Question: PAPFS operates from the docklands area of a large city

14 Aug 2024,8:21 AM

 

Task 8: Working at height

(a)     What should be considered when assessing the risk of falls while working at height in the filming studios?

(b)     Based on the scenario only, evaluate existing work-at-height controls currently used in the filming studios.

 

DRAFT/STUDY TIPS

To critically analyze the health and safety issues within Pointed Arrow Production and Film Studios (PAPFS), the scenario provides a detailed description of the working environment across various workshops and studios, highlighting specific hazards and the potential consequences of neglecting safety protocols. This essay will evaluate the effectiveness of current safety measures, identify areas for improvement, and suggest strategies to enhance the overall safety of the organization. The analysis is structured around specific tasks that include the assessment of equipment safety, lighting conditions, reach-truck management, explosive atmosphere risks, maintenance practices, confined space hazards, emergency planning, and working at height.

Task 1: Bench-mounted Circular Saw and Safe Working Environment

1(a) Health and Safety Risks While Using the Bench-mounted Circular Saw

The use of the bench-mounted circular saw at PAPFS presents several health and safety risks that have not been adequately controlled. Firstly, the saw has been involved in multiple accidents, indicating a lack of proper maintenance and safety procedures. The vibration issue that led to a worker losing grip and cutting their finger suggests that the equipment is either poorly maintained or inherently unstable. This issue could have been mitigated by ensuring that the saw is securely mounted and regularly inspected for any mechanical issues.

Additionally, the incident where a worker approached a rotating blade, mistaking it for being stationary, highlights a lack of proper training and awareness. Workers should be trained to recognize that a blade may still be rotating even after the machine has been switched off, and proper signage or visual indicators could help prevent such accidents.

The most serious incident involving the circular saw occurred when a worker’s sleeve became entangled in the blade, causing a deep laceration. This accident could have been prevented by enforcing the use of tight-fitting clothing and ensuring that all guards are in place and properly adjusted before use. The worker’s decision to lift the adjustable guard and remove eye protection during operation was a critical mistake, demonstrating a lack of adherence to safety protocols.

1(b) Improvements to the Existing Working Environment in the Wood Workshop

To improve the working environment in the wood workshop, several changes should be implemented. Firstly, a regular preventive maintenance schedule must be established to ensure that all equipment, including the circular saw, is in safe working condition. This would involve regular inspections, prompt repairs, and replacement of faulty parts.

Secondly, the workshop should be reorganized to reduce clutter and ensure that all tools and materials are stored safely and accessibly. The accumulation of waste, such as wood dust and off-cuts, should be addressed through the use of a modern LEV (Local Exhaust Ventilation) system to minimize fire hazards and improve air quality.

Thirdly, the lighting in the workshop needs to be upgraded. The current setup, with flickering fluorescent tubes and poorly positioned halogen floodlights, creates an unsafe working environment. Properly diffused and shadow-free lighting should be installed to ensure that all work areas are adequately illuminated.

Lastly, there should be a formal system for reporting and addressing safety concerns. The fact that two recent accidents were not followed up by the manager indicates a lack of accountability and oversight. A safety officer or committee should be appointed to regularly review safety procedures and ensure compliance.

Task 2: Lighting

2(a) Lighting Hazards in the Wood Workshop

The lighting in the wood workshop at PAPFS presents several hazards that compromise the safety of workers. The flickering fluorescent tubes are a significant concern as they can cause eye strain, reduce visibility, and potentially lead to accidents due to poor perception of moving parts. Moreover, the halogen floodlights, which cast shadows across the equipment, create an inconsistent lighting environment, making it difficult for workers to clearly see their tasks.

The combination of these lighting issues increases the risk of accidents, particularly when operating machinery that requires precise handling. For instance, shadows can obscure the position of a rotating blade, leading to misjudgments that could result in severe injuries. Additionally, inadequate lighting can contribute to worker fatigue, further increasing the likelihood of accidents.

2(b) Actions to Improve General Lighting Levels

To ensure that the general lighting levels in the wood workshop are suitable and sufficient, PAPFS can take several actions. Firstly, replacing the outdated fluorescent tubes with modern LED lighting would provide consistent, flicker-free illumination. LED lights are energy-efficient, long-lasting, and offer better color rendering, which is crucial for tasks that require attention to detail.

Secondly, the workshop should be equipped with adjustable task lighting at individual workstations. This would allow workers to direct light precisely where it is needed, reducing the risk of accidents caused by poor visibility. The task lighting should be positioned to avoid casting shadows on the workpiece and to minimize glare.

Thirdly, the layout of the workshop should be reviewed to ensure that all areas are evenly lit. This might involve repositioning existing lights or installing additional fixtures to eliminate dark spots. The windowsill, currently used for storage, should be cleared to allow natural light to enter the room, which can improve the overall lighting quality and reduce dependence on artificial sources.

2(c) Placement of Emergency Escape Lighting

Emergency escape lighting at PAPFS should be strategically placed to ensure safe evacuation in case of an emergency. This includes the reception area, the workshops, and along the evacuation routes leading to the exits. The staircases and lift access points should also be equipped with emergency lighting to guide workers and visitors to safety. Additionally, the escape lighting should cover the filming studios, particularly near the stage area and around the mobile tower scaffold, as these locations pose a higher risk during an evacuation due to the presence of heavy equipment and elevated structures.

Task 3: Reach-truck Management

The management of battery-powered reach truck activities at PAPFS is highly unsatisfactory, posing significant risks to both workers and equipment. The scenario describes several incidents that underscore the lack of proper training, inadequate supervision, and the absence of safe operating procedures.

Firstly, the fact that untrained workers are allowed to operate the reach truck in the absence of the designated operator is a major safety concern. The incident where a worker was injured by a falling load while trying to steady it illustrates the dangers of allowing untrained personnel to handle heavy machinery. Proper training is essential to ensure that operators are aware of the truck’s capabilities, limitations, and safety features, such as the flashing beacon and horn.

Secondly, the practice of using workers to weigh down the back of the truck to prevent it from tipping over is extremely dangerous and unprofessional. This indicates a lack of understanding of the truck’s load capacity and stability requirements. Such practices not only endanger the lives of workers but also risk damaging the equipment and delaying production.

Thirdly, the storage and charging of the reach truck are also problematic. The damaged insulation on the charger connection and the sparking observed during charging pose a fire hazard, especially given the proximity of flammable materials in the storeroom. Proper maintenance of the charging equipment and the establishment of a safe charging area away from flammable substances are crucial to preventing accidents.

To address these issues, PAPFS should implement strict training and certification requirements for reach truck operators. Only trained personnel should be allowed to operate the truck, and a supervisor should be present to oversee its use during critical tasks. Additionally, the truck should undergo regular maintenance checks, and any damaged parts should be repaired or replaced immediately to ensure safe operation. Finally, a designated charging area should be established, with clear safety protocols to prevent electrical fires.

Task 4: Risk of Substances Forming an Explosive Atmosphere

The spray-painting activities in the spray cabinets at PAPFS present a significant risk of an explosive atmosphere due to the use of solvent-based paints and cleaning solvents, many of which are labeled as flammable and toxic. When assessing the risk of an explosion, several factors need to be considered.

Firstly, the concentration of flammable vapors in the spray cabinets is a critical factor. The ventilation and extraction systems in place must be capable of effectively removing these vapors to prevent the buildup of an explosive atmosphere. The fact that the extraction system in the walk-in spray room was last serviced over three years ago raises concerns about its effectiveness. Regular maintenance and testing of the extraction systems are essential to ensure that they are functioning correctly and that the concentration of flammable vapors remains below the lower explosive limit (LEL).

Secondly, the ignition sources within the spray cabinets and the spray room need to be identified and controlled. The light fittings in the metal cupboards, which are brittle and cracked, pose a potential ignition source. Any electrical equipment used in these areas should be intrinsically safe and designed to prevent sparks that could ignite flammable vapors. Additionally, static electricity generated during the spraying process can also serve as an ignition source. Measures such as grounding and the use of anti-static materials should be implemented to minimize this risk.

Thirdly, the storage and handling of flammable substances should be carefully managed. The large quantities of paints and solvents stored in the workshop, combined with the presence of partially-used spray cans scattered around, increase the risk of an accidental release of flammable vapors. Proper storage in fire-resistant cabinets and the immediate disposal of empty or partially-used containers are necessary to reduce this risk.

Lastly, the training and awareness of workers regarding the hazards associated with spray-painting activities are crucial. Workers should be trained to recognize the signs of an explosive atmosphere, such as a strong odor of solvent or visible fumes, and should know how to respond in such situations. Emergency procedures, including the use of personal protective equipment (PPE) and evacuation protocols, should be clearly communicated and regularly practiced.

Task 5: Maintenance Strategies

5(a) Benefits of Implementing Planned Preventative Maintenance

Implementing planned preventative maintenance (PPM) in the other workshops at PAPFS would bring several benefits. Firstly, it would reduce the likelihood of equipment failure and accidents, as machinery would be regularly inspected and maintained. This proactive approach helps identify potential issues before they become serious problems, ensuring that all equipment operates safely and efficiently.

Secondly, PPM would improve production efficiency by minimizing unplanned downtime. When equipment fails unexpectedly, it can cause significant delays and disrupt the entire production process. By scheduling maintenance during periods of low activity, PAPFS can ensure that equipment is always ready for use when needed, thereby improving productivity.

Thirdly, PPM would extend the lifespan of equipment by preventing excessive wear and tear. Regular maintenance, such as lubrication, calibration, and replacement of worn parts, helps keep machinery in optimal condition. This reduces the need for costly repairs and replacements, saving the organization money in the long run.

Finally, PPM would contribute to a safer working environment by ensuring that all equipment is compliant with safety standards. Workers are less likely to be injured by faulty machinery if it is regularly maintained and inspected. Additionally, PPM can help identify hazards such as worn insulation on electrical equipment or loose guards on machines, allowing them to be addressed before they cause an accident.

5(b) Critical Analysis of the Lubrication Schedule of Metal-working Machinery

The lubrication schedule for the metal-working machinery at PAPFS appears to be based on a fixed interval rather than the actual condition of the equipment. While this approach ensures that lubrication is performed regularly, it may not always be the most effective method.

One potential issue with a fixed-interval lubrication schedule is that it may not account for variations in equipment usage. Machinery that is used more frequently or under harsher conditions may require more frequent lubrication, while equipment that is used less often may not need lubrication as frequently. Without monitoring the condition of the lubricants and the equipment, there is a risk of over-lubrication or under-lubrication, both of which can lead to equipment failure.

Over-lubrication can cause problems such as seal failure, increased operating temperatures, and contamination of the workspace with excess lubricant. On the other hand, under-lubrication can lead to increased friction, wear, and ultimately, equipment failure. Both scenarios can result in costly repairs, downtime, and safety hazards.

To improve the effectiveness of the lubrication schedule, PAPFS should consider implementing a condition-based lubrication program. This approach involves regularly monitoring the condition of the lubricants and the equipment, using techniques such as oil analysis, vibration analysis, and thermal imaging. By tracking the actual condition of the equipment, the organization can determine the optimal time to perform lubrication, ensuring that machinery operates smoothly and efficiently.

Task 6: Hazards of Working in Confined Spaces

The work involving access to the trench within the roadways between buildings at PAPFS presents several hazards that need to be addressed. The trench is a confined space, which means it is an area that is not designed for continuous occupancy and has limited means of entry and exit. Working in confined spaces poses significant risks, including exposure to hazardous substances, asphyxiation, entrapment, and difficulties in emergency evacuation.

One of the primary hazards of working in a confined space like the trench is the potential presence of hazardous gases, vapors, or fumes. The trench may contain substances such as methane or carbon dioxide, which can displace oxygen and lead to asphyxiation. Additionally, the use of chemicals in the trench, such as solvents or adhesives, can create toxic fumes that are harmful to workers.

Another hazard is the risk of entrapment due to the narrow and enclosed nature of the trench. Workers may become trapped if the walls of the trench collapse or if equipment or materials shift unexpectedly. The limited means of entry and exit also make it difficult for workers to escape in an emergency, increasing the risk of injury or death.

To address these hazards, PAPFS should implement a comprehensive confined space entry program that includes the following elements:

1. Hazard Assessment: Before any work begins, a thorough assessment of the trench should be conducted to identify potential hazards, including the presence of hazardous gases, the structural integrity of the trench, and the availability of safe entry and exit points.

2. Ventilation: If hazardous gases or fumes are detected, the trench should be properly ventilated to ensure that the air quality is safe for workers. This may involve the use of mechanical ventilation systems or the introduction of fresh air through natural means.

3. Permit System: A permit-to-work system should be established for all confined space entries. This system ensures that all necessary precautions are taken before workers enter the trench, including the use of appropriate personal protective equipment (PPE) and the presence of a standby person to monitor the work and initiate rescue procedures if necessary.

4. Emergency Procedures: Clear emergency procedures should be established and communicated to all workers involved in the trench work. These procedures should include instructions for evacuating the trench in the event of an emergency, as well as the use of rescue equipment such as harnesses, lifelines, and breathing apparatus.

5. Training: All workers involved in confined space work should receive specialized training on the hazards associated with confined spaces, the use of PPE, and emergency procedures. Regular drills should be conducted to ensure that workers are prepared to respond effectively in the event of an emergency.

Task 7: Emergency Planning

Emergency planning at PAPFS is a critical aspect of ensuring the safety of workers and minimizing the impact of accidents or incidents. Given the variety of hazards present in the workshops and studios, a comprehensive emergency plan is essential.

The plan should include clear procedures for responding to different types of emergencies, such as fires, chemical spills, explosions, and equipment failures. These procedures should be communicated to all workers and regularly reviewed and updated to reflect any changes in the working environment or the introduction of new hazards.

One key element of the emergency plan is the establishment of an emergency response team, consisting of trained personnel who are responsible for coordinating the response to emergencies. This team should be equipped with the necessary tools and equipment to carry out their duties, such as fire extinguishers, first aid kits, and communication devices.

Regular drills should be conducted to test the effectiveness of the emergency plan and to ensure that all workers are familiar with the procedures. These drills should simulate different types of emergencies and should be evaluated to identify any areas for improvement.

In addition to the emergency response team, PAPFS should also establish clear lines of communication with local emergency services, such as the fire department and ambulance service. This ensures that external responders are aware of the specific hazards present at the site and can respond quickly and effectively in the event of an emergency.

Task 8: Working at Height

Working at height, such as on the mobile tower scaffold in the filming studio at PAPFS, presents several risks that need to be carefully managed. The primary hazard associated with working at height is the risk of falls, which can result in serious injury or death.

To mitigate this risk, several safety measures should be implemented. Firstly, the mobile tower scaffold should be properly assembled and inspected before use to ensure that it is stable and secure. The scaffold should be equipped with guardrails, toe boards, and other fall protection systems to prevent workers from falling off the platform.

Secondly, workers should be trained in the safe use of the scaffold, including how to properly ascend and descend the structure, how to secure tools and materials, and how to recognize and respond to potential hazards.

Thirdly, a risk assessment should be conducted before any work at height begins. This assessment should identify potential hazards, such as unstable surfaces or overhead obstacles, and should determine the appropriate control measures to mitigate these risks.

Finally, all workers involved in working at height should be provided with personal fall protection equipment, such as harnesses and lanyards. This equipment should be regularly inspected and maintained to ensure that it is in good condition and capable of providing effective protection in the event of a fall.

Conclusion

The health and safety issues at Pointed Arrow Production and Film Studios (PAPFS) are significant and require immediate attention. The current working environment is fraught with hazards, ranging from poorly maintained equipment and inadequate lighting to unsafe practices and a lack of proper training. To address these issues, PAPFS must implement a comprehensive safety management system that includes regular maintenance, proper training, effective emergency planning, and strict adherence to safety protocols. By doing so, the organization can create a safer working environment for all employees and reduce the risk of accidents and injuries.