CASE STUDY: HOW WE DEAL WITH HAZARDS

In the following pages youll find a number of case studies specific to the plastics and rubber
industry. While they are focused on examples in the injection moulding segment, the types of
hazards are common to the industry as a whole.
In particular, weve used case studies with a lot of connection to the most common, and costly
injury causes in the industry, as indicated by statistics gathered by WorkCover Corporation.
To deal with hazards in the workplace we use a very simple discipline, which is represented by
the logo in the top left hand corner of each case study sheet. It is a process of Identifying the
Hazard, Assessing the Risk, and using the Hierarchy of Controls to Control the Risk to
acceptable levels. We then repeat the process to establish a Continuous Improvement Cycle
targeting to ultimately eliminate the risk.

Identify the HAZARDS

Assess the RISK

Take actions to CONTROL the RISK

Our special thanks to Viscount Plastics for staging the case study photo shoot for this project

Case Study 1

CASE STUDY: WORKING AT HEIGHTS

HAZARDS
During production, access to the back of
machinery is barricaded by guarding.
During maintenance it may be necessary
to remove guards to access tooling.
Serious fall onto floor or into machinery
Access to moving parts
RISK ASSESSMENT
High - frequency of occurrence
- severity of injury
The consequence is moderate and the
likelihood is possible
RISK CONTROL
Implement appropriate guarding, isolation
and interlock techniques. (i.e. the key
should be removed from the lock and held
by the operator to make sure the machine
cant operate while hes in the danger
zone)
Hold posts to help operator stabilise
balance
Non-slip matting

Case Study 2

CASE STUDY: CHEMICALS

HAZARDS
Fire
Explosion
Burns
Unintended use
RISK ASSESSMENT
High the consequence could be
major and the likelihood is possible
RISK CONTROL
Provide appropriate chemical storage
facilities
Display Material Safety Data Sheets
(MSDSs)
Label & store chemicals appropriately
Provide fire-fighting equipment

Case Study 3

CASE STUDY: FLASHBACK

HAZARDS
While releasing blockages from the
process there is potential for hot plastic to
flashback onto operator

RISK ASSESSMENT
Moderate the consequence could be
moderate and the likelihood is unlikely

RISK CONTROL
Purge guards fitted
Develop Standard Operating
Procedures (SOPs)
Wear PPE appropriate to the task

Case Study 4

CASE STUDY:FORKLIFT TRUCKS & SHARED WALKWAYS

HAZARD
Workplace layout that allows people and
moving vehicles to interact.
A key injury source in the industry
people struck by moving objects

RISK ASSESSMENT
Very High the consequence could be
catastrophic and the likelihood is possible

RISK CONTROL
Consider substituting forklifts with more
pedestrian friendly load shifting
equipment eg walker stackers
Implement Forklift alert systems
Mark designated walkways on floor
Introduce physical barriers, such as
barricades, to ensure that people stick to
walkways.
Insist that designated walkways are kept
clear & uncluttered.

Case Study 5

CASE STUDY: USE OF KNIVES

HAZARDS
Deflashing of moulded product presents
a risk of laceration with unprotected knives
Cuts

RISK ASSESSMENT
Moderate the consequence is minor but
the event is likely
RISK CONTROL
Develop tooling maintenance schedule to
reduce occurrence and severity of flashing
Use appropriate knife for activity (eg.
Deburring tool)
Wear appropriate PPE when using knives

Case Study 6

CASE STUDY: MANUAL HANDLING

AWKWARD POSTURE
HAZARDS
Soft tissue damage (back, shoulders,
arms, neck)
Musculo-skeletal disorder

RISK ASSESSMENT
High sprains and strains handling
product. The consequence is moderate
and the likelihood is possible.
RISK CONTROL
Automate stacking process
Consider inclined racks that enable the
operator to stack product at an acceptable
height before tipping for transport
Provide better access to reach
Provide appropriate equipment to
enable safe lifting

Case Study 7

CASE STUDY: MANUAL HANDLING

MINOR INGREDIENTS
HAZARDS
Muscular stress while lifting, placing or
carrying product
Soft tissue Injury
Musculo-skeletal disorder

RISK ASSESSMENT
High - poor lifting conditions
- high incidence in the industry
The consequence is moderate and the
likelihood is possible
RISK CONTROL
Install a vacuum lifter to avoid need for
manual lifting
Store minor ingredients in an easily
accessible location
Avoid carrying minor ingredients long
distances by storing them in close
proximity to equipment

Case Study 8

CASE STUDY: MANUAL HANDLING

REPETITIVE STRAIN
HAZARDS
Repetitive strain injury
Musculo-skeletal disorder

RISK ASSESSMENT
Moderate assembly of parts can involve
high frequency repetitive activity. The
consequence is moderate and the
likelihood is unlikely
RISK CONTROL
Automate assembly process
Provide appropriate equipment to
facilitate assembly
Job rotation.

Case Study 9

CASE STUDY: MANUAL HANDLING

PURGE MATERIALS
HAZARDS
Burns from handling hot materials
Risk of combustion if hot material comes
into contact with other materials (such as
rags or cardboard)

RISK ASSESSMENT
High material left on floor could be at
200C but no-one can tell. The
consequence is moderate and the
likelihood is possible.
RISK CONTROL
Purge guards fitted.
Use specific trays to collect purge material
(ideally the trays would have handles to
facilitate lifting and castors to avoid
carrying).
Develop administrative controls such as
Standard Operating Procedures (SOPs)
Wear appropriate PPE when handling
purge materials

Case Study 10

CASE STUDY: MANUAL HANDLING

WITHDRAWING PRODUCT
HAZARDS
Strains and sprains from handling
product

RISK ASSESSMENT
High awkward posture and lifting
relatively low weights at a distance from
the body
The consequence is moderate and the
likelihood is possible
RISK CONTROL
The big products are a real challenge
look at how a handling aid might help eg
a wheel-in rack to direct the product out of
the press when it opens, that allows the
operator to withdraw the product without
the need to reach into the daylight area
Automate product handling

Case Study 11

CASE STUDY: HOUSEKEEPING

MAINTENANCE
HAZARDS
During production access to the back of
machinery is barricaded by solid cages.
During maintenance it may be
necessary to remove cages to access
parts.
Collision with equipment at head height
Serious fall onto floor or into machinery
Obstruction of emergency exit
RISK ASSESSMENT
High the consequence is moderate and
the event is likely
RISK CONTROL
Barricade the area during maintenance
If in an emergency access way, ensure
the activity keeps the walkway clear
Never obstruct an emergency exit
Bollard in-front of emergency exit

Case Study 12

CASE STUDY: HOUSEKEEPING

OIL SPILLS
HAZARDS
Fall from same level on oily floors
Fractures
Contusions

RISK ASSESSMENT
High Consequence could be
moderate and the likelihood is possible.

RISK CONTROL
Focus on preventing oil leaks it can be
tough with high pressure hydraulic systems
but can be improved with effort
Build bunding to keep oil leaks off
walkways
Lay non-slip surfacing
Perform regular housekeeping checks
Regularly clean affected areas

Case Study 13

CASE STUDY: HIT BY MOVING OBJECT

HAZARDS
Use of crane to move a tool at height over
areas in which people are working.
crush
fracture
fatality
RISK ASSESSMENT
High the consequence could be
catastrophic and the event is unlikely
RISK CONTROL
Service crane regularly to avoid failures
Ensure that all lifting equipment is
regularly inspected and maintained in good
condition
Allocate specific travel paths for overhead
gantry (i.e. tool to be
transported at far back end of
gantry clear of people working
underneath).

CASE STUDY: HYDRAULIC HOSE BURST

Case Study 14

HAZARDS
Major hydraulic fluid spill
Impact from lashing hose end
Potential hot fluid burn
RISK ASSESSMENT
Moderate the consequence may be
moderate and the likelihood is unlikely
RISK CONTROL
Cable tethers on each hose to prevent
lashing about when hose or coupling fail
Install cages to prevent hoses impacting
operators, and to keep passers by out of
harms way in event of a hose burst

Case Study 15

CASE STUDY: SAFE HANDLING OF UNUSUAL ITEMS

HAZARDS
Yes, its a drill press on 2 pallets on the
top rack unsecured and a nightmare to
lift down safely
Crush
Property Damage
RISK ASSESSMENT
Moderate low frequency activity with
moderate risk of drill press falling from
pallet, potentially striking forklift
The consequence is moderate and the
likelihood is unlikely
RISK CONTROL
Bolt or strap the item securely to the
pallet
An unusual example of a very nonroutine activity presenting an unexpected
hazard. Storage of frequently used items
is a surprisingly frequent source of
unexpected hazards using the risk
control process is always worthwhile