Date of Issue 22/12/2015

Version 01
MECHANICAL RISK MANAGEMENT [Link] 1 de 14
Controlled Document
Elaboration: Jairo Gamez Review: Adriana Urquijo Approved: Fecha de Actualizacion:
HSE Coordinator HSEQ Advisor

JUSTIFICATION
The machine operators and other workers in the companies daily face the risk of suffering
mechanical accidents, that is, whenever a production process is in operation that
involve moving machinery or hand tools, an unexpected event may occur that
I finished violating the integrity of the personnel.
In our country, one in five work accidents is related to machines or the use of
tools. Many times, people who work suffer injuries and mutilations to their bodies and
they may even lose their lives due to work interactions with their machines or equipment. It is estimated
that 75% of accidents with machines could be avoided with safety guards, these being one of the
risk control methods.
Often, safety elements exist but are poorly designed or made from inappropriate materials.
inadequate or do not undergo the necessary inspections and periodic controls. At other times, they hinder the
the execution of the work and even pose a risk in themselves.
But without a doubt, the greatest cause of these workplace accidents is the human element and its factors.
behaviors that violate and omit the rules and preventive measures for the control of these risks.
According to accident statistics conducted by the Labor Risk Administrator Colmena Seguros
In small and medium-sized enterprises, taking a sample of 36 companies as the object of study, it was found
that 78% of accidents are due to the mechanical risk factor, mainly due to entrapment
also representing 79% of the total days of incapacity of the studied working population. With
Based on this data, there is a need to design and implement a program whose purpose is to
identification, measurement and determination of controls for the mechanical risk present in the development of the
operations that the company SERVICIOS Y SUMINISTROS DE INGENIERIA LTDA currently executes.

GENERAL OBJECTIVE
Promote and implement a management program to improve the health and well-being conditions of the
workers and prevent property damage, creating a culture of self-care in prevention
accidents generated in the use of equipment, tools, and transportation equipment.

SPECIFIC OBJECTIVES

Establish a methodology for the identification, evaluation, prevention, and control of mechanical risk.
derived from the use of equipment, tools, and transportation equipment.
2. Develop an intervention plan in the source, environment, and man, to reduce the likelihood of occurrence.
of mechanical accidents, property damage or environmental damage.
3. Verify the impact level of the current program on the safety of the working population or the damage.
al ambiente, que pudieran afectar la sostenibilidad de la empresa.
4. Update the current mechanical risk prevention program to ensure its continuous improvement.

SCOPE
 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 2 of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo Approved: Update Date:
HSE Coordinator HSEQ Advisor

The present risk management program is applicable to the mechanical risk conditions listed in the
hazard identification matrix, risk assessment and establishment of controls for the company SYS
ENGINEERING LTD.
NORMATIVITY
RESOLUTION 2400 OF 1979: By which some provisions on housing, hygiene and
safety in the workplaces.
NFPA 70: Standard for the Installation of Electrical Wiring and Equipment.
COLOMBIAN TECHNICAL GUIDE 45: Guide for identifying hazards and assessing risks in
occupational safety and health.
DECREE 1072 OF 2015: Through which the Single Regulatory Decree of the Labor Sector is issued.

DESCRIPTION OF MECHANICAL RISK

The mechanical risk is associated with any machine, device, instrument, or installation used in the
work. In
This program will describe the risks derived from working with tools and machines or equipment.
work.
Risks associated with working with tools:
Although there is a wide variety of different tools, we can basically distinguish two types of
tools: manual and motorized.
Hand tools are the oldest working instruments and are so familiar to us that
we do not think they can be dangerous. However, they cause many accidents. The main risks
associated with the use of manual tools are:
Cuts and bruises caused on the hands by the tools themselves.
Eye injuries caused by particles from the objects being worked on.
Hits in different parts of the body due to the dismissal of the tools themselves.
Sprains from overexertion or violent gestures.
Indirect electrical contacts.
The main risk factors that contribute to the occurrence of accidents are:
-use in tasks for which they are not designed;
use of tools with inadequate features for the operation: for example too small or
big.
dangerous operations directed towards a part of the body; maintenance inadequate of the
tool. -
inadequate transportation or storage.
Portable motor tools are tools that require a power source to operate.
electric, pneumatic or thermal. These tools perform rotational or translational movements and
percussion. The main risks involved are:
-due to contact with the moving parts of the machine;
due to the power supply (electrocution, breakages or leaks of compressed air, etc.);
by projections of particles from the machine itself or from the material being worked on.
Risks arising from working with machines
 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 3 out of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo Approved Date of Update:
HSE Coordinator HSEQ Advisor

The work with machines leads to a series of risks that, if they materialize, cause injuries and/or
mutilations in the human body and even can cause death. The most common risks of the job
with machinery are:
-by contact with the moving parts of the machine:
-for projections of objects ejected during the operation of the machine: either parts of the machine itself
machine or parts of the material being worked on.
The most common injuries resulting from working with machines are therefore: crush injuries,
shearing, cutting or sectioning, dragging, impact, punching, friction or abrasion, and projection of
materials.
But in addition, working with machinery involves a number of other health risks for the people who operate them.
they manipulate or are located in the place of the machines, these are:
Electrical risk: it can cause injuries from electric shock or burns and can be caused by
direct or indirect electrical contacts, electrostatic phenomena or thermal phenomena derived from
short circuits or overloads.
Explosion risk: whenever the equipment uses a power source provided by fuels
flammable or deflagrating substances pose a risk of explosion; also if energy is given in the process
from activation coming from pressurized gases.
Thermal risk: it can cause burns from contact with objects or materials at extreme temperatures.
or by radiation coming from heat sources.
Electromagnetic radiations: they manifest in the form of radiations (visible, UV, IR, etc.) with damage
potential to the organs of vision or the skin.
-Noise: All equipment must emit below 80 dB (A) and 135 dB (C). Even so, concentration and
the simultaneous operation of several machines can produce noise levels well above those
values. Repeated exposure to high noise levels can lead to the disease known as
professional hearing loss or deafness; it can also cause accidents due to masking of signals
acoustics or by reducing the level of concentration and attention required.
Vibrations: a risk that accompanies noise, but in this case the transmission of energy or wave of
variable intensity does so through a solid medium. Often it is due to a lack of
maintenance or adjustment of the equipment parts.
Ergonomic risk: it can materialize in musculoskeletal injuries due to inadequate design of
checkpoint, repetitive movements, forced or maintained postures, screen or display control,
monotony, etc.

MECHANICAL ACCIDENTS: THEIR CAUSES AND HOW TO PREVENT THEM.

As a result of the investigation into the causes of mechanical accidents, it has been possible to
establish those with the greatest impact among which are:
Machines
What is the risk?
Work accidents with machines can be due to contact or entrapment in moving parts and by
hits with machine elements or with objects ejected during operation of the
Same. Hence, the injuries are mainly due to one of these reasons: crushing,
shearing, cutting or sectioning, dragging impact, piercing, friction or abrasion and projection of
materials.
Where is the risk?
 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 4 out of 14
Controlled Document
Elaboration: Jairo Gamez Review: Adriana Urquijo Approved Update Date:
HSE Coordinator HSEQ Advisor

1. In the moving parts of the machine. Upon coming into contact with the moving parts of the machine, the person
can be hit or trapped.
 Date of Issue 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT [Link] 5 of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo I approve: Update Date:
HSE Coordinator HSEQ Advisor

2. In the materials used.

Another danger arises from the material processed in the machine, either by contact with it or because the material
makes contact with the moving part of the machine. For example: a bar that rotates in a lathe, a
metal plate in a press.
3. In the projection.
Projection of parts of the machine itself, such as a loom shuttle, broken piece in a press, the
burst of an abrasive tooth, etc. The projection can also be of parts of the material on which it
is working.
Risk prevention
It is usually distinguished between measures integrated into the machine and measures not integrated into the machine.
integrated prevention includes all safety techniques applied in the design and construction of the
machine. Non-integrated prevention refers to personal protection, training, work methods
and the company's rules and the maintenance of the machines.
Among the various options for enhancing safety in machines, we have:
Intrinsic prevention: refers to the design of the machine, arrangement, and assembly of its
elements so that they do not pose a risk in themselves (dimensioning of the parts
mechanics, circuit design in which failure is not possible, removal of protrusions and edges
cutters, isolation of dangerous transmission mechanisms, etc.)
Protection techniques: when risks persist after the above, they can be incorporated.
security elements, such as:
a) safeguards: serve as a barrier to prevent contact of the body with
the dangerous part of the machine;
b) presence detectors: stop the machine before it occurs
the contact of the person with the danger point;
c) protective devices: require keeping parts of the body with possible risk out of the area of
danger.
 Date of Issue 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT [Link] 6 of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo Approved: Date of Update:
HSE Coordinator HSEQ Advisor

Protection techniques in machines

1. Safeguards:
Fixed: they are the safest and should be installed whenever possible. They serve as a barrier to
prevent contact of any part of the body with the dangerous part of the machine. They must be
consistent and firmly attached to the machine. The need for access to the protected part,
For lubrication, cleaning, etc., it should be minimized.
Mobile guard: it is mechanically associated with the machine frame via hinges or guides.
of sliding; it can be opened without using tools.
Distance guards: they are fixed safeguards that do not cover the entire danger zone, but they are placed
outside the normal range. They are used when it is necessary to manually feed the machine.
Of interlocking: it is a mobile safeguard connected through an interlocking device to the
demand mechanisms of the machine in such a way that it cannot operate unless the
safeguard is closed and locked.
Body guards and safety barriers: they are used to prevent access to the machine in operation,
but access is necessary to feed or extract the piece. The hand separation device
it is considered an insecure system, as any failure in the scanning system would not stop the
machine.
Safeguards associated with command: they meet the following conditions:
The machine does not operate with the guard open, closing the guard initiates the operation and if
It opens when the dangerous parts are in motion, it stops.
Adjustable and self-adjusting guards: they are fixed guards that incorporate an adjustable element.
the self-regulating that partially acts as a protective element. It usually protects the
cutting area that remains exposed in a specific operation. The fact that the piece acts
partially as a protective element makes it necessary to use at the end of the operation
another pushing element as a complementary safety element.
2. Presence detectors:
Eliminate or reduce the risk before the danger point can be reached, stopping the machine or its
dangerous elements and, if necessary, reversing the movement. They can be mechanical, photoelectric,
ultrasonic, capacitive and pressure-sensitive.
3. Devices:
Two-handed demand: it is used mainly in presses, shears, guillotines, etc., where there is a risk of
entrapment. With both hands occupied on the controls, they necessarily find themselves outside.
from the danger zone. It must be ensured that the machine will only operate with both controls and that
éstos no pueden ser accionados con una sola mano.
Of residual movement or inertia: devices associated with a locking safeguard
they are designed to prevent access to the dangerous parts of the machine that, due to their inertia
they remain in motion. The device can be a timer, a rotation detector, or a
brake.
Mechanical retention: for hydraulic or pneumatic machines with risk of entrapment. It is a
separation element (shim, pivot, tile, etc.) that is located between the molds when they are
in maximum separation position or in the guides of the moving parts. For machine work
stop.
Regarding feeding and extraction: it is about ensuring that the worker cannot insert their hands into the area.
peligrosa durante estas operaciones. La alimentación se puede hacer de forma automática o
 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 7 out of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo Approved: Fecha de Actualizacion:
HSE Coordinator HSEQ Advisor

semiautomatic by channel, piston, sliding matrices, etc. The extraction can be carried out
through various methods of expelling the piece.
Warnings: technical instructions for transportation, storage, installation, assembly,
commissioning, maintenance, etc., as well as markers to indicate hazard points and signals of
visual, luminous, or audible warnings.
Supplementary provisions: these are emergency stop devices, rescue devices.
of people and instructions on how to remove the power source or block dangerous parts and
fluid pressure verification, electrical tension, etc.
Something more than protection
The protective elements are just one of the conditions to make a machine safe. It is also
important:
1. The participation of workers in the election and design of protective elements
suitable for their needs.
2. Observe if the work process can be changed to eliminate the most dangerous machines (e.g.
automatic feeding.
3. Ensure the necessary training and education, especially for new workers.
4. Proper maintenance. The safety elements of the most dangerous machines must be checked.
Every day recording the result of the inspection.
5. Correct signage of safety devices and easy access to emergency stop devices.
6. Ensure that the protection extends not only to the operator but also to anyone located in the area.
influence.
7. Ensure that the controls are designed and placed in such a way that their operation is only possible
intentionally.
If you work with machines
Make sure...
What you know to stop the machine before using it.
That the fixed guards are installed correctly and are functioning.
That the materials used do not hinder the movements of the
machine.
That the work area around the machine is clear, clean, and free of obstacles.
That the person in charge is aware when a machine is not functioning correctly.
You have the necessary personal protective equipment.

Never...
Use a machine while you are not authorized and trained to do so.
Clean a machine while it is running, stop it and disconnect it.
Use a machine or tool that has a danger sign or card placed on it. This type of
Only the authorized person should remove the signs.
You wear hanging chains, unbuttoned clothes, gloves, rings, or long loose hair that can
get tangled in the moving parts.
Distract the person who is operating a machine.
Tools
Hand tools
 Issue Date December 22, 2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 8 of 14
Controlled Document
I elaborate: Jairo Gamez Review: Adriana Urquijo Approved: Fecha de Actualizacion:
HSE Coordinator HSEQ Advisor

They are the oldest working tools and are so familiar to us that we do not think they could be
dangerous. However, they cause many accidents. Main risks:
Use in tasks for which they are not designed, e.g.: using a screwdriver as a lever or
chisel.
Use of inadequate feature tools for operation, e.g.: chisel too small
Oh, too big a key.
Dangerous operations aimed at a part of the body, e.g.: holding the piece in the palm of the hand
while it is unscrewed or cut.
Inadequate maintenance of the tool, e.g.: unsharpened cutting area, dull file, head
of deformed chisel, etc.
Lack of training and education in its proper use.
Improper transport, e.g.: carrying tools in the pocket.
Storage anywhere, instead of using cases, boxes, or specific supports.
Safe work with hand tools is, like in other activities, a mix of common sense,
safe procedures and smart observation. Some golden rules for working with tools
manuals are:
The tool must be made with the most suitable material and quality for its use, they must be
in smooth shapes without edges or sharp angles.
Use the right tool for each type of job.
Avoid tools that may produce sparks in environments with flammable materials or
explosives.
Keep the tools in good condition, inspect them periodically and repair or replace them.
when necessary.
Store and organize the tools safely and neatly (panels, shelves, cabinets or
boxes).
Use the necessary personal protective equipment.
Safety conditions
Hammers:
Head and handle well secured.
good terms of use
Keys:
fixed keys whenever possible
do not put a tube to extend the handle
do not hit at the end of the handle
use appropriately sized keys
do not fill the gap between the key and the screw with another piece or material
Chisels:
do not use chisels with a deformed head
chisel in the opposite direction to the body
keep the haircut in good condition
use eye protection
Screwdrivers:
do not give them any use other than their own
 Fecha de Emisiòn 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT [Link] 9 out of 14
Controlled Document
Elaborate: Jairo Gamez Review: Adriana Urquijo Approve: Update Date:
HSE Coordinator HSEQ Advisor

piece held on a firm support, never in the other hand

Appropriate size for each operation.
Limes:
never use a file without a handle and make sure it is securely held
do not use it for other purposes: lever
keep it clean and in good condition
Knives:
mango and leaf firmly held
for work with greasy materials, incorporate a guard between the handle and the blade
store them in special supports or protect the edge
Ladder stairs:
do not use ladders if the job involves carrying your hands occupied
The stairs must be sturdy with the necessary support and fastening elements.
They should not be used as walkways or for the transportation of materials; ladders should not be used.
Portable power tools
They are tools that require an input of electrical, pneumatic, or thermal energy to operate.
rotational or translational movements and percussion. Their use is becoming increasingly widespread, as they provide
greater efficiency and speed in task execution and save effort. The main risks are:
By contact with the machine.
Due to the power supply (electrocution, breaks or leaks of compressed air, etc.)
By particle projections (eye injuries).
Risks and prevention
Circular saws:
Risks:
saw blade blockage and possible sudden machine backlash
removal of the machine from the cutting point
transfer of the tool
Prevention:
protection of the saw blade with a movable casing
divider knife to complete safety
Drills:
Risks:
oculars by projection of materials
falls from working at height and without a firm base
of fastening
Prevention:
use the appropriate drill bit in size and cut
pressure on the machine suitable for the resistance
of the material to be drilled
Use safety glasses.
Risks arising from working with tools
Although there is a wide variety of different tools, we can basically distinguish two types of
tools: manual and motorized.
The main risks associated with the use of hand tools are:
 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 10 out of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo I approve: Update Date:
HSE Coordinator HSEQ Advisor

Blows and cuts caused on the hands by the tools themselves.

Ocular injuries from particles generated by the objects being worked on.
Injuries in different parts of the body due to the dismissal of one's own tools.
Sprains due to exertion or violent gestures.
Indirect electrical contacts.

The main risk factors that encourage accidents to occur are:

use in tasks for which they are not designed;

use of tools with inadequate features for the operation: for example, too small or
big
dangerous operations aimed at a part of the body; maintenance inadequate of the
tool
inadequate transport or storage.

Portable powered tools are tools that require an energy source to operate.
electric, pneumatic or thermal. These tools perform rotational or translational movements and
percussion. The main risks involved are:

-by contact with the moving parts of the machine;

by the power supply (electrocution, breaks or air leaks, etc.);
by particle projections from the machine itself or from the material being worked on.

Safe tools

Tools, whether manual or mechanical, must:

Be made with durable materials;

The union between its elements must be firm, so as to avoid breakage or projections.
the same ones;
Their handles or grips should be of appropriate dimensions and of an ergonomic design;
To be of smooth shapes, without sharp edges, or corners, or cutting angles;
Without slippery surfaces;
Insulators if necessary;
They must have the mark.

Some power tools require protective devices: for example, grinders, saws.
circular saws or staplers and nail guns

Risks arising from working with machines

The work with machines leads to a series of risks that, if materialized, result in injuries and/or
mutilations on the human body and can even lead to death. The most common risks of the work
with machinery are:
 Date of Issue 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT [Link] 11 out of 14
Controlled Document
Elaboration: Jairo Gamez Review: Adriana Urquijo Approved: Update Date:
HSE Coordinator HSEQ Advisor

by contact with the moving parts of the machine:

for projections of objects thrown during the operation of the machine: either parts of the machine itself
machine or parts of the material being worked on.

The most common injuries resulting from working with machines are therefore: crush injuries, shearing,
cutting or sectioning, dragging, impact, punching, friction or abrasion and projection of materials.

But furthermore, working with machinery involves a series of other health risks for the people who use them.
they manipulate or are found in the place of the machines, these are:

Electrical risk: it can cause injuries from electric shock or burns and can be caused by
direct or indirect electrical contacts, electrostatic phenomena or thermal phenomena derived from
short circuits or overloads.

Explosion risk: whenever the equipment uses a driving energy provided by fuels
flammable or deflagrating substances pose a risk of explosion; also if energy is involved in the process.
from activation coming from pressurized gases.

Thermal risk: it can lead to burns from contact with objects or materials at extreme temperatures.
or by radiation from heat sources.

Electromagnetic radiation: it manifests in the form of radiations (visible, UV, IR, etc.) that cause damage.
potential to the organs of vision or the skin.

Noise: All equipment must emit below 80 dB (A) and 135 dB (C). Even so, concentration and
the simultaneous operation of several machines can produce noise levels well above those
values. Repeated exposure to high noise levels can lead to the disease known as
hearing loss or occupational deafness; it can also cause accidents due to masking of signals
acoustic or by reducing the level of concentration and attention required.

Vibrations: risk that accompanies noise, but in this case the transmission of energy or wave of
variable intensity occurs through a solid medium. Often, it is due to a lack of
maintenance or adjustment of the equipment parts.

-Ergonomic risk: it can manifest in musculoskeletal injuries due to inadequate design of the
checkpoint, repetitive movements, forced or maintained postures, screen or display control,
monotony, etc.
WARNING signs: define dangerous areas where there is an associated risk.
 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 12 out of 14
Controlled Document
Elaborated by: Jairo Gamez Revised: Adriana Urquijo Approved: Update Date:
HSE Coordinator HSEQ Advisor

CHARACTERIZATION OF ROAD RISK IN THE COMPANY

COMPANY DESCRIPTION
NAME ENGINEERING SERVICES AND SUPPLIES LTD.
NIT: 900365289-2
LOCATION LA LOMA CESAR DISTRICT
LEVEL OF RISK the V
A.R.L COLMENA INSURANCE
Number of workers 10
EQUIPMENT MACHINES AND TOOLS

NUMBER OF ACCIDENTS DUE TO MECHANICAL RISK

RESPONSIBLE

MANAGEMENT.
Assume the utmost responsibility for the execution of this mechanical risk prevention program,
asignando los recursos físicos, técnicos y humanos.
Comply with preventive maintenance and safety inspections of machines and equipment according to the
planned times.
Allow suitable spaces to carry out the training and other established training sessions.
activities of the current program.
Motivate the working population to participate in the current program.
HSE COORDINATOR AND ASSISTANT.
To inform all employees, whether direct or subcontracted by the company, about the current management program.
Define the timing of activities and ensure their execution.
Comply with the activity schedule of the current program and monitor it periodically.
Ensure that preventive maintenance and safety inspections are carried out.
Update the current program to ensure its continuous improvement.
WORKERS.
Meet the demands of the current management program.

STRATEGIES FOR PROGRAM DEVELOPMENT

 Date of Issue December 22, 2015
Version 01
MECHANICAL RISK MANAGEMENT [Link] 13 out of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo Approved: Fecha de Actualizacion:
HSE Coordinator HSEQ Advisor

1. Identify and assess the inherent mechanical risk in production processes.

The first phase of the program seeks to characterize the mechanical risk present in all processes of the
organization (from planning to production), which together put into function the reason of
his lord.
In the implementation of the organization's vision-mission, a series of elements come into interaction.
related to each other, to carry out the proposed objectives and goals that allow them to acquire solidity and
sustainability in the market.
Within those elements we can identify:
Element man, who is responsible for strategic planning.
Resource element that ensures the execution of projects and the solvency of needs that
presented within the defined deadlines.
Element Machines and tools, Assistants of man for the materialization of what
programmed ensuring its quality, effectiveness, and efficiency.
Space element, which allows interaction between the aforementioned elements.
In the organization, mechanical risk and its degree of impact can vary due to the following conditions
The degree of exposure to risk.
Type of work to be carried out.
The type and use of the machines, equipment, and tools used in each activity.
The conditions and distribution of the workplace.
The knowledge and skills of the workers.
The barriers or preventive measures against risk, whether established at the source, medium or
individual.
The activities to be carried out in this first phase to allow for the identification and measurement of mechanical risk.
son
Define the nature of positions, specifying functions and responsibilities, and thus recognize in a formal manner.
more specific about where the mechanical risk is present.
Detail the step-by-step of each task or activity of each position, identifying the tools.
machines, equipment, supplies and personal protective equipment used for the execution of these;
Once the information is collected, a risk assessment is conducted along with its degree of impact.
Inventory of mechanical risk in each position, based on the step-by-step process of each task; the
The instrument used for measuring mechanical risk will be the IPEVAR Matrix GTC 45 methodology.
from Colombia.
Inventory of machines, equipment, and tools used for the development of the activities, is
It will take into account its condition, complexity, criticality, and the manufacturer's recommendations.
2. Prevention and control measures for mechanical risk.
Once the identification and measurement of mechanical risk has been carried out, the next step is the intervention of the risk.
from prevention and control as a first measure.
The preventive management process against mechanical risk basically consists of:
Acquisition of equipment, after the needs assessment, that meet security guarantees in their
design (marked).
Hazard identification and risk assessment.
Design of preventive measures.
Elimination and control of risk.
 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 14 out of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo Approved: Date of Update:
HSE Coordinator HSEQ Advisor

When developing preventive actions against mechanical risk, a distinction is usually made between prevention.
integrated into the machine or not integrated. Integrated prevention includes all safety techniques
applied in the design and construction of the machine or work equipment. Non-integrated prevention refers to
to personal protection, training, work methods, and behavior standards in places
of work. Therefore, the preventive actions against mechanical risk in the company must
to be carried out before the damage occurs and should focus on:
Safe conception of all the mechanisms of the equipment.
Protection and safeguarding of the moving parts of the equipment and against projections.
Clear work area and maintenance of safety distances.
Training and information for the people operating the machine or tool.

BASIC PREVENTIVE MEASURES AGAINST MECHANICAL RISK

GENERAL ORGANIZATION
Distribution of the spaces.
The distribution of spaces becomes especially important when working with teams.
In the case of machines, for example, it is essential to have a complete view of the various pathways.
and machine actions.
The crowding of workers around a machine can cause involuntary activations and
accidents, which is why it is important to establish safety distances when approaching danger zones.

Safe machines
To ensure that machines are safe, the best option is intrinsic prevention, that is, the design of the
machine, arrangement and assembly of its elements so that they do not pose a risk themselves.
When acquiring, evaluating, or simply before using a piece of equipment, there are a series of aspects to consider.
to consider from a legal and regulatory standpoint, and that is that each machine must have:
If possible, have the Instruction Manual in Spanish.
Marked
Minimal elements of intrinsic safety in machines:

The drive organs must be clearly visible and identifiable and be indicated with
proper signage (color coding, pictograms, etc.).
The drive mechanisms must be located in such a way that they are outside the areas
dangerous of the machine.
The drive components must be designed in such a way that they cannot be activated accidentally.
or involuntarily.
The deployment of a work team can only be carried out through an action.
voluntary on a drive organ provided for this purpose.
Each work team must be provided with a driving mechanism that allows it to stop.
total in safety conditions. The stop order of the work team will take priority over
the start-up orders.
If necessary, based on the risks of the work team and the normal downtime, said
The equipment must be equipped with an emergency stop device.
 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 15 out of 14
Controlled Document
Elaboration: Jairo Gamez Review: Adriana Urquijo Approved: Update Date:
HSE Coordinator HSEQ Advisor

Power supply system

Every work team must be equipped with clearly identifiable devices that allow
separate it from each of its energy sources.
Work teams must be able to clearly and easily disconnect from their power source.
quick, in this way in case of an accident it is possible to prevent the energy supply from enhancing the effect
from the damage.

Regarding the electrical installation for each equipment, it must have:

Power supply disconnection device.
Cut-off device against sudden starts.
Overcurrent protection device.
Protection against direct electric contacts.
Protection against indirect electrical contacts.
Double insulation.
Grounding and residual current circuit breaker.

Maintenance
Proper maintenance of machines and tools is in itself a means of prevention.
In the case of the machines, it is necessary to check, in addition to their proper functioning, that the elements of
safety is in good condition. The design of the machine or equipment must ensure its
maintenance. The distribution of spaces must also consider and respect a perimeter zone.
where maintenance staff can enter to repair the equipment. There must be a good
lighting that facilitates the distinction of details.

All equipment and machines must be included in a preventive maintenance program.

In the case of tools, they should be inspected periodically and repaired or replaced when necessary.
necessary.

MEANS OF PROTECTION

Collective protective elements

When it is not possible to have machinery or motor tools that have systems and designs
Intrinsic prevention elements must be incorporated into machines or motor tools.
security as:

Safeguards and barriers.

Machines must have guards and barriers to:
all its parts in motion,
-hot or what may to project solids, liquids, gases or vapors.

The safeguards must prevent access to the enclosed space by the safeguard and/or retain materials, pieces of
work, dust, fumes, gases, noise, etc. that the machine can project or emit, in addition to demands
particular aspects related to electricity, vibrations, visibility, etc.
 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 16 out of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo Approved: Last Updated:
HSE Coordinator HSEQ Advisor

The safeguards must to be of material solid y resistant of manner what:

prevent their breakage due to physical impacts,
it prevents the penetration of the upper limbs of the person manipulating them,
cannot be deliberately manipulated,
do not pose an additional risk to those inherent to the machine and
safeguard the integrity of the worker or student operating the machine, but also of the people
that occur in the vicinity of the team.

Protection devices
The protective devices must:
Be of strong and resistant construction.
To be located a minimum distance from the dangerous area known as the 'safety distance.'
Do not cause additional dangers.
They should not be easily reversible.

When selecting the appropriate protective equipment for each machine or power tool, it is necessary to
previously carry out the assessment of the risks corresponding to that work team.

Personal protective equipment.

PPE against mechanical risks are essentially designed to prevent abrasions, punctures, cuts and
impacts. PPE must be provided with usage and maintenance instructions, which must be followed.
by the user.

the most suitable individual protections:

Helmets: they should always be worn when there is a risk of head impact.
Safety glasses: They should be worn whenever mechanical starting work is being done.
from shavings (grinders, milling machines, lathes, etc.), in work with drills, in operations of
cutting materials with saws and welding.
Hearing protectors: There are various different models of plugs, headphones, and helmets. They should be
use in those operations that due to noise level or repetitiveness throughout the day may
cause discomfort or disturbances in hearing.
Gloves: the gloves must resist abrasion, blade cut resistance, tear resistance
and resistance to drilling. Additional requirements may include resistance to shearing.
impact and volumetric resistance.
Footwear: Protective footwear must be worn in all operations that involve risk of
blow from falling objects, entrapment, etc.
Trunk protection: Personnel exposed to welding work must wear protective clothing.
fireproof and leather aprons. It must also apply to personnel performing oxy-fuel cutting operations.
This protection aims to shield the user against small projections of molten metal.
and the short contact with a flame.

HYGIENIC AND CONDUCT STANDARDS

 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 17 of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo Approve: Update Date:
HSE Coordinator HSEQ Advisor

Among the minimum hygiene and conduct standards in the company, the following should be included:
A machine or tool should only be assigned to a person who knows it thoroughly.
functioning and its risks.
A machine or motorized tool should not operate without having the safety systems installed.
foreseen.
It must be monitored that the actual use corresponds to the planned work method (including the use of
protectors and personal protective equipment.
Strict rules on work attire should be established, evaluating them according to the machine.
concrete, in addition to:
Wearing tight clothes, especially at the cuffs and waist. or Not wearing 'hanging' garments like
ties, handkerchiefs, etc.
Wear hair short or tied up with a hairnet or cap. Or do not wear rings, bracelets, or similar adornments.

INFORMATION AND TRAINING

It is necessary to have the required information about the machinery, equipment, and tools with which one operates.
they work or practice, as well as on their possible risks, preventive measures, and methods of
insurance work.
The signage "warns" of the existence of a risk, but it does not eliminate or protect against it; however
his knowledge alerts to the possibility of the materialization of harm.
Sources and means of information
The main source of information about the machine or tool in question is its instruction manual.
This must be in Spanish and should indicate the following aspects:
Reminder of the instructions contained in the device's labeling, completed if applicable, by
instructions that facilitate maintenance (for example, the address of the importer, the
repairers...)
Indication of the intended conditions of use.
Instructions (including plans and diagrams, if necessary) to carry out the operations safely
or commissioning,
use, or maintenance,
transport (also indicating the mass of it or its parts), or installation, assembly and disassembly,
regulation, maintenance and if applicable the characteristics of the tools to be used,
learning instructions (complex equipment case).
If necessary, the instructions manual will warn about the contraindications of use.
Based on the above, the activities for the second phase of the program will be aimed at intervening the
source, the medium and the individual.
Intervention measures at the source:
List the equipment, machines, and tools of the organization and design for each of them their
resume, which includes acquisition date, brand, series, maintenance dates, etc.; this is
It will be done together with the preventive maintenance program.
Define and execute regulated time periods for the preventive maintenance of all
machines, equipment, and tools that are in operation.
 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 18 of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo I approve: Update Date:
HSE Coordinator HSEQ Advisor

Define and execute regulated time periods for conducting safety inspections for
each machine, equipment, and tool listed.
Design pre-operational diagnostic instruments for those machines, equipment, and tools.
which are considered critical and can negatively affect workers (understood as
as it criticizes that machine, equipment, or tool that by its design, capacity, and operation
requires additional non-integrated preventive measures
At SYS INGENIERIA, critical machines and equipment are considered:
Welding machines.
Oxy-fuel cutting equipment.
Polisher.
Drills.
Understood.
Design a safety manual for the use of tool and equipment insurance.
Maintain the manufacturer's manual for those critical equipment and machines.
In the event of the need for the acquisition of a new machine, equipment, or tool,
the recommendations described in section 2 of this program will be taken into account, and before
The risks will be assessed upon their inclusion in the operation and preventive measures will be established.
integrated to ensure that the risk is controlled.
If any of the machines or equipment used in the operation pose hazards either due to their design
or due to its condition, it will be determined whether it is possible to integrate devices, safeguards, or barriers.
protection or if it has reached the end of its useful life, replace it.

Measures of intervention in the environment.

Ensure the correct distribution of spaces and workstations so that there is distance.
required between the machine and man.
Include the lighting of the workplaces in the maintenance program.
Warn about mechanical risks in workplaces and job positions through signage.

Intervention Measures in the Individual.

Informing workers about mechanical risks and their dangers, prevention and control measures.
Identify the appropriate personal protective equipment for the development of each task and
provide them to the workers; teach them their use and maintenance.
Timely train workers on the importance of self-care and estimation.
of the body and its parts: sensitization to mechanical risk.
Design safe work procedures.

3. Measure the degree of mechanical risk management.

 Date of Issue 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT [Link] 19 of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo Approved: Date of Update:
HSE Coordinator HSEQ Advisor

As the third phase of the program, it is to understand the functioning of the Program, the real effects of the
control activities in the mechanical risk factor and serve as a basis for making the adjustments that
require
The evaluation will be carried out through the following indicators

INDICATOR FORMULA META

Number of activities executed/Number of activities
Compliance 90%
programmed x100
No. No workers who received the socialization of
programs exposed to mechanical risk
Coverage 100%
prioritized/Not Total number of workers exposed to
mechanical risk primarily.
Effectiveness of the system No. Accidents due to mechanical risk. 0

4. Implementation and Update of the program

As a final strategy, it is determined that the activities established in this program will be carried out at
starting from the year 2016, and quarterly follow-ups will be conducted to monitor the behavior of the
indicators and their trend analysis; and as evidence of continuous improvement, their general review will be carried out within
from the year following its execution.

ELABORATED REVIEWED APPROVED

Nombre y Cargo Nombre y Cargo Name and Position
Jairo Gámez Adriana Urquijo
CONTROL HSE Coordinator Industrial Engineer ESP.S.O DE
CHANGES

VERSION MODIFICATION DATE

01 Creation of the document 22/12/2015

 Issue Date 22/12/2015
Version 01
MECHANICAL RISK MANAGEMENT PROGRAM. Page 20 of 14
Controlled Document
Elaborated by: Jairo Gamez Review: Adriana Urquijo Approved: Update Date:
HSE Coord. HSEQ Advisor