How can you design conveyor systems to reduce worker injury risk?

1. Guarding and Enclosures: Install guards and enclosures around moving parts of the conveyor system, such as belts, rollers, gears, to prevent workers from coming into contact with them. Ensure that guards are secure and cannot be easily bypassed. 2. Emergency Stop Devices: Implement emergency stop devices along the conveyor system that allow workers to quickly halt operation in case of emergencies or unsafe conditions. These devices should be easily accessible and clearly marked. 3. Clear Communication: Provide clear instructions and training to workers on safe operating procedures for the conveyor system. Make sure workers understand the risks associated with working near or on the conveyor and know how to properly use safety equipment.

1. Check part loading in ergonomic standard . 2. Check worker moment around conveyor , cover all electric parts like motors by guarding . 3 .Try to put motors as far as away from loading area . 4. Use light curtain ,scanner to restrict operator movement . 5. In a case of robots interference use safe robots , mechanical stopper , SRM concept .

In my experience on Capital projects and existing production-packaging systems, you must begin accessing key areas in the preliminary design phase. Perform re-assessments on existing conveyors-connected equipment and operators as new product innovations could change operating parameters. Proceed through the modes of operation of the work performed by humans (maintenance teams, operators, cleaning crews, compliance tasks, quality checks). Perform hazard analysis and risk assessment during the design phase, into fabrication, and complete it in the initial production start-up phase. Finally, design out product variables causing the production line not to run as planned, requiring unplanned intervention-increasing the risk of injury.

Assessing the hazards before installation . Controls like pull cord switch should be installed to prevent injury to the operator,this will be useful in any emergency. Local push button emergency stop should be given to stop conveyor in case of any unforeseen circumstances.Belt misalignment switch should be preferably installed . Employees working near conveyor should not wear loose clothes .Conveyor motors should be 360 guarded.Photoelectric sensors are best suited for conveyor applications .ASME B20.1-2021 standards should be followed while designing conveyors .

- Assess all related equipment connected to the belt conveyor are still in operation or not before you work, conduct further hierarchy control such as LOTOTO and other control measeured required

Hierarchy of controls are extremely important not only in conveyor systems but all processes. After doing the hazard assessment, it is essential to look at possibilities of eliminating the hazards wherever possible, if that is not possible look at substitution of the process with a new process if that is compatible, if that also is not possible look at isolating the hazard, provide appropriate engineering controls and look at administrative controls as a last but non negotiable requirement. In case of a conveyor, all hazardous areas are to be isolated and engineering controls should adequately warn much in advance and trip the system before any eventuality happens. It is that modifications are to be permitted after studying the implications

Identification of risk, Hazards related to conveying materials is essential. Conveyor system main hazard created due to spillages, cleaning activities. Most of incidents happened during cleaning activities. Conveyor belt design such like that minimal emissions, spillages. Can design pipe conveyor or 45 Deg idler frame. Discharge chute with proper chute level switch and interlocking system

I think everyone is overengineering this from their view point and history. First thing to do in my opinion? Interview and talk to the workers on the existing line. See what they have to say about safety and the impact of the process on their bodies. So many times I've seen "well thoughtout and engineered systems that forgot about the worker". How many times do companies complain and ask why there employees are getting injuries on this new line? Because the boxes come in at 12" off the ground and they have to bend and pick up a 40# box. Or they have to reach over a 3' wide container to grab a 20# box. Many of the responders are adding at the end "oh then provide the workers PPE equipment so they dont get hurt from the designs.

1. Elimination: Objective: Completely remove the hazard at the point of access Application: Redesign the conveyor system to eliminate the need for workers to access the specific point by automating tasks or altering the layout 2. Substitution: Objective: Replace the hazard with a less risky alternative Application: Consider alternative conveyor system designs or technologies that inherently reduce the risk of injury at the point of access 3. Personal Protective Equipment: Obj: Protect individuals from the residual risk using personal protective gear Application: Provide workers with appropriate PPE, such as gloves, safety glasses or other protective equipment However, PPE should be considered as a last resort after other control measures

Designing conveyor systems to reduce workers' injury risk involves implementing safety measures such as installing safety guards, emergency stop controls, sensors, clear signage, providing proper training, conducting regular maintenance, designing with ergonomics in mind, and conducting risk assessments.

Design, construction and installation of the conveyors depend on many parameters. The parameters such as purpose of transfer of material (transfer vertically or horizontally), characteristics of the material to be transferred such as size, friction between the material particles, temperature, horizontal distance and/or elevation, available space and plant layout, ambient condition, wind velocity and direction, etc. In the preliminary study phase of the project and with taking to account the above characteristics the designer should decide on the conveyor type (i.g. steel cored or simple belt, with of the belt, inclination of the belt in case of elevation transfer, bucket type belt conveyor) as well as making it in one length or multiple

In pulp and paper industry Some times we seen that material fed to conveyor falls down from side guard it is dangerous for workers working there, Side guard hight should be increased to a safe level.

Consider that not all ‘pick stations’ are created equally. Opting for a ‘pick station’ where the operator is encouraged to move their feet to interact with the equipment rather than a fixed stance and twisting from the trunk.

In my experience from being in the field the Conveyor layout and design needs to be more concerned with space issues when it comes to inspection and service. Design must also provide clear sightlines that make it easy to view ALL of the integral parts of the system when on the catwalks during routine inspections. When the system needs adjustments, lubrication, conveyor component replacement, addressing any belt injury, or belt replacement the maintenance person must have ample space to work in to address the issue(s) at hand. More space and clear sightlines also reduce job injuries and keep everyone safe. Safety is job#1.

El diseño debe incluir dispositivos de seguridad pasivos, que aíslen a las personas de las máquinas peligrosas; y activos, que pongan a las máquinas en un estado seguro cuando una persona acceda a la zona de peligro. Esos dispositivos activos deben estar diseñados a prueba de fallos. Cualquier fallo en los mismos, debe ser detectado y debe provocar que la máquina quede en un estado no peligroso para las personas.

Maintenances related- 1-Do not try to adjust the belt while it is running. 2-Take work permits & follows LOTOTO system for any maint. Job. 3-Fix all related safety guard in position before starting. 4-Arrange proper supports before any work at G. take up at belt conveyor. 5-Do not share the belt until it has no tension & it should be clamp at both the end. 6- Do not accept any sort cart way. 7- Always follows Safety guideline of belt conveyor.

Implement conveyor safety guards: They are designed to protect employees from getting caught in the moving parts of the conveyor system and can be made of materials such as metal, plastic or mesh. Moreover, they can be designed to fit around specific areas of the equipment.

In my experience overseeing conveyor systems,the commitment to regular maintenance and inspections proved instrumental. during a scheduled maintenance cycle,we followed the manufacturer's guidelines, paying meticulous attention to details like lubrication points and wear indicators. Keeping a comprehensive record of each activity, including dates and actions taken, facilitated not only accountability but also identified potential issues before they escalated. I agree that a proactive stance is essential. We implemented a reporting system encouraging workers to communicate defects, malfunctions, or incidents. This effort not only empowered our team but also allowed us to take corrective actions, keeping an efficient and safe conveyor system.

Continuous monitoring ,preventive maintenance is the key to prevent accidents and failure, a commitment to regular maintenance and inspections, attention to details like lubrication points and wear indicators, work permits and following LOTOTO system during a scheduled maintenance

Continuous monitoring ,preventive maintenance is the key to prevent accidents.failure mood effect analysis,Reliability Centre maintenance will help .

Display Do's and Don't Visual Sign Boards Training for Negligence and Overconfidence Bypassing the Safety Devices-Possible Accidents

Reward and recognition for workers Quarterly awards Safety and equipment trainings Champions and super users roll out Kaizen and continuous improvement mechanism with dash board Safety index and rewarding safe employees

- You need to let your team understand their tasks clearly and what kind of risks they might face during the work. - perform training and safety sessions will definitely build a system to achieve zero injury or reduce it to the minimum.

In my experience involving workers is critical if the goal is improving workplace safety. A safety program is best when you have buy-in from the people executing the tasks. By soliciting the perspectives and opinions of the team, you spread a sense of ownership in the safety program. A sense of ownership drives better idea generation and therefore a better safety program. Additionally, the culture of the team improves when employees feel like they are safe and they belong. Is there a better way to enhance a feeling of belonging than by valuing a person’s opinion?

The process owners are the masters. Empower them to own their areas and always listen to suggestions from them. Without their voices the opportunity to improve processes is stagnated.

1. Design and selection of E&I based on the Area & Zone Classification i.e (Hazardous/Non hazardous, Dust/Gas/Weather Proof etc). 2. Proper selection of Safety Switches. 3.Proper Design of Guards for rotating/sliding equipments such as Rollers, Pulleys, Take-up, Couplings, Gates etc. 4. Selection of proper Gaskets and Seals for equipments. 5. Design and Selection of proper de-dusting system. 6. Proper design of maintenance platforms, ladders, walkways, handrails etc. 7. Selection of ATEX/PESO/CIMFR etc Certified E&I incase of hazardous area classification. 8. Proper selection of Hoist's/lifting equip. 9. Implement Automation&Control philosophy. 10. Design of proper earthing system. 11. Installation of LCS/LPBS near field equipment.

1. Apply mechanical and electrical safe design checks. 2. Design out any safety hazards- Eliminate safety hazards by design 3. Design safeguards over any safety hazard where applicable. 4. Test the design for safety validation once approved and produced.

The CAD models of conveyor parts can be developed. We will assemble and check the mechanism of the components. Also we will conduct ergonomics studies on the same assembly. Generate the report from study and paste on the wall besides the conveyor and indicate safety switches, like safety cable pull switch,tripper postion switch and standard height of the belt conveyor etc. Ergonomics is the study of the people in the work place,strives to make workplaces and surroundings better in order to lower the chance of injury.Always check most important safety device for conveyor i.e belt misalignment switch known as run off switch which is used to monitor the postion and tracking of the belts.

O que sempre considerei nestas situações é nunca ter uma opinião isolada. A análise precisa ser bem criteriosa e envolver vários profissionais. O ponto de vista de todos deve ser ouvido e considerado. Os arquivos, memoriais e instruções são muito importantes. Mas nada como a avaliação no GEMBA para evidenciar as oportunidades e mitigar os riscos futuros que podem prejudicar a saúde do colaborador!

Risk assessment and mitigation will be the key of success. Once we are going to conduct risk assessment it must not be restricted to worker safety, it must also include product safety, user safety. Process design, layout and all other critical process parameters depend on how effective risk assessment performed.