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1. KOMORI
Safety Measures for Power Press
Mark (Masahiro) Komori
[email protected]
Komori Safety Device Lab. Co. Ltd.
1, Overview of press accident and measures in Japan
2, How to prevent press accident
3, Proposal to Malaysia

2. KOMORI
Masahiro Komori ( Nickname MARK), born 1950
Working for Komori Safety Device Laboratory Co., Ltd. As a Chairman
Public Service :
Chairman of Press Inspectors Association (JISHA)
Executive of Japan Forming Machinery Association
Executive of Press Safety Device Association
Lecturer for JISHA Press education and Others
Overseas experience
Short term Expert to Singapore National Productivity Board
Short term Expert to Singapore Ministry of Labor
Seminar at Singapore, Korea, Taiwan, and others
Technical corporation with Italy, Germany and U.S.A.
SELF INTRODUCTION

3. KOMORI
KOMORI SAFETY DEVICE LAB. CO., LTD.
Company Established 1955, Apr.
Started as Metal Stamping Factory
Changed to Safety Device Manufacturer from 1951
COMPANY OUTLINE
Supported in
3 basic business
1, Safety Device
Light Curtain, Barrier Guard,
Pull-out, Area Sensor etc.
Other Machinery Safety products
And Consulting Machine Safety System
2, Compulsory
Inspection
Safety Education
3, Other Accessories
Brake Stop Timer,Tonnage monitor,
Forming Analysis,
Production Engineering
URL : http://www.komorisafety.co.jp
e-mail : [email protected]
Singapore agent :
J V Engineering [phone]

4. KOMORI
1, Overview of press accident and measures in Japan
　　　　
13000
12000
11000
10000
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
4 2 4 3 44 4 5 4 5 4 7 48 4 9 5 0 5 1 5 2 5 3 54 5 5 5 6 5 7 5 8 5 9 60 6 1 62 6 3 H1 2 3 4 5 6 7 8
Phase 1: 1955 to 1971
Phase 2: 1972 to 1990
Phase 3; 1991 to Present situation
①
②
③
2010：559
12,000→7,000
7,000→4,000
3,000→559
7000
4000
12000
1972 1990

5. KOMORI
Phase 1 : 1955 to 1971
　　After WW2,
Every Press Machine must install Safety Device
Phase 2 : 1972 to 1990
　　Safety and Health Law established
Inherent Safety Measure
①Top Priority :No Hand in the Die
②Construction Code Press Machine and Safety Device
③Compulsory Inspection System established
Phase 3 : 1991 to 2010
　　 ①Adopt ISO standards
②Risk Assessment and OSHMS
③New regulation and construction code
Preventive　measures by Phase
12,000→7,000
7,000→4,000
3,000→559
2010 :559

6. KOMORI
1, Size of Company : Below 30 workers (70%)
2, Numbers of Presses : Below 30 Machines (90%)
3, Foot pedal or switch operation (80% of Full Revolution)
4, Size of Press Machine : Below 100 tons (80%)
5, Type of Clutch : Part Revolution 45%, Full Revolution 33%
Hydraulic 7%, Press Brake 7%
5, Increasing Fatal Accidents at Big scale Press Machine
6, Still insufficient Safety Device, Small Protective Height
7, Many Human Error Reasons
8, Standard Operation 80%, Tool and Die Operation 20%
　
Trend of Press Accident
Remark : Many Press Accidents Happens , following
Small and Medium size factory, Below 30 presses
equipped, Below 1000kN

7. KOMORI
Prevention of Dangers Due to a Press MachinePrevention of Dangers Due to a Press Machine
Ordinance Article 131Ordinance Article 131
TOP Priority : No Hand in the Die
All the operation must use Safety Enclosure,Guard
Safety Die (Die equipped with safety Guard)
Small stroke Press (Below 6 mm stroke length)
Automatic Feeding Press (with Safety Guard)
Second Priority : Hand in the Die with Safety System Press Machine
Safety Power Press Authorized M.H.L.W
Interlock Guard , Two Hand Push button, Light Curtain, PSDI,
Third Priority : Hand in the Die and Use Proper Safety Device
Interlock Guard, Two hand push switch, Light curtain, Pullout

8. KOMORI
Comprehensive Measures for Press Machine Accident
Prevention (Guideline 1998)
Main Points
(1) Promoting the safety of press machinery
(2) Full implementation of press machine safety devices etc.
(3) Effective measures in accordance with the situation at workplaces where
press machine is installed
Promoting Press Machine Safety
•Steps to secure the safety of press machine
•Appropriate selection and management of safety device
•Switching from foot-pedal to both-hand push button operation
•Improving the safety of press machine operation
•Using proper metal dies
•Securing safety at the manufacturing and installation stages

9. KOMORI
2, How to prevent press accident
•HardwareHardware
1,Danger of the Press machine
2,Compulsorily Inspection
•SoftwareSoftware
1, Operation Chief system
2, Operator Safety education
3, From the Top Management

10. KOMORIHardwareHardware
1,Danger of the Press machine
•Two types of Stopping Mechanism
No stopping Mechanism Full revolution Positive Clutch
⇒
Most Dangerous but simple and cheap Machine
Emergency stop Mechanism Part revolution and Hydraulic
⇒
Possible to use sensor device
Full revolution Positive clutch
Part revolution Friction clutch

11. KOMORI
•Operate with Safety Measure
1,No Hand in the Die
Safety Enclosure, Automatic Feeding, Hand tool e.t.c.
2,Hand in the Die
Select proper Safety Device
Safety Enclosure, Automatic Feeding, Hand tool e.t.c
Machine Guarding

12. KOMORI
•Interlock Guard
•Two Hand Control
•Light Curtain
•PSDI　(Presence Sensing Device Initiation)
•Laser Beam (for Pressbrake)
•Pull Out
Kinds　of Safety Device

13. KOMORI
2, Compulsorily Inspection
•Annual Inspection by Qualified Expert
Inspection Agency
Inside company Inspector
•Monthly and Daily Inspection
Operator
Maintenance by Operation Chief
•Use Checklist
Annual Inspection
Monthly and Daily Inspection

14. KOMORI
SoftwareSoftware
1, Operation Chief system
Every 5 Presses
2, Operator Safety education
New Operator’s education
3, From the Top Management

15. KOMORI
New Regulative Approach in Japan
Japanese MHDL released New regulation and construction
code at 2011.
As follows:
1, To protect all operator from Machine with stroke edge
Automatic feeding requires new protective way.
Many accidents happens and some fatal accidents.
Tarret Puch press ,Moving bolster,
2, Pressbrake Safety Devices
Introduced from EU way
3, Guard Area must be considered not only opeator, but die
setter and some other members
4, New Construction code for Press machine and Safety device

16. KOMORI
3, Proposal to Malaysia
•Case Study
•Proper Timing Inspection
•Safety Operation
•Safety Training
•Legal Enforcement
•Risk Assessment
⇒
　OSHMS