SAFETY & ADPI HEAT TREATMENT (HT) Training ProgrammeINDEX:
4. Reporting accidents and hazards:
6. Personal protective equipment (p.p.e.):
7. Fire prevention:
9. Emergency procedure:
10. Safety training:
11. Hand tools:
This document is intended for use as guidelines for the Wooden Pallet Heat Treatment Process. It contains all the basic steps to complete the Heat Treatment Cycle from the initial stage and up to the delivery and the basic safety. Through the initial safety induction course, safety awareness should be promoted at all levels. It is imperative that it is explained in clear and concise terms, the vital importance of safety for the protection of all personnel involved with this project. This is a basic safety induction course, not intended to be comprehensive safety instructions for all aspects of the project. Further safety instruction will be given at toolbox talks where job specific and unusual activity requirements will be filly explained to all concerned.
The contents of this document should not be used as complete material for the basic safety induction, additional information should be given with examples of safety hazards, items of damaged or unsafe equipment should be used as examples. It is not desirable that this document be quoted "word for the word". Personnel holding induction courses should whenever possible use their own ideas and expressions as a means of getting the safety message across.
The ultimate objective of a safety induction course is to instill confidence in the workforce that the management hold the safety, health and welfare of all involved in this project to be of prime importance but that only through the assistance and cooperation of all can a safe efficient and economical workplace exist.
It must be stressed that all are important to and for safety, regardless of position or status.
2.1 Welcome to the ADPI Wooden Pallet Heat Treatment Training Course.
This lecture will take approximately 2 hrs, during this time the basic requirements of Heat Treatment Process and its related correspondence will explain. It is therefore vitally important that attention is paid at all times and that anything that is not understood is questioned.
2.2 Everyone involved with ADPI, regardless of position or status has an equal responsibility for their duty in order to complete the Heat Treatment Cycle.
2.3 Your actions could result in stopping the cycle, therefore we all have to work together and of course to complete the work in the scheduled time with out any delay.
2.4 If there is ever any doubt or confusion you must ask your immediate supervisor. He will explain what is required or get the necessary information.
2.5 Everyone involved in this project, regardless of position or status has an equal responsibility for their own safety and for the safety of all others.
2.6 Your actions could result in an injury to yourself or to others working with or near you, therefore we all have to work safety and consider the safety of others.
2.7 The information you will be given during this lecture is only the basic safety requirements for this project. Further safety training will be given in the form of toolbox talks amongst others, given by your foremen, supervisors, engineers or safety officers.
2.8 If there is ever any item of safety you are unsure about you must ask you immediate supervisor. He will explain what is required or get the necessary information from the safety department and pass it on to you.
2.9 Safety on site is not a nuisance or a hindrance. It is for your protection. No one wants to be injured and only be following the safety requirements at all times can you and those working around you. Leave the site each day in the same condition that you arrived in.
2.10Accidents and injuries cause pain, misery and suffering, not only to the injured person, but also to his immediate family members. An injured man cannot earn a living to support his family, they will have to care for him until he is well enough to work again, if the accident is serious enough this could be never! An injured man cannot provide food and clothing for his family, instead of being a provider he becomes a burden.
2.11You should consider the consequences of your actions and those of others at all times, when you think the safety rules are tiresome. Think of your family and friends. Then it should be obvious why we have to work safely.
3.1 Who is responsible for the Heat Treatment Process? The Work related to the cycle will be distributed to each person by the supervisor or the Management. And each person will work as per the given schedule.
3.2 Everyone in ADPI, regardless of position or status, has an equal responsibility for their work.
3.3 Who is responsible for looking after your safety? At the end of the day you are no matter how much the safety officers and supervisors watch over people, they cannot guarantee the safety of anyone who does not follow the safety rules and recommendations.
3.4 Everyone on this project, regardless of position or status, has an equal responsibility for their own safety and that all others on this project form the very top management to the new starter on his first day.
3.5 Management are responsible for ensuring that the safety department is vigilant and diligent in its duties, to pass on the necessary information, to ensure that this information is acted upon and that the highest safety standards are kept at all times.
3.6 The safety managers and officers have a duty to ensure there are no lapses in safety standards. That all are aware of what is required of them and those they work with and that corrective action is taken before work starts to ensure that an accident or incident dies not happen.
3.7 Engineers and supervisors are responsible for ensuring that all safety requirements and recommendations are compiled with by all those under their control. Any person committing an unsafe act or in the area of an unsafe work condition must obey the safety direction given weather the person giving the instructions is their immediate supervisor or not safety rules and regulations are for all without exception.
3.8 Once safety instructions have been given it is everyone's responsibility to see that they are followed anyone who does not want to follow the safety rules should leave the site now. There is no place for the unsafe worker on this project.
3.9 Safety has a friendly face. It is here for your protection. But anyone who chooses to deliberately ignore the safety rules will be removed from the project, for his own safety and that of others who do wish to work safely.
4. REPORTING ACCIDENTS AND HAZARDS:
4.1 For any safety department to be able to operate in an efficient manner, it must receive the necessary information, not just who is working here, doing what and when, but also what happens whilst they are performing their tasks.
4.2 In order for a safety department to find ways to prevent an accident from happening it must have the background information to work on.
4.3 Everyone, no matter what their position or status, should think of themselves as a safetyman. If you see someone working unsafely, or a piece of equipment in an unsafe condition, then it is everyone's duty to either correct the unsafe act or condition or report to their immediate supervisor.
4.4 In an unsafe act or condition is corrected on the spot then this is the ideal situation, but it is still necessary to report what happened so that the information can be passed on to others so that the same mistakes are not repeated.
4.5 Reports to safety are not used to apportion blame. The safety department is not primarily interested in whose fault something was rather to make sure there is no reoccurrence of the same unsafe practices.
4.6 The safety department needs to be informed of all accidents and incidents no matter how small accidents lead to major disasters so the safety department must be able to act on a minor incident to prevent any future catastrophe. Events that may seem fairly insignificant can eventually lead to serious incidents or injuries. Reporting safety infringements or hazards can help to eliminate these hazards.
4.7 As far as any safety department is concerned the most important item to be reported is the near miss. This is when there is almost an accident but nothing actually happens, such as two vehicles that almost collide. A crane that almost makes contact with an overhead power line. A man that almost gets fingers in a bandsaw or grinder. All these near misses can be prevented from re-occurring provided the safety department is given the information to act upon.
4.8 A near miss may seem quite insignificant at the time but it is importance cannot be stressed enough.
5.1 Whilst ever you are employed on this project it will be apparent to all that security has a very high profile. The security guards here act as policemen and has very similar powers.
5.2 Once you have completed this induction course, if you do not already have them, you will be issued with the necessary passes to enable you to enter the work site. You must show your security passes to the security guards on entry to the site and whenever requested to do so by a security guard or any person from management or supervision.
5.3 Your security pass is your means of identification whilst in the work site. It entitles you to enter the site provided your employer has informed security that you will be working on that day. It would be used to identify you should an accident occur.
5.4 You should carry your security pass with you at all times whilst on the work site, If you forget your security pass in the morning security may issue a temporary pass. But this is not guaranteed. They may well refuse entry to the site and a day's wages will be lost.
5.5 Security will ensure safety rules. Such as vehicles speeds on site. Amongst others are adhered to and will apprehend any person in violation. They may contact the offending persons security pass and escort him form the site. In which case they would almost certainly be terminated from the project.
5.6 Security will also apprehend any person involved in dangerous horseplay or any person tempering or interfering with any item of safety, fire extinguishers, safety notices, and even safety posters. All these will be grounds for instant dismissal.
5.7 Camera's radio's personal stereo's such as walk-man's or any similar electrical goods are not allowed on site and security will confiscate any of these items unless prior permission has been obtained in writing.
5.8 Security has the power to search all bags and lunch boxes both on entry and exit form the site.
5.9 Security will search all vehicles on entry and exit from the site.
5.10Refusal to comply with a request to search baggage or vehicle may be seen as ground for dismissal and will almost certainly result in refusal of entry to the site.
5.11Security will work closely with safety to ensure compliance. This is for your own protection as well as that of the company's assets.
6. PERSONAL PROTECTIVE EQUIPMENT (P.P.E.):
6.1 All personnel employed on this project as well as visitors are required to wear the appropriate personal protective equipment at all times whilst on site.
6.2 This P.P.E. will be provided by your employer but it is up to the individual to ensure his PPE is in good usable condition. Any items of PPE, which are worn out, will be replaced but items, which are lost any well, be charged for. It will be necessary to show the worn out items at the stores before they will be replaced.
6.3 Deliberately damaging or tempering with PPE is the same as for any item of safety equipment and is grounds for instant dismissal.
6.4 The basic requirements for all personnel on this project are a hard hat, safety equipment and are grounds for instant dismissal.
6.5 Additional PPE will be provided as necessary and mist be worn or used.
6.6 Refusal to wear or use PPE will result in the offending person being terminated from the project.
6.7 Additional PPE will include items such as safety goggles to be worn when burning, grinding, chipping concrete, and drilling, mixing or using chemicals.
6.8 Gloves shall be worn when handling wire ropes, cut steel, concrete chemicals and solvents.
6.9 Dust masks or respirators will be worn when grist blasting, using cement powder, painting using chemicals or in any dusty environment.
6.10Ear defenders or ear plugs are required when working with jack hammers, in close proximity to running generators, compressors or welding machines in a confined space or when noise levels are above 90 dbA, which is translated as when normal conversation becomes severely hampered.
6.11A safety harness or lifeline must be worn when working above 1.5 meters if edge protection such as a handrail is not provided.
6.12Personal protective equipment and with all safety equipment is provided for your protection and all personnel have a duty to make use of it.
6.13Any person suffering an injury who is subsequently found to have not been using the provided PPE may have no right for compensation or wages whilst unable to work.
6.14Every employer on this contract has a duty to provide the required PPE but no worker should commence his activities until he is in possession of this PPE otherwise the above statement will once again apply.
7. FIRE PREVENTION:
7.1 Fire is the major cause of property damage. Material damage, serious injury and loss of life, fire prevention has one of the highest priorities on this project. Every person on this project must be aware of fire prevention requirements, fire fighting facilities and the available fire fighting training.
7.2 Designated fire fighters and firewatchers will receive training in their individual responsibilities and the practical use of fire extinguishers or other fire fighting equipment.
7.3 Keeping the site tidy is one of the first steps in fire prevention, once again we consider housekeeping.
7.4 All combustible materials must be removed from any area of hot work welding, burning, grinding, etc. A firewatcher will be assigned to each area equipped with a portable fire extinguisher and it will be his duty to ensure the areas has been cleared and that fire does not break out once work has commenced.
7.5 Any fire, no matter how small, must be immediately reported to the site security services and safety manager.
7.6 Under no circumstances should any person attempt to fight a large fire with a fire extinguisher, large fires are a job for the qualified fighting services. You should never put your own life at risk. Properly and materials can be replaced, you can not.
7.7 If you are in the area of a fire leave the area immediately, walking, never run, do not delay to collect personal belongings, if there is time all equipment should be turned off. But only if completely safe to do so.
7.8 If you are the first person to spot a fire, should fire, fire and make sure others have heard your alarm. If there are fire alarms in the area break the glass and then either try to put out a small fire with an extinguisher or if unsafe to do so, leave the area.
7.9 You must be aware of the position of fire alarms if available in your area sn of the telephone number of security, safety manager.
7.10Pre-arranged personnel points to go to in the event of an alarm will be prepared to ensure all personnel have left the area of an emergency. You must be aware of your muster point, others lives could be lost when searching for a 'lost' man.
8.1 Medical facilities are provided for all personnel employed on this project. It should be understood that these facilities are for the treatment of injury or illness sustained whilst on site only. Any illness contracted whilst at home should be dealt with any the local doctor or heath clinic.
8.2 Any injury, no matter how small should be reported to your First Aid Officer or the Project Medic. Failure to report an injury will result in any future treatment or infection being recorded as not having happened on site. If you have an injury on Monday you must report it immediately, if you wait until another day you will not be able to provide where the injury happened and will be unable to make any claim in the future.
8.3 Every contractor on this project will have a first aid kit for the treatment of minor injuries. You must seek attention at your company's first aid post and make sure the details are recorded.
8.4 Those in charge of first aid kits must ensure that whenever an item is used from the first aid kit is replaced. To be available for the next person.
8.5 Even small cuts can easily become infected so it is very important to seek medical attention.
9. EMERGENCY PROCEDURE:
9.1.1 Fire has already been dealt with, but what should you do if you witness or come upon an accident.
9.1.2 Quickly and carefully inspect the area and size up the situation.
9.1.3 Make the area safe. If there is machinery running switch it off. If there is an electrical hazard do not approach. Should an injured person be in touch with live electrical wires try to switch off the electrical supply. If this is not possible try to push the injured person a way from the electrical source with a wooden pole or board. Do not use anything metal and do not touch the injured person until he is well clear of the electrical hazard. Only then can you be any assistance to the injured person.
9.1.4 The first priority has to be to make the area safe. Do not become a possible accident case yourself whilst trying to help someone else.
9.1.5 Once the area has been made safe first aid can begin under no circumstances should you move an injured person once the area has been made safe. You would only ever move an injured person as part of the making safing an area,
9.1.6 You must immediately inform the security and medical services by telephone or send someone else to contact a supervisor who can make the necessary telephone call. Make sure you have all the details and that you pass them on clearly.
9.1.7 You need to state exactly where you are. The emergency services must be able to find you and an injured person as quickly as possible. If you can explain what has happened and how the person was injured.
9.1.8 Stay with the injured person until medical assistance arrived. First aid is only really for those who are qualified to give it. But no one must be allowed to suffer for the sake of a little common sense. If a person is bleeding badly you must do what you can to stop the flow of blood.
9.2 Whatever assistance you give it is very important that clean materials are used. Do not wipe a wound and try to put a pad on heavy bleeding using a dirty handkerchief or an only rag, it could be harmful.
9.3 Under all circumstances get help from the emergency services as soon as possible. Time is the most important factor.
10. SAFETY TRAINING:
10.1 Every one involved on this project will receive some form of safety training. This induction course is your first safety training session.
10.2 Every Monday morning before stating work toolbox talks are held. These tool box talks are used to pass on safety information on all subjects. From excavations to scaffolding and traffic rules, amongst many others.
10.3 At these tool box talks you will be given safety information about the weeks work ahead, it is very important that you pay attention it could save you from an accident, a reprimand from your supervisor or even loosing your job. Listen to what is said and make sure you understand what is required from you.
10.4 Toolbox talks are for all to take part in. Therefore if there is something you do not understand or have not heard properly you must not be afraid to say so and ask for it to be repeated or explained more clearly. It is for your safety and the safety of those around you so you must be sure you to understand.
10.5 If you have seen something that you thought was unsafe. You should have reported this to you supervisor at the time. But you should also mention what you saw at the tool box talk so that all will be aware of the hazard and will know how to correct it should it occur again. When you make comment at toolbox talks your supervisors will know who paus attention to safety matters.
10.6 Other safety training is available to those who require it. Fire extinguishers training for fire watches, first aid training. Crane signals training for those working with cranes. When you show that you are interested and pay attention to safety you could be sent for further safety training on way of earning promotion.
10.7 The more persons who receive safety training the safer a site becomes.
11. HAND TOOLS:
11.1 Hand tools may appear to be simple and reasonably harmless to use, but if they are not looked after and kept in good working condition they can become just as hazardous as heavy machinery.
11.1.1 Most injuries from hand tools are small, requiring some medical treatment with the person returning to work immediately, but some hand tool injuries particularly those from misuse or tools in poor condition can be severe enough to put a person out of work for weeks, months or in the case of an eye injury, possibly permanently.
11.1.2 Always use the correct tool for the job never use a screwdriver as a chisel never hammer a spanner that was not specifically designed for that purpose always use the correct spanner for the size of nut.
11.1.3 Cutting edges on hand tools must be kept sharp and should be protected during transport or storage.
11.1.4 All files must have a handle. The injury caused by slipping on to a file end can be very serious.
11.1.5 The striking heads of tools such as hammers must be tightly wedged. A loose head could fly off and injur someone not even involved with the job.
11.1.6 All tool shafts must be in good condition, split or shattered shafts must be replaced immediately or the tool taken out of use until repaired.
11.1.7 Never use a screwdriver on work held in the hand. Again a small slip could lead to a very painful and serious injury.
11.1.8 Any tool that is worn or damaged beyond repair must be thrown ayay, so that no other person can use it.
11.1.9 Chisels and punches with mushroom heads must be ground to the correct shape; a piece of flying from the mushroom head of a chisel will certainly puncture and eyeball. Possibly even through safety glasses. Once an eye is damaged in this way it is extremely unlikely to ever be of any use again.
11.1.10 Never use 'home made' tools. Chisels should be of the correct steel and tempered in order to do their job correctly and sagely. Steel handles should not be welded to sledge hammerheads. They are very difficult to grip your hands, once again possibly injuring some one passing by. All tools are given special treatment by the manufacturer in order to perform their function. 'Home made' tolls cannot begin to copy this treatment.
11.1.11 Always wear the correct personal protective equipment. Gloves will provide some protection to your hands when happening glasses or goggles should always be worn when hammering or chipping.
12 MATERIAL LOG:
Material Log is dedicated for the following process.
12.2Incoming Material recording
12.3Everything, no matter regarding the importance, should keep a separate track in the system with respect tot he date, time, batch number and the space where it is being stored. It is not only to help the each finding but to get a clear information about the stock in order to avoid the delay or stop in the Heat treatment cycle.
13 CHAMBER LOG:
Chamber Log is the place where we need to keep all recordings about the heat treatment report.
13.2It is more important to keep all the information regarding the Heat Treatment Report in the special file.
13.3It will help us to find out each batch’s heat treatment record.
14 CERTIFICATION LOG:
Certification Log will keep up a clear record about the certification provided by ADPI
14.2The person who is in charge of certification will keep all the certificates provided by ADPI in the specified file.
14.3It will sort out the batch number and certification number. So that we can easily identify which final product will leave the factory with the specified batch number and the certificate.