the operator must be able to control operation of the parts on which he is
working at the adjustment point.
Software.
Interactive software between the operator and the command or control system of a machine
must be user-friendly.
Both rigid and flexible pipes carrying fluids, particularly those under high pressure, must be
able to withstand the foreseen internal and external stresses and must be firmly attached
and/or protected against all manner of external stresses and strains; precautions must be
taken to ensure that no risk is posed by a rupture (sudden movement, high pressure jets,
etc).
Where the material to be processed is fed to the tool automatically, the following
conditions must be fulfilled to avoid risks to the persons exposed (e.g. tool breakage):
When the work piece comes into contact with the tool the latter must have attained
its normal working conditions.
When the tool starts and/or stops (intentionally or accidentally), the feed movement
and the tool movement must be coordinated.
be of robust construction;
not give rise to any additional risk;
not be easy to bypass or render non-operational;
be located at an adequate distance from the danger zone;
cause minimum obstruction to the view of the production process;
enable essential work to be carried out on installation and/or replacement of tools
and also for maintenance by restricting access only to the area where the work has
to be done, if possible without the guard or protection device having to be dismantled.
by the machinery. To that end the manufacturer must take steps to:
The same precautions must be taken if the manufacturer foresees the use of the machinery
in a potentially explosive atmosphere. Electrical equipment forming part of the machinery
must conform, as far as the risk from explosion is concerned, to the provision of the specific
Directives in force.
Noise.
Machinery must be so designed and constructed that risks resulting from the emission of
airborne noise are reduced to the lowest level, taking account of technical progress and the
availability of means of reducing noise, in particular at source.
Vibration.
Machinery must be so designed and constructed that risks resulting from vibrations
produced by the machinery are reduced to the lowest level, taking account of technical
progress and the availability of means of reducing vibration, in particular at source.
Radiation.
Machinery must be so designed and constructed that any emission of radiation is limited to
the extent necessary for its operation, and that the effects on exposed persons are
nonexistent or reduced to non-dangerous proportions.
External radiation.
Machinery must be so designed and constructed that external radiation does not interfere
with its operation.
Laser equipment.
Where laser equipment is used, the following provisions should be taken into account:
2.13 - Maintenance.
Machinery maintenance.
Adjustment, lubrication and maintenance points must be located outside danger zones. It
must be possible to carry out adjustment, maintenance, repair, cleaning and servicing
operations while machinery is at a standstill. If one or more of the above conditions cannot
be satisfied for technical reasons, these operations must be possible without risk. In the
case of automated machinery and, where necessary, other machinery, the manufacturer
must make provision for a connecting device for mounting diagnostic fault-finding
equipment. Automated machine components which have to be changed frequently, in
particular for a change in manufacture or where they are liable to wear or likely to deteriorate
following an accident, must be capable of being removed and replaced easily and in safety.
Access to the components must enable these tasks to be carried out with the necessary
technical means (tools, measuring instruments, etc) in accordance with an operating method
specified by the manufacturer.
Access to operating position and servicing points.
The manufacturer must provide means of access (stairs, ladders, catwalks, etc) to allow
access in safety to all areas used for production, adjustment and maintenance operations.
Parts of the machinery where persons are liable to move about or stand must be designed
and constructed to avoid falls.
Isolation of energy sources.
All machinery must be fitted with means to isolate it from all energy sources. Such isolators
must be clearly identified. They must be capable of being locked if reconnection could
endanger exposed persons. In the case of machinery supplied with electricity through a plug
capable of being plugged into a circuit, separation of the plug is sufficient. The isolator must
also be capable of being locked where an operator is unable, from any of the points to which
he has access, to check that the energy is still cut off. After the energy is cut off, it must be
possible to dissipate normally any energy remaining or stored in the circuits of the
machinery without risk to exposed persons. As an exception to the above requirements,
certain circuits may remain connected to their energy sources in order, for example, to hold
parts, protect information, light interiors, etc. In this case, special steps must be taken to
ensure operator safety.
Operator intervention.
Machinery must be so designed, constructed and equipped that the need for operator
intervention is limited. If operator intervention cannot be avoided, it must be possible to carry
it out easily and in safety.
Cleaning of internal parts.
The machinery must be designed and constructed in such a way that it is possible to clean
internal parts which have contained dangerous substances or preparations without entering
them; any necessary unblocking must also be possible from the outside. If it is absolutely
impossible to avoid entering the machinery, the manufacturer must take steps during its
construction to allow cleaning to take place with the minimum of danger.
2.14 - Indicators.
Information devices
The information needed to control machinery must be unambiguous and easily understood.
It must not be excessive to the extent of overloading the operator. Where the health and
safety of exposed persons may be endangered by a fault in the operation of unsupervised
machinery, the machinery must be equipped to give an appropriate acoustic or light signal
as a warning.
Warning devices
Where machinery is equipped with warning devices (such as signals, etc), these must be
unambiguous and easily perceived. The operator must have facilities to check the operation
of such warning devices at all times. The requirements of the specific Directives concerning
colours and safety signals must be complied with.
Warning of residual risks
Where risks remain despite all the measures adopted or in the case of potential risks which
are not evident (e.g. electrical cabinets, radioactive sources, bleeding of a hydraulic circuit,
hazard in an unseen area, etc), the manufacturer must provide warnings. Such warnings
should preferably use readily understandable pictograms and/or be drawn up in one of the
languages of the country in which the machinery is to be used, accompanied, on request, by
the languages understood by the operators.
Marking
All machinery must be marked legibly and indelibly with the following minimum particulars:
Furthermore, where the manufacturer constructs machinery intended for use in a potentially
explosive atmosphere, this must be indicated on the machinery. Machinery must also bear
full information relevant to its type and essential to its safe use (e.g. maximum speed of
certain rotating parts, maximum diameter of tools to be fitted, mass, etc). Where a machine
part must be handled during use with lifting equipment, its mass must be indicated legibly,
indelibly and unambiguously. Interchangeable equipment must bear the same information.
Instructions
All machinery must be accompanied by instructions including at least the following:
a repeat of the information with which the machinery is marked, together with any
appropriate additional information to facilitate maintenance (e.g. addresses of the
importer, repairers, etc);
workstation(s) likely to be occupied by operators;
instructions for safe:
putting into service;
use;
handling, giving the mass of the machinery and in various parts where they are regularly to be transported separately;
assembly, dismantling;
adjustment;
maintenance (servicing and repair);
where necessary, training instructions;
where necessary, the essential characteristics of tools which may be fitted to the machinery.
Where necessary, the instructions should draw attention to ways in which the machinery
should not be used.
The instructions must be drawn up by the manufacturer or his authorised representative
established in the EU in one of the languages of the country in which the machinery is to be
used and should preferably be accompanied by the same instructions drawn up in another
EU language, such as that of the country in which the manufacturer or his authorised
2.15 - Additional essential health and safety requirements for certain categories of
machinery.
Agri-foodstuffs machinery.
In addition to the essential health and safety requirements set out previously, where machinery is intended to prepare and process foodstuffs (e.g. cooking, refrigeration, thawing,
washing, handling, packaging, storage, transport or distribution), it must be so designed and
constructed as to avoid any risk of infection, sickness or contagion and the following hygiene
rules must be observed:
(a) materials in contact or intended to come into contact, with the foodstuffs must satisfy the
conditions set down in the relevant Directives. The machinery must be so designed and
constructed that these materials can be cleaned before each use;
(b) all surfaces including their joinings must be smooth, and must have neither ridges nor
crevices which could harbour organic materials;
(c) assemblies must be designed in such a way as to reduce projections, edges and recesses to a minimum. They should preferably be made by welding or continuous bonding.
Screws, screw heads and rivets may not be used except where technically unavoidable;
(d) all surfaces in contact with foodstuffs must be easily cleaned and disinfected, where possible after removing easily-dismantled parts. The inside surfaces must have curves of a radius sufficient to allow thorough cleaning;
(e) liquid deriving from foodstuffs as well as cleaning, disinfecting and rinsing fluids should
be able to be discharged from the machine without impediment (possibly in a "clean" position);
(f) machinery must be so designed and constructed as to prevent any liquids or living creatures, in particular insects, entering, or any organic matter accumulating in areas that cannot
be cleaned (e.g. for machinery not mounted on feet or casters, by placing a seal between
the machinery and its base, by the use of sealed units, etc);
(g) machinery must be so designed and constructed that no ancillary substances (e.g. lubricants, etc) can come into contact with foodstuffs. Where necessary, machinery must be designed and constructed so that continuing compliance with this requirement can be checked.
Portable hand-held and/or hand-guided machinery.
Portable hand-held and/or hand-guided machinery must conform to the following essential
health and safety requirements:
Portable hand-held machinery must be designed and constructed to allow, where necessary,
a visual check of the contact of the tool with the material being processed.
The instructions must give the following information concerning vibrations transmitted by
hand-held and hand-guided machinery.
The weighted root mean square acceleration value to which the arms are subjected, if it
exceeds 2.5m/s2 as determined by the appropriate test code. Where the acceleration does
not exceed 2.5m/s2, this must be mentioned. If there is no applicable test code, the
manufacturer must indicate the measurement methods and conditions under which
measurements were made.
2.17 - Essential health and safety requirements to offset the particular hazards due to
the mobility of machinery.
Machinery presenting hazards due to mobility must be designed and constructed to meet
the requirements below. Risks due to mobility always exist in the case of machinery which is
self-propelled, towed or pushed or carried by other machinery or tractors, is operated in
working areas and whose operations requires either mobility while working, be it continuous
vibrations transmitted to the driver to the lowest level that can be reasonably achieved. The
seat mountings must withstand all stresses to which they can be subjected, notably in the
event of rollover.
Where there is no floor beneath the driver's feet, the driver must have footrests covered with
a slip-resistant material. Where machinery is fitted with provision for a rollover protection
structure, the seat must be equipped with a safety belt or equivalent device which keeps the
driver in his seat without restricting any movements necessary for driving or any movements
caused by the suspension.
Other places.
If the conditions of use provide that operators other than the driver are occasionally or regularly transported by the machinery, or work on it, appropriate places must be provided which
enable them to be transported or to work on it without risk, particularly the risk of falling.
Where the working conditions so permit, these work places must be equipped with seats.
Should the driving position have to be fitted with a cab, the other places must also be protected against the hazards which justified the protection of the driving position.
Controls.
The driver must be able to actuate all control devices required to operate the machinery
from the driving position, except for functions which can be safely activated only by using
control devices located away from the driving position. This refers in particular to working
positions other than the driving position, for which operators other than the driver are responsible or for which the driver has to leave his driving position in order to carry out the
manoeuvre in safety. Where there are pedals, they must be so designed, constructed and
fitted to allow operation by the driver in safety with the minimum risk of confusion; they must
have a slip-resistant surface and be easy to clean.
Where their operation can lead to hazards, notably dangerous movements, the machinery's
controls, except for those with preset positions, must return to the neutral position as soon
as they are released by the operator. In the case of wheeled machinery, the steering system
must be designed and constructed to reduce the force of sudden movements of the steering
lever caused by shocks to the guide wheels.
Any control that locks the differential must be so designed and arranged that it allows the
differential to be unlocked when the machinery is moving.
Starting/moving.
Self-propelled machinery with a ride-on driver must be so equipped as to deter unauthorised
persons from starting the engine. Travel movements of self-propelled machinery with a rideon driver must be possible only if the driver is at the controls.
Where, for operating purposes, machinery must be fitted with devices which exceed its normal clearance zone (e.g. stabilisers, jib, etc), the driver must be provided with the means of
checking easily, before moving the machinery, that such devices are in a particular position
which allows safe movement. This also applies to all other parts which, to allow safe movement, have to be in particular positions, locked if necessary.
Where it is technically and economically feasible, movement of the machinery must depend
on safe positioning of the aforementioned parts. It must not be possible for movement of the
machinery to occur while the engine is being started.
Travelling function.
Without prejudice to the provisions of road traffic regulations, self-propelled machinery and
its trailers must meet the requirements for slowing down, stopping, braking and immobilisa-
tion so as to ensure safety under all the operating, loading, speed, ground and gradient
conditions allowed for by the manufacturer and corresponding to conditions encountered in
normal use. The driver must be able to slow down and stop self-propelled machinery by
means of a main device.
Where safety so requires in the event of a failure of the main device, or in the absence of the
energy supply to actuate the main device, an emergency device with fully-independent and
easily-accessible controls must be provided for slowing down and stopping.
Where safety so requires, a parking device must be provided to render stationary machinery
immobile. This device may be combined with one of the devices referred to in the second
paragraph, provided that it is purely mechanical. Remote-controlled machinery must be designed and constructed to stop automatically if the driver loses control.
Movement of pedestrian-controlled machinery.
Movement of pedestrian-controlled self-propelled machinery must be possible only through
sustained action on the relevant control by the driver. In particular, it must not be possible for
movement to occur while the engine is being started. The control systems for pedestriancontrolled machinery must be designed to minimise the hazards arising from inadvertent
movement of the machine towards the driver, in particular crushing or injury from rotating
tools.
Also, the speed of normal travel of the machine must be compatible with the pace of a driver
on foot. In the case of machinery on which a rotary tool may be fitted, it must not be possible
to actuate that tool when the reversing control is engaged, except where movement of the
machinery results from movement of the tool. In the latter case, the reversing speed must be
such that it does not endanger the driver.
Control circuit failure.
A failure in the power supply to the power-assisted steering, where fitted, must not prevent
machinery from being steered during the time required to stop it.
the manufacturer or his authorised representative must, for each type of structure concerned, perform appropriate test or have such tests performed. In addition, the earth-moving
machinery listed below with a capacity exceeding 15kW must be fitted with a rollover protective structure:
Falling objects.
Where, in the case of machinery with a ride-on driver and possibly ride-on operators, there
is a risk due to falling objects or material, the machinery should be designed for, and fitted
with, if its size allows, anchorage points allowing it to be equipped with a falling object
protective structure (FOPS). This structure must be such that in the case of falling objects or
material, it guarantees the ride-on operators an adequate deflection-limiting volume (DLV).
In order to verify that the structure complies with the requirement laid down in the second
paragraph, the manufacturer or his authorised representative must, for each type of
structure concerned, perform appropriate tests or have such tests performed.
Means of access.
Handholds and steps must be designed, constructed and arranged in such a way that the
operators use them instinctively and do not use the controls for that purpose.
Towing devices.
All machinery used to tow or to be towed must be fitted with towing or coupling devices
designed, constructed and arranged to ensure easy and safe connection and disconnection,
and to prevent accidental disconnection during use. In so far as the tow-bar load requires,
such machinery must be equipped with a support, with a bearing surface suited to the load
and the ground.
Transmission of power between self-propelled machinery (or tractor) and recipient
machinery.
Transmission shafts with universal joints linking self-propelled machinery (or tractor) to the
first fixed bearing of recipient machinery must be guarded on the self-propelled machinery
side and the recipient machinery side over the whole length of the shaft and associated
universal joints. On the side of the self-propelled machinery (or tractor), the power take-off to
which the transmission shaft is attached must be guarded either by a screen fixed to the
self-propelled machinery (or tractor) or by any other device offering equivalent protection.
On the towed machinery side, the input shaft must be enclosed in a protective casing fixed
to the machinery. Torque limiters or free wheels may be fitted to universal joint transmissions
only on the side adjoining the driven machine. The universal-joint transmission shaft must be
marked accordingly.
All towed machinery whose operation requires a transmission shaft to connect it to selfpropelled machinery or a tractor must have a system for attaching the transmission shaft so
that when the machinery is uncoupled, the transmission shaft and its guard are not
damaged by contact with the ground or part of the machinery. The outside parts of the guard
must be so designed, constructed and arranged that they cannot turn with the transmission
shaft. The guard must cover the transmission shaft to the ends of the inner jaws in the case
of simple universal joints, and at least to the centre of the outer joint or joints in the case of
"wide-angle" universal joints. Manufacturers providing means of access to working positions
near to the universal joint transmission shaft must ensure that shaft guards as described in
the sixth paragraph cannot be used as steps unless designed and constructed for that
purpose.
Moving transmission parts.
In the case of internal combustion engines, removable guards preventing access to the
moving parts in the engine compartment need not have locking devices if they have to be
opened either by the use of a tool or key or by a control located in the driving position if the
latter is in a fully enclosed cab with a lock to prevent unauthorised access.
The latter requirement does not apply to machinery intended solely for underground working
and having no electrical power.
Remote-controlled machinery which, under normal conditions of use, exposes persons to
the hazards of impact or crushing must be fitted with appropriate means to signal its
movements or with means to protect exposed persons against such hazards.
The same applies to machinery which involves, when in use, the constant repetition of a
forward and backward movement on a single axis where the back of the machine is not
directly visible to the driver. Machinery must be so constructed that the warning and
signalling devices cannot all be disabled unintentionally. Where this is essential for safety,
such devices must be provided with the means to check that they are in good working order
and their failure must be made apparent to the operator.
Where the movement of machinery or its tools is particularly hazardous, signs on the
machinery must be provided to warn against approaching the machinery while it is working;
the signs must be legible at a sufficient distance to ensure the safety of persons who have to
be in the vicinity.
Marking.
The minimum requirements must be supplemented by the following:
Instruction handbook.
Apart from the minimum requirements already explained, the instruction handbook must
contain the following information:
(a) regarding the vibrations emitted by the machinery, either the actual value or a figure
calculated from measurements performed on identical machinery:
the weighted root mean square acceleration value to which the arms are subjected, if
it exceeds 2.5 m/s2; should it not exceed 2.5 m/s2, this must be mentioned;
the weighted root mean square acceleration value to which the body (feet or posterior) is subjected if it exceeds 0.5 m/s2; should it not exceed 0.5 m/s2, this must be
mentioned.
Where the harmonised standards are not applied, the vibration must be measured using the
most appropriate methods for the machinery concerned. The manufacturer must indicate the
operating conditions of the machinery during measurement and which methods were used
for taking the measurements;
(b) in the case of machinery allowing several uses depending on the equipment used,
manufacturers of basic machinery to which interchangeable equipment may be attached and
manufacturers of the interchangeable equipment must provide the necessary information to
enable the equipment to be fitted and used safely.
2.20 - Essential health and safety requirements to offset the particular hazards due to
a lifting operation.
Definitions.
(a) "lifting accessories" means components or equipment not attached to the machine and
placed between the machinery and the load or on the load in order to attach it;
(b) "separate lifting accessories" means accessories which help to make up or use a slinging
device, such as eyehooks, shackles, rings, eyebolts, etc;
(c) "guided load" means the load where the total movement is made along rigid or flexible
guides, whose position is determined by fixed points;
(d) "working coefficient" means the arithmetic ratio between the load guaranteed by the
manufacturer up to which a piece of equipment, and accessory or machinery is able to hold
it and the maximum working load marked on the equipment, accessory or machinery
respectively;
(e) "test coefficient" means the arithmetic ratio between the load used to carry out the static
or dynamic tests on a piece of equipment, an accessory or machinery and the maximum
working load marked on the piece of equipment, accessory or machinery;
(f) "static test" means the test during which the machinery or the lifting accessory is first
inspected and then subjected to a force corresponding to the maximum working load
multiplied by the appropriate static test coefficient, and then re-inspected once the said load
has been released to ensure no damage has occurred;
(g) "dynamic test" means the test during which the machinery is operated in all its possible
configurations at maximum working load with account being taken of the dynamic behaviour
of the machinery in order to check that the machinery and safety features are functioning
properly.
Protection against mechanical hazards.
Risks due to lack of stability.
Machinery must be so designed and constructed that stability is maintained both in service
and out of service, including all stages of transportation, assembly and dismantling, during
foreseeable component failures and also during the tests carried out in accordance with the
instruction handbook. To that end, the manufacturer or his authorised representative must
use the appropriate verification methods; in particular, for self-propelled industrial trucks with
lift exceeding 1.80 m, the manufacturer or his authorised representative must, for each type
of industrial truck concerned, perform a platform stability test or similar test, or have such
tests performed.
Machinery must be provided with devices which act on the guide rails or tracks to prevent
derailment. However, if derailment occurs despite such devices, or if there is a failure of a
rail or a running component, devices must be provided which prevent the equipment,
component or load from falling or the machine overturning.
Mechanical strength.
Machinery, lifting accessories and removable components must be capable of withstanding
the stresses to which they are subjected, both in and, where applicable, out of use, under
the installation and operating conditions provided for by the manufacturer, and in all relevant
configurations, with due regard, where appropriate, to the effects of atmospheric factors and
forces exerted by persons.
This requirement must also be satisfied during transport, assembly and dismantling.
Machinery and lifting accessories must be designed and constructed so as to prevent failure
from fatigue or wear, taking due account of their intended use. The materials used must be
chosen on the basis of the working environments provided for by the manufacturer, with
special reference to corrosion, abrasion, impacts, cold brittleness and ageing.
The machinery and the lifting accessories must be designed and constructed to withstand
the overload in the static tests without permanent deformation or patent defect.
Pulleys, drums, chains or ropes.
Pulleys, drums and wheels must have a diameter commensurate with the size of rope or
chains with which they can be fitted. Drums and wheels must be so designed, constructed
and installed that the ropes or chains with which they are equipped can wind round without
falling off. Ropes used directly for lifting or supporting the load must not include any splicing
other than at their ends (splicings are tolerated in installations which are intended from their
design to be modified regularly according to needs for use).
Complete ropes and their endings have a working coefficient chosen so as to guarantee an
adequate level of safety; as a general rule, this coefficient is equal to five. Lifting chains
have a working coefficient chosen so as to guarantee an adequate level of safety; as a
general rule, this coefficient is equal to four. In order to verify that an adequate working
coefficient has been attained, the manufacturer or his authorised representative must, for
each type of chain and rope used directly for lifting the load, and for the rope ends, perform
the appropriate tests or have such tests performed.
Separate lifting accessories.
Lifting accessories must be sized with due regard to fatigue and ageing processes for a
number of operating cycles consistent with their expected life-span as specified in the
operating conditions for a given application.
Moreover:
(a) the working coefficient of the metallic rope/rope end combination is chosen so as to
guarantee an adequate level of safety; this coefficient is, as a general rule, equal to five.
Ropes must not comprise any splices or loops other than at their ends;
(b) where chains with welded links are used, they must be of the short link type. The working
coefficient of chains of any type is chosen so as to guarantee an adequate level of safety;
this coefficient is, as a general rule, equal to four;
(c) the working coefficient for textile ropes or slings is dependent on the material, method of
manufacture, dimensions and use. This coefficient is chosen so as to guarantee an
adequate level of safety; it is, as a general rule, equal to seven, provided the materials used
are shown to be of very good quality and the method of manufacture is appropriate to the
intended use. Should this not be the case, the coefficient is, as a general rule, set at a
higher level in order to secure an equivalent level of safety. Textile ropes and slings must not
include any knots, connections or splicing other than at the ends of the sling, except in the
case of an endless sling;
(d) all metallic components making up, or used with, a sling must have a working coefficient
chosen as to guarantee an adequate level of safety; this coefficient is, as a general rule,
equal to four;
(e) the maximum working capacity of a multi-legged sling is determined on the basis of the
safety coefficient of the weakest leg, the number of legs and a reduction factor which
depends on the slinging configuration;
(f) in order to verify that an adequate working coefficient has been attained, the
manufacturer or his authorised representative must, for each type of component referred to
in (a), (b), (c) and (d) perform the appropriate tests or have such tests performed.
Control of movements.
Devices for controlling movements must act in such a way that the machinery on which they
are installed is kept safe:
(a) machinery must be so designed or fitted with devices that the amplitude of movement of
its components is kept within the specified limits. The operation of such devices must, where
appropriate, be preceded by a warning;
(b) where several fixed or rail-mounted machines can be manoeuvred simultaneously in the
same place, with risks of collision, such machines must be so designed and constructed as
to make it possible to fit systems enabling these risks to be avoided;
(c) the mechanisms of machinery must be so designed and constructed that the loads
cannot creep dangerously or fall freely and unexpectedly, even in the event of partial or total
failure of the power supply or when the operator stops operating the machine;
(d) it must not be possible, under normal operating conditions, to lower the load solely by
friction brake, except in the case of machinery, whose function requires it to operate in that
way;
(e) holding devices must be so designed and constructed that inadvertent dropping of the
loads is avoided.
Handling of loads.
The driving position of machinery must be located in such a way as to ensure that widest
possible view of trajectories of the moving parts, in order to avoid possible collisions with
persons or equipment or other machinery which might be manoeuvring at the same time and
liable to constitute a hazard. Machinery with guided loads fixed in one place must be
designed and constructed so as to prevent exposed persons from being hit by the load or
the counter-weights.
Lightning.
Machinery in need of protection against the effects of lightning while being used must be
fitted with a system for conducting the resultant electrical charges to earth.
2.21 - Essential health and safety requirements for machinery intended solely for
underground work.
Risks due to lack of stability.
Powered roof supports must be so designed and constructed as to maintain a given direction when moving and not slip before and while they come under load and after the load has
been removed. They must be equipped with anchorages for the top plates of the individual
hydraulic props.
Movement.
Powered roof supports must allow for unhindered movement of exposed persons.
Control devices.
The accelerator and brake controls for the movement of machinery running on rails must be
manual. The deadman's control may be foot-operated, however. The control devices of
powered roof supports must be designed and laid out so that, during displacement operations, operators are sheltered by a support in place. The control devices must be protected
against any accidental release.
Stopping.
Self-propelled machinery running on rails for use in underground work must be equipped
with a deadman's control acting on the circuit controlling the movement of the machinery.
Fire.
The braking system of machinery meant for use in underground working must be designed
and constructed so as not to produce sparks or cause fires. Machinery with heat engines for
use in underground working must be fitted only with internal combustion engines using fuel
with a low vaporising pressure and which exclude any spark of electrical origin.
Controls should meet the criteria that are laid down in Schedule 3 of the Supply of Machinery (Safety) Regulations 1992. This says that they must be:
Clearly visible.
Appropriately marked.
Positioned for safe operation.
Designed so that movement of the control is consistent with the effect required.
Located outside the danger zone, except for certain controls, e.g. emergency stop.
Positioned so that their operation cannot cause additional risk.
Designed to prevent unintentional operation.
Made to withstand foreseeable strain, particularly emergency controls.
Fitted with dials, etc. if required for safe operation.
Starting of the machine can only be by means of the control, particularly after adverse conditions, e.g. a power cut.
Stopping devices to be fitted.
Emergency stopping devices to be fitted, clearly marked and to work effectively.
The control must override any part of the system except the emergency control.
Any fault or failure must not lead to danger.
Interactive software must be user-friendly to the operator.
Displacement.
Operating force.
Friction, inertia or drag.
Number of positions.
Direction of movement.
Predetermined stops (detents).
Appropriate identification.
Compatibility with displays.
Size.
Minimise the number of controls; the fewer there are, the less chance of the wrong
one being operated.
Arrange them to encourage a range of postures for the operator, thus allowing
movement to keep the body "fresh".
Arrange them so that the sequence of operations is in an arc, so that the control layout is representative of the process.
Where large forces are required to be exerted, use foot pedals or have power assistance.
Have a clear distinction between normal and emergency controls.
Keep consistent groupings of displays and controls; ideally the display should be
above the control.
Prevent accidental operation by recessing or shielding the control or by distance to
prevent them being knocked by an elbow, etc.
Selection of appropriate controls is therefore vital and the following table is of particular use:
Control Type Use at Speed Accuracy
Mounting
Space Required
Ease of Use
in an Array
Ease to
Check
Reading in
Array
toggle switch good
good
small
good
good
good
small
good
fair
push button
very good
very poor
small
good
poor
rotary
selector
good
good
medium
good
good
knob
fair
fair
small-medium poor
good
hand wheel
poor
good
large
poor
poor
crank
fair
poor
medium-large poor
poor
lever
good
fair
large
good
good
foot pedal
good
poor
large
poor
poor
'Table 1'
should require some form of confirmation in addition to the start command. Furthermore, the
results of the actuation should be displayed
Reg 15: Stop controls.
Regulation 15(1) requires that the action of the stop control should bring the equipment to a
safe condition in a safe manner. This acknowledges that it is not always desirable to bring all
items of work equipment immediately to a complete stop if this could result in other risks. For
example, stopping the mixing mechanism of a reactor during certain chemical reactions
could lead to a dangerous exothermic reaction.
The stop control does not have to be instantaneous in its action and can bring the equipment to rest in sequence or at the end of an operating cycle if this is required for safety. This
may be necessary in some processes, for example to prevent the unsafe build-up of heat or
pressure or to allow a controlled run-down of large rotating parts with high inertia.
Regulation 15(2) is qualified by 'where necessary for reasons of health and safety'. Therefore, all accessible dangerous parts must be rendered stationary which may mean they need
to be locked into position and may be allowed to idle. However, parts of equipment which do
not present a risk, such as suitably guarded cooling fans, do not need to be positively
stopped.
Regulation 15(3) requires that the control should switch off all sources of energy from the
equipment after it has stopped, if this is necessary to prevent or minimise risk to health or
safety. Where it is necessary to retain power for production reasons and a hazard could
arise due to unexpected movement giving rise to risk of injury, control systems should be
designed so as to immediately remove the power, should such an event occur. Where internally-stored energy could lead to risk, it should be cut off by the action of the stop control.
For example, horizontal plastic injection moulding machines may store hydraulic energy in
internal hydraulic reservoirs which, under certain fault conditions, may cause uncovenanted
movements which could cause injury. In this case, the stop control should effectively isolate
or dissipate the stored energy so as to ensure safety.
The stop control should take priority over any operating or start control. Where possible, it
should not require anything other than a short manual action to activate it, even though the
stop and disconnection sequence so initiated may take some time to complete. Further information on the categories of stop function can be found in BS EN 60204-1. Although this
standard (which deals with specifications for general requirements for an individual machine)
applies to new machinery, it gives valuable guidance which may be useful for any equipment
- new or used.
Regulation 16: Emergency stop controls
An emergency stop control should be provided where the other safeguards in place are not
adequate to prevent risk when an irregular event occurs. However, an emergency stop control should not be considered as a substitute for safeguarding.
Where it is appropriate to have one, based on the risk assessment, you should provide an
emergency stop at every control point and at other appropriate locations around the equipment so that action can be taken quickly. The location of emergency stop controls should be
determined as a follow-up to the risk assessment required under the Management Regulations. Although it is desirable that emergency stops rapidly bring work equipment to a halt,
this must be achieved under control so as not to create any additional hazards.
As emergency stops are intended to affect a rapid response to potentially dangerous situations, they should not be used as functional stops during normal operation.
Emergency stop controls should be easily reached and actuated.
Common types are mushroom-headed buttons, bars, levers, kick-plates, or pressuresensitive cables. Guidance on specific features of emergency stops is given in national,
European and international standards.
Regulation 17: Controls.
It should be possible to identify easily what each control does and on which equipment it
takes effect. Both the controls and their markings should be clearly visible. As well as having
legible wording or symbols, factors such as the colour, shape and position of controls are
important; a combination of these can often be used to reduce ambiguity. Some controls
may need to be distinguishable by touch, for example inching buttons on printing machines.
Few controls will be adequately identifiable without marking of some sort.
The marking and form of many controls is covered by national, European and international
standards either generic or specific to the type of equipment (BS 3641, prEN 50099). However, additional marking may often be desirable.
Regulation 17(2).
Controls used in the normal running of the equipment should normally not be placed where
anybody using them might be exposed to risk. However, controls used for setting-up and
fault-finding procedures may have to be positioned where people are at some risk, for example on a robot-teaching pendant. In such cases, particular precautions should be employed to ensure safety; examples include using hold-to-run controls, enabling controls,
emergency stop controls. Further precautions include the selection of reduced/limited capability of the work equipment during such operations.
Regulation 17(3)(a).
The provisions of regulation 17(3) (a) apply where physical safeguarding methods employed
in accordance with regulation 11 (2) (a) and (b) do not completely prevent access to dangerous parts of work equipment, or where people are at risk from other aspects of the operation, e.g. noise, or harmful radiation. The preferred aim is to position controls so that operators of equipment are able to see from the control position that no-one is at risk from anything they set going. To be able to do this, operators need to have a view of any part of the
equipment that may put anyone at risk. A direct view is best, but supplementing by mirrors
or more sophisticated visual or sensing facilities may be necessary.
There will normally be little difficulty in meeting this requirement in the case of small and
compact equipment. With larger equipment, there is normally some latitude in the positioning of controls and the safety aspect should be considered in deciding their location; this
would apply, for example, on large process plant such as newspaper printing machinery or
chemical plant.
Where people are at risk from dangerous parts of machinery, normal safeguarding procedures should restrict the need for surveillance to vulnerable areas; an example would be on
large newspaper printing machines. However, where regular intervention is necessary,
which involves entry into, removal of, or opening of safeguards, for example for maintenance
purposes, interlocks or similar devices may be necessary as appropriate to prevent start-up
while people are at risk. You may need to employ additional measures to ensure that people
do not remain inside safeguards at start-up. Similarly, where sensing devices are employed
to aid surveillance, they may be interlocked with the controls so as to prevent start-up when
people are at risk.
If anyone other than the operator is also working on the equipment, they may use permissive start controls. Such controls can indicate to the operator that everyone is clear and
permit a start. These can be located at a position of safety from where they can ascertain
chemical process, however, could create further hazards. Care should be taken to fully assess the consequences of such events and provide further protection, i.e. standby power
plant or diverting chemicals to a place of safety. It should always be possible to recover to a
safe condition.
There are national, European and international standards both current and in preparation
(BS EN 60204- 1, BS EN 954-1) which provide guidance on design of control systems so as
to achieve high levels of performance related to safety. Though they are aimed at new machinery, they may be used as guidance for existing work equipment
2.24 - Reducing the need for access (automation and remote systems).
Automation.
Replacing workers with automated (automatic) systems can be achieved by the use of computer which controls the work through robots, etc. This system takes away the need for the
human and with it the likelihood of human factors becoming a hazard i.e. fatigue, behaviour
etc. However, maintenance procedures and repairs are required which are also hazards.
Remote systems.
This system refers to the process where an employee or operator operates the equipment
removed from the place where the equipment is housed or located. This has the advantage
of segregating the employee from the equipment (and its hazards).
2.25 - Lighting.
Lighting is covered by Schedule 3 of the Supply of Machinery (Safety) Regulations
1999 and is stated as:
The manufacturer must supply integral lighting suitable for the operations concerned
where its lack is likely to cause a risk, despite ambient lighting of normal intensity.
The manufacturer must ensure that there is no area of shadow likely to cause nuisance, that there is no irritating dazzle and that there are no dangerous stroboscopic
effects due to lighting provided by the manufacturer.
Internal parts requiring frequent inspection and adjustment and maintenance areas
must be provided with appropriate lighting.
Lighting is also covered under regulation 21 of the PUWER 1998 which states:
"Every employer shall ensure that suitable and sufficient lighting, which takes account of the
operations to be carried out, is provided at any place where a person uses work equipment."
Further advice in the Approved Code of Practice continues with the following
guidance:
Any place where a person uses work equipment should be suitably and sufficiently
lit. If the ambient lighting provided in the workplace is suitable and sufficient for the
tasks involved in the use of the equipment, special lighting need not be provided. But
if the task involves the perception of detail, for example to comply with the regulation.
The lighting should be adequate for the needs of the task.
When the construction of the machine and/or its guards renders the normal lighting
inadequate for the safe and efficient operation of the machine, you should provide
local lighting of the work area. Local lighting may be needed to give sufficient view of
When the work piece comes into contact with the tool, the latter must have attained
its normal working conditions.
When the tool starts and/or stops (intentionally or accidentally) the feed movement
and the tool movement must be coordinated.
2.27 - Training.
PUWER 1998 calls for:
(1) Every employer shall ensure that all persons who use work equipment have received
adequate training for purposes of health and safety, including training in the methods which
may be adopted when using the work equipment, any risks which such use may entail and
precautions to be taken. The regulations go on to further state:
(2) Every employer shall ensure that any of his employees who supervises or manages the
use of work equipment has received adequate training for purposes of health and safety,
including training in the methods which may be adopted when using the work equipment,
any risks which such use may entail and precautions to be taken.
What is 'adequate training'?
It is not possible to detail here what constitutes 'adequate training' as requirements will vary
according to the job or activity and work equipment etc.
In general, you will need to:
evaluate the existing competence of employees to operate the full range of work
equipment that they will use;
evaluate the competence they need to manage or supervise the use of work equipment; and
train the employee to make up any shortfall between their competence and that required to carry out the work with due regard to health and safety.
take account of the circumstances in which the employee works. For example, do
they work alone or under close supervision of a competent person?
if the risks to which people are exposed change due to a change in their working
tasks; or
because new technology or equipment is introduced; or
if the system of work changes.
Also, you should provide refresher training if necessary. Skills decline if they are not used
regularly. Pay particular attention to people who deputise for others on occasions, as they
may need more frequent refresher training than those who do the work regularly.
Training for young people:
Training and proper supervision of young people is particularly important because of their
relative immaturity and unfamiliarity with the working environment. Induction training is of
particular importance. There are no general age restrictions in legislation relating to the use
of work equipment although there is some ACOP material in the relevant publications
dealing with lifting, power presses and wood working; all employees should be competent to
use work equipment with due regard to health and safety regardless of their age.
The Management Regulations contain specific requirements relating to the employment of
young people under the age of 18. These require employers to assess risks to young people
before they start work, taking into account their inexperience, lack of awareness of potential
risks and their immaturity. Employers must provide information to parents of school-age
children (for example when they are on work experience) about the risks and the control
measures introduced and take account of the risk assessment in determining whether the
young person should undertake certain work activities.
850
550
230
130
'Table 1'
Fingers:
Dimensions in millimetres
Part of Body
Opening
Fingertip
Slot
Square
Round
e4
4<e6
20
10
10
6<e8
40
30
20
8 < e 10
80
60
60
10 < e 12
100
80
80
12 < e 20
900(1)
120
120
20 < e 40
900
550
120
30 < e 100
900
900
900
'Table 2'
1800
2000
2200
2400
2500
2400
100
100
100
100
100
100
100
100
2200
600
600
500
500
400
350
250
2000
1100
900
700
600
500
350
1800
1100
1000
900
900
600
1600
1300
1000
900
900
500
1400
1300
1000
900
800
100
1200
1400
1000
900
500
1000
1400
1000
900
300
800
1300
900
600
600
1200
500
400
1200
300
200
1100
200
1100
200
'Table 1'
Minimum distance for high risk:
Height of
danger
zone
1200
1400
1600
1800
2000
2200
2400
2500
2700
2600
900
800
700
600
600
500
400
300
100
2400
1100
1000
900
800
700
600
400
300
100
2200
1300
1200
1000
900
800
600
400
300
2000
1400
1300
1100
900
800
600
400
1800
1500
1400
1100
900
800
600
1600
1500
1400
1100
900
800
500
1400
1500
1400
1100
900
800
1200
1500
1400
1100
900
700
1000
1500
1400
1000
800
800
1500
1300
900
600
600
1400
1300
800
400
1400
1200
400
200
1200
900
1100
500
'Table 2'
3 - Maintenance.
When equipment is maintained, there is always a risk of hazards being realised
through a number of ways. The following is a suggested list of some of the hazards
that may present themselves and should be considered in the risk assessment process:
Hazardous substances (paints, solvents, thinners, greasers, chemical, acids and alkalis etc.)
Physical hazards such as manual handling.
Isolation procedures - ensuring that the equipment cannot be turned on when being
maintained.
Cuts from sharp edges.
Confined spaces and restrictions on movement.
Hot work that may be required.
Noise.
Environmental issues such as lighting levels, heat, ventilation etc.
Obviously this is not an exhaustive list, but does give a flavour of the types of hazards that
must be controlled.
Maintenance management.
The extent and complexity of maintenance can vary substantially from simple checks on
basic equipment to integrated programmes for complex plant. In all circumstances, for
maintenance to be effective it needs to be targeted at the parts of work equipment where
failure or deterioration could lead to health and safety risks. Maintenance should address
those parts which have failed or are likely to deteriorate and lead to health and safety risks.
A number of maintenance management techniques could be used:
1. planned preventative;
2. condition-based;
3. breakdown.
Appropriate techniques should be selected through risk assessment and used
independently or in combination to address the risks involved.
Simple hand tools usually require minimal maintenance, but could require repair or
replacement at intervals. More complex powered equipment will normally be accompanied
by a manufacturer's maintenance manual, which specifies routine and special maintenance
procedures to be carried out at particular intervals. Some of the procedures will be
necessary to keep the equipment in working order; others will be required for safety
reasons.
It should be remembered that different maintenance management techniques have different
benefits.
Planned preventive maintenance involves replacing parts and consumables or making
necessary adjustments at preset intervals so that risks do not occur as a result of the
deterioration or failure of the equipment.
Condition-based maintenance involves monitoring the condition of safety-critical parts and
carrying out maintenance whenever necessary to avoid hazards which could otherwise
occur.
Breakdown maintenance involves carrying out maintenance only after faults or failures have
occurred. It is appropriate only if the failure does not present an immediate risk and can be
corrected before risk occurs, for example through effective fault reporting and maintenance
schemes.
Where safety-critical parts could fail and cause the equipment, guards or other protection
devices to fail and lead to immediate or hidden potential risks, a formal system of planned
preventative or condition-based maintenance is likely to be needed.
Some equipment may not be owned by the user. Many items of plant and equipment are
hired. It is important for both the hire company and the person responsible for hiring
equipment to establish which party will carry out safety-related maintenance. This is
particularly important for equipment on long-term hire and the terms of the agreement set
out or recorded in writing.
In many cases, safety-related maintenance work is not carried out by the person with
ultimate responsibility for the work equipment, in the mistaken belief that the other party will
do it. If the hire company is some distance from the user site, it would be uneconomical for
their staff to carry out simple checks and make minor adjustments, so the user may agree to
carry them out. However, both parties should agree on a clear delineation of responsibilities.
What importance does the work equipment play in the overall business?
Costs of the equipment maintenance in terms of direct costs and indirect costs, i.e.
indirect costs of down time for parts if the equipment is not maintained, and direct
costs of labour etc.
The dependency of the equipment on other machines. Is it a stand-alone piece of
equipment or does it play a part in a much bigger system?
Can the equipment be easily replaced?
Does the equipment require any peculiar parts - that may have to be ordered in ad-
Regulations
the inspections or even to carry them out may not be available in-house, in which case the
help of another body with relevant competence may be necessary. An example of this will be
the person who carries out the annual inspection under these Regulations of some
fairground rides.
(c) where there is, in his opinion, a defect in the lifting equipment involving an existing or
imminent risk of serious personal injury, send a copy of the report as soon as is practicable
to the relevant enforcing authority.
(2) A person making an inspection for an employer under regulation 9 shall:
(a) notify the employer forthwith of any defect in the lifting equipment which in his opinion is,
or could become, a danger to persons;
(b) as soon as is practicable make a record of the inspection in writing.
(3) Every employer who has been notified under paragraph (1) shall ensure that the
lifting equipment is not used
(a) before the defect is rectified; or
(b) in a case to which sub-paragraph (c) of paragraph 8 of Schedule 1 applies, after a time
specified under that sub-paragraph and before the defect is rectified.
(4) In this regulation "relevant enforcing authority" means:
(a) where the defective equipment has been hired or leased by the employer, the Executive;
and
(b) otherwise, the enforcing authority for the premises in which the defective equipment was
thoroughly examined.
(1) Every employer shall ensure that before lifting equipment is put into service for
the first time by him, it is thoroughly examined for any defect unless either:
(a) the lifting equipment has not been used before; and
(b) in the case of lifting equipment for which an CE declaration of conformity could or (in the
case of a declaration under the Lifts Regulations 1997) should have been drawn up, the
employer has received such declaration made not more than 12 months before the lifting
equipment is put into service; or if it is obtained from the undertaking of another person, it is
accompanied by physical evidence referred to in paragraph (4).
(2) Every employer shall ensure that, where the safety of lifting equipment depends
on the installation conditions, it is thoroughly examined:
(a) after installation and before being put into service for the first time; and
(b) after assembly and before being put into service at a new site or in a new location, to ensure that it has been installed correctly and is safe to operate.
(3) Subject to paragraph (6), every employer shall ensure that lifting equipment which
is exposed to conditions causing deterioration which is liable to result in dangerous
situations is:
(a) thoroughly examined:
(i) in the case of lifting equipment for lifting persons or an accessory for lifting, at
least every 6 months;
(ii) in the case of other lifting equipment, at least every 12 months; or
(iii) in either case, in accordance with an examination scheme; and
(iv) each time that exceptional circumstances which are liable to jeopardise the
safety of the lifting equipment have occurred; and,
(b) if appropriate for the purpose, is inspected by a competent person at suitable intervals
between thorough examinations, to ensure that health and safety conditions are maintained
and that any deterioration can be detected and remedied in good time.
(4) Every employer shall ensure that no lifting equipment:
(a) leaves his undertaking; or
(b) if obtained from the undertaking of another person, is used in his undertaking, unless it is
accompanied by physical evidence that the last thorough examination required to be carried
out under this regulation has been carried out.
unless clear verifiable records indicate that this has been done, for example at a recent
thorough examination, and that any defects have been rectified.
The competent person will need to see records of electrical maintenance and evidence that
this has been done in accordance with the manufacturer's instructions (if still available) or
another reasonable maintenance regime. If this evidence is not available, the competent
person may ask the employer to obtain it. This may involve having tests carried out where
the competent person considers this necessary following a visual inspection and other
relevant functional checks.
Pipe-work.
Pressure system.
Relevant fluid.
Pipe-work.
Pipe-work means a pipe or system of pipes together with associated valves, pumps,
compressors and other pressure-containing components and includes a hose or bellows but
does not include a pipeline or any protective devices.
Pressure System.
Pressure system means:
(a) a system comprising one or more pressure vessels of rigid construction, any associated
pipe-work and protective devices;
(b) the pipe-work with its protective devices to which a transportable pressure receptacle is,
or is intended to be, connected; or
(c) a pipeline and its protective devices, which contains or is liable to contain a relevant fluid,
but does not include a transportable pressure receptacle.
Relevant fluid.
Relevant fluid means:
(a) steam;
(b) any fluid or mixture of fluids which is at a pressure greater than 0.5 bar above
atmospheric pressure, and which fluid or mixture of fluids is
(i) a gas, or
(ii) a liquid which would have a vapour pressure greater than 0.5 bar above atmospheric pressure when in equilibrium with its vapour at either the actual temperature
of the liquid or 17.5 degrees Celsius; or
(c) a gas dissolved under pressure in a solvent contained in a porous substance at ambient
temperature, and which could be released from the solvent without the application of heat.
The maintenance and examination requirements for pressure systems will be discussed in
detail in Element IC11: Pressure System Hazards and Controls .
Induction
Changes in work activity
Introduction of new technology and equipment
Refresher training
Induction
One of the first things that a new employee requires is an introduction to the company, but
this does not just mean the geographical details, such as the location of the toilets, the fire
escapes and the coffee machine (although these are important). The new entrant will be at a
disadvantage unless they quickly acquire a knowledge of such things as the company
culture, both formal and informal and the company ethos on such things as bullying,
behaviour, harassment, discrimination and ethical behaviour.
An induction programme therefore needs to take these things into account or it will come as
no surprise when the new entrant feels isolated and unable to integrate into the work
environment - particularly to become known among other staff members. Departmental tours
and personal introductions are an absolutely vital part of induction. Organisations depend on
its people being able to work together, to liaise and cooperate - these capabilities in turn
depend on contacts and relationships. Well-planned induction training can greatly accelerate
the development of this crucial organisational capability.
Changes in work activities
There is, in any organisation, a certain inertia that tends to mean things continue much as
they have been. It is often the case that a change in the way that a company carries out
certain activities can founder on the rock of inertia unless positive and proactive action is
taken to ensure that the members of staff who are going to be involved in or affected by the
change are fully trained on the implications of the change and the knowledge requirements
that it will need.
These changes are often more than just moving a few desks around or changing offices.
They bring with them a new way of thinking and acting and therefore a single training
session with no follow-up or reinforcement will not suffice to embed the new system. Without
monitoring and evaluation of how the changes are progressing, they will most likely become
memories rather than everyday thought and deed, eventually becoming just another
management initiative that didn't work out.
Introduction of new technology
Technology progresses and unless a company wants to be left behind, it too must
embrace changes in the way that its industry works. Making use of all the available
resources when introducing new technology can greatly enhance the chances of it
being a success.
Manufacturer's training facilities
Input of staff on their training needs
Pre-change training
Initial facilitation training
Follow-up checks with staff on how the changes are being handled
Repeated training if it is clear that this is needed
The introduction of new equipment and technology can be viewed by elements of the
workforce with suspicion but well-handled, the changes can be an opportunity to
bring the workforce along on the journey and the benefits can be increased thereby.
Consolidation of training
Gaining basic training and a certificate of competence should only be seen as an entry into
industry; the training and development process lasts throughout an entire career. The initial
step following entry-level training is consolidation of the training, which is usually in the form
of a probationary period operating under supervision among qualified and experienced
colleagues.
Only when newly qualified workers have demonstrated their ability and experience over a
length of time should they be considered as fully proficient and qualified. The length of this
period will vary according to the individual, but advice is that six months is likely to be a
minimum. A record should be kept of their work and tasks completed. It is the responsibility
of the worker and their employer to keep this record (for example by the use of checklists) to
demonstrate their experience and developing levels of proficiency.
Update or refresher training
There is a risk that when workers spend time on other tasks, their proficiency can lapse.
This, along with the introduction of new techniques, brings with it a need for refresher and
update training at various stages in the worker's career. This occasional further training
should add value to the worker's growing skills and experience and provide a structure for
staff development.
In general, proficient workers who regularly practise their skills in the presence of colleagues
and employers will require training less often. However,
advances in technology may justify specific update training, and certain trained skills will
need specific, regular practice and updating. This can often be incorporated as part of
training for more advanced skills. It is important to record and plan for refresher/update
training and the employer must record the structure of the training received by the worker
based on the type of work undertaken.
For most machinery operations, recorded refresher/update training should take place at
least every five years. However, where a supervisor identifies specific weaknesses in an
operator's abilities, this will need to be addressed, irrespective of the date of previous
training.
However, young people may operate high-risk woodworking machinery during training
providing they are sufficiently mature and are adequately supervised. They should also be
properly supervised after training until they reach the appropriate level of competence and
can work safely unsupervised. The Approved Code of Practice and Guidance Safe use of
woodworking machinery: Provision and Use of Work Equipment Regulations as applied to
woodworking contains further information.
A recent HSE study of woodworking accidents found that a quarter of those injured under
the age of 25 had received no specific training or instruction for the machine they were
working on and in small firms, half of those injured had received 'on the job' training only.
Keeping records
Once the operator has received the necessary training and has demonstrated their
competence, it is good practice to authorise them in writing for the machines and operations
that they can use.
Self-supervision
The concept of supervision in the workplace environment has been studied by many
professional experts. Self-supervision became a critical area of research since experts want
to find out whether self-supervision can be obtained relying heavily on technology and
resources or with a change in the organisational structure.
If self-supervision is practised in the workplace for utilising technology, it means that the
workers function on their own without a supervisor to guide or direct them as long as there
are sufficient resources and technology needed to carry out the tasks. On the other hand, if
self-supervision is used in a company to modify the traditional hierarchical structure, it
means that direct supervision is removed and employees are taught to become crossfunctional in order to be equipped with the right skills and knowledge needed for
management functions.
There are various models of self-supervision, which are the results of experts' studies on
different working conditions.
Supervision Models
Candidates must successfully achieve all Assessment Activities unless otherwise specified.
stock is inserted, held, or withdrawn by hand. Safeguards are designed to eliminate the possibility of the operator or other workers from placing hands or any other body part from making contact with hazardous moving parts. Operators should never remove or tamper with
safeguards.
A power press can be made safe but only its user can prevent machine guarding injuries.
Press operators must receive a minimum of eight hours of on-the-job training under supervision before being assigned to operate a press. Operators of complex equipment may need
two weeks or more of training before they run the equipment alone. Those working with
presence-sensing device initiation equipment must receive training at least annually.
Press operators must know how to use press controls, where possible pinch points or moving parts are located, and where safety devices are located. Operators should be trained to
lock out machinery, lubricate it, remove stuck work, and know to whom they should report
any problems. Training should also include why, when, and how too use personal protective
equipment.
Supervisors must understand all the hazards associated with power presses, how the safeguards work, and how to adjust them. They must check the setup and ensure that each operator has been properly trained. Supervisors should visually inspect each press at the start
of a shift or whenever a new operator comes on duty. Each press must be inspected weekly
to be sure that all functions are operating properly; and periodically, an in-depth inspection
must be conducted.
The Power Presses Regulations have now been superseded by the Provision and Use of
Working Equipment Regulations (PUWER).
Young people (under 18 years) should not be allowed to use a power press unless they
have the necessary maturity and competence. This includes having successfully completed
appropriate training. However, they may operate a power press during training as long as
they are adequately supervised. They should also be supervised after training if considered
insufficiently mature.
Refresher training
You should provide refresher training if necessary. Skills decline if they are not used regularly. Pay particular attention to people who deputise for others on occasions - they may
need more frequent refresher training than those who do the work regularly.
When should training take place?
The Management of Health and Safety at Work Regulations 1999 specify that health and
safety training should take place within working hours.
Young People
Young people are often exposed to risks to their health and safety when using work equipment as a consequence of their immaturity, lack of experience or awareness of existing or
potential risks. Therefore you should not allow such people to use a power press unless they
have the necessary maturity and competence which includes having successfully completed
appropriate training. However, during the training they may operate a power press providing
they are adequately supervised. Adequate supervision should also be provided after training
if a young person is not sufficiently mature.
'Young person' means any person who has not yet reached the age of eighteen.
Competence and maturity are not simply a matter of the age of the worker. Training in itself
will not ensure competence but it is part of what is necessary. The level of supervision
needed will depend on how mature the worker is and whether they can work safely without
putting themselves or others at risk. Even when they have been trained, young people need
to be supervised to ensure that they do not act irresponsibly or take short cuts which put
common injuries arising from accidents which occur when using abrasive wheels. The main
hazards arise from contact with the wheel and trapping of fingers between the wheel and
work rest, but there is also the risk of fragments being ejected from the machine at very high
speed which can cause severe damage to the unprotected operator.
The number of accidents and the circumstances in which they occur show that most can be
avoided by a knowledge of the risks and by adopting safety measures.
There is no substitute for thorough practical training in all aspects of the mounting
and use of abrasive wheels. Any training programme should cover at least the following:
1. hazards and risks arising from the use of abrasive wheels and the precautions to be
observed;
2. methods of marking abrasive wheels with their type, size and maximum operating
speed;
3. how to store handle and transport abrasive wheels;
4. how to inspect and test abrasive wheels for damage;
5. the functions of all the components used with abrasive wheels such as flanges, blotters, bushes, nuts etc;
6. how to assemble abrasive wheels correctly to make sure they are properly balanced
and fit to use;
7. the proper method of dressing an abrasive wheel (removing dulled abrasive or other
material from the cutting surface and/or removing material to correct any uneven
wear of the wheel);
8. the correct adjustment of the work rest on pedestal or bench grinding machines;
9. the use of suitable personal protective equipment, for example eye protection.
It is recommended that a record of training in the safe mounting of abrasive wheels is kept,
showing the trainee's name and date of training.
Training courses are offered by many organisations which usually provide a certificate of
attendance, not competence. Further information can be obtained from the British Abrasives
Federation.
Question 1.
An Operator is defined as the person or persons given the task of
Multiple Choice (HP)
Answer 1:
All of these
Response 1:
Jump 1:
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Answer 2:
installing
Response 2:
Jump 2:
This page
Answer 3:
operating
Response 3:
Jump 3:
This page
Answer 4:
adjusting
Response 4:
Jump 4:
This page
Answer 5:
maintaining
Response 5:
Jump 5:
This page
Answer 6:
cleaning
Response 6:
Jump 6:
This page
Answer 7:
repairing
Response 7:
Jump 7:
This page
Answer 8:
transporting machinery
Response 8:
Jump 8:
This page
Question 2.
CE marking is not a quality mark
True/False (HP)
Answer 1:
True
Response 1:
Jump 1:
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Answer 2:
False
Response 2:
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Question 3.
It is primarily the task of the ____________ to design and construct new machinery so that it
can be used safely.
Multiple Choice (HP)
Answer 1:
Manufacturer
Response 1:
Jump 1:
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Answer 2:
Operator
Response 2:
Jump 2:
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Answer 3:
Cleaner
Response 3:
Jump 3:
This page
Answer 4:
Supplier
Response 4:
Jump 4:
This page
Question 4.
The manufacturer must supply _____________ suitable for the operations concerned where
its lack is likely to cause a risk despite ambient lighting of normal intensity.
Multiple Choice (HP)
Answer 1:
Integral lighting
Response 1:
Jump 1:
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Answer 2:
Cleaning fluid
Response 2:
Jump 2:
This page
Answer 3:
Response 3:
Jump 3:
This page
Question 5.
Following safe systems of work and the provision of information, instruction and training are
examples of
Multiple Choice (HP)
Answer 1:
software measures
Response 1:
Jump 1:
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Answer 2:
hardware measures
Response 2:
Jump 2:
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