Dr L Budeli
Manufacturing processes [Link]
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Lecturer information
Name : Lalamani Budeli
Position : Senior Lecturer IEOMME (Part-time)
Qualifications : B- Tech Degree Electrical Engineering (VUT), BSc Honours Eng Tech Manage (UP),
Master’s Engineering (NWU), Master in Business Administration-MBA (RBS) and PHD eng (NWU)
Work Experience: ArcelorMittal South Africa , CBI-Electric, Eskom
Director: BLIT , Mothapo management consulting and Toto Chemicals
Email: lalamanib@[Link]
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Introduction to the course
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Assessments
Assessment Test dates Scope
Semester Test 1 22 March 2026 Chapters 1, 2, 3, 4, 6 & 7
Semester Test 2 3 May 2026 Chapters 8, 9, 10, 11, 13 & 14
Practical TBA Chapter 6
Final Year Mark = 0.30(Test1) + 0.30(Test2) + 0.40(Prac)
Final Mark = 0.5 (Year Mark) + 0.5 (Exam)
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Dr L Budeli
Chapter 1 – Safe practices [Link]
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Safety workplace statistics
Globally, an estimated 2.78 to 3 million people die annually due to work-related accidents and diseases,
equating to over 7,500 daily fatalities. Of these, approximately 2.6 million deaths are attributed to work-
related diseases, and 330,000 to 395,000 deaths are caused by fatal accidents.
In SA, 198,000 workplace accidents and 22,000 occupational diseases contracted per annum, totaling
220,000 occupational incidents every year.
• High-Risk Sectors: Construction, agriculture, forestry, fishing, and manufacturing account for over 60%
of fatal injuries.
• Disease Prevalence: The top three causes of work-related death are circulatory diseases, malignant
neoplasms (cancers), and respiratory diseases.
• Regional Trends: In 2022, the U.S. reported 5,486 fatal workplace injuries.
• Gender Disparity: Men account for a higher proportion of fatal injuries, often exceeding 90% in certain
jurisdictions.
• Impact: Beyond the loss of life, these incidents cause immense, ongoing suffering for families, while
non-fatal injuries and illnesses total over 374 million annually
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Introduction
• Almost everyone working in a factory has at some stage in his or her career suffered an injury requiring
some kind of treatment or first aid.
• It may have been a cut finger or something more serious.
• The cause may have been carelessness by the victim or a colleague, defective safety equipment, not
using the safety equipment provided or inadequate protective clothing.
• Whatever the explanation given for the accident, the true cause was most likely a failure to think
ahead.
• You must learn to work safely.
• Your workplace will have its own safety rules so obey them at all times.
• Ask if you don’t understand any instruction and do report anything which seems dangerous, damaged
or fault
• The surface from which work at height can be carried out is referred to by the Regulations as a working
platform.
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Health and Safety at Work Act 1974 (HSWA)
• This Act of Parliament came into force in April 1975 and covers all people at work except domestic
servants in a private household. It is aimed at people and their activities, rather than at factories and
the processes carried out within them.
• The purpose of the Act is to provide a legal framework to encourage high standards of health and
safety at work.
Its aims are:
• To secure the health, safety and welfare of people at work;
• To protect other people against risks to health or safety arising from the activity of people at work;
• To control the keeping and use of dangerous substances and prevent people from unlawfully having or
using them;
• To control the emission into the atmosphere of noxious or offensive substances from premises
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Health and safety organisation
• The HSE’s mission is: ‘the prevention of death, injury and ill health to those at work and those affected by
work activities ’ .
• HSE’s aims are to protect the health, safety and welfare of people at work, and to safeguard others, mainly
members of the public, who may be exposed to risks from the way work is carried out.
HSE’s statutory functions include:
• Proposing new and updated laws and standards;
• Conducting research;
• Providing information and advice;
• Making adequate arrangements for the enforcement
of health and safety laws. The main purposes of guidance are to:
• Help people understand what the law says;
• Help people comply with the law;
• Give technical advice.
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Employer’s responsibilities
• Employers have a general duty under the HSWA ‘to ensure, so far as is reasonably practicable, the health,
safety and welfare at work of their employees ’ .
• The principle of ‘so far as is reasonably practicable’ applies to all the following areas and means that an
employer does not have to take measures to avoid or reduce the risk if they are technically impossible or if
the time, trouble or cost of the measures would be grossly disproportionate to the risk.
The HSWA specifies five areas that are covered by the employer’s general duty.
• Provide and maintain machinery, equipment and other plant, and systems of work that are safe and
without risk to health.
• Ensure ways in which particular articles and substances (e.g. machinery and chemicals) are used,
handled, stored and transported are safe and without risk to health.
• Provide information, instruction, training and supervision necessary to ensure health and safety at
work.
• Ensure any place under their control and where their employees work is kept in a safe condition and
does not pose a risk to health
• Ensure the health and safety of their employees ’ working environment (e.g. heating, lighting,
ventilation, etc.) 10
Safety Representatives and Safety Committees Regulation
Employers have a duty to consult on the following matters:
• The introduction of any measure at the workplace which may substantially affect the health and safety of
employees;
• Arrangements for getting competent people to help them comply with health and safety laws;
• The information they must give their employees on the risks and dangers arising from their work, measures to
reduce or eliminate these risks and what the employees should do if exposed to a risk;
• The planning and organisation of health and safety training;
• The health and safety consequences of introducing new technology.
The functions of an appointed safety representative include
• Investigating potential hazards and dangerous occurrences in the workplace;
• Investigating complaints relating to an employee’s health, safety or welfare at work;
• Making representations to the employer on matters affecting the health, safety or welfare of
employees at the workplace;
• Carrying out inspections of the workplace where there has been a change in conditions of work, or
there has been a notifiable accident
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Safety committees
The main objective of such a committee is to promote co-operation between employers and employees in setting
up, developing and carrying out measures to ensure the health and safety at work of the employees.
The committee can consider items such as:
• Statistics on accident records, ill health and sickness absence;
• Accident investigation and subsequent action;
• Inspection of the workplace by enforcing authorities, management or employee health and safety
representatives;
• Risk assessments;
• Health and safety training;
• Emergency procedures;
• Changes in the workplace affecting the health,safety and welfare of employees.
If the health and safety committee is discussing accidents, the aim is to stop them from happening
again, not to give blame.
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Committees and Employees ’ responsibilities
If the health and safety committee is discussing accidents, the aim is to stop them happening again, not to give
blame. Committees should:
• Look at the facts in an impartial way;
• Consider what precautions might be taken;
• Recommend appropriate action;
• Monitor progress of any action taken.
Under the HSWA it is the duty of every employee while at work:
• To take reasonable care for their own health and safety and that of others who may be affected by
what they do or don’t do.
• To co-operate with their employer on health and safety.
The six regulations are:
Management of Health and Safety at Work Regulations 1999; Provision and Use of Work Equipment, Regulations 1998;
Workplace (Health, Safety and Welfare) Regulations 1992; Personal Protective Equipment at Work Regulations 1992;
Health and Safety (Display Screen Equipment) Regulations 1992; Manual Handling Operations Regulations 1992.
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Working at Height Regulations 2005
Falls from height are one of the biggest causes of workplace fatalities and major injuries. Common causes are falls
from ladders and through fragile roofs. As part of the Regulation, the employer must ensure:
• All work at height is properly planned and organised;
• Those involved in work at height are competent (have had instruction and have sufficient skills, knowledge
and experience);
• The risks from work at height are assessed, and appropriate work equipment is selected and used;
• The risks from working on or near fragile surfaces are properly managed;
• The equipment used for work at height is properly inspected and maintained.
Before working at height the following simple steps should be considered:
• Avoid working at height where it is reasonably practicable to do so.
• Where work at height cannot be avoided, prevent falls using either an existing place of work that is
already safe or the right type of equipment.
• Minimise the distance and consequences of a fall by using the right type of equipment where the risk
cannot be eliminated.
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Safe use of ladders/stepladders
• Always position ladder on a firm level base which is clean and free from loose materials.
• Take all necessary precautions to avoid vehicles or people hitting the bottom of the ladder (protect the area
using suitable barriers or cones).
• Make sure the ladder is at 75° – use the one in four rule (i.e. one unit out for every four units up).
• Make sure the ladder is long enough for the task, at least 1 m (three rungs) above where you are
working.
• Always grip the ladder and face the rungs while climbing or descending.
• Maintain three points of contact while climbing and wherever possible at the work position (this
means a hand and two feet).
The employer also has duties to:
• Assess the risks and PPE intended to be issued and that it is suitable; maintain, clean and replace PPE;
• Provide storage for PPE when it is not being used; and ensure that PPE is properly used;
• Give training, information and instruction to employees on the use of PPE and how to look after it.
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Personal Protective Equipment at Work Regulations
PPE is defined as all equipment that is intended to be worn or held to protect against risk to health and safety.
This includes most types of protective clothing and equipment such as: eye protection, safety helmets, safety
footwear, gloves, highvisibility clothing and safety harness. It does not include hearing protection and most
respiratory equipment, which are covered by separate existing regulations.
• Eye protection - Serves as a guard against the hazards of impact, splashes from chemicals or molten
metal, liquid droplets (chemical mists and sprays), dust, gases and welding arcs. Eye protectors include
safety spectacles, eye shields, goggles, visors, welding filters, face shields and hoods.
• Head protection - Includes industrial safety helmets to protect against falling objects or impact with
fixed objects; industrial scalp protectors to protect against striking fixed obstacles, scalping or
entanglement and caps and hairnets to protect against scalping and entanglement.
• Feet and leg protection - Serve to guard against the hazards of electrostatic build-up, abrasion, wet,
slipping, cuts and punctures, falling objects, chemical and metal splash.
• Hand and arm protection - Gloves, gauntlets, mitts, wrist cuffs and armlets provide protection against a
range of hazards such as abrasion, temperature extremes, cuts and punctures, impact, chemicals,
electric shock, skin infection, disease or contamination
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The Reporting of Injuries
The employer must report incidents and keep appropriate records of:
• Work-related accidents which cause death;
• Work-related accidents which cause serious injuries (reportable injuries);
• Diagnosed cases of certain industrial diseases;
• Certain dangerous occurrences (incident with potential to cause harm).
Reportable occupational diseases are:
• Diagnosis of certain occupational diseases where these are likely to have been caused or made worse
by their work.
• Certain specified ‘near miss’ events, where something happens that does not result in an
injury, but could have done. These include:
• The collapse, overturning or failure of loadbearing parts of lifts and lifting equipment;
• Plant or equipment coming into contact with overhead power lines;
• Explosions or fires causing work to be stopped for more than 24 hours.
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Control of Noise at Work Regulations 2005
• Health surveillance - The Regulations are designed to protect against risks to both health and safety from
exposure to noise at work – the health risk of hearing damage to those exposed and safety risks such as noise
affecting the ability to hear instructions or warnings.
• Control of Vibration at Work Regulations 2005 - These Regulations are designed to protect persons
from the risk to their health and safety of the effects of exposure to vibration. There are two types of
vibration, hand–arm vibration (HAV) and whole-body vibration.
• Electrical hazards - Electrical equipment of some kind is used in every factory. Electricity should be
treated with respect – it cannot be seen or heard, but it can kill. The major hazards arising from the
use of electrical equipment are Electric shock, Electric burn, fire, arcing, and Explosion. These
precautions include: Double insulation, Earthing, Use of safe voltages.
• The Health and Safety (Safety Signs and Signals) Regulations 1996 - These Regulations cover various
means of communicating health and safety information.
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Causes of accidents
• Workplace accidents can be prevented – you only need commitment, common sense and to follow the safety
rules set out for your workplace.
• Safety doesn’t just happen – you have to make it happen.
• Most accidents are caused by carelessness, through failure to think ahead or as a result of fatigue.
Fatigue may be brought on by working long hours without sufficient periods of rest or even through
doing a second job in the evening.
• Serious injury and even death have resulted from horseplay, practical jokes or silly tricks. There is no
place for this type of behaviour in the workplace.
• Accidents can occur as a result of the workplace environment, e.g. poor ventilation, temperature too
high or too low, bad lighting, unsafe passages, doors, floors and dangers from falls and falling objects.
• They can also occur if the workplace, equipment and facilities are not maintained, are not clean and
rubbish and waste materials are not removed.
• Many accidents befall new workers in an organisation, especially the young, and are the result of
inexperience, lack of information, instruction, training or supervision all of which is the duty of the
employer to provide.
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General health and safety precautions
As already stated, you must adopt a positive attitude and approach to health and safety. Your training is an
important way of achieving competence and helps to convert information into healthy and safe working
practices. Remember to observe the following precautions:
Horseplay - work is not the place for horseplay, practical jokes, or silly tricks.
Hygiene - always wash your hands using suitable hand cleaners and warm water before meals, before
and after going to the toilet, and at the end of each shift. Dry your hands carefully on the clean towels or
driers provided.
Housekeeping - never throw rubbish on the floor. keep gangways and work area free of metal bars,
components. If oil or grease is spilled, wipe it up immediately or someone might slip and fall.
Moving about - Look out for and obey warning notices and safety signs.
Personal protective equipment - use all personal protective clothing and equipment, such as ear and eye
protectors, dust masks, overalls, gloves, safety shoes and safety helmets
Machinery - ensure you know how to stop a machine before you set it in motion
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General health and safety precautions (Cnt)
Harmful substances - before you use a substance find out what to do if it spills onto your hand
or clothes. Do not put liquids or substances into unlabelled or wrongly labelled bottles or containers.
Electricity - make sure you understand all instructions before using electrical equipment. Always switch off
or isolate before connecting or disconnecting any electrical equipment
Compressed air - never use compressed air to clean a machine it may blow in your face or someone else’s
and cause an injury.
Fire - take care when using flammable substances and know the location of fire extinguishers. Smoking -
smoking in public places and the workplace is dealt with as a public health matter in Great Britain and not
by the HSE.
First aid - have first aid treatment for every injury however trivial. know the first aid arrangements for your
workplace
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The End!!
If you have any questions, please email me at lalamanib@[Link]
I will answer all questions in detail, sending the answers to the entire class, but
nobody will know who asked the question!
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