Training Green Book Endric Rev hay. 12.ppt

Sach ve tai lieu honda

1. Occupational Health & Safety Department
PT Honda Prospect Motor
PT Honda Prospect Motor
TRAINING
GREEN BOOK (HONDA STANDARD)
Revisi 0 : 28/ 02/ 2019

2. PT Honda Prospect Motor
2
Occupational Health & Safety Department
PT Honda Prospect Motor
AccidentCaseRelatedtoSafetyGuard
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedtoSafetySensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

3. PT Honda Prospect Motor
3
Occupational Health & Safety Department
PT Honda Prospect Motor
AccidentCaseRelatedtoSafetyGuard
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedtoSafetySensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

4. 4
Occupational Health & Safety Department
PT Honda Prospect Motor
1.Therearepotentialhazardinaprocesssofproductionandnon-productioninPTHondaProspectMotor
thatusingmachineandequipment.
2.Therearestillnon-conformityofmachinery&equipmentintheDept.ofRiskOwnerbasedonHonda
Standard.
3.AlignmentofknowledgeandabilitiesrelatedtounderstandingtheGreenBookstandard(HondaStandard)
bothDept.ofProductionandSupportProductionatPT.HondaProspectMotor.
4.TherearearegulationrelatedtomachineryandequipmentstandardinPT.HondaProspectMotor.
1.Decreasepotentialhazardofmachinery&equipmentinaprocessofproductionandnon-productioninPT.
HondaProspectMotor.
2.Increaseaconformityofmachinery&equipmentintheDept.ofRiskOwnerbasedonHondaStandard.
3.Dept.ofproductionandsupportproductionatPT.HondaProspectMotor.
4.Complimentaregulationrelatedtomachinery&equipmentstandardinPT.HondaProspectMotor.
AllofAssociatefromstafflevelupinMaintenanceProductionandNon-ProductionofDept.ofRiskOnwer
Background
Purpose
Target
PT Honda Prospect MotorBackground, Purpose and Target

5. PT Honda Prospect Motor
5
Occupational Health & Safety Department
PT Honda Prospect Motor
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
ProductionMachine
Definition
AccidentCaseRelatedtoSafetyGuard
AccidentCaseRelatedtoSafetySensor
GoodImplementationBasedOnGreenBook
HPM
Implementation

6. Followingistheconstitutionofthisstandard:
a.OperationManagementRules
b.StandardA(BasicSafetyStandard)
•EssentialSafeDesign
•RiskAssessment
c.StandardB(GroupSafetyStandard)
•SafetyDistance
•SafetyGuard
•SafetyFunction
•SafetyOperation
•WorkEnvironment
•Indicationconcerningsafetyandwarningdevices
d.StandardC(IndividualSafetyStandard)
•Machiningtoolsindividually
•SafetyGuard
•SafetyFunction
PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Definition
What is Green Book ??
6
GreenBookissafetymachinerystandardforasafetylawregardingthemachineryandequipmentthatmustbeimplementedfor
HondaGlobalstandardization
What is the Purpose of Green Book ??
Thepurposeofthisstandardistoregulaterequiredinformationforthesafetyofthefacilities,machineryandequipmenttoensurethe
safetyofthepeopleinvolvedforthefacilities.Safetyinthisstandardistodecreaserisksattheallowablelevel.
Why Green Book must be implemented ??
Themachineswithnewmanufacturingmethodfornewmaterialprocessingarealwaysplannedshouldbereviewedfortheessential
safetybasedonthisstandard,thespecificdetailedspecificationsshouldbedeterminedtomakethemsafe.
Green Book Contents

7. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Definition
7
Hierarchy of Controls a Hazard Risk from Most Effective to Least Effective
1. Elimination
•Eliminate human interaction
•Eliminate pinch points
•Automate material handling
2. Substitutions
•Replace a hazardous product, process, or piece of
equipment with one that is less hazardous
3. Engineering Controls
•Mechanical hard stops
•Guards
•Interlocked Guards
•Presence-sensing devices
•Two-hand controls
4. Awareness Controls
•Warning signs and labels
•Light, beacons and strobes
•Computer warnings
•“Restricted Space” painted on floor
•Beepers
•Horns and Sirens
5. Administrative Controls
•Safe work procedures
•Equipment inspections
•Training
•Lockout
6. Personal Protectiove Equipments
•Safety eyewear and face shields
•Hearing protection
•Gloves
•Repirators
Most
Effective
Least
Effective

8. PT Honda Prospect Motor
8
Occupational Health & Safety Department
PT Honda Prospect Motor
KecelakaanKerjaAkibatBahanKimiadiPTHPM
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedSensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

9. 9
Occupational Health & Safety Department
PT Honda Prospect Motor
Section 1-Safety distance to prevent the upper limbs from reaching the danger zone
1. Reaching above or over the protection structure
High Risk
Height of
danger zone
“a” (mm)
Height of the guard “b” (mm)
1400160018002000220024002500 2700
Horizontal safety distance to danger zone “c” (mm)
2700 0 0 0 0 0 0 0 0
2600 700 600 600 500 400 300 100 sd
2400 900 800 700 600 400 300 100 sd
2200 1000 900 800 600 400 300 sd sd
2000 1100 900 800 600 400 sd sd sd
1800 1100 900 800 600 sd sd sd sd
1600 1100 900 800 500 sd sd sd sd
1400 1100 900 800 sd sd sd sd sd
1200 1100 900 700 sd sd sd sd sd
1000 1000 800 sd sd sd sd sd sd
800 900 600 sd sd sd sd sd sd
600 800 sd sd sd sd sd sd sd
400 400 sd sd sd sd sd sd sd
200 sd sd sd sd sd sd sd sd
0 sd sd sd sd sd sd sd sd
Low Risk
Height of
danger zone
“a” (mm)
Height of the guard “b” (mm)
1400 1600 1800 2000 2200 2400 2500
Horizontal safety distance to danger zone “c” (mm)
2500 0 0 0 0 0 0 0
2400 100 100 100 100 100 100 sd
2200 500 500 400 350 250 sd sd
2000 700 600 500 350 sd sd sd
1800 900 900 600 sd sd sd sd
1600 900 900 500 sd sd sd sd
1400 900 800 100 sd sd sd sd
1200 900 500 sd sd sd sd sd
1000 900 300 sd sd sd sd sd
800 600 sd sd sd sd sd sd
600 sd sd sd sd sd sd sd
400 sd sd sd sd sd sd sd
200 sd sd sd sd sd sd sd
0 sd sd sd sd sd sd sd
Thesafetydistanceforreachingaboveorovertheprotectionstructureshouldbebasedonthe
riskassessment.
Inadditiontheriskassessmentshouldbebasedonthefrequencyofrecognizingarisk,the
possibilityofinjury,andtheseriousnessofinjury.
•WhentheriskisHigh
ThelevelsareLevelAandlevelBbasedontheestimateaccordingtotheuserrisk
assessmentprocedure
•WhentheriskisLow
ThelevelsareLevelC,LevelD,andLevelEbasedonestimateaccordingtotheuserrisk
assessmentprocedure
PT Honda Prospect MotorSafety Distance

10. 10
Occupational Health & Safety Department
PT Honda Prospect Motor
Example 1 Calculation of height “b” for a guard –low risk
Initialdata
Height“a”ofthedangerzoneis1500mmanditshorizontaldistance“c”withrespecttotheplannedguardis700mm.
When a danger zone is at a height of 1400 mm and at a horizontal
distance “c” between 100 mm and 800 mm, height “b” of the guard
must be at least 1800 mm;
When a danger zone is at a height of 1600 mm and at a horizontal
distance “c” between 500 mm and 900 mm, minimum height “b” of the
guard must be at least 1800 mm.
In this example, a minimum height “b” of 1800 mm is obtained in both
cases.
Solution
Theminimumheight“b”ofthefixeddistanceguardistherefore
1800mmwhenheight“a”ofthedangerzoneis1500mm,andits
horizontaldistance“c”*withrespecttotheguardis700mm
Fixed
distance guard
Danger
zone
Reasoning
Theguardprovidingthegreatestsafetymustalwaysbechosen.Sinceheight“a”(1500mm)ofthedangerzonedoesnot
appearinTable1(forlowrisks),theclosestsmallerheight“a”(1400mm)andtheclosestlargerheight“a”(1600mm)
mustbe
considered.Then,foreachofthesetwo“a”heights,youmustdetermineinwhichintervalofTable1isthehorizontal
distance“c”of700mm,aswellasheight“b”oftheguardcorrespondingtothisinterval:
Low Risk
Height of danger
zone “a” (mm)
Height of the guard “b” (mm)
1400 1600 1800 2000
Horizontal safety distance to danger zone “c” (mm)
2500 0 0 0 0
2400 100 100 100 100
2200 500 500 400 350
2000 700 600 500 350
1800 900 900 600 sd
1600 900 900 500 sd
1400 900 800 100 sd
1200 900 500 sd sd
Table 1

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Occupational Health & Safety Department
PT Honda Prospect Motor
PT Honda Prospect MotorSafety Distance
2. Reaching around
No Restriction of Movements Safety Distance (sr) Illustrations
1
Restriction on the movement of
the shoulder and beyond
≥ 850 mm
2Arm supported up to the elbow ≥ 550 mm
3Arm supported up to the wrist ≥ 230 mm
4
Arm and hand supported up to the
joints of fingers
≥ 130 mm
Section 1-Safety distance to prevent the upper limbs from reaching the danger zone
Note :
Sr : Safety Distance
A : Danger Zone

12. 12
Occupational Health & Safety Department
PT Honda Prospect Motor
PT Honda Prospect MotorSafety Distance
3. Reaching through an opening
Part of the Body Illustrations Opening
Safety Distance (sr)
Rectangular Square Circular
Finger tip
e ≤ 4 ≥ 2 ≥ 2 ≥ 2
4 < e ≤ 6 ≥ 10 ≥ 5 ≥ 5
Finger or hand up to the
joint of a finger
6 < e ≤ 8 ≥ 20 ≥ 15 ≥ 5
8 < e ≤ 10 ≥ 80 ≥ 25 ≥ 20
4 < e ≤ 6 ≥ 100 ≥ 80 ≥ 80
4 < e ≤ 6 ≥ 120 ≥ 120 ≥ 120
4 < e ≤ 6 ≥ 850 ≥ 120 ≥ 120
Arm up to the base point
of the shoulder
4 < e ≤ 6 ≥ 850
NOTE 1
≥ 200 ≥ 120
4 < e ≤ 6 ≥ 850 ≥ 850 ≥ 850
Note1:Whenthelengthoftherectangularopeningis65mmorless,thethumbworksasastopper.Thus,thesafety
distancecanbereducedto200mm.
e
e
e
Section 1-Safety distance to prevent the upper limbs from reaching the danger zone
e : Dimension of the opening

13. 13
Occupational Health & Safety Department
PT Honda Prospect Motor
PT Honda Prospect MotorSafety Distance
4. Reaching through an unspecifiable –shaped opening
Section 1-Safety distance to prevent the upper limbs from reaching the danger zone
The following steps should be executed
a.The first item to be determined is dimension through which the unspecified –shaped
opening could be fully contained.
•Diameter of the minimum circular opening
•Side the minimum square opening, and
•Side the minimum square opening, and
b.In accordance with the table 3 of the reaching through an opening, the three safety
distances should be determined.
c.Use the minimum safety distance among the three values determined in the step (b)
5. Effectiveness of additional protection structures in terms of the safety distance
Restriction of movements Safety distance (sr) Illustration
Restriction on the movement of
the shoulder and beyond :
One of the two independent
protection structure permits the
movement of the wrist and
beyond, and other permits the
movement of the elbow and
beyond.
Sr1 ≥ 230
Sr2 ≥ 550
Sr3 ≥ 850
Restriction on the movement of
the shoulder and beyond :
This is a single protection
structure which permits the
movement of the finger up to the
base of the base of the clenched
hand.
Sr3 ≥ 850
Sr4 ≥ 130
Illustration 1

14. 14
Occupational Health & Safety Department
PT Honda Prospect Motor
Section 2-Safety distance to prevent the lower limbs from reaching the danger zone
PT Honda Prospect MotorSafety Distance
Lower Limb Illustrations Opening
Safety Distance (sr)
Rectangular Square or circular
Toe e ≤ 5 0 0
Toes
5 < e ≤ 15 ≥ 10 0
15 < e ≤ 35 ≥ 80
NOTE 1
≥ 25
Foot
35 < e ≤ 60 ≥ 180 ≥ 80
60 < e ≤ 80 ≥ 650
NOTE 2
≥ 180
1. Reaching through an unspecifiable –shaped opening
The following steps should be executed for an unspecifiable-shaped opening.
a)The first item to be determined is the dimension through which the unspecified-shaped opening could be fully contained.
b)In accordance with the of the reaching through an opening, the three safety distances should be determined
c)Use the minimum safety distance among the three values determined in the step (b)
Unit : mm

15. 15
Occupational Health & Safety Department
PT Honda Prospect Motor
Section 2-Safety distance to prevent the lower limbs from reaching the danger zone
PT Honda Prospect MotorSafety Distance
Lower Limb Illustrations Opening
Safety Distance (sr)
Rectangular Square or circular
Leg (toe to knee) 80 < e ≤ 95 ≥ 1100
NOTE 3
≥ 650
NOTE 2
Foot
95 < e ≤ 180 ≥ 1100
NOTE 3
≥ 1100
NOTE 3
180 < e ≤ 240 Unpermissible ≥ 1100
NOTE 3
NOTE 1 : When the length of the opening is 75 mm or less, the distance can be reduced up to 55 mm.
NOTE 2 : The value matches the leg (toe to knee)
NOTE 3 : The value matches the leg (toe to thigh)
1. Reaching through an unspecifiable –shaped opening Unit : mm

16. 16
Occupational Health & Safety Department
PT Honda Prospect Motor
Section 2-Safety distance to prevent the lower limbs from reaching the danger zone
PT Honda Prospect MotorSafety Distance
2. Preventing free movement under the protection structure
Unit : mm
Distance h
Distance s
Case 1 Case 2 Case 3
h ≤ 200 ≥ 340 ≥ 665 ≥ 290
200 < h ≤ 400 ≥ 550 ≥ 765 ≥ 615
400 < h ≤ 600 ≥ 850 ≥ 950 ≥ 800
600 < h ≤ 800 ≥ 950 ≥ 950 ≥ 900
800 < h ≤ 1000 ≥ 1125 ≥ 1195 ≥ 1015
Note :
a.Reference surface
b.Hip joint
c.Protection structure
s. Safety distance for prevention
h. Height to the protection structure

17. 17
Occupational Health & Safety Department
PT Honda Prospect Motor
Section 3–Minimum gap to prevent a body part from being pinched
PT Honda Prospect MotorSafety Distance
1. Minimum Gap
Table 1. Minimum Gap
How to identify minimum gap in your workplace ?
a.Identify the hazard of the pinching
b.When the risk is assessed, check another item below :
•When various parts of the body may be expected to be pinched
because of the hazard
•Whether a part of the body may entering the pinching zone see table
1
c.Selectappropriateminimumgapforthesectionsofthebodyfrom
Table1.
d.When the appropriate safety cannot be obtained with the minimum
gap selected from table 1, alternative measure or additional measures
should be implemented.
Example:
Theprotectionstructurethathasthefollowingrestrictiveopeningasfigure
1canbepreventthelargersectionsofthebodyfromgettingclosetothe
pinchingzone.
•Gap“a”betweenthefixed
sectionandthemoving
sectionorbetweenthetwo
movingsection
•Depth“b”ofthepinching
zone
•Size“c”oftheopeningineh
protectionstructureandthe
distance“c”fromthe
pinchingzone.
•Size“d”oftheopeningineh
protectionstructureandthe
distance“d”fromthe
pinchingzone.
Figure 1. Example

18. 18
Occupational Health & Safety Department
PT Honda Prospect Motor
Section 4–Safety distance when the light curtain sensor is installed
PT Honda Prospect MotorSafety Distance
What is general requirements for installed light curtain sensor ??
1.Response time from the point when the light curtain detects the existence of an object to the point when the hazard stops
2.Size of the minimum size of the object to be detected
(With the combination of (1) and (2) above, the safety distance between the light curtain and the hazard is spceified
1. When the intrusion is at a right angle to light curtain
1.Safety Distance (S)= The distance between the hazard and the area.
2.Speed (K) = The insurtion to the detecting zone of the light curtain.
3.Response Time (T) = The point when the light curtain detects the existence of an object to the point when the hazard stops.
4.Additional Distance(c)= Distance calculated from the minimum size to of the object to be detected by light curtain.
S= (K x T) + c
Formula
Forthecalculationabove,thefollowingconditionsareadded.
•K= 2000 (mm/s)
•T= Response time of Light curtain + response time of the machine (s)
•C= 8 x (Minimum size of the object to be detected by the light curtain size d (mm) –14 (mm))
2. When the intrusion is parallel to the light curtain
Forthecalculationabove,thefollowingconditionsareadded.
•K= 1600 (mm/s)
•T= Response time of Light curtain + response time of the machine (s)
•C= (1200–0,4 x Height of the optical axis H (mm))
However, C should be 850 mm or greater.
The highest permissible optical axis height H is :
15 x (Minimum size of the object to be detected by light curtain d (mm) –50) ≤ H ≤ 1000 mm
Figure 2. Illustration
Figure 3. Illustration
Formula
Formula
Note: When H is 300 mm or greater for the calculation assuming d ≤ H/15 + 50 mm,
consideration should be made for the fact that there is an access risk from beneath the optical
axis where detection is impossible.
Note: For the above condition, when the safety distance (S) is less than 100 (mm), It will be 100
(mm). When the safety distance (S) exceeds 500 mm, the formula is recalculated with K 1600
(mm/s). When K = 1600 (mm/s) is less than 500 (mm), it will be 500 (mm)

19. 19
Occupational Health & Safety Department
PT Honda Prospect Motor
Section 4–Safety distance when the light curtain sensor is installed
PT Honda Prospect MotorSafety Distance
Forthecalculationabove,thefollowingconditionsareadded.
•K= 2000 (mm/s)
•T= Response time of Light curtain + response time of the machine (s)
•C= 8 x (Minimum size of the object to be detected by the light curtain size d (mm) –14 (mm))
3. When the intrusion is diagonal to the light curtain
Figure 3. Illustration
Formula
Note:
The angle of the intrusion should be of the range 5
0
≤ β≤ 8.5
0
angle intrusion.
When βis larger than 30 degrees, this is included in the case of the right
When β is smaller than 30 degrees, this is included in the case
S = Distance to the farthest optical axis and its height is 1000 mm or smaller the lowers optical height
is calculated for d ≤ H/15 + 50 mm.
Questions :
Light Curtain Specification :
Type: GL-R60H
(Detection Capability d = 25 mm
(0.98”) and 60 beam axes)
Speed (K) : 2000 mm/s (78.7 inch/s)
Response Time (T) :
t1 (GL-R60H response time) = 0.00157s
t2 (Maximum time required by the machine to stop) =
0.1s
Figure 4. Illustration
Howlongsafetydistance(S)between
machineandoperator?
Answer :
Light Curtain Specification :
Type: GL-R60H
(Detection Capability d = 25 mm
(0.98”) and 60 beam axes)
Speed (K) : 2000 mm/s (78.7 inch/s)
Response Time (T) :
t1 (GL-R60H response time) = 0.00157s
t2 (Maximum time required by the machine to stop) = 0.1s
Positionof Light Curtain is Stand
Formula :
C= (8 x (25 mm –14 mm) : 88 mm
T = Light Curtain Respond Time + Maximum Time for Machine Stop)
= 0.00157s + 0.1s = 0.10157s
S = (K x T) + C
= 2000 x (0.10157) + 88 = 291.14 mm
IfS is greater than 500 mm. Please do calculation again with K equal to 1600
mm. If the newly calculated results gives S less thanor equalto 500, set S to
500.

20. PT Honda Prospect Motor
20
Occupational Health & Safety Department
PT Honda Prospect Motor
KecelakaanKerjaAkibatBahanKimiadiPTHPM
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedSensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

21. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety Guard
Section 1–Guard (Safety Partition)
SafetyGuardisastructurethatseparatespeopleandhazard.Guardsincludethesafetyfence,safetycover,accessdoor,
coverforaspecificarea,andwindowformaintenance,accordingtotheirpurposeorapplication.
Generalrequirements
1.Whenasafetydoorisopenedorwhenanaccessdoorisdetectedtobeopenedwhilethemachineisrunning,the
machinewillbestopped.
2.Theguardshouldbeproperlydesignedandinstalledfortheintendeduse,consideringthemechanicalandother
hazards.
3.Theguardshouldbesuitablefortheworkenvironmentofthemachinefacility.Itshouldbedesignedandinstalledso
thatitsfunctioncannotbeeasilycancelled.
4.Theguardshouldgiveaslittlehindranceaspossibletoanyaspectoftheoperationtomaximallydiscourageany
intentiontocancelit.
5.Whentheguardisdesigned,theriskassessmentshouldbeconductedwithregardtoitsdimensions.
Purpose of the Safety Guard
1.To prevent intrusion and insertion to the danger zone of the machine.
2.To prevent falling from a height or into a pit.
3.To prevent scattering or dropping of work pieces or products.
4.To protect the machines and facility from external forces.
5.To prevent scattering of high temperature debris and to prevent people from contacting high temperature areas.
6.To contain or catch material, parts, chips, and fluid which may be dropped or released from the machine.
7.To reduce emissions that may be generated from the machine (hazardous materials such as noise, radiation, dust,
smoke, and gas).
21
What is the Requirements & Purpose of Safety Guard ??

22. PT Honda Prospect Motor
22
Occupational Health & Safety Department
PT Honda Prospect Motor
Surrounding Guard Power –Operated
Guard
Adjustable Guard
1 2
Self Closing Guard
4
Guard With Interlock & Lock
5
Guard With Interlock
& Starting Function
6
1.FixedGuard
a.SurroundingGuard
Theguardthatpreventsaccesstodangerzonefrom
anydirection
b.DistanceGuard
Thisdoesnotsurroundthedangerzonecompletely,
butwithitsdimensionanddistance,itpreventsor
reduceaccess
2.MovableGuard
Theguardthatcanbeopenedwithoutusinganytool
a.Power-OperatedGuard
b.Self-ClosingGuard
c.GuardwithInterlock
d.GuardwithInterlockandLock
e.Guardwithinterlockandstartingfunction
3.AdjustableGuard
Irrespectivetowhetheritisfixedormovable,theguard
thatcanbeadjustedasawholeortheonethathas
adjustableparts.Theadjustablepartshouldremain
unchangedduringoperation.
1
2
3
4
5
7
6
7
Safety Guard
Section 1–Guard (Safety Partition)
A.Typesoftheguards
Illustration
Distance Guard
3

23. Not Good Implementation Good Implementation
23
Occupational Health & Safety Department
PT Honda Prospect Motor
Example 1 Safety Guard Example Risk

24. PT Honda Prospect Motor
24
Occupational Health & Safety Department
PT Honda Prospect Motor
B. Safety Fence
Thispreventsintrusionandinsertionfromoutsideofthemachinefacilityandpartitionsthedangerzonewiththerequirements:
1.Forthemachinethathasmovingorprotrudingpart,thesafetyfenceshouldbesetupoutside.
2.Theconstructionandlocationoftheintrusion/insertionpreventiondeviceshouldbedeterminedtoensurethesafetydistancefrom
thedangerzone.
3.Thesafetyfencethatrequiresopeningforworkpiecesshouldbedesignedsothatoperatorcannotaccidentallygothroughitto
enterthedangerzonewhilethemachineisrunning.
4.Safetyfencecouldhaveasafetydoorifnecessary.
Section 1–Guard (Safety Partition)
Illustration General Requirements of Safety Fence Installation Standard
1.Height of safety fence must be installed 1400 mm or higher
2.Gap of frame between safety fence frame is 120 mm or less
3.Distance of the bottom safety fence from the floor : 135 mm or less
4.Installation of safety fence :
a.Directly attached (with anchor bolts)
b.Insertion type should be fixed with bolts
5.Frame and crosspieces
6.Construction
a.The frame and crosspieces should be welded.
b.No horizontal crosspieces which a person can step on to climb over the fence to
enter the danger zone should be installed
7.Considering the expected risk and the strength required, commercial fence could be
used to reduce cost. When the conditions are met :
a.Where there is no heat
b.Where the strength is not needed
For pipes For Square Pipes For Rods
Outer Frame25Ø or greater28 x 28 x 1,6 t or greater
Vertical Piece25Ø or greater24 x 24 x 1,6 t or greater9Ø or greater
Sample location for commercial location : Golf net, commercial fence, net, etc.
4b
4a
1
2
3
Safety Guard
1
2
3
4a
4b

25. PT Honda Prospect Motor
25
Occupational Health & Safety Department
PT Honda Prospect Motor
B. Safety Fence
Section 1–Guard (Safety Partition)
Safety Guard
1. Safety Fence for When Machine can be Reached
Illustration 1
Illustration 2
a.Whenthemovingpartsofthemachinecanbereached,the
requirementsisbelow:
•expandedmetalormetalscreenthatdonotallowfingerstogo
throughshouldbeused.
•Metalscreenshouldnotbeeasilyremovable
•Expandedmetalhasnoburnmaterials.
b.Measuretheheightofthesafetyfenceandthedistancetothemoving
parts
c.Measuretherelationshipbetweenopeningoftheexpandedmetal/
metalscreenandthedistancetothedangerzone
d.Inprincipleallmetalscreenshouldbesecuredwithbolts
e.Forthoseoftheconstructionoutofnecessityduetoassembly/
disassembly,theinterlockshouldbeinstalledsothatthemachinebe
stopped
Requirements
2. Sample of Attaching Expanded Metal
Finishingtheedgeofexpandedmetal,expandedmetalhaspressed
edges.Theseedgesshouldbefinishedtobenotsharp.
Requirements

26. a.Standardforsafetyfenceforfallingprevention
1.Heightofsafetyfencemustbeinstalled1300mmorhigher
2.Gapofframebetweensafetyframeis120mmorless
3.Distanceofthebottomsafetyfencefromtheflooris135mmorless
4.Installationofsafetyfence:
•Directlyattached(withanchorbolt)
•Insertiontypeshouldbefixedwithbolts
5.FrameandCrosspieces
6.Construction
•Theframeandcrosspiecesshouldbewelded
•Nohorizontalcrosspieceswhichapersoncanstepontoclimbover
thefencetoenterthedangerzoneshouldbeinstalled.
PT Honda Prospect Motor
26
Occupational Health & Safety Department
PT Honda Prospect Motor
B. Safety Fence
Section 1–Guard (Safety Partition)
Safety Guard
For pipes For square pipes for rods
Outer Frame 25Ø or greater28 x 28 x 1,6 t or greater
Vertical Pieces20Ø or greater24 x 24 x 1,6 t or greater9Ø or greater
3. When the Fence is to Protect a facility close to corner
4. Safety Fence for a Height (Falling Prevention)
Whenthefenceistoprotectafacilityclosetoacornerofthepassageway
oranimportantfacilitybythepassageway.
•Theheight,frames,crosspieces,andconstructionshouldsatisfythe
requirementsforprotection
Requirements
Requirements
Illustration 1
Illustration 2

27. PT Honda Prospect Motor
27
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety Guard
Application range of the safety fence construction guideline
(The general rule is to install the safety fence all around the machine) :
1. Continuous Machine Facility
2. Single Machine Facility
3. Other
Example : Automatic aerial conveyance systemExample : Extremely small robot/automated machine
Topreventscattering/droppingofobjectsandtopreventapersonfrom
puttinginahand,acovermaybeinstalledatthetopandbottomofthe
machine.
Note
1. Painting of Safety Fence
Shouldbethewarningcolor(Yellow)for
conditionasbelow:
a.Frameofthesafetydoor
b.Outsideedgeofthesectionthatcan
beremoved.
2. Painting of Expanded Metal
a.Both sides should be painted.
b.The color should be chosen so that
the facility inside it can be easily
seenthrough it.
(Except when the color is specified)
Section 1–Guard (Safety Partition)
Illustration 1
Illustration 2 Sample Implementation

28. PT Honda Prospect Motor
28
Occupational Health & Safety Department
PT Honda Prospect Motor
6. Safety Cover
Section 1–Guard (Safety Partition)
Safety Guard
Thispreventsintrusionandinsertionfromoutsideofthemachinefacilityandpartitionsthedangerzone.
•Thisshouldbeabuilt-intypeinprinciple.Itcanbeeasilyattachedandshouldbesecurelyattached.
•Itshouldhaveaconstructionthatallowseasymaintenanceandadjustingsuchascleaning,lubricant,inspection,and
servicingofthemachine.
•Itshouldhaveaconstructionthatpreventsfingerandotherbody[artsfromenteringthedangerzone.
•Thecoverfortheworkpieces,chips,spatters,cuttingfluid,andmoldreleaseagentshouldhaveaconstructionsothat
theycannotbeeasilysprayedontotheoperatororontothefloor.Thematerialshouldbeanti-corrosiveortreatedtobe
so.
a.Cover height : 1,800 mm or higher
b.The clearances within the M/C, behind the M/C, and to the M/C
moving parts should observe the amount specified in Chapter 1 :
Safety distance to prevent pinching.
c.Construction of the cover
a) Thick steel plate : thickness of 1.6t
b) Net
Outer frame angles : 35 x 35 x 3t
Expanded metal : 25 x 25 x 3t
Requirements
Safety Cover Technical Guideline
Illustration 1

29. PT Honda Prospect Motor
29
Occupational Health & Safety Department
PT Honda Prospect Motor
7. Access Door With Interlock
Section 1–Guard (Safety Partition)
Safety Guard
Thisisadoorthroughwhichtheoperatorattaches/detaches,putsin,andtakesouttheworkpiecesforeverycyclein
thedangerzone.
a.Thedoorshouldhaveasafetyswitchtodefectthatdoorisclosed.However,whenalimittypeswitchisemployed,bothopeningand
closingshouldbedetected.Theswitchshouldbeofthesafetylimittype.
b.Thegapofthedoorisleesthan8mmwhenthedoorisdetectedtobeclosed.
c.Theautomaticdoorshouldhaveameasuretopreventpinchingifnecessary.
d.Apartofthedoorbesee-throughtoobservetheoperation.Thematerialshouldbeheatproofandchemical-proof,andthe
constructionshouldbeimpact-proof.
e.Thedoorshouldhaveahandleatapositionwheretheoperatorsdonothavetheirfingerpinched.
f.Theaccessdoorthatmovesverticallyshouldnevermovedownwardbyitsweight.
g.Thedoorclosuredetectionswitchshoulddetectedanyerrorforeverycyclewithitserrordetectioncircuit.Ifanerrorisdetected,the
switchshoulddisablethemachinewithitsinterlockmechanisminthenextcycle.
h.Thedoorclosureswitchprovidesoneoftheconditionsforthemachinetobestarted.
i.Whentheswitchdetectsthatthedoorisopenwhilethemachineisrunning,itshouldsendoutastopsignalofthestopfunction
category“0”or“1”.(Forthestopfunctioncategory,refertoChapter3:FunctionSection3.)
1)Safetyfunction
a.Safetyfunctioncanbecheckedforeachcycle.
b.Theoperatorcannoteasilycancelthesafetydevice.
c.Thesafetydeviceshouldbeofafail-safesign.
2)Thedooropeningshouldbe1800mmorhigher
3)Constructionofthedoor
a.AdoorpocketshouldbeinstalledifthedoorislargerthantheM/C.
b.Thehandleforopening/closingthedoorshouldbepositionedsothatthe
operatorwillnothavethehandpinched.
c.Thedoorcanbeeasilymovedbyhand.
d.Thedoorshouldlap20mmormorewhenclosed.
Access Door With Interlock
Requirements
Illustration 1

30. PT Honda Prospect Motor
30
Occupational Health & Safety Department
PT Honda Prospect Motor
8. Safety Door (Guard With Interlock)
Section 1–Guard (Safety Partition)
Safety Guard
Thisisadoormarked“SpecifiedEntrance”inthesafetyfence.
1)Whentheworksuchasproductionprocesschecking,adjustment,inspection,lubrication,andservicingisrequired,thesafetydoorshouldbe
installedasandentrance.
2)Thedoorshouldhaveasignboarddescribingtheprecautionsforenteringthedangerzone.
3)Theentranceshouldhaveasafetyswitch.Theopeningshouldbelessthan120mmifthedoorisforcedopenwiththesafetyswitch
activated.
4)Thesafetydoorshouldhaveainterlockmechanismlinkedtotheoperationofthemachine.
a.Whentheswitchdetectsthatthedoorisopenwhilethemachineisrunning,itshouldsentoutastopsignalofthestopfunctioncategory
“0”or“1”.However,themanualoperationisallowedifcombinedwithothersafetymeasuresonlywhenpowersourceisrequiredfor
operationsuchasinspection,adjusting,andservicing.
b.Theinterlockfunctionshouldbeofafail-safedesign.
5)Theoperatorcannoteasilycancelthedoorclosuredetectionswitch.
6)Ifsafetycannotbeensuredduetoinertiaorhightemperatureafterpowerisshutoff,thedoorshouldnotallowentranceuntilsafetyis
confirmed.
7)Theoperatorshouldberequiredtoconducttwostepstoopenthesafetydoor:removetheactuator(key)ofthesafetyswitchandopenthe
door.However,asinglestepoperationisallowedforanelectromagneticlock.
1)Safetyswitch
•Theswitchunitandtheactuator(key)shouldbeofseparateitems.
2)Wire
•Wireshouldbecrimped
•Thewireshouldbeshortenoughsothattheopeningshouldbeless
than120mmifthedoorisforcedopenwiththeactuator(key)
inserted
3)Doorhandle
•Thisshouldbeweldedinprinciple.
Whenitisboltedon,theholesshouldbefilledsothatatoolcannot
accessthebolts.
Safety Door (Guard With Interlock)
Requirements
1 2
Illustration 1

31. PT Honda Prospect Motor
31
Occupational Health & Safety Department
PT Honda Prospect Motor
9. Cover for Specific Area
Section 1–Guard (Safety Partition)
Safety Guard
Thisistoeliminatethehazardofcontactingthemovingpartofthepowertransmissionsectionofthemachineandtoprotecttheoperator
fromflyingdebrisoftheworkpiecesorpartsofthemachine.
1)Thereshouldbenogapsthattheoperatormayhavethefingerorhandpinchedbetweenthemovingsectionofthemachineandthecover
2)Thepowertransmissionsectionandtherotatingpartsshouldnotbeexposed.Thecovershouldbestrongenoughtostoptheflyingdebris
fromacomponent.
3)Ifthereisapotentialhazardofgettinghurtbyrotatingcoolingfan,itshouldbecoveredwithprotectivenetorcover.
4)Theelevatingdeviceandthebalancerweightshouldbecovered.
5)Ifthereisapossibilityofthecoverbeingcorrodedwithachemical,thecovershouldbeofanti-corrosivematerialortreatedtobeso.
6)Thecoverforasectionthatrequiresregularinspectionshouldbedesignedconsideringtheeaseofmaintenance
Cover for Specific Area Technical Guideline
Illustration 1 Illustration 2 Illustration 3
1)Thecoverforrotatingshouldhavefoldedsectionssothatitcanwraparoundthe
partsasmuchaspossibleincludingthesidesoftheparts(SeeIllustration1).
2)Thecovershouldbestrongenoughagainsttheflyingdebrisfromacomponent.
3)Thecovershouldbeweldedtoformastrongone-piececonstruction.
4)ThecovershouldbeattachedwithM6orlargerbolts.
5)Thecomersshouldberound-chamfered.
Requirements

32. PT Honda Prospect Motor
32
Occupational Health & Safety Department
PT Honda Prospect Motor
10. Windows for Maintenance
Section 1–Guard (Safety Partition)
Safety Guard
Thisisawindowtohelpconductadjustment,inspection,andlubricationofamachine
a.Thesizeandquantityofthewindowsshouldbeminimum.
b.Donotputawindowlargeenoughforhumanbodytogothrough.
c.Thewindowshouldbeattachedwithbolts.
d.Thewindowformaintenanceshouldhavecautionplatedescribingthesafetyprecautions.
e.Ifthereisapossibilityofthewindowbeingcorrodedwithachemical,thewindowshouldbeofanti-corrosivematerial
ortreatedtobeso.
f.Thewindowformaintenanceinstalledatthemovingsectionofthemachineshouldbeequippedwithadeviceto
detecttheclosureofthewindow.
1)Construction of the window
a)The size should be minimum for the work
b)The lid (cover) of the window should be attached with bolts.
c)There should be no leakage of cutting fluid from the gap around the bolts
and lid (cover).
2)Marking on the window cover
a)The caution plate for the window for maintenance
should be attached.
Window for Maintenance Technical Guideline
•Window for Replacing / Adjusting A Device
•Window for Regular Inspection/Lubrication
Requirements

33. PT Honda Prospect Motor
33
Occupational Health & Safety Department
PT Honda Prospect Motor
11. Falling Object Protective Net
Section 1–Guard (Safety Partition)
Safety Guard
Thisisanetagainstthehazardoffallingobjectsfromaheightoraninspection/adjustmentpassagewayor
scaffolding.
1.Theoverheadconveyorshouldhaveasafetyprotectionnettocatchobjectsthatmayfallduringconveyance.
2.Thefallingobjectsafetyprotectionnetthatalsofunctionsasaninspectionpassagewayshouldbedesignedto
preventworkersfromfalling.
1)Strength
The strength of the frame and net should be calculated considering the
weight of the falling objects and impact load multiplied by the safety factor.
2)Construction
a)The joints of the outer frame should be welded
b)The safety net should also be installed on the sides so that the falling
objects do not bounce on the net to go outside of the net.
c)The safety protection net should be attached to the attachment stays
with bolts.
d)The bolts should be locked in some way.
e)When the oil pan is installed, a cover should be provided to prevent any
oil leakage from the joints. (Refer to Illustration2)
Safety Protection Net Technical Guideline
Requirements
Illustration 1
Illustration 2

34. PT Honda Prospect Motor
34
Occupational Health & Safety Department
PT Honda Prospect Motor
KecelakaanKerjaAkibatBahanKimiadiPTHPM
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedSensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

35. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety Function
Section 1–Safety Mechanism
1.Pressure 2.Device&Mechanism
1.Thehydraulicandpneumaticsystemshouldnotposeanyriskto
thepeopleintermsofthefollowing.
•Surgepressureandincreasedpressure
•Pressurelossandpressuredrop
•InternalandExternalrisk
2.Thehydraulicandpneumaticsystemsshouldbefollowtherole
below:
•Designed,assembled,andadjustedtominimizethesurge
pressureandincreasedpressure.
•Shouldbemaintaintheirratedpressureintheirsystem
•Equippedwithsafetydevicetopreventexcessivepressure
increase
•Equippedwithapressuregaugeforitsmaincircuit
•Shouldnotallowedanyeasyadjustmentofpressureandflow
exceedingtherangeforwhichthesystemcanoperatesafely
•Beequippedwithpressurecontrolandflowcontrolvalvesthatdo
notbecomefaultyorposeriskduetothechangesinpressure,
temperature,andload.
•Operationalmechanismshouldnotuseapneumaticallyoperated
systeminprinciplewherecompressibilityofairmaycause
instabilityinoperation.
•Thecircuitshouldwhichusesanaccumulatorshouldbe
interlocked
•Irrespectivetothecontrolpowersupplysystems(hydraulic,etc.),
thesystemshouldnotposeanyrisk.
•Thehydraulicsystemsshouldallowtheirsystempressuretobe
releasedeasilyandsafelywithpowersource
•Thepneumaticsystemsshouldhaveashutoffvalveofthe
pressureopentypeintheirmaincircuitandallowtheirsystem.
•Particularlyintermsofmaintenanceandservicing,themachine
shouldbeequippedwithamechanismtoturnoffthepower
supplyandtoreleasetheresiduepressureasnecessary
•Anycircuitthathasaresiduepressureriskshouldbeexplicitly
indicatedinthehydraulicandpneumaticsystem.
•Machineshouldstoppromptlywhenthemovementcausedby
inertiamayposearisktotheoperator.
•Thefeedmechanismshouldbeequippedwithalimitstopper.
•Therotatingmechanismandpowertransmissionmechanism
shouldbeequippedwithoverloadprotectivedeviceas
necessary(detachingdevice,torquelimiter,etc.).
•Theemergencybrakeshouldbeabletooperatewhenpoweris
shutdown.
•Thedrivingsectionshouldbeequippedwithanti-looseningand
anti-detachingmechanisms.
•Theoperatingmechanismforwire/chainsuchasahoisting
winchshouldbeequippedwithasafetymechanismtoprevent
tangledhoisting.
•Thesafetyvalve,governorswitch,orshearpinshouldnotpose
anyrisktotheoperatorifitisactivatedduetoanabnormalload
whilethemachineisrunning.
•Anylid,door,orvalvehandleshouldbearrangedordesignedin
suchawaythattheoperatorshouldnotbepinchedwhen
operated.
•Theoperatingleversandhandlesshouldbeequippedwitha
mechanismtopreventunintentionalactivation.
•Foramachinewhosetablemovesvertically,asafetyfenceto
preventloadedobjectsfromfallingshouldbeinstalled.
•Anelectromagneticvalveofthedouble-solenoidthreeposition
typeshouldbeusedforthehydraulicandpneumaticsystemsin
principle.Otherwise,thefacilitysafetytrustmanagerandthe
machineryplannershouldagreetoselectthosesuitableforthe
systemintermsofthesafetymechanismandsafetydevices.
35

36. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety Functions
Section3–EmergencyStopandStop
Example : Emergency Stop Switch
(for Operation Panel)
Example : Emergency Stop Switch
(Independently Located)
Example : Name Plate for
Emergency Stop Switch
36
Stop function
category
Definitions
0 Uncontrolled stop
Stopping the machine by directly shutting off the power to the
mechanical actuator (see Uncontrolled stop “JIS B9960-1-3.56”)
1
Controlled stopping by shutting off
power
Controlled stopping in which power is first supplied the mechanical
actuator to stop and then power is shut off when stopped (see
Controlled stop “JIS B9960-1-3.11”)
2
Controlled stopping with power
being supplied
Controlled stopping in which power to the mechanical actuator
continues to be supplied
1.EmergencyStop
a.Anemergencystoppushbuttonswitchshouldalwaysbeinstalled.
b.Thefacilityshouldnotposeanyrisktotheworkerswhenitstopsforemergency.
c.Poweroutageshouldbefunctionallythesameastheemergencystop.
d.Whentheemergencystopdeviceissuesanemergencystopcommandasitistriggered,itshouldretainthe
commanduntilitisresetbyaperson(manualreset).Themanualresetshouldbeabletobeconductedonlyatthe
machineforwhichthestopcommandisissued.
e.Theemergencystopfunctionoverridesalltheotherfunctionsinanyoperationmode.
f.Theemergencystopfunctionshouldnotimpairtheeffectivenessoftheotherdevicesthathaveotherprotection
devicesorimportantsafetyfunctions.
g.Theemergencystopdeviceshouldbeabletobeeasilyoperatedbytheworkeroranotherpersonwhoneedsto
operatetoit.Withform:MushroomshapedbuttonandWire
h.Anemergencystopdeviceshouldbeinstalledonthecontrolpanel,startupbox,andotherlocationwhere
emergencystopisneeded.Theemergencystopdeviceshouldbeeasilyaccessiblebytheoperator.Itshouldbe
installedatalocationwhereitcanbesafetyoperated.
i.Theemergencystopdeviceshouldemployadevicewhichretainsitspositionbylatching(mechanical
engagement).Theemergencystopsignalshouldberetaineduntiltheemergencystopdeviceisreset(unlatched)
j.Thesectiontobeoperatedoftheemergencystopdeviceshouldbeinred.Ifpractical,thebackgroundofthe
controldeviceispreferablyinyellow.(e.g.,nameplace,switchguard,etc.
k.TheemergencystopshouldbeeitherStopfunctioncategory0orStopfunctioncategory1.Theemergencystop
includesisolatingthepowersourceofthemachine.However,thisdoesnotapplywhenariskisexceptedifpower
isisolated.Turningoffpowerofthemotor(output)andTurningoffpower(hydraulicandpneumatic)ofthemachine
andsuppressingthepressure.
l.TheemergencystopfunctionoftheStopfunctioncategory0shouldnotemployaprogrammableelectronicdevice.
2.Stop&Pause
a.“Stop”and“Pause”push-buttonswitchesshouldbeinstalledasnecessary
b.TheControlcircuitof“Pause”and“Restartimmediately”maybeinstalledasnecessary.
c.TheStopandPauseshouldbeofStopfunctioncategory2.
d.Thestopfunctionactivatedbyaprotectiondeviceshouldbringthemachinetothesafestatepromptlyasmaybe
necessarywhenitistriggered.Thisstoppingshouldoverridestoppingforthenormaloperation.
e.Whentheprotectivedevicestopsmultiplemachineslinkedtogether,itshouldissueastopcommandtoallthelinked
machinestobringallthemachinestothesafestate.

37. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety Functions
Section 4–Safety Circuit
37
HoldtoRunisonlyforamachinethatrequirescontinuousoperationofthecontrol
deviceforoperation.Forinstance,amachineoperatesonlywhenthepushbuttonis
pressedandheld,andwhenthebuttonisreleased,themachinestepsimmediately.
Enablingdeviceisgenerallybuiltintoahandheldcontroldevicesuchasarobot
teachingpendantoragripswitch.Itallowsthemanualoperationofthedeviceorrobot
Three-positionenablingswitchesarerequiredintheindustrialrobotstandardthe
machiningtoolstandard.
SafetyDeviceisaprotectivedevice.Safetydevicesincludelightcurtains,laser
scanners,doorswitches(withlockingmechanism),limitswitches,emergencystop
switches,enableswitches,mattswitches,safetyrelays,andsafetyunits.
1. Safety Device
2. Enabling Device
Inchingisusedforoneofthefollowing.InchingisdefinedtobedifferentfromHold-
to-run.
•Whenthebuttoncontinuestobepressed,themachineoperatesonlyuptoa
certaindistanceorangle.
•Whenthebuttoncontinuestobepressed,themachineoperatesonlyuptoa
certaindurationoftime.
•Whenthebuttonispressedonce,themachineoperatesforacertaindistanceor
duration(sleepingoperation).
3. Hold to Run
Mutingismeansatemporalsuspending(disabling)ofthesafetyfunctionofthe
safety-relatedsectionofthecontrolsystem.Forinstance,thesafetylightcurtainis
temporallydisabled(muted)attheupper(opening)endofthepressfitunitwhenthe
operatorattaches/removethework.
5. Muting
ManualResetisafunctionbuiltinthesafety-relatedsectionofthecontrolsystemin
ordertorecoverthesafetyfunctionofthemachinemanuallybeforetherestartingof
themachinery.
6. Manual Reset
4. Inching
Enable Switch
(Operationof the
three-position
type)
Howto Grip
(Grip Type)
Howto Grip
(Pendant Type)
Position 1
Swtich is not
Pressed
(Off State)
Position2
Switch Half State
(Enable State)
Position 3
Switch is beyond
the mid position
(Off State)
Example Safety Device
Light Curtain
Example Safety Device
Safety Door Lock Switch

38. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety Functions
Section 4–Safety Circuit
38
A.Safetycircuit
1.Forsafetyoperation,thenecessaryprotectiveinterlockshouldbeimplemented.Whenthemachinestopsforwhateverreason,
unintentionalrestartingshouldbeprevented
2.Thesectionswhichmaycausecontradictoryoperationssuchasclock-wiserotationvs.counter-clock-widerotation,damagingofthe
facility,orpersonalinjuryshouldbeinterlockedwithandexternalcircuit.Whenapotentialfailuremayleadtopersonalinjury,a
safetyrelayshouldbeemployed.
3.Theelectricallyactivateddevicessuchasrelays,solenoids,clutches,andbrakes,shouldbeabletomaintaintheirsafetyfunctions
evenifpoweristurnedoffandtheybecomeunexcited.
4.Themotorshouldhaveandoverloadprotectiondevice.Whenoverloadisdetected,analarmshouldbeissued.
5.Whenanoverload/overcurrentprotectivedeviceofanactuatorofamechanicalbrakesystem(e.g.,motorbrake)istriggered,the
mechanicalactuatorrelatedtothesystem(e.g.,motor)shouldstopsupplyingpower(electricity)aswell.
6.Ifthereisapossibilityofthemovingsectiongoingoveracertainlimit,apositionsensororalimitswitchshouldbeinstalledto
providepropercontrol.
7.Whenthemachineisstoppedotherthanduringtheautomaticoperation(continuousautomatic,one-cycleautomatic,
semiautomatic),nomechanismshouldbeactivatedifthedetectorisactivated.
8.Whenasafety-relatedparameter(e.g.,position,speed,temperature,pressure)exceedsthelimitthathasbeensetbeforehand,the
controlsystemshouldstopthemachine,issueanwarningsignal,oractivatethealarm.
9.Forinstance,iftemporaldeactivationofthesafetyfeaturesisrequiredforsetup,adjustment,maintenance,orrepair,themode
shouldbefixed(mechanicallyorotherwise)atamodeinwhichautomaticoperationisdisabled.Inaddition,itispreferabletoapply
thefollowingmeasures.
a.Themachineshouldbeoperatedwithahold-to-rundevice.
b.Anemergencystopdeviceoraportablecontrolpanelwithanenablingdeviceshouldbeusedasnecessary.Onlythatcontrol
panelshouldbeallowedtocontrolthemachine.
c.Theoperatingspeedshouldberestricted(madetolower)ortheoutputofthemachineshouldberestricted(non-operable).
d.Theoperatingrangeofthemachineshouldberestricted(withmechanicalstoppers).
10.Itispreferablethathard-wiredsafetydevicesbeusedforallthesafety-relatedstopfunctions.However,thesafetyPLCandsafety
networkcompatiblewiththeSafetycategory4definedin"EN954-1"maybeused.
11.Formonitoringortestingofthesafety-relateddevicesorforbackingupthedata,aprogrammableelectronicdevicemaybeused.
However,theyshouldnotimpedethenormaloperationofthesafety-relatedstopfunctions.

39. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety Functions
Section 4–Safety Circuit
39
B.Electrosensitiveprotectiveequipment(ESPE)
(Safetylightcurtain,safetylaserscanner)
1)Thedevicesfortheelectrosensitiveprotectiveequipmentshouldsatisfythesafety
categoryrequirementsinaccordancewiththeintendeduse.Whenanabnormallyis
detected,theysoldacttomakethefacilitysafeiftriggered.Inadditional,asafetyrelay
shouldbeemployedforthecontrolcircuitoftheelectrosensitiveprojectiveequipment.
2)Thesafetycategoryshouldbedeterminedbasedontheresultoftheriskevaluation.
Andthesafetycategory1shouldbechosen.
3)Theelectrosensitiveprotectiveequipmentshouldbeemployedwhenthereisa
possibilityofapersonorobjectcomingintoorexistinginthedetectionarea.Adevice
thatprovidesthestatusoftheelectrosensitiveprotectiveequipmentshouldbe
employed.
4)Theelectrosensitiveprotectiveequipmentshouldbelinkedwiththecontrolsystemof
themachineandsatisfybythefollowingconditions.
a)Itshouldissueasignalimmediatelyandstopthemachinewhenapersonorapartof
thebodyisdetected.
b)Themachineshouldnotrestartwhenthedetectedpersonorpartofthebodygoes
outofthedetectionrange.
c)Theoutputsignaloftheelectrosensitiveprotectiveequipmentshouldberetainedby
thecontrolsystemuntilitismanuallyresetbyaperson.
d)Themachineshouldbeabletorestartedonlywhentheoperatorintentionally
operatesthecontroldevicelocatedoutsideofthedangerzonewhichcanviewedby
theoperator.
5)Thestopcommandshouldberetaineduntilallthesafetyrequirementsforrestarting
areasatisfiedonceisactivatedbytheelectrosensitiveprotectiveequipment.
6)Theelectrosensitiveprotectiveequipmentshouldbeabletoberesetonlywhenan
operatorintentionallyoperatesthecontroldeviceforresettinglocatedoutsideofthe
dangerzone.Inaddition,theresetdeviceshouldbelocatedatasafepositionwhere
theoperatorcaneasilyseeandverifythatthereisnopersoninthedangerzone.
7)Themachineshouldnotbeabletobeoperatedduringthemanualresettingofthe
electrosensitiveprotectiveequipment.
8)Mutingshouldnotputanypersonatarisk.Duringmuting,thesafetyconditionsshould
beensuredwithothermeasures.
9)Mutingcomesintoeffectwithtwoormoreindependentmutingsignals.Allthemuting
signalsshouldstayOnduringmuting.IfoneofthemutingsignalsbecomesOff,the
mutingshouldbecancelledimmediately.Mutingsignalsshouldbehardwired.
10)Anindicatorformutingthatcanbeeasilyviewedfromtheoperatingpositionshould
beinstalled.Itshouldbeturnedonduringmutingtohelpthewarningtoberecognized.
11)Whenmutingisover,allthesafetyfunctionsofthesafety-relatedsectionsofthe
controlsystemshouldberestored.
[Sample of Muting]
Forinstance,thesafetylightcurtainistemporallydisabled(muted)atthe
upper(opening)endofthepressfitunitwhentheoperatorattaches/removes
thework,withthefalling(closing)preventionactivatedcheckswitchofthe
falling(closing)preventionmechanism.

40. PT Honda Prospect Motor
40
Occupational Health & Safety Department
PT Honda Prospect Motor
KecelakaanKerjaAkibatBahanKimiadiPTHPM
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedSensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

41. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Section 1–Operation
Safety Operation
1.OperationDevice
41
1.Theswitchesusedforstartingshouldnotbeturnedonevenifanarmoranobjectaccidentallytouches
it.
2.Theoperationpowerswitchesshouldbeequippedwithakey.
•Thekeyshouldbetakenoutatthepositiontosecuresafety.
3.Thedirectionofthehandlematchesthatofthemovementofthemachine.
4.Theleversforchangingthemainspindlespeedandfeedshouldbeabletobesecurelyheldatthe
selectedpositions.
5.Topreventerroneousoperation,theoperationdeviceshouldbeclearlymarkedwiththepurposeso
thattheoperatorscanidentifythem.Theyshouldalsobearrangedforeasyaccessbytheoperators.
6.Thecentralizedoperationpanelofthemachinesofthesamemechanismshouldbeoftheidentical
operationmethodtopreventerroneousoperation.
7.Theportableandpendanttypeoperationpanelandthosecontroldevicesshouldbeselectedand
arrangedtominimizetheunintentionaloperationofthemachineduetoimpactsandvibrations
8.Ontheelectronicoperationpanel(touchpanel),thecontentsoftheoperationsshouldbeclearly
indicatedifmultipleoperationscanbeexecutedonit,andtheyshouldbeabletobeconfirmedas
necessary.
9.Theoperationpanelshouldbearrangedasfollowstopreventrisksduetoerroneousoperation.
•Theoperationdevicesshouldbelocatedoutsidethedangerzoneexceptforthosesuchas
emergencystopdevicesandteachingpendantswhicharetobeinstalledinthedangerzone.
•Thestartingoperationdevicesshouldbelocatedatapointwheretheoperatorcanvisuallycheckthe
entiremachinerywhenhe/sheoperatesthedeviceswhereverpossible.
•Thestoppingoperationdeviceshouldbelocatedclosetothestartingoperationdevices.
•Theoperationdevicesshouldbedividedintogroupsaccordingtotheoperationsequenceandthe
purposesofthemachinesordevices.
10.Operatingandoperationdeviceshouldnotposeanyotherrisks.
11.Theoperatorsshouldbeabletoverifythattheirintendedoperationsareactuallyexecuted.
12.Theoperationdevicesshouldnotputthemachinesinunknownordangerousconditionwhen
operated.Thefollowingerroneousoperationpreventiveavoided.
•Locatetheoperationdeviceinsideapit,orinstallacoveroverit.
•Increasetheforcerequiredtooperateit.
•Locatetheoperationdeviceatalocationwhereanaccidentalimpacthardlyreaches.
•Useacombinationoftheoperationdevicesthatrequiresequentialactions.
•Employthebothhandscontrolsystem.
•Usetheenabledevice.
•Adoptalockout(locking)system.
Illustration 1

42. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Section 1–Operation
Safety Operation
2.Coloroftheelectricoperationdevices
42
Apply the “Push –Button Colors” in the table below as the color of the operation devices
No Color Meaning Description Honda’s Application
1Red Emergency Activatedforahazardousoremergencyoccasion
Emergencystop
Pause
2Yellow Failure
Activatedwhen a failure occurs
Intervention to control a failure
Chime
Emergency Return
3Green Normal Activated to Start
Operation Preparation
Automatic Starting
Starting (BothHands)
4Blue Forced
Activatedin the state in which an action is
required
Reset Function
Reset
5Black
Unspecified
Start (On) / Stop(Off) (High Priority)
Active (Out)
Cycle stop
Universal starting other than emergency stop
Start (On)(High Priority) / Stop (Off)
Lamp Check
Passive (Return)
Original position return
6White
7Orange
Automatic Starting
(Illuminated)
Button Illustration

43. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor 43
Safety Operation
Section 2–Operation Mode Section 3–Automatic Starting Method
Allthemachinesshouldbeequippedwithmodeswitching
devicesothattheycanbefixedinspecificmode.
1.Themodeshouldbeeasilyidentifiable
2.Operationisallowedonlywhenonecontroloroperation
modeselected
3.Therightsideisselectedasdefaultforthemodeselect
switch,inaddition,thekeyscanbepulledoutwhenthe
leftsideisselectedforthekey-equippedswitches.
4.Noselectedmodeshouldputthemachineinadangerous
condition.Selectingamodeshouldnotstartthemachine
torun.Thesystemshouldrequireaspecificoperationby
theoperatortostartthemachine.
Figure 1. Operation Mode Switch
Figure 2. Control Mode Switch
1.Operationdevicesforstartingthemachines
a.Theboth-handsoperationmethodshouldbeemployedinprinciple.
•Theyshouldbeseparatedfromotheroperationswitches
•Theyshouldnotbeabletooperatedwithsinglehandintermofdistanceorstructure
2.Ifboth-handsoperationisnotpossible,twoormoresafetydevicesshouldbeinstalled
3.Iftheoperator’sbodydoesnotgoinsidethedangerzonewhilestartingthemachine,the
single–handstartingmethodisallowed.
4.Startingwithafootpedalswitchisprohibited.However,iftheoperator’sbodycanstayat
least200mmawayfromthemovingrangeduetotheconstructionofthemachine,orif
thesafetyoftheoperatorcanbeensured,thisdoesnotapply.Thefootpedalswitch
shouldhaveacoverandalockingmechanism.
5.Itispreferablethattheentiremachinebeabletobeviewedfromthepositionwherethe
operatorstartsthemachineforautomaticstarting.
6.Whenbooththecentralizedmonitorpanelandthecontrolpanelonthemachinecanstart
andstopthemachine,thecontrolpanelonthemachineshouldhaveprecedence.The
operationconditionshouldbeindicatedonbooththecentralizedmonitorpanelandthe
controlpanelofthemachine.
7.Whenthemachinerunsintheautomaticsinglecycleoperationorthecontinuous
automaticoperation,theconditionsfortheprotectiondevicesshouldbesatisfiedatthe
beginningofeachcycle.
8.Thepush-buttonswitchusedforstartingshouldnotbeabletostartthenextcyclewhenit
hasashort-circuitfailureorwhentheoperatorpressesandholdsit(returnfailure).This
restrictionshouldapplyifonethemultiplepush-buttonswitchedbecomesfaulty.

44. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor 44
Safety Operation
Section 4–Manual (Pressing the Push Buttons and Changing the Jigs Tools)
1.Themechanismoperatedbyapush-buttonswitchshouldrunwhenthebuttonispressedandhelditshouldstopwhenitsisreleased.The
operationofthehold-to-runsystemsorthepush-buttonswitchesshouldrequirebothhandtooperatethem.However,thosewhichdonot
poseanyriskduetotheirinherentmechanismareexcluded.
2.Theoperationswitchesforexchangingjigsandbladetoolsshouldbelocatedseparatelyfromthenormallyusedoperationpanel,orthey
shouldbeclearlyseparatedontheoperationpanel.
Duringexchanging,thenormaloperationshouldbedisabledelectricallyandmechanically.
3.To make attaching/detaching of the work pieces easy, a mechanism to temporally support the work pieces should be installed sothat the
operator does not have to take a difficult posture while exchanging the blade tools and jigs.
4.To prevent erroneous operation of the operator, the following measures should be consider.
a.Specify the priority among the operation commands.
b.Simplify the operation sequence (grouping) of the operation devices (operation sections).
c.Control interlock
d.Hold-to-run operation
5.The operation commands should be enabled only when the dedicated operation devices (operation sections) are intentionally operated

45. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor 45
Safety Operation
Section 5–Status Indication and Alarms
Allthemachinesshouldbeequippedwithmodeswitchingdevicesothattheycanbefixedinspecificmode.
1.Theoperationstatusofthemachineshouldbeindicatedwithindicators.
2.Operationisallowedonlywhenonecontroloroperationmodeselected
3.Forthemachinethatcoverawiderangeorthosewhichrequirecooperativework,thefollowingsafety
indicatorsanddevicesshouldbeinstalledwhentheoperatorsneedstocheck.
1.Themachinesshouldhaveasafetyindicator
•Thesafetyindicatorhasfourstagesstartingfromthetop:Green,Yellow,RedandWhite
•Theindicatorshouldhavethesignboardsasinthefollowingsamples.
(Theindicatorshouldnotbeusedforpurposesotherthansafety)
2.Thecommunicationsystem(intercom)shouldbeprovidedforeachsection.
3.Whenitisnecessarytocheck
4.Theindicatorsofthecontrolpanelsandoperationpanelsshouldbelocatedatpositionwheretheycan
bereadilyviewedandeasilyidentifiable.
Apply the “Colors of Safety Indicators (Signal Tower)” in the table below !
No Color Meaning Description Honda’s Application
1Green Safe
NormalState
Arbitrary
Key Switch Off
(Operation power off)
2Yellow Caution
Failure / Being inimminent danger
Monitoring and/or intervention
(e.g., reconfiguration of the intended functions)
Teaching (On)
ExchangingJigs / Blade Tools
JOG Operation
3Red Danger
Hazardous situation
Immediate responseto hazardous situation
(e.g., emergency stop operation)
Comprehensive failure
4White Neutral
Other states: When using red, yellow, green, or blue is doubtful
Monitoring and/or intervention
(e.g., reconfiguration of the intended functions)
Automatic Operation
Illustration1. Safety Indicator

46. PT Honda Prospect Motor
46
Occupational Health & Safety Department
PT Honda Prospect Motor
KecelakaanKerjaAkibatBahanKimiadiPTHPM
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedSensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

47. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 1–Noise
Section 2–Standards for Selecting the Means of Approaching Equipment
1.Inallstagesofthelifecycleofmachineryandequipment,themachineryand
equipmentmustbedesigned,fabricated,andinstalledinawaythatallows
workerstoapproachallzonesandlocationswheretheneedtoapproachthe
machineryorequipmentisforeseenfromthegroundorfromthefloor.
2.ifapproachingthemachineryorequipmentisimpossibleorimpractical,any
oneofthealternativemeansofapproachgivenbelowcanbeselectedand
usedasanappropriatebasicsolutionbelow:
1.Stairs
Anascending/descendinginstallationwithanangleofgradientbetween
20and45degrees,withthelevelcomponentsbeingthestairtreads.
2.StepLadder
Anascendinginstallationwithanangleofgradientbetween45and75
degrees,withitslevelcomponentsbeingtreads.
3.FixedLadder
Anascendinginstallationwithanangleofgradientbetween75and90
degrees,withitslevelcomponentsbeingrungs.
4.Aprotectivefencemustbeinstalledwherethereisapossibilityoffalling
fromaheightof500mmormore.FollowtheStandardsforGuardforthe
requirementsconcerningthematerialsandstructureofprotectivefences
5.Forlarge-sizedmachineryandequipment(longconveyors,transfertype
equipment,etc.),astairbridgemustbeinstalledasnecessarytocrosswithin
theoperatingzoneofthemachineryorequipment.
Machineryandequipmentmustbedesignedsothattheriskofnoiseproducedbymachineryandequipmentisreduced
totheminimumpracticallevelaccordingtothecharacteristic.
Noise Standard
GreenBook 80 dB
IndonesianRegulation 85 dB
47

48. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 3–Standard for Installing a Ladder
GeneralRequirements:
1.Ifclimbheightofafixedladderis6000mmormore,suchaladdermusthaveatleastoneplatform,ifthetargetarealess
than10.000mmtheladdercanbeanon-platform(single-climb)ladder
2.Iftherearemultipleclimbs,theclimbsheightofeachladdersection(distancebetweenthestartingpointofclimb
destinationmustbe6.000mmorless)
Single Climb Ladder Multiple Climb Ladder
48

49. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 4–Lighting
GeneralRequirements
1.Installlightssuitablefortheworkinplaceswheremaintenance,inspection,andotherworksuchasoperationand
adjustmentofmachinery&equipmenttakeplace(pit,controlpanelmount,etc.)standardilluminationis150luxor
higher.
2.Forlight,uselightingapparatusthathasaguard,waterprooffunction,orprotectagainstexplosionaccordingtothe
workenvironment.
3.Lightfixturesinstalledfornon-stationaryworkshouldhavestructurethatenablesthelighttobeturnedonandoffas
necessary.
4.Lightingapparatususedinlocationsthathavetheriskofflammablevapororcombustiblegasreachinga
concentrationwhereanexplosionmayoccursmustbecompliantwiththeexplosionproofconstructionstandardfor
electricalmachinery&equipment.
5.Takenecessarymeasurestoeliminateexcessiveluminancecontrastanduncomfortableglaresfromfieldofview.
6.Installlightingdevicesthatsuittheenvironmentindarkplacessuchasdoorwaysformachineryandequipment
inspectionwithstandard150luxorhigher.
Emergency Lamp Explosion Proof Lamp
49

50. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
1.WorkPlatformsandPassageways
a.Generalrequirements
•Theworkplatformorpassagewaymustbedesigned,manufacturedandinstalledforthesafetyofapersonwhoisonitforoperating,
installing,monitoring,repairingoranyworkrelatedtomachineryandequipment,andensuretheworker’sprotection.
•Thematerialsoftheworkplatformorpassagewaymustbeselected,designed,andmanufacturedtosustainforeseeableusage
conditions.Thespecificminimumaspectsthatshouldbeconsideredaregivenbelow:
a.Selectionofcomponents(includingbrackets,connectingparts,bearers,andbases)anddimensionsthatensuresufficientstiffness
andstability.
b.Resistanceofthewholeinstallationagainstenvironmentalimpacts(climate,chemical,corrosivegas,etc.).Forexample,corrosion-
resistantmaterialsorappropriatecoating.
c.Arrangementofstructuralmembersthatpreventswaterretention.Forexample,thejointparts.
d.Useofmaterialsthatminimizeelectrochemicalcorrosionortemperatureexpansiondifferences.
e.Selectionofdimensionsinaccordancewithavailableanthropometricdata.
f.Workplatformsandpassagewaysmustbedesignedandmanufacturedtopreventhazardsourcesarisingfromfallingobjects.
Protectivefence,baseboard,protectiveinstallationsforflooropenings.
g.Itisdesirablethatanypartofthemachineryorequipmentcanberemovedatanytimewithoutmovingtheprotectivefence,floor
members,orotherstandingprotectiveinstallations.
•Workplatformsandpassagewaysmustbedesignedandmanufacturedtoallowtheirsafeuse.Thespecificminimumaspectsthat
shouldbeconsideredaregivenbelow:
a.Anypartthatcanbecontactedbyapersonmustbedesignedandmanufacturedsothatapersonissafelyprotectedfromfailures
anddefects.
b.Workplatformsandpassagewaysmustbedesignedandmanufacturedsothatthewalkingsurfacehasadurableslip-prooffunction.
c.Workplatformsandpassagewaysmustbedesignedandmanufacturedsothatnopersonfallsfromthepartofthemachineryor
equipmentwherepeoplewalkorstand.
d.Workplatformsandconnectedascendingequipment(stairs,ladders,etc.)mustbeinstalledsothatintheeventofahazard,people
canquicklymoveawayfromtheareaorcanquicklyrescueotherpeoplewhennecessary,thusallowingfortheireasyevacuation.
•Handrailsandothersupportsmustbedesigned,manufacturedandarrangedtoallowoperatorstoinstinctivelyusethem.
a.Standardforworkplatformsandpassageway.
b.Generalrequirementsforthefloorsurface
b.StandardforWorkPlatformandPassageways
•Work platforms and passageways should be located as far away as possible from areas where harmful materials and materials that
release chemicals or can cause slipping accumulate.
•Work platforms should be located so as to enable people to work in an ergonomic position.
•The desirable height of work position is between 500 and 1,700 mm above the floor of a work platform.
50

51. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
51
1.WorkPlatformsandPassageways
b.StandardforWorkPlatformandPassageways
•Theinnerlengthandwidthofpassagewaysandplatformsforoperationandmaintenancearedeterminedbasedonthefollowing
conditions.
a.Workrequirements(position,natureandspeedofmovement,applicationofforce,etc.)
b.Whetherornottoolsand/orsparepartsarecarried
c.Frequencyanddurationofworkanduse
d.Maximumnumberofoperatorsthatcanbeontheplatformorpassagewayatthesametime
e.Possibilityofotheroperatorspassingby
f.Evacuationofinjuredpersons
g.Whetherornotthepassagewayhasadead-end.
h.Needforfreedomofworkoperationandtheneedforthespacetousethetoolsrequiredfortheoperation.
•Thestandardminimumoverheadspaceforworkplatformsandpassagewaysis2,100mm.
•Theoverheadspacecanbeloweredbyupto200mmtoaheightof1,900mmiftherelevantapplicationcomplieswiththeexceptional
conditionsandthatitisnecessarytodoso.
Exceptionalcondition1:Whentheworkplatformorpassagewayisonlyoccasionallyused
Exceptionalcondition2:Whenthelowsectionisshort
•Thestandardinnerwidthforpassagewaysis800mm.
•Ifthenormalpurposeofthepassagewayisforseveralpeopletowalkonorcrossatthesametime,thestandardinnerwidthforsuch
passagewaysis1,000mm.
•Theinnerwidthcanbenarrowedtoaminimumwidthof500mmiftherelevantapplicationcomplieswiththeexceptionalconditionsand
thatitisnecessarytodoso.
Exceptionalcondition1:Whentheworkplatformorpassagewayisonlyoccasionallyused
Exceptionalcondition2:Whenthereductionofinnerwidthisoverashortsection
•Ifthereisanobstacleinthesectionwithreducedoverheadheightorinnerwidthinaccordancewiththeexceptionalconditions,
implementmeasuresontheobstacletoprotectpeoplefromit,takemeasurestopreventpersonalinjuries,andalsoconsiderwarning
signs.
•Passagewaysandworkplatforms500mmormoreabovethegroundorfloormusthaveaprotectivefenceinstalledinaccordancewith
theprovisionsonsafetyfencesinChapter2.
•Ifthereisapossibilityofcarryingandmovingheavyloadsthroughapassagewayorplatform,suchapassagewayorplatformmust
haveappropriatefixturesandfittingsthatallowthecarrierstocarryheavyloadswithoutrollingorlayingitonthefloor.

52. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
52
1.WorkPlatformsandPassageways
c.GeneralRequirementsforFloorSurface
Apartoftheserequirementsappliestothegroundsurfacesandundergroundpitfloorsurfaces.
•Floorsurfacemustbedesignedinawaythatallowsanyspiltliquidtodrainaway.
•Iftheconditionin1)cannotbemetforaparticularreason,therisksthatcanarisefromspiltliquidmustbepreventedorminimized
byimplementingandappropriatealternativemethod.
•Floorsurfacemustbedesigned,manufactured,andconstructedinawaythatpreventstheaccumulationofdust,snow,iceorany
othersubstance.Constructthefloorsurfaceusingpermeableflooring,suchasgratingandholedsteelplates,asnecessary.
•Ifapermeablefloormaterialcannotbeusedtoconstructthefloor,apparatusforremovingaccumulatedsubstancesmustbe
providedinthenecessaryplace.
•Inordertoavoidtheriskoftripping,themaximumleveldifferencebetweenadjacentfloorsurfaces(jointpartsinafloorsurface)
mustnotexceed4mm.
•Requirementsforselectingholedflooringwhentherearepossiblerisksoffallingobjects
a.Ingeneral,thesizeoftheflooringmeshshouldnotallowa35mm-diameterballtofallthrough.
b.Iftheflooringistobeusedforthefloorsurfaceofanareawherepeopleareconstantlypassingorworking,thesizeofthe
meshofsuchflooringshouldnotallowa20mm-diameterballtofallthrough.
c.Iftheriskofobjectsfallingorpassingthroughafloorsurfaceusingholedflooringisgreaterthantheassessedriskofslipping
orfallingonthefloorsurface,donotuseholedflooring.
•Ifthedistancebetweenajointpartinthefloorsurface,aconstructionadjacenttotheedgeofthefloor,oraconstruction
penetratingthefloorsurface(pipes,containers,etc.)andtheedgeoffloorsurfaceopeningexceeds30mm,abaseboardmustbe
installed.
•Ifthefloorsurface,forexample,hadastructurethatallowsthefloortoberemovedbasedonthepremiseofconducting
maintenanceondevicesinstalledunderthefloor:
a.Theconstructedflooringmustbefixedusingclamps,stoppersandsuchtosustainallhazardousexternalforces.
b.Inspectionsmustbeabletodiscoverslightcorrosion,loosening,andpositionalchangesoftheclamps,stoppers,andother
fasteners.
•Floorsurfacemusthaveafinishedsurfacedesignedtoreducetheriskofslipping.
•Clearlynotethedesignloadinthelistofspecificationsofworkplatformsandpassageways.
•Theminimumworkingloadsusedforthecalculationofthestrengthoflandings,passageways,andplatformsareasfollows:
a.Distributedloadonstructuralmembersshouldbe2kN/m2.
b.Concentratedloadper200mm200mmatthemostload-demandinglocationonthefloorsurfaceshouldbe1.5kN.
•Whenthedesignloadisappliedonthefloor,theflexureofthefloorsurfacemustnotexceed1/200ofthedistancebetweenthe
fulcrums.
•Whenthedesignloadisappliedonthefloor,theleveldifferenceattheedgeoftheadjacentnon-loadedfloorsurfacemustnot
exceed4mm.
•Thesafetydesignstrengthofthefloorsurfaceistobeverifiedbycalculationortesting.

53. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
2.StandardforStairsandStepLadders
a.GeneralRequirementsformaterialanddimensionofstairsandstepladder
•Materialsmustberesistanttocorrosionfromlocalenvironmentaleffects.
•Thepartsforstairsandstepladdersmustbedesignedandconstructedsothattherearenosharpedges,
roughweldedsurfacesoredges.
•Nopotentialforslippingfortreadsandlanding.
•Brackets,hinges,fasteners,bearersandmountsshouldbeassembledrobustlyandsolidly
•Thestairsandstepladdermustbeabletosustainaloadofupto1,5kN/m
2
foroccasionaltransitornon-load
transit5kN/m
2
andupto5forfrequenttransitorloadedtransit.
•Ifthetreadwidth(w)isnarrowerthan1,200mmtherequiredsustainableloadis1,5kN/100mm
2
atthetipof
thestep,inthecenterwidthofthestairs.
•IfthetreadwidthWis1,200mmormore,therequiredsustainableloads1.5kNper100mm
2
ateachofthe
pointswiththehighestloaddemand,takenevery600mmatthetipofthestep.
•Theflexurebetweentheconstructionandthetreadunderloadshouldbe1/300ofitsdistanceor6mm,
whicheverissmaller.
53

54. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
b.TheSafetyRequirementsApplicabletoStairsareasfollows:
•Ifthehorizontalmovedistanceisg,andtheheightofastepish,theymust
satisfytherelation600≤g+2h≤660.
•Theoverlapoftreadsrmustbe10mmorgreater.Thisisalsoapplicableto
landingsurfacesandfloorsurfaces.
•Theheighteachstepmustbeconstantinaseriesofclimbsinastaircase.
•Ifconstantstepheightcannotbeprovidedbetweenthestartingsurfaceand
theloweststairtread,thatheightcanbereducedupto15%.
•Thetopmoststairtreadmustbeonthesameplaneasthelandingsurface.
•Overheadspaceeshouldbe2,300mmormore.
•SpacingCshouldbe1,900mmormore.
•Theinnerwidthofstairsshouldbe800mmorwider
•Ifmorethanonepersonistopassatthesametime,theinnerwidthshould
beatleast1,000mm.
•ClimbheightHshouldbe3,000mmorless.Alandingshouldbeprovided
beforethecontinuingfightofstairs.Thewidthofthelandingshouldbe
equivalenttoorwiderthanthestairwidth,andthelengthofthelandingL
shouldbe800mmormore.Onlywhenthestaircasecanbestructuredwith
oneflightofstairs,theclimbheightHcanbeextendedupto4,000mm.
c.Thesafetyrequirementsapplicabletostepladdersareasfollows:
•Thelengthoftreadsmustbe80mmorgreater.
•Theheightofeachstephmustbe250mmorbelow.
•Theoverlapoftreadsrmustbe10mmorgreater.
•Theinnerwidthoftreadsshouldbe600mmorgreater.
•Theheightofeachstepmustbeconstantinaseriesofclimbs.
However,iftheconstantstepheightcannotbeprovidedfortheheightfrom
thestartingsurfacetothefirststep,thisheightcanbereducedupto15%.
•Overheadspaceeshouldbeatleast2,300mm.
•SpacingCshouldbeatleast850mm.
•ClimbheightHofaseriesofstepsonastepladdershouldbe3,000mmor
below.
54
1
1
1

55. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
3.StandardforLadders
a.Typesofladders
•Fixeddualsupportladders
Fixedladderwithtoverticalsidememberstosuppporttheloadsandrungsaligned
betweenthesesidemembers
•Fixedsinglesupportladders
Fixedladderwithoneverticalmembertosupporttheloadsandrungsonbothsidesof
thissupportingmember
b.Safetyrequirementsforladders
•Aladdermustbedesignedtomeetthesamerequirementfortheinstallationof
machineryandequipment.Ifnecessary,severeenvironment,vibrationandother
conditionshouldbeconsidered.
•Fixedladdersshouldbedesignedwithtwosidememberswhereverpossible.
•Underexceptionalconditions,afixedsinglesupportladdercanbeprovided(For
example,aserialladderwithvaryinganglesorvaryingrungspacing,orwhenthereis
notenoughspaceforadualsupportladder)
•Allpartswhichausercomesintocontactwithmustbedesignedandconstructedso
thattheydonotcatch,scratchorbeinthewayofaperson.(sharpedges,rough
weldedsurfacesoredges,roughedges)
•Brackets,hinges,fasteners,bearersandmountsshouldbeassembledrobustlyan
solidforstiffnessandstability,andensurethesafetyoftheuserundernormalusage
conditions.
•Thestrengthrequiredofaladderistherequirementindicatedintheinspection
standardsforladder.
c.Basicdimensionofladders
•The spacing of a series of rungs must be constant and between 225 and 300mm
•It is desirable for the spacing between the surface and the first rung and the spacing
between the landingsurface and the rung closets to the said landing surface to have
the same spacing as the spacing of the series of rungs of that ladder.
•If the same spacing as the spacing of the series of rungs cannot be secured between
the starting surface and the first rung, that spacing can be adjusted within the range of
the spacing between consecutive rungs.
•The length of the rungs of a fixed dual support ladder (inner widthbetween the two
side members)must be between 400 and 600 mm.
55
Illustration 1
1
1
2
2

56. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
3.StandardforLadders
c.BasicDimensionofLadders
•Thetopmostrungmustbeatthesameheightasthedestinationwalkingsurface.
•Thegapbetweenthetopmostrungandthedestinationwalkingsurfacemustbewithin75
mm.Ifthegapisgreaterthan75mm,thefloorsurfaceofthedestinationareamustbe
extendedtonarrowthegap.
•RungsthatareU-shapedorwithapolygonalshapemustbealignedsothatthewalking
surfacesarelevel.
•Ashortrungnoshorterthan300mmistoleratedonlywhenalongerrungisnotpossible
duetothesurroundingenvironmentorlackofsuitablepositiontoinstalltheladder.
•Thediameterofthecross-sectionoftherungsmustbe20mmorgreater.Inthecaseof
polygonalorU-shapedrungs,therungsurfacewhereapersonwalksmustbeatleast20
mmdeep.
•Thecross-sectionaldimensionsoftherungsmustnotbesuchthattheycreatedifficultyfor
userstograspontowiththeirhands.Thediameteroftherungsmustbe35mmorless.
•Thesurfaceoftherungsmustnotbesuchthattheycauseinjurytothehands.
•Thesurfaceoftherungsmustbeaslip-proofwalkingsurface.Iftheriskofslippingis
increasedduetoenvironmentalfactors(oil,ice,etc.),specialmeasuresmayberequiredin
somecasestopreventslipping.
•Theedgepartsofrungsofafixedsinglesupportladdermusthaveamprotectivedeviceto
preventslippingandfallinginthetransversedirectionoftherungs.Slip-proofdevicesmust
haveaheightofatleast20mm.
•Theinnerwidthofthedistancebetweenthesupportandslip-proofdeviceinthecaseofa
fixedsinglesupportladdermustbebetween150and250mm,andthewidthofthesupport
mustbe80mmorbelow.
•Therungsofafixedsinglesupportladdermustbeatthesameheightsonbothsidesofthe
support.
d.StandardofInstallingLadders
•The clearance between the adjacent obstacle and the front side of therungs should be 650
mm or greater on the ascending side of the ladder. Ifthe obstacle is discontinuous, the
minimum clearance is 600 mm.
•The clearance with the obstacle on the back side of the ladder should be200 mm or greater.
If the obstacle is discontinuous, the minimumclearance is 150 mm.
•The length of the intermediate platform provided between two laddersmust be 700 mm or
greater. This platform must also satisfy therequirements provided in the provisions on work
platforms andpassageways.
56
1
1
Illustration 1
Illustration 2
Illustration 3
2
3
2
3
4
4

57. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
3.StandardforLadders
d.StandardforInstallingLadders
•Ifthestartingpointofafixedladderwithasafetyfenceisanelevatedplatformor
such,andthehorizontaldistancebetweenthatprotectivefenceandtheladderis
1,500mmorless,theprotectivefenceshouldbeextendedupward.Alternative,the
structureofthesafetyfenceontheladdercanbeextendeddownwardtothe
protectivefence.Theupwardextensionofaprotectivefenceshouldmeetanyoneof
thefollowingrequirements:
a.Theheight/lengthofthesafetyfenceandextensionshouldbe400mmorless.
b.Theanglebetweenthelinethatconnectsthetoppartoftheextensionandthe
closestpartonthesafetyfenceandtheperpendicularlineshouldbe45degrees
orgreater.Thedownwardextensionofthestructuralmemberofthesafetyfence
shouldmeetthefollowingrequirements.
c.Anyspacecreatedbystructuralmembersshouldhaveahorizontalwidthof300
mmorbelow.
d.Thesquaremeasureofthespaceshouldbe0.40m2orless.
•Acrossarrangementofladderclimbs,whichsetstwocontinuousladdersadjacently
toeachother,canbeadoptedinthecasewhereanindividualplatformcannotbe
providedduetotheconditionsoftheinstallationlocationorthearrangementof
machineryandequipment.
•Forcross-arrangedladders,thelowerladdermusthavethetopmostrungatleast
1,680mmhigherthantheconnectingrestplatform.
•Thewidthoftherestplatformshouldbe700mmormore.
•Theheightoftheprotectivefenceontheplatformshouldbe1,600mmormore.
•Theinnergapbetweentheplatformandthelowermostringofthesafetyfenceofthe
upperladdermustbebetween2,200and2,300mm.
e.RequirementsfortheDestinationAreaofLadders
57
•Evenwhenthedestinationareaofaladderisonaplatformconstruction,itmust
haveastructurethatfulfillstherequirementsforaplatform.
•Installafenceforfallprotectiononbothsidesoftheverticalsupportsoftheladderin
thedestinationarea,coveringalengthofatleast1,500mmoneachside.
•Ifthetotallengthofthedestinationareaofaladderislessthan3,000mm,afence
shouldbeinstalledforfallprotectionalongtheentirelength.
Illustration 1
Illustration 2
3
2
4
4
6
6
7
7
1
1
2
3
5
5

58. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
3.StandardforLadders
e.RequirementsfortheDestinationAreaofLadders
•Evenwhenthereisanotherfallpreventiondeviceinthedestinationareaofaladder,a
fenceforfallprotectionshouldbeprovidedseparately.
•Provideanexitinthefrontorsideofthedestinationareaofaladder.Thewidthofthe
openingshouldbe500–700mm.
•Adoormustbeprovidedforanopeningmadeinthedestinationareaofaladder.The
requirementsareasbelow:
a.Thedirectioninwhichthedooropensmustnotbetowardthefallingside(outward).
b.Thedoormustbedesignedforeasyopening.
c.Thedoormustcloseautomaticallyandsafely,drivenbysprings,ownweight,etc.
d.Thedoormustbeofadesignthatensuresthestoppingofthedoorattheclosingend
bymeansofstoppersandsuch.
e.Thedoormusthavethesamestrength,dimensionsandshapeasthefenceforfall
preventiontowhichthedoorisarticulated.
•Iftechnicallyrequired,anopeningforascendinganddescendingfromthebottomsurface
(floorsurface)canbeprovidedintheplatformofthedestinationareaofaladder.
•Asahazardpreventionmeasureagainstfallsfromtheopeningprovidedinthebottom
surface(floorsurface),atrapdoororadoorcombinedwithaprotectivefencemustbe
installed.
•Therequirementsforatrapdoorareasfollows:
a.Theopeningmustatleastmeettherequireddimensionsforthesafetyfenceofa
ladder.
b.Thetrapdoormustnotopendownward.Itmustopenupwardorhorizontally.
c.Thetrapdoormustbemanuallyandeasilyopened.
d.Asafepassagewaymustbesecuredontheplatformorsuchwhenthetrapdooris
open.
e.Afterapersonhaspassedthroughatrapdoor,thetrapdoormustclosewithoutthe
mediationoftheperson,basedonaclosingmethodbyspringsorhydraulicpressure.
58

59. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
4.StandardforFallsPreventionFromLadders
•Theconditionsthatrequiretheinstallationofafallprotectionequipmentareasfollows:
a.Whentheclimbheightofaladderexceeds3,000mm
b.Whentheclimbheightofaladderis3,000mmorbelow,withariskoffallingfromthe
heightofthestartingsurface---inthiscase,afallprotectionequipmentisrequiredwhenthe
totalfalldistanceexceeds3,000mm,startingfromthetopoftheladder
•Thefallprotectionequipmentforafixedladdershouldbeasafetyfenceorfallprevention
device.
a.Asafetyfencemustbetheprimaryselection.
b.Areducedformoffallpreventiondevicecanonlybeselectedincaseswherethesafety
fencecannotbeused.However,thisisonlyapplicableforladdersusedinfrequentlyfor
specialpurposes(maintenance,etc.).Theuseofafull-harnesssafetybeltequippedwitha
slidingapparatusisalsomandatory.
•Thecombinationofafallpreventiondeviceandladder(s)mustbesuchthatstopstheuserfrom
fallingallthewaydown.
•Whenusingareducedformoffallpreventiondevicewithafixeddualsupportladder,theinner
widthbetweenthefixingguideonthepreventiondeviceandthesupportoftheladdermustbeat
least150mm,andthethicknessofthefixingguidemustbe80mmorless.
•Aladderwithareducedformorfallpreventiondeviceshouldonlybeusedbytrained,well-
equippedpersonswhohavepermissiontousetheladder.Anappropriatesafetyequipment
(lockingdevice,etc.)thatensurestheabovemustalsobeprovided.
•Warninglabels/signsandaudiosignalsarenotsafetyequipment.
59
3.StandardforLadders
f.RequirementsforLadderWithoutFallProtection
•Aladderwithoutafallprotectionequipmentcanbeappliedtoladderswithaclimbheightof
upto3,000mm.
•Adualsupportladdermustbeextendedtothehandrailsatthedestinationareaandfixedto
theprotectivefence.
•Asinglesupportladdershouldhaveahandrail,startingfromthefrontofthelastrung,on
bothsidesoftheladder,andthathandrailshouldbeextendedtotheheightofthehandrail
oftheprotectivefenceatthedestinationareaandconnectedtotheprotectivefenceatthe
destinationarea.
Illustration 2
2
2
Illustration 1
1
1

60. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
5.StandardforSafetyFencetobeUsedwithLadders
a.Thelowermostringofsafetyfenceshouldbestartfromtheheight
2.200–3000mm.
b.Thesafetyfenceontheclimbingsurfacesidemustnothavebeneathit
anymemberinhibitingtheapproachtothefrontoftheladder.
c.Thesafetyfencemustbeextendedtotheheightoftheprotectivefence
inthedestinationareaoftheladderwithminimumheight1,100
d.Theinnerdimensionoftheringsofsafetyfencemustbebetween650
and800mm
e.Thedistancefromthefrontoftherungstothesafetyfencemustbe
between650and800mm
f.Thedestinationareaconsistingofsafetyfenceandladdershouldhave
anexitatthefrontorside,openingontoplatformorpassageway.
g.Theinnerdimensionofsafetyfenceatdestinationareamustbe500–
700mmalongthehorizontalaxisoftherungsoftheladder
h.Thedistancebetweentheringsofthefenceshouldbe1500mmorless
i.Theintervalbetweenverticalmembersjoiningtheringsofthesafety
fenceshouldbe300mmorless.
j.Theverticalmemberandtheringsofsafetyfencemustbealigned
perpendicularly
k.Theverticalmembersofsafetyfencemustbefixedequidistantlyonthe
insideoftherings
l.Thesafetyfencemustbedesignedsothatthedistancebetween
membersisalways0.40m
2
orless.
m.Iftheperipheralconstruction(s)inthefrontandsideofaladder(wall,
partofmachineryorequipment)functionsasprotectionofthesame
level(e.g.existingwithdimensionssimilartotheprotection
requirements),asafetyfenceisnotneeded.
1
3
5
2
1
2
3
4
4
60
5
Illustration 2Illustration 1
Illustration 3 Illustration 4
Illustration 5

61. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Work Environment
Section 5–Reference Documents on Work Environment
6.StandardforLadderStrengthInspection
Theladderstrengthmustbeinspectionbeforeused,thisinspectionistomake
suretheconditionoftheladderisalreadyappropriatewithHondastandard.The
inspectiontestbasedonHondaGreenBookstandardsisexplainbelow:
a.Strengthtestforadualsupportladder
b.Bendingtestforadualsupportladder
c.Horizontalbendingtestforadualsupportladder
d.Bendingtesttherungofadualsupportladder
e.Twistfortherungofadualsupportladder
f.Testforafixedsinglesupportladder
g.Bendingtestfortherungofafixedsinglesupportladder
h.Strengthtestforthesupportofafixedsinglesupportladder
i.Strengthtestfordualsupportladderfixingpoints
j.Strengthtestforsinglesupportladderfisxingpoints
k.Supplementarynotesontheladderstrengthtest
2
1
2
1 3
3
Illustration 1 Illustration 2 Illustration3
61

62. PT Honda Prospect Motor
62
Occupational Health & Safety Department
PT Honda Prospect Motor
AccidentCaseRelatedinOtherGenpo
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedSensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

63. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety-RelatedIndicationsandAlarmSystem
Section 1–Safety Signs and Alarm System
a.Definitionsafetysignandlabel:Anindicationthatcommunicatessomekindofsafetyinformationthrough
pictographsthatusesimplifiedshapes,symbolsandmarksthatforeasyunderstanding.
b.Theattachmentofsignsandwarninglabelsshouldbecomplywiththefollowingrules:
(Otherrelevantindicationsincludenameplates,markingsandidentification
plates)
1.Labelsshouldbeattachedtoanappropriatelocationonmachinery&equipment,includingthesideand
top.
2.Labelshouldallowclearreadingoftheirindicationthroughoutthelifecycleofthemachinery&equipment
3.Labelsshouldnotdetacheasily
4.Labelsandwarningsignsshouldcomplywiththefollowingrules:
•Labelsshouldexplainthetypeanddescriptionofhazard
•Labelsshouldallowclearandimmediateunderstandingoftheirdescription
•Labelsshouldprovideprohibitionsorinstructionsonwhattodo
•Re-providingoflabelsshouldbepossible
a.Definitionalarmsystem:Anindicationthatcommunicatesinformationtotheoperatorsofmachinery&
equipmentthroughaudioorvisualsignalssuchasanalarmwhistle,siren,buzzerorlight,etc.
b.Alarmsystemsshouldcomplywiththefollowingrules:
1.Alarmsusingaudiosignalsorvisualsignalsshouldbeusedasnecessary
2.Alarmsshouldbeinstalledinappropriatelocationsonmachinery&equipment,includingtheinside,
sideandtop
3.Alarmsshouldconveytopeoplethesafeusageofmachinery&equipmentaswellassafety
informationformonitoring
•Alarmshouldnotbeunclear
•Alarmshouldensuretheirdetectionorrecognitionandbedistinguishablefromanyother
signal
•Thelocationthatreleaseasignalshouldallowforeasyinspection
Alarm System
Photo Implementation
Sample
Photo Implementation
Sample
Safety Signs & Label
63

64. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety-RelatedIndicationsandAlarmSystem
Section 2–Marking
Safetymarkingisusedtoinformsthehazardouslocationsisa
combinationofsafetycolors,yellowandblackthatshownbelow:
Whenthereisresidualriskfromcontactorapproachingwithhazardous/dangerlocation:
•CatchingHazardYellowMarking
•HazardousLocationSafetyMarking
•HighTemperatureLocationSafetySign
•ElectricShockSafetySign
45
0
Safety Sign Sample of Implementation
Electrical Hazard Fire Hazard Pinching Hazard
64
Slippery Hazard
Sample Implementation
Safety Marking
Machine Direction
Potential Hazard

65. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety-RelatedIndicationsandAlarmSystem
Section 3–Piping Color Standards
1.Identification
Color Name Color Sample Color Name Color Sample
Red Yellow
Dark Red Blue
Light Yellow –
Red
Gray-Purple
Yellow –Red Red-Purple
Brown White
Light Yellow Black
No Substance Identifier Color
1 Water Blue
2 Vapor Dark Red (Rust Color)
3 Air White
4 Gas Light Yellow
5 Acid or Alkali Gray-Purple
6 Oil Brown
7 Electricity Light Yellow -Red
8 Type 1 Organic Solvent Red
9 Type 2 Organic Solvent Yellow
10 Type 3 Organic Solvent Blue
1.1 Indication of Substance
Substance that flows through pipping should be indicated in the combined application of rules provided in a) and b)
a)The identification of the type of substance in the pipe is indicated using the 10 identifier colors listed in table 1.
Note 1 : Electricity is not a substance, but identification of conduits is handled in the same manner as for the pipping
Note 2 : When identifier colors are needed for othe substances, identifier colors other than those provided here are to be used
b) The indication of the names of the substance in the pipping should compy with the following rules :
1.Text substance name and the chemical symbol of the substance should be provuded over the identifier color, using safety colors,
white or black respectively
2.Substance name can be indicated in full name or using the chemical symbol
Example 1 : Drinking Water, Sulfuric Acid
Example 2 : H
2O, H
2SO
4
1.2IndicationofState
a)Indicationofthedirectionofflow
•Arrowsareindicatedusingwhiteorblack
•Theindicationshouldbeprovidedneartheidentifiercolor
b)Indicationofpressure,temperauture,velocityandothercharacteristic
Ifthereisneedtoindicatethecharacteristicoftheinpipesubstance,suchaspressure,temperature,andvelocity,thenumericvalue
andunitsymbolshouldbeprovided.
65

66. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety-RelatedIndicationsandAlarmSystem
Section 3–Piping Color Standards
1.PipeMarking
Illustration1.Examplesofsubstance
indicationbyidentifiercoloraroundthepipe
Illustration2.Examplesofsubstance
nameindication(Inthecaseofair)
Illustration3.Examplesofflowdirection
indication(Inthecaseofsulfuricacid)
Illustration4.Examplesofsubstance
indicationbyidentifiercoloraroundthepipe
Illustration5.Examplesof
HazardIndication
Illustration6.Examplesof
ExtinguishingIndication
66

67. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Safety-RelatedIndicationsandAlarmSystem
Section 4–Name Plate
Nameplateshouldbeattachedtomachinery&equipmenttoidentifytheproductorknowledgerelatedtomachineusage.Indicationsof
Nameplateshouldbesatisfythefollowingrequirements:
1.MarkingrelatedtoMachinery/EquipmentHazardousSource
•Allowableload
•Operationdirection
•MaximumRPMofrotatingpart
•GrossWeightofMachinery/Equipment
2.ControlEquipmentMarking
Controlequipmentmustbeprovidedwithaclear,permanentmarking
thatisclearlyvisibleafterinstallingtheequipment,withthefollowing
information:
•Supplier
•Certifiedindication(ifdemanded)
•Manufacturingyearandmonth
•Serialnumber(ifgiven)
•Ratedvoltage,numberofphase,frequency(inthecaseofalternate
current)andmaincircuitbreakercapacity
•Electricaldiagramnumberorsearchnumberforelectricaldrawing.
•Nameormodelofmachinery&equipment
•Indicationofcompliancewithenforcedrequirements
3.Machinery&Equipment(FinishedProducts)Marking
•Nameofsupplier
•Nameormodelofmachinery/equipment
•Serialnumber,ifgiven
•Manufacturingyearandmonth
•Designatedratedvalues(fluidpressure,airpressure,etc.)
•Indicationofcompliancewithenforcedrequirements
4.Allwiring,pipping,andconnectorsmusthavealignmentmarksas
necessarytohelpensurecorrectconnection
5.IndicationofSafetyInformation
•Devicesymbol
•Stopvalveopen/closeindication
•Functionalindicationofsafetydevice
•Purposeofuseandhowtoadjustthedevice
•Temperature,pressure(normalvalues,valuesforregularuse,
riskvalues)
6.OtherImportantSafetyMatters
Example:
•Prohibitions(Notrespassing,Nooperating,Waterinjection
strictlyprohibited,Exposuretofirestrictlyprohibited,etc.)
•Hazardawareness(Powertransmitted,Highvoltage,High
temperature,Pitentrance,Protrusion,Overheadcaution,etc.)
•Requiredprotectivegear(helmet,lifeline,gloves,mask,safety
boots,etc.)
•Handlingandoperationproceduresthatrequirespecificsafety
cautions.
•ProductLiabilityActplate
Example : Nameplate in Control Panel Equipment
67

68. PT Honda Prospect Motor
68
Occupational Health & Safety Department
PT Honda Prospect Motor
KecelakaanKerjaAkibatBahanKimiadiPTHPM
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedSensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

69. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Machine Tools
Section 1-Lathe Machine
Section 2-Drilling Machine
LatheMachineisamachinetoolthatmainlyrotatesaworkpieceforperformingprocessing
suchaslatheturning,boring,cuttingoff,facemilling,andthreadcutting,usingcuttingtools.
DrillingMachineisamachinetoolthatperformsdrillingworkonaworkpiecemainlyusingadrill.
Never apply a two-step operating method using the same lever. (Example: clamping and starting up.)
Lathe Machine
Drilling Machine
Safety Operation
Safety Function
•Alathewithpowerchuckshouldcomplywiththefollowingrules:
1.Theconditionforopeningthepowerchuckclawisthatthemainspindleisstopped.Andthe
conditionsforstartingthemainspindleshouldincludetheclosingofthepowerchuckclaw.
2.Apressuremetershouldbeprovidedinalocationwheretheactivationofthepowerchuck
canbeconfirmed.
3.Theleverforopening/closingthepowerchuckshouldbesecurelyheldbyanotchora
similarmechanism.
•Basically,anoverloadsafetydeviceshouldbeprovidedatthefeedpowertransmissionarea.
•Boththetailstockandthetailspindleshouldhaveafullyfunctionalclampmechanism.
•Foranautomaticlathe,suchdevicesshouldbebasicallyinterlockedwiththerotationofthemain
spindle.
•Foralathetowhichacolletchuckisattached,partssuchastheclawforopening/closingthe
colletandtheclawholdershouldbedesignedsothattheydonotbecomelooseduringrotation.
Forchucksusedtoholdtoolssuchasadrillandtap,thereshouldbenoprotrusions.
Safety Guards
Safety Function
•Foraworkpieceandworkjig,askidorslippreventionmechanismshouldbeprovided.
•Amechanismforstoppingrotationasneededatthespindleoriginpositionshouldbeprovided.
•Anoverloadtripdeviceshouldbeprovidedasneededattheautomaticfeedpowertransmissionarea.
•Themainspindleheadofadrillingmachineorthearmliftingdeviceofaradialdrillingmachine
shouldbeprovidedwithanoverrunorfallpreventionmechanismasneeded.
69

70. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Machine Tools
Section 3-Boring Machine
Section 4-Milling Machine
BoringMachineisamachinetoolthatperformsboringusingaboringcuttingtoolattachedtothe
mainspindlebyfeedingthespindle.Thecuttingtoolrotatesinconjunctionwiththemainspindle;feed
movementisappliedtotheworkpieceorthecuttingtool.Inmanycases,aboringmachineisprovided
withamillingmechanism.
MillingMachineisamachinetoolthatperformssuchprocessingassurfacegrindingandgrooving
usingamillingcutter.Themillingcutterrotatesinconjunctionwiththemainspindle;feedmovementis
appliedtotheworkpiece
Boring Machine
Milling Machine
Safety Function
Safety Guards
Forchucksusedtoholdtoolssuchasadrillandtap,thereshouldbenoprotrusions.
•Foraworkpieceandworkjig,askidorslippreventionmechanismshouldbeprovided
•Amechanismforstoppingrotationasneededatthespindleoriginpositionshouldbeprovided.
•Anoverloadtripdeviceshouldbeprovidedasneededattheautomaticfeedpowertransmission
area.
•Handlessuchasanautomaticfeedhandleandacrankhandleprovidedataspindletowhich
automaticfeedisappliedshouldbedesignedwithinterlockssothatmanualfeedcanbeapplied
onlywhenautomaticfeedisdisabled.Inaddition,theyshouldbedesignedsothatwhenthe
operatorreleasesthehandfromtherelevanthandle,theclutchisdisengagedandthehandle
switchestoanidlingstate
Safety Function
•Handlessuchasanautomaticfeedhandleandcrankhandleprovidedataspindletowhich
automaticfeedisappliedshouldbedesignedwithinterlockssothatautomaticfeedandmanual
feedcannotbeappliedatthesametime.
•Inaddition,theyshouldbedesignedsothatwhentheoperatorreleasesthehandfromtherelevant
handle,theclutchisdisengagedandthehandleswitchestoanidlingstate.
•Amillingmachineshouldbedesignedinsuchawaythatcutterreplacementcanbeperformed
easilyandsafely.Andamillingmachinetowhichamajordiametercuttercanbeattachedshould
beprovidedwithacutterreplacementdevice.
•Arotarymillingmachineshouldbeprovidedwithaworkpieceunclampdetectiondevice.
•Amillingmachinewhereautomaticfeedcanbeappliedshouldbeprovidedwithfeedstoplimit
switchesforsuchsectionsasthestockandthe
70

71. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Machine Tools
Section 5-Grinding Machine
Grinding Machineis a machine tool that performs grinding on a workpiece using a grinding wheel.
Safety Function
•Thebalanceweightforthegrindstoneshouldadoptamechanismsuchasareversetaperandshouldbe
designedtobenon-detachable.
•Theclampingscrewforthegrindingstonespindleshouldbeturnedinthedirectionofrotationfor
tightening.
•Thegrindingstonecoversshouldbespecifiedasbelow.
Note:thatthisstandarddoesnotapplytoequipmentusingagrindingstonewithadiameteroflessthan
50mm.
Coversforagrindingstonewhosesidesurfaceisintendedtobeusedshouldbeattachedtoits
circumferencesurfaceaswellastothesidesurfaceatthefixedside.
Coversshouldbeprovidedtoagrindingstoneexceptforthepartusedforgrinding.(Internalgrinding
machinesexcluded.)Inaddition,dependingonthetypeofgrindingmachine,thesectionsusedfor
grindingshouldbeasshowninthefiguresbelow.
Coversshouldbefreefromholesorgroovesthatmightdecreasetheirstrength.
(a)Cylindricalgrinding
machine,centerlessgrinder,
toolgrindingmachine,
universalgrinder,andother
similargrindingmachines
(b)Portablegrindingmachine,
swinggrindingmachine,billet/slab
grindingmachine,andothersimilar
grindingmachines
(c)Surfacegrindingmachine,
grindingcutter,andothersimilar
grindingmachines
Surface Grinding Machine
(Vertical Spindle Rotating)
Surface Grinding Machine
(Horizontal Spindle Rotating)
71

72. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Machine Tools
Section 5-Grinding Machine
Surface Grinding Machine
(Vertical Spindle Rotating)
Safety Function
•Ifthereisariskofaworkpiecefallingdowntothewheelspindlestocksideandcausingdamageorinjury,
aprotectionmechanismshouldbeprovided.(Cylindricalgrindingmachines).
•Inprinciple,agrindingmachinerequiringendfacingshouldbeprovidedwithamechanismbywhichthe
endpositioncanbeconfirmed.
•Forthemagnetchuckmethodadoptedbyasurfacegrindingmachine,ifthereisariskofdamageorinjury
causedbyreducedsuctionforce,measuresshouldbetakentoensuresafety.
•Fortheclampingmethodforthemagnetchuckofasurfacegrindingmachine,themagnetchuckshould
beinterlockedwiththeactivationofthestock.
•Forthetailstockdeviceofagrindingmachine,anoverrundetectioncircuitshouldbeprovidedtoprevent
interferencewiththegrindstonewheninanidlingstate.
•Thegrindingmachineshouldhaveanemergencyreturnbutton,whichprovidesafunctionforimmediately
returningthegrindingstoneunit.
•Agrindingmachineshouldbedesignedinsuchawaythatgrindstonereplacementcanbeperformed
easilyandsafely.Agrindingmachinetowhichalargediametergrindstonecanbeattachedshouldbe
providedwithagrindstonereplacementdevice.
•Interlockingshouldbeadoptedsothatgrindingfluidsupplystartsafterthegrindingwheelspindlestarts
rotatingandstopsbeforethegrindingwheelspindlestops.
•Theadvanceofthewheelspindlestockshouldbeinterlockedwiththeconfirmationofgrindingfluid
delivery.
•Anindicationshouldbemadeasneededtoshowthegrindstonestatuswhenrotating.
(d)Table-topgrindingmachine
orfloor-topgrindingmachine
intendedforusewhen
performingcastingfinremoval
(e)Table-topgrindingmachineor
floor-topgrindingmachinewhere
onlytheupperpartofthegrinding
stoneisused.
(f)Table-topgrindingmachine
orfloor-topgrindingmachine
otherthanthoselistedin(d)and
（e),andothersimilargrinding
machines
Surface Grinding Machine
(Horizontal Spindle Rotating)
72

73. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Machine Tools
Section 5-Grinding Machine
Safety Operation
Safety Related Indications and Alarm System
•Inprinciple,thegrindingwheelspindlecannotbestartedunlesslubricantsupplycanbeconfirmed.
•Forthegrindingmachineequipmentthatperformsprocessingwithoutwateroroil(dryprocessing)andperforms
processingusingagrindingstonewithadiameterbeforeuseof300mmorgreater,follow"Ordinanceon
PreventionofHazardsduetoDust"(theMinistryofHealth,LabourandWelfare).
Agrindingmachineshoulddisplaycontentsdescribedin5)and6)aswellasnormallydisplayedcontents
describedin1)to4)onlocationswheresuchindicationscanbeeasilyseen.
1Manufacturer Name 4Rotationspeed without load
2Manufactureer Yearand Month 5Diameter, Thickness and Hole diameter ofusable grinding stone
3Rated Voltage 6Direction ofgrinding stone rotation
Section 6–Metal Sawing Machine
Safety Guard
MetalSawingMachineisamachinetoolthatcutsaworkpieceusingasaw.Metalsawingmachines
usingdifferentsawsareavailablesuchasahacksawing,bandsawing,andcircularsawingmachines.
Metal Sawing Machine
For sawing machines (sawing machines for wood machining excluded), sections other than blades, which
are required for cutting, and saw wheels should be provided with covers or fences.
Safety Function
•Ametalsawingmachine(abandsaw)withasawheadswingmechanismshouldbeprovidedwith
afreefallpreventionmechanism.
•Ametalsawingmachine(abandsaw)shouldbeprovidedwithabladecontact/engagement
preventionmechanism.
73

74. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Machine Tools
Section 7–Other Machine Tools
Safety Function
•Atabletopgrindingmachineorfloortopgrindingmachineshouldbeprovidedwithaworkrestthatcan
adjustthegapbetweenthecircumferenceofthegrindingstoneandtheworkrestto3mmorbelow.
•Acoverusedforatabletopgrindingmachineorfloortopgrindingmachineshouldbedesignedsothatfor
partsrequiringgrinding,thegapbetweenthecircumferenceofthegrindingstoneandthecovercanbe
adjustedto10mmorbelowbyamethodsuchasattachinganadjustmentpiece.
•Atabletopgrindingmachineorfloortopgrindingmachineshouldbeprovidedwithadustcollection
mechanism.
Section 8–Equipment Attached to Machine Tools
Safety Guard
OtherMachineToolsisamachinetoolthatmainlyformametalworkpieceintoadesiredshapeby
removingtheunneededpartthroughcuttingandgrindingoperationsorthroughtheapplicationofelectricalor
otherenergy.
Notethatthosetobeheldbyhandorfixedusingamagneticstandwheninuseshouldbeexcluded.
•Anauxiliarymechanismfortransfershouldbeprovidedwithabrakingmechanism.
•Anautomaticchute,lifter,etc.shouldbeprovidedwithamechanismforworkpieceoverfeed,overshoot,
andfallprevention.
•Thelidonthepitinspectionentranceshouldbelightenoughtobehandledeasilyanddesignedsothatfalls
canbeprevented.
•Cuttingfluidconcentrationequipmentshouldbeprovidedwithanoverflowpreventionmechanism.
•Auxiliaryequipmentshouldbeprovidedwithanabnormalitydetectioncircuitandinterlockedwiththemain
equipmentifnecessary.
•Auxiliaryequipmentshouldbealsoprovidedwithemergencystopbuttons;morethanonebuttonshouldbe
providedasneeded.
Safety Function
•Equipmentforsuchpurposesastransfer,reversal,andloading/unloadingshouldbeprovidedwithsafety
netsandcuttingfluidtrays.
•Protrudingmetalfixturesshouldnotbeusedatbeltjoints.
•Foratransferdevicewithcolumnsthatmightmoveorfalldownduetovibrations,protectionmeasures
againstsuchaccidentsshouldbetaken.
Other Machine Tools
74

75. PT Honda Prospect Motor
75
Occupational Health & Safety Department
PT Honda Prospect Motor
KecelakaanKerjaAkibatBahanKimiadiPTHPM
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedSensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

76. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Industrial Machine
Section 1–Welder Standard
SafetyGuards
Forequipmentinalarge-sizedfacility,suchassystemequipment,withperipheraldevicesstandingtogetherin
largenumbers,careshouldbetakentoensurethatamachinesurroundedbysuchdevicesisvisible.
SafetyFunctions
•Theadopteddesignshouldbesuchthatthefixingboltforthemaincylinderofastationorunitdoesnot
directlyreceivepressure.
•Thebuttons(electricalandmechanical)ontheweldingjigusedforoperationssuchasclampingandlocating
shouldbecoveredandshouldnotbeeasytoactivateunlesstheoperatorintendstooperatethem.(Abutton
withguardring,etc.shouldbeused.)
•Amachinedrivenbyanair/hydraulicpressurepumpshouldadoptacircuitthatsendsanadvancestartup
alarmforacertainperiodoftimewhentheoperatingpowersupplyisturned"ON“.
However,thisdoesnotapplytoastandalonemachineswithoutstations.
•Forthesecondarypowersupplyfortheweldingtransformer,avoltagetogroundof30Vorlowershould
alwaysbemaintained.
SafetyOperations
•Foramanual/autoselectorswitch,thestatus,AutoorManual,shouldbeclearlyindicatedontheoperation
panelusinganindicatorlamp,etc.
•Foraportablespotwelder,theswitchesforturningON/OFFtheweldingcircuitandtheoperatingpower
supplyshouldbeprovidedneartheoperatingstation.
•Forstartupusingautomatedoperation,evenifthestartbuttonswitchispressedandthejigorthesectionfor
liftingtheslidestartstomove,untiltheclearancebecomestoonarrowtoallowfingerstogetin,theoperation
shouldstopimmediatelywhenthestartbuttonswitchisreleased.
However,thisdoesnotapplytoamachinewithamovablejigforwhichsafetyatthetimeofstartupoperation
isensured.
•Astartupmethodusingafootswitchshouldbeprohibited.
However,thisdoesnotapplytoamachinesuchasastationaryspotwelderwherebymachiningisperformed
byholdingaworkpiecewithtwohands.
Safety-relatedindicationsandalarmsystem
•Importantmaintenancepartsthatmightcauseaccidentsshouldbepaintedyellowanddistinguishedfrom
otherparts.(Example:heavilyloadednutsandbolts,andoperationdevices)
•Alineincludingalargemachineshouldbeprovidedwithanindicatorlampdisplayingtheirstatus.
76
Welding Machine

77. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Industrial Machine
Section 2–Press Machine Standard
Press machine are devided into two category there are :
2.1Mechanical Press Machine.Example : Servo press machine, Die spotting machine, Shearing machine
2.2 Hydraulic Pressure Press Machine.Example : Hemming press machine, etc.
SafetyGuards
•Outsidetheoperatingrangeofanautomatedsystem,safetyfenceswithaninterlockfunctionshouldbe
provided.
•Heatinsulatinginordertoprotectpeopleshouldbeperformedonheatedsectionsandareasofequipment
wheretheoperatormightcomeintocontactwith.
Otherwise,suchareasshouldbeprovidedwithacover.
•Transparentmaterial,ifusedinpartforacover,etc.,shouldhavesufficientqualityandstrengthtocope
withdiebreakage,flyingfragments,etc.
SafetyFunctions
1.SafetyBlock
•Apowerpressmachineshouldbeprovidedwithasafetyblockthatcanpreventtheslidefromsuddenly
dropping,andaninterlockthatdisablestheslidemovementwhilesuchasafetyblockisinuseshouldbe
provided.
2.SafetyDevice
•Guard-typedevice
Itshouldbeensuredthattheslidecannotbeoperatedwithoutclosingtheguard.
Theguardshouldbedesignedsothatitcannotbeopenedwhiletheslideisoperating.However,this
doesnotapplytocasesinwhichthepressmachineisinchingandidlingusingsomeothersafetydevice.
•Two-handcontrol
a.Theslideshouldnotbepossibletooperatewithoutpressingmorethanonebuttonwithbothhandsat
thesametime,andeachtimeoneorbothbuttonsisreleased,theslideoperationstopsonaone-cycle
basis.
b.Forthespacebetweenbuttons,theshortestdistanceinwardshouldbeequaltoorgreaterthan300mm.
c.Buttonsshouldbebuiltintothepressunitandshouldnotprotrudefromthesurface.Ortheyshouldbe
containedinbuttoncasesandshouldnotprotrudefromthecasesurface.
•Lightbeam-typedevice
Amechanismshouldbeadoptedthatstopstheslideoperationwhendetectingblockageoflightbeamsby
evenpartoftheoperator'sbody.
General Requirements
77
Press Machine Illustration
Illustration 1
Illustration 2
Illustration 3

78. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Industrial Machine
Section 2–Press Machine Standard
SafetyFunctions
2.Safetydevice
Lightbeam-typedevice
a.Amechanismshouldbeadoptedthatstopstheslideoperationwhendetectingblockageoflightbeamsbyevenpartoftheoperator's
body.
b.Thesafeoperatingrangeshouldbethecombinedlengthoftheslidestrokelengthandtheslideadjustmentamount.
However,iftheabovetotallengthispartiallycoveredbyanenclosure,etc.,thecoveredportionshouldbereduced.And,ifthetotallength
exceeds400mm,thesafeoperatingrangecanbelimitedto400mm.
c.Boththelightemitterandthelightreceptorshouldhavemorethanoneopticalaxis,anintervalbetweenwhichshouldbeequaltoorless
than50mm.However,foralightbeamtypesafetypressmachinewiththehorizontaldistanceinrelationtothedangerlimitexceeding
500mm,theaboveintervalcanbeequaltoorlessthan70mm.
d.Thelightreceptorshouldbedesignedtobesensitivetoonlylightbeamscomingfromthelightemitter.
e.Theheightoftheshearfromthestocksurfaceshouldbeequaltoorsmallerthanadistance0.67timesasmuchasthehorizontal
distanceinrelationtothesheardangerlimit.Ifsuchadistanceexceeds180mm,theheightcanbelimitedto180mm.
3.EmergencyStopDevice
Apowerpressmachinewithanemergencystopmechanismshouldbeprovidedwithadevicethatcanimmediatelystoptheslideoperationin
anemergency,anddesignedinsuchawaythatwhentherelevantemergencystopdeviceisactivated,automaticstartupcannotbeperformed
withoutreturningtheslidetothestartup(topdeadcenter)state
4.AnEmergencyStopButton
Thisbuttonshouldbeprovidedateachoperatingstation,onthefrontandonthebackifanuprightexists.
5.InchingMechanism
Apowerpressmachinewithquickstopmechanismshouldhaveaninchingmechanism.
6.KeySwitch
Akeyswitchisusedforthecyclechangeswitchandoperationchangeswitch.Thecycletypeoroperationmethodshouldbeclearlyindicated
ineachchangeposition.Thekeyswitchshouldbeofamechanismthatallowstheoperatortokeepthekeypositionintheswitchingposition
aswellaspullitoutfromeachposition.
7.Apowerpressshouldbeprovidedwithalamp,etc.indicatingthatthemachineisreadyforoperation.
8.Vibration-proofingmeasuresshouldbetakenbetweenthepressmainunitandelectricalcomponentsmountedonit.
9.Apressmachinewithautomaticdieclampingdeviceshouldbeprovidedwithaninterlockbetweenclampingconfirmationandslideoperation.
(AnautomaticclampingdeviceshouldbedesignedtoretainclampingforceevenifthepoweristurnedOFF.)
10.Aninterlockcircuitshouldbeprovidedsothatwhileperformingsupplementaryworksuchasapplyingamoldreleaseagent,operationcannot
startevenifthefootswitchissteppedon.
78

79. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Industrial Machine
Section 3–Injection Machine Standard
SafetyGuards
•Ifthereisariskofevenpartoftheoperator'sbodyenteringthedangerareaoftheslide,aninjectionmachine
shouldbeprovidedwithcoversordoors.(Ontheoperationside,thesideoppositetotheoperationside,andthe
upperpartoftheslideoperatingrange.)
However,thisdoesnotapplytoaninjectionmachinewithalight-beamsafetydevice.
•Hotareassuchastheheatcylindersectionshouldbeprovidedwithheatinsulationcoversforprotection
SafetyFunctions
•Thesafetydoorcompliantwith"Stopfunctioncategory0"shouldbeprovidedintheslideoperatingrange.Notethat
duringdiereplacement,bychangingaspecificmodekeyswitch,theabovefunctioncanbedisabled.
•Stopfunctioncategory0(Stopbydirectlyshuttingoffthepowerofthemechanicalactuator)
•Amechanisminwhichresidualpressureremainsshouldhaveafunctiontobleedoffsuchpressure.
•Whenanaccumulatorisused,asafetyvalve,pressuregauge,andstopvalveshouldbeprovidedinthecircuit;
containersandpipingdevicescompliantwiththeHighPressureGasRegulatoryLawshouldbeselectedandused.
•Forequipmentusinganaccumulator,astopvalvetopreventahigh-pressuregasfromflowingbackwardintothe
hydraulictankshouldbeprovided.Inaddition,acircuitshouldbeprovidedthatchecksthelowerlimitpressurefora
gassuspectedofdanger,signalsanalarm,andclosestheaccumulatorcircuittostoptheaccumulator.
•Topreventaccidentssuchasfreefallandmalfunction,asafetydevicetolocktheslideshouldbeprovided
•Foractivationofthepumpmotorofamachinedrivenbyanair/hydraulicpressurepump,acircuitshouldbe
providedthatactivatesthepumpmotoraftersendinganadvancestartupalarmforacertainperiodoftime.
•Formanualoperationoftheslideinjectionunit,acircuitshouldbeprovidedthatactivatessuchoperationafter
signalinganalarmforacertainperiodoftime.
•Forheatertemperaturecontrol,overtemperaturedetectionshouldbeperformedperzone,andacircuitshouldbe
providedthatentirelycutsofftheheaterpowersupplywhenanabnormaltemperatureisdetected.
•Whilethedoorontheoperationsideoronthesideoppositetotheoperationsideisopen,theslideshouldnot
operate.And,acircuitshouldbeprovidedthatstopsthehydraulicpressureonthesideoppositetotheoperation
side.
•Onlythedoorontheoperationsideshouldbeprovidedwithadoubleinterlock(mechanicalorhydraulicandelectric)
tofurtherensurethattheslidedoesnotoperatewhilethedoorisopen.
•Power-drivendoorclosingoperationsshouldbebasedontwo-handcontrol.
•However,acircuitshouldbeprovidedthatoperatesthedooronlywhiletherelevantbuttonsarehelddownuntilthe
doorclosesandstopstheoperationimmediatelywhentheyarereleased.
•Theinjectionnozzlesectionshouldbeprovidedwithacovertopreventresinfromejectingout.And,acircuitshould
beprovidedthatprohibitsinjectionwhilethecoverisopen.
79

80. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Industrial Machine
Section 3–Injection Machine Standard
SafetyOperations
Acircuitshouldbeprovidedthatensuresthatoperationscannotstartevenwhenthestartbuttonswitchispressed
unlessthesafetydeviceconfirmsthattheslideisinitshomeposition.
SafetyAncillaryEquipment
a.Extractiondevice
•Amachineshouldbedesignedsothatnopartofthebodycaneasilyentertheswingormovingrangeofthe
extractiondevice.
•Afunctiontostopoperationwhenapartofthebodyentersthedangerareaintheswingingormovingrange.
•Whentheextractiondeviceisinuse,alarge-sizeddisplaylampshouldbeputinalocationwhereitcanbeseen
easily.
•Afunctiontomovetoapositionwheresafetycanbeensuredduringdiereplacementoperationsshouldbe
provided.
•Anemergencystopbuttonshouldbeputwhereitisneeded.
•Adesignshouldbeadoptedthatpreventsfragmentsfromflyingoutoftheclampingmechanismduetodropped
moldedproductandposingadangertooperatorsorotherpersonnel.
b.Diechanger
•ItshouldbemadepossibletoperformdiechangebyturningakeyswitchON/OFF.
•WhenONisselectedfordiechange,theclampingdeviceshouldonlybepermittedtooperateinmanualmode.
•Duringdiechangework,alarge-sizedindicatorlampshouldbeputinaplacewhereitcanbeeasilyseen.
•Thediechangecarriageshouldbeprovidedwithamechanicalstoppersothatthediesdonotmovewhilethe
machineisrunning.
Inaddition,afunctionshouldbeprovidedthatimmediatelystopsthemachine'soperationifadiemoveswhile
themachineisrunning.
80

81. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Industrial Machine
Section 4–Casting Machine Standard
SafetyGuards
•Heatinsulationprocessinginordertoprotectpeopleshouldbeperformedonorcoversshouldbeprovidedforareastheoperator
mighttouchduringordinaryworkintheheatedsectionofmachineequipmentandworkpieces.
•Ifthereisariskoffirecausedbyasplashofspilledoil,etc.,afire-retardanthydraulicfluidshouldbeusedandacoverforfire-
preventionshouldbeprovided.Notethatafire-retardanthydraulicfluidshouldbeselectedusing"Hydraulicfluidselectioncriteria".
•Coversshouldbedesignedtopreventcastingfinsordiefragmentscreatedbybreakagefromflyingovertheoperator'spositionand
thefloorsurface.
•Nearthediematchingsurfaceandliquidinlet,electricalequipment,wiring,piping,etc,shouldnotbeinstalledwithintherangeover
whichliquidmetal,etc.mightspillandfly.However,consideringtheequipmentdesign,ifthereisnoalternativebuttoinstallanyof
theaboveinthesaidrange,protectivemeasuresshouldbetaken.
•Amechanismshouldbeadoptedthatcanpreventburnsandotherhazardscausedbyflyingorspillinghotobjects.
•Asafetyvalveorexhaustoutletoverflowoutletshouldbeplacedsothatitcannotobstructtheoperatororotherequipmentandshould
bedesignedtocausenoharmwheninoperation
SafetyFunctions
•Avalvedesignedtofillfluidsbyapplyingpressureonthefluidsurfaceshouldbeofbalancetypeorprovidedwithmorethanone
safetydevice.Whenanabnormalityoccurs,pressureshouldbebledfromthefluidsurface.
•Whenanaccumulatorisused,asafetyvalve,pressuregauge,andstopvalveshouldbeprovidedinthecircuit;containersandpiping
devicescompliantwiththeHighPressureGasRegulatoryLawshouldbeselectedandused.
•Areassuchasanaccumulatorwheretheresidualpressuremightcauseharmshouldbeidentified.
•Foramachineusinganaccumulator,astopvalvetopreventahigh-pressuregasfromflowingbackwardintothehydraulictank
shouldbeprovided.Inaddition,acircuitshouldbeprovidedthatchecksthelowerlimitpressure,signalsanalarm,andclosesthe
accumulatorcircuittostoptheaccumulator.
•Apressureadjustmentcircuitdesignedtouseair/hydraulicpressureshouldbeprovidedwithapressuremeter.
•Topreventaccidentssuchasfreefallandmalfunction,asafetydevicetolockthemovablediemachineinitshomepositionshouldbe
provided.Inaddition,forequipmentwithverticalorclampingdesigns,amanualsafetybarorblockshouldbealsoprovided.
•Anautomaticdieclampingdeviceshouldhaveadesignorcircuittosecurelymaintaintheclampingforcewhenadieisremovedor
whilethemachineisstopped.
•High-speedinjectionshouldnotbepermittedwithoutcheckingtheclampinglimit.
•Arotarycastingmachineshouldbecapableofstoppingoperationinanypositioninemergenciesandhaveamechanicallocking
function.
•Inprinciple,arotarycastingmachineshouldbeprovidedwithmorethanonesafetydeviceandwithacircuitthatsendsanalarm
duringrotation.(Manualoperationexcluded.)
Casting Machine are devided into two category there are :
2.1 High Pressure Die CastingMachine.
2.2 Low Pressure Die CastingMachine.
General Requirements
81

82. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Industrial Machine
Section 4–Casting Machine Standard
SafetyFunctions
•Amanuallyoperatedsafetybarorblockshouldbeprovidedwithapumpactivationinterlock.
•Forsafetydevices,thosethathavepassedtheinspectionrequiredbytheMinistryofMinistryofHealth,LabourandWelfare
orequivalentonesshouldbeused.
•High-pressurepowerreceivingequipmenttobeinstalledinthefieldshouldbeofcubicletype;thedoorsshouldbedesigned
sothattheycanbelocked;and,ifused,safetydevicesthathavepassedtheinspectionrequiredbytheMinistryofMinistry
ofHealth,LabourandWelfareorequivalentonesshouldbeused.
•Whenaninjection,clamping,orslidingcoredetectiondevicebecomesfaulty,errordetectioncyclesshouldnotbe
sustained.
•Asafetydevice'selectricalcircuitshouldbeprovidedwithalampindicatingthepossibilityofoperationorerrorstatus.
•Itshouldbeensuredthatacastingmachineequippedwithanautomaticfluidfillingdeviceisinterlockedwithsuchadevice.
•Averticalcastingmachineshouldhaveacircuitthatcanstopoperationinanypositionduringdescendingmovementand
maintainthatposition.
General Requirements
SafetyOperations
•Anoperationmodechangeswitchshouldhavestepsarrangedintheorder:"Manual"-"OFF"-"Auto"-"Fullauto"andthe
statusshouldbeclearlyindicated.Forakeyswitch,itshouldbepossibletopulloutthekeywhentheswitchisinOFF
position.
-Achangeoverswitchshouldnotrotate360degrees.
•Continuousoperationshouldnotbeavailableforequipmentinwhichaworkpieceismountedorremovedbyhand.
•Foractivationbyautomatedoperation,cyclesshouldnotcontinuetooperateuntilthebuttonSWispressedandthedooris
closedorwithoutholdingdownthebuttonSWuntilthemovablediemachineadvancesordescendstowardthefixeddie
machineandmovesintoapositionwherefingerscannotgetin.
•Itshouldbeensuredthatautomaticactivationcannotbeperformedwithoutconfirmingthateachmechanismisinitshome
position.
•Inawiderangeofmechanicalequipmentandjointoperations,besideactivationconditionsfordifferentsetsofmechanical
equipment,confirmationandpermissionbyoperatorsofdifferentsetsofmechanicalequipmentmayberequired.Forthat
purpose,oneofthefollowingshouldbeprovided.(Parallelinstallationincluded)
(a)Communicationfacilitydedicatedtoeachsection
(b)Monitordisplaythatcanmonitortheentiresystem
(c)Foranunattendedarea(insideapit,ahighelevation,etc.)requiringthecheckingoftheequipmentoperating
status,equipmentwithwhichtheoperatorcanvisuallycheckthestatus
•Foroperationsofancillaryequipment,acircuitshouldbeprovidedthatenablesmanualoperation,operationlinkedwiththe
machineryorequipmentmainunit,andstandaloneone-cycleautomatedoperation.(Aquickdiechangerexcluded.)
•Wheninmanualoperation,highspeedandpressureadditionduringinjectionshouldbeprohibited.
•Fordiechange,etc.,whenasub-operationpanelisprovidedseparately,achangeoverswitchshouldbeprovidedsothat
boththemainoperationpanelandthesub-operationpanelcannotbeoperatedsimultaneously.
82

83. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Industrial Machine
Section 4–Industrial Machine Standard
SafetyGuards
•SafetypartitionsshouldcomplywithBStandard,"Chapter2Guards(safetypartitions)andouterstructure".
•Safetypartitionsandsafetyfunctionsshouldbeprovidedeffectivelynotonlyfortheoperatorbutalsoforothers.
•Theequipmentlayoutshouldbearrangedsothataworkspacerequiredforsafelycarryingoutindustrialrobotrelatedwork
canbesecured.
•Electricaldevicesshouldbeinstalledwherefins,spatters,etc.donotflyover.
•Ifthereisnoalternativebuttoinstallanelectricaldeviceinsuchaplace,afullyeffectivecovershouldbeprovided.
•Controldevicesandoperationpanelsshouldbeinstalledoutsidetheguards.
SafetyFunctions
•Topreventhazardsthatmightbecausedtotheoperatorduetorobotmalfunction,amechanicalstoppershouldbe
provided.
•However,ifitisnotpossibletoprovideastopper,amechanismshouldbeprovidedthatcandetectabnormalitiesusingtwo
limitswitches,oralightcurtainandscannerphotoelectricscreensensor.NotethatSafetycategory3orhighershould
apply.
•Amechanicalstoppershouldbecapableofstoppingtherobotevenwhentherobotiscarryingtheratedloadatthe
maximumspeed.
•Theactivationcircuitforanelectricalstoppershouldbeseparatefromthecontrolcircuitoperatedbyanindustrialrobot's
program.
•Arobotshouldbedesignedtostablyholdanobjectevenwhenapoweroutage,fault,oremergencystopoccurs.
•However,ifthisisnotpossible,safetyshouldbeassuredbyprovidingaprotectionfencethatpreventsaheldobjectfrom
goingoutofthedangerarea.
•Arobotshouldbedesignedtobecapableofstablyoperatingatitsmaximumspeedevenifholdingaload1.2times(safety
ratio)asmuchasthemaximumtransportableweight.
•Alight-beamoroscillatingsafetydeviceshouldbeinstalledsothatdetectioncanbemadefromanangleeffectivetowork
movement.Whentherobotsystemstoppedbecauseitssafetydevicewasactivated,ifanotherdangerisnotsupposedto
occurbyrestarting,therobotsystemcanrestartfromthepositioninwhichitstopped.
•Powercut-offdevices(electromagneticswitches,clutches,solenoidvalves)shouldoperateindependentlyofotherdevices.
•Powercut-offdevicesshouldnotoperateorreturnsuddenlyduetocontact,vibration,etc.
•Itshouldbeensuredthatemergencystopbuttonswitches(redmushroomtype,lockswitches)areprovided.
•Touseapowercut-offdeviceasanemergencystopfunction,measurestoquicklystoptherobotshouldbetakensuchas
usingamechanicalbraketogetherwithsuchadevice.
Afunctionthatimmediatelystopstherobotbyimmediatelyreleasingtherobotdrivingenergyorcuttingsuchenergyoff.
IndustrialMachineisamachinewithamanipulatorandstoragedevice(includingavariablesequencecontroldeviceanda
fixedsequencecontroldevice)thatcanperformtelescopic,bendingandstretching,up/down,left/right,andswing
movementsorseveralsuchmovementscombinedtogetherofthemanipulatorbasedondataofthestoragedeviceandthat
accompaniesteachingoperation.
83

84. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Industrial Machine
Section 4–Industrial Machine Standard
SafetyFunctions
•Manualoperationorresetoperationforrestartingtherobotsystemafteranemergencystopshouldbeperformedoutsidethedangerarea.
•Acircuitshouldbeprovidedthatwhentherobotdetectsanabnormality,operationcannotstart.
•Inaddition,ifdetectinganabnormalityduringoperation,therobotshouldeitherimmediatelystoporemergencystop.
•(Whenmultiplerobotsarebeingused,seeStandardB,Chapter3,Section5Interlockingbetweenadjacentsetsofequipment.)
•Adetectioncircuitshouldbeprovidedthatcanpreventmalfunctionduetowirebreakageordetectorabnormality.
•Whenoperationisstartedfromtheoperationpanelfortherelatedequipment,theremotemodeshouldbeactiveontherobotside.
•Inprinciple,afailsafefunctionshouldbeprovidedsuchasstoppingtherobottopreventdangerwhenanabnormalityoccurssuchasavoltage,
oil,orairpressurefluctuationandpoweroutage.
•Inprinciple,afunctionshouldbeprovidedthatsendsanalarmoutsideifoperationstopsduetoanabnormalityoccurringintherobot.
•Arobotdrivenbyhydraulicpressureorairpressureshouldbedesignedsothattheresidualpressureintheactuatorusedforrobotdrivingcanbe
safelyandeasilyreleased.
•Terminalsforreceivingemergencystopsignalsofexternaldevices,etc.
SafetyOperations
•Ateachboxshouldbeprovidedwithanemergencystopbuttonswitch.
•Amodeswitchshouldbeprovidedwithakey.Whenin"Teach"mode,itshouldbemadepossibletopullthekeyoutsothatthemodecannot
change.Or,akeyswitchforpermittingteachingshouldbeprovidedsothatthekeycanbepulledoutwhentheteachingworkpermittedsideis
selectedandothermodesarethendisabled.
•Modeselectionorchangeshouldbepermittedonlybyoperatingthemodeselectionswitch.
•Themodeselectionstatusshouldbeclearlyindicated.
•Forarobotsettotheteachmodebyoperatingthemodeselectionswitch,asafeoperatingspeedshouldbeautomaticallyset.Arobotshouldnot
operateatspeedsexceedingasafeoperatingspeedof250mm/sec.
•Availablebuttonoperationforteachingshouldbelimitedtoinching.
•Afunctionshouldbeprovidedthatindicatesthestatusoutsidewhiletherobotisoperatingorstandingbyinautomaticmode.
•Tocarryoutworksuchasteaching,preparation,andadjustmentforaplayback-typerobot,afunctionshouldbeprovidedthatcarriesoutsuch
workafterreleasingorcuttingofftherobot'sdrivingenergy.
•Thisdoesnotapplytocasesinwhichafunctionthatlimitsthespeedoftherobot'sarmendto250mm/secisprovided.
•Operationmodechangeshouldbedirectlyoperatedbytheoperator.
•Forateachboxusedwheninteachmode,adeadman’sswitchshouldbeused,sothatwhentherelevantswitchisreleasedorevenwhenitis
heldtightly,thepoweroftheindustrialrobotcanbeautomaticallycutoff(servo-off).
SafetyRelatedIndicationsandAlarmSystem
•Anindicatorthatdisplaystheoperatingconditionoftherobotaswellasdanger,ifany,shouldbeprovided.(Alamp,buzzer,soundalarm,etc.)
•When"Teach"modeisselected,anindicationdisplayingthatstatusforsafetyshouldbemade.(SeeBStandard-Chapter4Operations,Section
5Statusdisplayandalarm.
•Thefollowinglabelsshouldbeattachedtotherobot:
a.Maximumloadcapacity
b.Weightofrobot
c.Manufacturer,manufacturingyearandmonth,andmanufacturinglotnumber
d.Modelanddrawingnumber
e.Ratedoutputofmotor
f.Othernecessaryitems
84

85. PT Honda Prospect Motor
85
Occupational Health & Safety Department
PT Honda Prospect Motor
KecelakaanKerjaAkibatBahanKimiadiPTHPM
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialsMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedSensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

86. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 1–General Conveyor Equipment
SafetyGuards
•Thestructureshouldbesuchthatpreventstheconveyorchainsoftheinspectionelevationgate,inspectionpassageway
andsuchfromeasilymakingcontactwithhumanbody.
•Asneeded,hangers,trolleysandsimilaritem,shouldbeprovidedwithmechanismthatpreventknockingandsideways
shaking.
•Safetyprotectionnetsshouldbeofsufficientstrengthandstructuresoastonotbreakwhensubjectedtofallenparts,
conveyorconstructionsandotherpossibleitems.
•Asafetyfenceshouldbeinstalledasnecessaryintheoperatingareaofelevatingandtransfersections.
•Asneeded,bucketsandsimilaritemshouldbeprovidedwithmechanismthatpreventsidewaysshaking
•TensionequipmentfortrolleyconveyorsshouldbeprovidedwherethechainU-Turns.
•Thegapbetweenthechainrailunderthefloorsurfaceandthefloorsurfaceedgeshouldbeminimizedfortheoperator’s
safetyandacovershouldbeprovidedwhennecessary.
•Thesidesandconnectingunitsofaconveyorshouldhaveastructure,suchasacoversufficientstrength,thatprevents
theentryoftheoperator’sbodylimbsorotherbodyparts.
•Thedriveanddrivenunitsofconveyorshouldhaveastructure,suchasacoverofsufficientstrength,thatpreventsthe
entryoflimbsandotherbodypartsaswellaspreventingthemfrombeingpulledin.
•Anelevatedoroverheadconveyorsystemshouldhaveaninspectionpassageway.
SafetyFunctions
•Thedriveunitshouldusewhennecessary,aself-lockspeedreduceroranequivalenttopreventfreeflowmovement
•Thetensionforthedriveanddrivenunitsshouldadopt,inprinciple,automatictensioncontrol
a.Tensionshouldhavefloatingdetection,andshouldstoprelevantmechanismincaseoferror
b.Thetensionweightboxshouldbeofsufficientstrengthandconstructedinsuchawaythatpreventsweightsfrom
fallingout
General Conveyor Equipment are devided into two category there are :
2.1 Overhead Conveyor
•Overhead Conveyor (P&F)
•Overhead Bucket Conveyor
2.2 Floor Conveyor
•Cart Conveyor
•Tow Conveyor
•Slat Conveyor
•Free Flow Conveyor
•Belt Conveyor
•Other Conveyor (Friction Conveyor, Spiral Conveyor, etc.)
86

87. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 1–General Conveyor Equipment
SafetyFunctions
•Afluidsupplydevicethatenablesfluidsupplywithoutcomingclosetodangerousmovingpartsshouldbeprovided.
•Thechainshouldhavesufficientstrength,withitsjointshavingarobustanddurablestructure
•Thedriveunitshouldhaveanerrorloaddetectionmechanismtostoprelevantmechanismincaseofabnormal
Conditions
•Ifthedistancebetweenthemotorandthecontrolpanelislargeorsuchthatitdoesnotallowtheoperatoronthecontrol
paneltoseethemotor,adeviceforshuttingdownthecircuitshouldbeprovidednearthemotor.
•IfmultiplesystemsarecontrolledbyonePLC,anoperatingpowerkeyswitchshouldbeprovidedforeachsystem
•Anemergencystopbuttonshouldbeprovidedinaneasilyaccessibleplaceontheoperationpanelandthedriveand
drivenunits.Anemergencystopbuttonorpausebuttonshouldalsobeprovidedinthefollowinglocations:
a.Operationlinesandoperationprocesses
b.Automatedmachinezones
c.Transiting,mergingorbranchingareas
d.Start/Stopareas
e.Otherareas,includingundergorundpitsandhazardszoneswithblindspot
SafetyOperations
•Onlyonesimulationsstartswitchshouldbeprovided,andwhenstarting,analarm(buzzer,bell,etc)shouldsettofffora
certainperiodoftimebeforehand.Analarmshouldbeinstalledinthefolloringlocations:
a.Operationlinesandoperationprocesses
b.Automatedmachinezones
c.Transitting,merging,orbranchingareas
d.Driveanddrivenunits
e.Otherhazardzoneswithblindspots
SafetyWorkEnvironment
•Theclearancebetweenhandrailandconveyeditemsshouldbesuchthatitpreventsahumanbodypartfromgetting
caught.
•Provideafluidpanunderthedriveanddrivenunitssothatgreaseandanyotherfluidsdonottripdown
•Theinspectionmountforthedriveanddrivenunits,controlpanelandsuchshouldhavesufficientspaceandstrength
•Themountforthedriveanddrivenunits,controlpanelandsuchshouldhavelightingwithilluminationsuitablefor
inspection.
•Apassagewaycrossingaconveyorshouldbeclearlydistinguished.
•Incaseofhavinganinspectionpassagewaynearanexposedchain,installaasafetycoveroversuchexposedchains.
•Provideaslip-proofinstallationoninclinedinspectionpassageways
87

88. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 2–Drop Lifter
SafetyGuards
•Thesafetyshuttershouldhavesufficientstrengthandastructurethatposesnorisktooperators
•Theweightsandsuchbestoredinasufficientlystrongbox
•Thestructureshouldnothaveanyhazardareas,includingrotationunits,exposed
•Anelevatingframeshouldhaveanequivalentbalanceweight,alongwithastructurethatpreventssuddenfallswhen
thebrakeisreleased.
SafetyFunctions
•Theelevatingchainandwireshouldconstructadouble-structure,equippedwithalooseningandbreakdetection
mechanism.Whenthemechanismactivates,thedropliftandotherrelevantmechanismshouldbestoppedimmediately.
•Asafetymechanicalstopperwithsufficientstrengthandacarrier/hangeroverrunstopsystemshouldbeprovidedat
bothendsoftheelevationrail.
•Thebalancerweight,counterweightandotherrelevantweightsshouldallbeequippedwithaguiderollerandslide
rollers
•Provideadetectionfunctionfordetectingover-loweringandover-lifting
•Installsafetyfencestopreventdangerswithinthelifters.Aninterlockshouldbeprovidedatthegateofsafetyfence,and
whenthegatesisopen,itshouldstoptherelevantequipment
•Safetymechanism,suchasshutters,shouldbeimplementedtopreventhangingobjectsfromfalling.
•Theliftershouldnotbeloweredunlessthesafetymechanism(safetyshutters,etc.)isoperating.Ifthesafetymechanism
cameoff,itsmotionshouldbestoppedimmediately.
•Whenperforminghigh-speedswitchingorstopoperation,theoperatingcurveshouldbesmoothandshock-absorbent.
•Forhydraulicallydrivenequipment,takeduecareofsurgepressureabsorption
•Forpneumaticallydrivenequipment,ensurethatthestructureisrisk-freethroughdueconsiderationofinitialejection
andcompressibility
•Ifalifterelevationareaincludesanoperationzone,analarmdevicemustbeinstalledinalocationthatenablesthe
operatorstoeasilyhearthealarm.
•Ifthedistancebetweenmotorandcontrolpanelislargeorsuchthatitdoesnotallowtheoperatoroncontrolpanelto
seethemotor,adeviceforshuttingdownthecircuitshouldbeprovidednearthemotor.
SafetyOperations
•Alarmshouldbeinstalledinthedriveunitsandotherhazardzoneswithblindspots
WorkEnvironment
•Theclearancebetweenthehandrailandcarriedobjectsshouldbesuchthatpreventsahumanbody(part)fromgetting
caugth.
•Provideafluidpanunderthedriveandslideunitssothatgreaseandanyotherfluidsdonottripdown
•Theinspectionmountforthedriveunitandsuchshouldhavesufficientspaceandstrength
•Themountforthedriveunit,controlpanelandsuchshouldhavelightingwithilluminationsuitableforinspection
Drop Lifter Illustration
Illustration 1
Illustration 2
88

89. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 3–Elevator
SafetyGuards
•Anelevatorinstalledinabuildingshouldhaveasafestructure,andsurroundingwallsandopeningofits
elevatingrouteshouldhaveastructurethatdoesnotinterfacewithfire-proofing
•Anemergencyescapehatchshouldbeprovidedintheceilingofanelevatorcagetoallowpeopleinthe
cagetoevacuatesafelyoutofthecageincaseofanemergencyinapassengerelevator
•Arobustwallorenclosure,anddoorshouldbeprovidedinordertopreventpeopleorcargooutsideofthe
elevatingroutetomakecontactwithcageorcagebalancerweightsandsuch.
•Thestructuresofthemaincable,sheave,drum,supportbeamandrailshouldcomplywithJapanese
Standard
•Theweightsandsuchshouldbestoredinasufficientlystrongbox
•Thesafetygate/doorshouldhavesufficientstrengthandastructurethatposesnorisktooperators
•Ladderwithbackcoveroranequivalentshouldbeprovidedneartheelevatingequipment
SafetyFunctions
•Installadetectionsystemandcircuitfordetectingloosenedorbrokenwires.
•Installsafetyrodsandstoppersinallnecessarylocationsinthecageforpreventingdisengagementand
cargofromfallingout.
•Foropeningandclosingthedoor/gate,themechanismemployedshouldonlyallowtheopeningorclosingof
thedoor/gateatthefloorwherethecageispresent.
•Thebalancerweight,counterweigthandotherrelevantweightsshouldbeequippedwithaguiderollerand
siderollers
•Whenperformingahigh-speedswitchingorstopoperation,theoperationingcurveshouldbesmoothand
shock-absorbent.
•Installemergencyintercom(In-cageoperationpanel,operationpanelateachfloor,controlpanel).
•Installasafetycatchandasafetygovernorlimitswitchfordetectingcageelevatingspeederrors
•Provideanemergencyescapehatchandsafetylimitswitchintheceilingofthecage.
•Installaspringand/orbufferthatreducestheimpactoffallingwhenthecagehangingcablebreaks
•Adeviceforshuttingdownthecircuitshouldbeprovidednearthemotor.
SafetyOperations
•Aftercheckingthatthedoor/gatehasclosed,thecageshouldebeabletomoveupwardordownwardby
operatingonthedestinationindicatingpush-buttonswitch
SafetyWorkEnvironment
•Thecontrolpanelmountshouldhavelightingwithilluminationsuitableforinspection
•Inthecaseofinstallingacontrolpanelontopofmachinerymount,ensuresafetyspacearoundit.
Safety-RelatedIndicationsandAlarmSystem
•Provideindicationsconcerningliveload,identifythepurposeoftheequipment(forcargo,passengers,or
bothandetc.)
Elevator Machine Illustration
Illustration 1
Illustration 2
89

90. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 4–Crane
SafetyGuards
•Thehangingpulleyunitshouldhaveasafetycover,withalatchonthehook
•Asafetynetshouldbeprovidedtocoverthegapsinthegirder
•Provideadeckhandrailwithsufficientspaceinlocationswheresuchinstallationarenecessaryforinsepction.Implement
slip-proofing
SafetyFunctions
•ForcranesthatuseanI-Beamrail,installdoublestoppersonthebothendsoftherail
•Thetrolleycableshouldhaveastructurethatpreventsitfromeasilyfallingout.Trolleysshouldnottobeusedinlocations
whereatrolleymayeasilymakecontactwithperson.
•Inthecaseofequippingmultiplecranes/hoistonarail,provideanelectricalormechnicakstoppertopreventcollision.
•Anendofrailalarmshouldsetoffwhenacrane/hoistreacheseitheroftheendsoftherail.
•Asafetyswitchshouldbeprovidedinlocationswhereanoperatorgetsonandoffthegirder.
•Morethanonedetectiondeviceforpreventingoverhoistshouldbeprovided,andwhenthesedetectiondevicesaresetoff,
thehoistingfunctionshouldbestopped.
•Thealarm(Buzzer,Bell)shouldbeabletobesetoffduringoperationwhenneeded.
•Whenremoteactivationisused,thecraneshouldhaveapreventionfunctionformalfunctionsandrunawatscausedby
radiointerface.
•Therotationunitshouldbeequippedwithstopperandhaveastructurethatretainsthespecifiedpositionwithoutfail(Jib
Crane)
•Theoperatingroomshouldhaveaspacethatprovidesaviewofthewholeloweroperationarea.andcommunicationdevice
asneeded
•Thecontrolpanelshouldbeequippedwithanearthleakagebreakerandanemergencystoppush-buttonswitch
•Theoperationpanelathandshouldallowpowershutoffbyakeyswitch.Removalofthekeyfromthekeyswitchwhenis
inasafetyposition
•Amagnetswitchforthemaincircuitshouldbeprovidedinordertopreventmotorrunawayatthetimeofcontactadhesion.
SafetyOperation
•Thefunctionofthecranesshouldnotallowforthree-directionoperations.
•Holdruntypeshouldbeusedforallcontrol
WorkEnvironment
•Holdruntypeshouldbeusedforallcontrol
Safety-RelatedIndicationsandAlarmSystem
•Powerindicationshouldbeprovidedinclearlyvisiblelocations,suchasontrolleycableandwiring.
•Thebottomsideofthegirdershouldhaveadirectionindicationplate.
•Clearlyimplementasignforalignmentwiththeelevationramp.
•Theentrancegateshouldhavea“RestrictedAreaIndication”
•Providedratedloadindications.
Crane Machine Illustration
Illustration 1
90

91. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 5–Automatic Guide Vehicle (AGV)
SafetyGuards
•Thecarriersshouldhaveaframethathasnoprotrusionsorsharpcorners
•ThebottomoftheAGV(MainUnit)shouldhavedimensionsandshapethatdonotcreateriskof
catchinghumanfingers
•ThebumpershouldbelargerthanthewidthoftheAGV(MainUnit)andshouldhaveastructurethat
doesnotpresentadangertopeoplethroughcontactandsuch.
SafetyFunctions
•AnAGVshouldbeequippedwithafunctionthatimmediatellystopsthevehiclewhenitgoesofits
designatedtrack
•AnAGVshouldbeequippedwithafunctionthatpreventsthevehiclefromdivingoutofcontrolwhen
agroundstationsufferapoweroutage.
•AnAGVshouldbeequippedwithafunctionthatimmediatellystopsthevehiclewhenthespecified
drivingspeedcannotbemaintained.
•AnAGVshouldbeequippedwithafunctionthatpreventscollisionwhenAGV’sareatamerging
pointordivingparalleltoeachother.
•AnAGVshouldhaveamechanismthat,whenmakingcontactwithahumanorobstacle,stopsthe
vehicleatadistancewhereitscontactareaisnotsubjecttodamagingpressure.
•AnAGVshouldhaveamechanismforpreventingcarrieditemsfromshifting,fallingandjumpingout
whilethevehicleismovingorwhenitomestoanemergencystop.
•Thebatteryshouldbechargedinanenvironemtnthatallowssafecharginginordertoavoidtherisk
offireandexplosionofhydrogengas.
Safety-RelatedIndicationsandAlarmSystem
•WhileanAGVisinautomaticoperation(IncludingstandbyMode),theindicatorlampshouldbelit.
•WhenanAGVsetsofffromstandbymodeorfromastation,apriorindicatoralarm(buzzer,bell,etc)
shouldberungforacertainperiodoftimebeforestart.
•WhenanAGVisdriving,acontinuousalarmorwarningligthsshouldbepresenttoindicatethe
status
•AnindicationshouldbegivenwhenanAGVorAGVsystemfailsorsufferanerror
•Thedrivingtracksandrangeshouldbeclearlymarkerdforthebenefitofthridparties
AnAutomaticGuidedVehicleisavehicleonwhichcargoisloadedonautomaticallyorbyhand,and
thatautomaticallydrivestothedesignatedpoint,wherethecargoisunloadedautomaticallyorbyhand.
AGV Machine Illustration
Illustration 1
Illustration 2
91

92. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 6–Furnace Systems
SafetyGuards
•Pippingthatsuppliescombustiblemattersuchasgasandfueloilaswellasgaugesandothermeasuring
instrumentsshouldbearrangedsothattheyarenotaffectedbyheat,impact,vibrationsandsuch.
•Agaspipeshouldbeequippedwithdrainvalveandapressuretightnesstestvalve,bothofwhichshouldbeblind-
pluggedatalltimes.LPGdischargeapertures
•Pippingshouldbeequippedwithajointthatabsorbsvibration.
•Afurnaceusingcombustiblematterssuchasgasandfueloilshouldcomplywiththefollowingrequirements:
a.Valvearoundaburnerthatautomaticallyopensandclosesshouldbeprovidedinatandemarrangementin
ordertopreventanaccidentduetogasleakagecausedbyfailureorfunctionaldeterioration.However,when
usingselenoidvalves,theyshouldbedirectoperatedselenoidvalves,normallyclosed.
b.Inprinciple,devicethatrequirefrequentinspectionandreplacementanddevicethat,whenmalfunctioningor
failed,cancauseaccidentsordamage,shouldebeinstalledinaparallelarrangement.
c.Thepipesshouldbeconnectedandfixedusingflangeandweldingshouldbeavoidedunlessstrictlynecessary
d.Pressuregaugeattachmentlocationsshouldhaveastopvalve
e.Fuelpippingshouldbeequippedwithanemergencyshutoffvalve(manual,power-off,activated
electromaneticallyclosedsafetyvalve)andstrainer.
•Apeepholeforequipmentwherethereisariskofexplosionshouldhaveadoorthathcanbemanuallyopenedand
closed
•Iftheequipmenthasasmallfurnacecapacity,itcanadopt,asnedeed,apartitionstructurethatenableseasier
maintenanceandinspection.
•Thefurnacewallshouldhaveapeepholethathallowsanoperatortochecktheconditioninsidethefurnacefrom
theoutsidewithsafetyglass
•Inthecaseofattachingawaterjacketforcoolingthefurnacebody,theweldedpartshouldbeconstructedonthe
periphery.
Furnace Systems are devided into four category there are :
2.1 Casting Furnace System
•Low-Frequency Induction Furnace
•Cupola Furnace
•Reverberatory Furnace
•Induction Heating Furnace
2.2 Heat Treatment Furnace Systems
2.3Drying Oven Systems
•Paint Drying Oven
2.4Brazing Furnace
General Requirements
92

93. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 6–Furnace Systems
SafetyGuards
•Thefurnacebodyshouldbefixedwithoutfail,andlocationswherethereisariskofimpactsshouldbe
protectedwithaprotectivefenceand/orstoppers.
•Thedoorofthefurnacebodyshouldbeaprotrudingdoorwithafall-proofstopper.
•Inthecaseofmanuallyignitionaburnerdevicethathasadoor,suchadeviceshouldadoptastrucutrethat
onlyallowsforignitionuponopeningthedoor.
•Thestructureshouldallowforeasycheckingofburnercombustionstate
•Equipmentwithastructurewhereatmospherecirculatesinaclosedcircuit,suchasahotairdryer,should
adoptintoitsstructureamechanismforpurginggasoutdoors.
•Theinsideofafurnaceshouldhaveastructurethatenableseasypurging,andtheexhaustventshouldbe
attachedtolocationwhereitposesnodangertotheoperator.
•Ifthereisariskofanoperatorincurringhazardsuchasfalls,burnsorsuffocationwhileperforming
operation,asafetyfence,hatchorcovershouldbeinstalled.
SafetyFunctions
•Equipmentthatusingcoolingtowershouldbeequippedwithafunctionthatpreventslowflowvolumeor
abnormallyhightemperature
•Locationswherethereisariskoffirefromabnormallyhightemperaturescausedbyexhaustorpurgeducts
shouldebeequippedwithtemperaturesensor,alongwithanalarmsystmeanddevicestopfunction.
•Ventpipinginacombustionpipingunitshouldbeprovidedforagascombustionfurnacealongwitha
functionthatallowstheventfunctiontobeautomaticallycontrolled.
•Valvesshouldnotbeprovidedonthesidewherecirculatingcoolingwaterisdischarged.
•Detectiondevicessuchaspressureswitches,windpressureswitches,rotationswitchesandframe-eye
systemsshouldbeinstalledinordertopreventexplosionsinafurnacethatusescombustiblematter.When
suchdetectiondevicesaresetoff,analarmandindicationsshouldbeprovided,aswellasastopfunctionif
necessary.
•Asathermometertobeusedforafurnace,athermometerequippedwithanupperlimitalarmshouldbe
providedalongwithacontrolthermometerofadifferentsystem.
•Aheatingsystemforfueloilshouldbeequippedwithafunctionthatstopstheoperationoftheburnerwhen
itreachestheupperorlowerlimitaswellasatemperatureadjustingfunction.
•Thestructureshouldbesuchthatitallowsanoperatortochecktheliquidlevelintheoiltank.Providea
liquidlevelswitch,andwhenthesupplyreachestheupperorlowerhazardlimit,analarmandindication
shouldbeprovided,alongwithasupplystopfunctionifneeded.
•Theburnercircuitshouldhaveanemergencyshutoffvalve.
•Afurnacethatusesaburnershouldhaveafunctionthatpreventsresidualcombustiblesfromexploding.
•Hydraulicfluidforusewithhigh-temperaturefurnacesshouldbefire-retardantfluids.
•Donotplacetheoperationpanelandmonitoringpanelinalocationwhereexplosionsorsplatteringofhigh-
temperaturematerialscanoccur.
•Aburnershouldhaveaclearindicationofitsinformationincludingmaximumburningcapacity,combustion
type,calorificvalueandgaspressure.Usethefuelandgasdesignatedfortheburner.
General Requirements
93

94. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 6–Furnace Systems
SafetyFunctions
•Furnacesoperatingwithatemperatureof760degreesCorbelowandfurnacesthataresubjecttofrequentignitionandextinguishingshould
beequippedwithapilotburnerwithstableflame,providingastructurethatenablesconstantstableburninginthemainburner.
•Thepilotburnershouldhaveaflameholdingcapacitythatmaintainssufficientflamestabilityundertheusageconditionsandusagescopeof
thefurnace.Itshouldalsohaveastructurethatpreventstheflamefrombeingblownoutbythehigh-capacitycombustionairflowatthetimeof
ignition.
•Implementmeasuresforpilotburnerstoadjusttheflowvolumeandair-fuelratiotoaccuratelyandstablymaintaintheflame,keepingit
unchangingduringextensiveuse.
•Installapilotburnerignitedcombustioncheckdeviceforaburnerattachedtoacombustionchambertoenablethedetectionoffailedignition.
•Formanualignitionoperation,installanignitionhole,adoptingastructurethatenablesthecheckingofignitionstate.
•Theburnershouldhaveastructurethatenableseasycleaning,inspectionandreplacement.
•Alarmdevicesshoulduseindicatorlampsthatclearlycommunicatetheintentionofthealarm.Theindicationsshouldbeimplementedin
locationseasilyseenbyoperators,asneeded.
•Provideindicationsforburnersandfanswhentheyareinoperation.
•Asafetycircuitshouldbeanindependentcircuit.
WorkEnvironment
•Anylocationwhereexplosionorsplatteringofhigh-temperaturematerialcanoccurshouldhaveitshazardareaindicatedbyaprotectivefence
and/orhazardsigns.
•Anylocationwherehigh-temperatureexhaust,highvolumeofsmoke,toxicgasordustispresentshouldbeequippedwithanaturalorforced
exhaustsystem.
•Equipmentthatdoesnottolerateexposuretowatershouldalwayshavefireproofsandpreparednearby.
•Anylocationwhereahighvolumeofgrease/oil-basedvapororcrackedgasispresentshouldbeequippedwithanexhausthoodandduct.
a.Ductsshouldbeasbentaspossible,withreducedcorners,andhaveastructurethatallowsforinternalinspectioninnecessaryspots.
b.Exhausthoodsshouldhaveafire-resistantnet.
c.Ablastholeshouldbeprovidedinasafelocation.
d.Ductsthatexhaustsootandoilsmokeshould,asneeded,beequippedwithanautomaticCO2extinguishersystem.
•Devices,jigsandtoolstobeusedinacaseofemergencyshouldalwaysbekeptclosetotheequipmentandmanaged.
(Fireproofsand,fire-resistantworksuit,etc.)
Safety-RelatedIndicationsandAlarmSystem
•Indicatetheescaperouteinformationinthecaseofanemergency(fire,earthquake,poweroutage,etc.)
•Providesignsthatindicatetheoperationpointsinthecaseofanemergency.
•Provideindicationsof"WaterReactive"or"WaterSupplyProhibited"infurnaceworkplaces.
a.Thesizeofeachtextcharacteronasignshouldbe,inprinciple,500mmorlarger.
b.Thecharactersshouldbeunderstandableevenduringnighttime.
c.Indicationsshouldbeprovidedoneachexternalsurfaceofabuilding.
d.Precautionaryindicationsshouldbeprovidedonhigh-temperatureequipment.
e.Indicatethelocationsof"supplyvalves"thatalsoareemergencyshutoffpointsforflammablegas,greaseandoils,andpowertobe
operatedincaseoffire.
f.Theburnerignitionconditionsanderrordetectionindicationsshouldallbeindicatedonthecontrol/operationpanels.
General Requirements
94

95. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 7–Inspection and Testing System
SafetyGuards
•Thestructureshouldnotimpactthemachineprecision,consideringthevehicleweightofthecompleted
vehicle.
•Theturntableshouldhaveastructurethatcanalwayssecureavehiclewhenitentersandleavesthepit.
•Thestructureshouldbesuchthatitminimizesthegapsthatexposetheoperating(up/down,open/close)
partsandinflictsnoharmonanoperator.
•Thestructureshouldbesuchthatmakesprecisionmaintenanceinspectioneasyandsafe.
•Thestructureshouldnotallowfallenobjectstoenterthedevice.
•Thestructureshouldallowfortheeasyremovalofoil,water,greaseandsuchthatdrippedfroma
completedvehicle.
SafetyFunctions
•Installaguiderollerthatmakestheentryofacompletedvehicleeasy.
•Provideaninterlockthatpreventsthevehiclefromstartingwhenthetiresarenotstraightorwhenthe
vehicleisundergoingin-pitoperations.
•Themechanismshouldbesuchthataclampwillnotimmediatedisengageinanomalouscases,including
poweroutagesandemergencystops.
•Measuresshouldbeimplementedintheopenings,includingthepit,topreventfalls.
SafetyOperations
•Theoperationbuttonsusedduringaninspectionshouldbeprovidedinlocationswhereanoperatorcan
easilyoperatethem.
•Inaninspectionandtestingsystemwheretheoperationpanelisinstalledeitherleftorrightdependingon
thetypeofcompletedvehicle,suchoperationpanelsmustbefixed.
WorkEnvironment
•Provideaventilationsystemthatemitstheexhaustfromacompletedvehicle.
•Provideafunctionthatreducesnoiseifnecessary.
Inspection and Testung Systems are devided into eight category there are :
7.1 Turning Radius Tester and Alignment Tester
7.2 Highlight Tester
7.3Driving Tester
7.4Brake Tester
7.5 Sideslip Tester
7.6 Test Stand for Completion Inspection
7.7 Two Post Lifter
7.8 Inspection Lift
7.1 Turning Radius Tester and Alignment Tester
Alignment Tester Illustration
Illustration 1
95

96. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 7–Inspection and Testing System
SafetyGuards
•Thetestershouldhaveadedicatedsystemorasharedmechanism.
•Eachoperatingsectionalwaysoperatessmoothly,andhasastructuresufficientlydurable.
•Thestructureshouldbesuchthatitmakesprecisionmaintenanceinspectioneasyandsafe.
•Theoperationofaheadlighttestingsystemshouldonlybeavailableunderastatewherea
vehicleisdetected.
SafetyFunctions
•Amechanismthathasthepossibilityofendangeringanoperator,suchasliftingandmoving
mechanisms,shouldbeequippedwithsafetydevicessuchasphototubes.
•Thetestershouldhaveamechanismthatimmediatelystopsthetesterwhenthesafety
deviceengages.
•Theheadlighttestingsystemshouldbeamechanismthatisnotdisengagedduringan
inspection.
•Thetestershouldhaveafunctionthatimmediatelystopsthetesterinanomalouscases
includingpoweroutagesandemergencystops.
•Thetestershouldemitawarningusingabuzzerorsuchwhiletheautomobiletobetestedis
beingliftedorlowered.
•Thetestershouldbeequippedwithanalarmdevice(chime,buzzer,etc.)thatactivateswhen
thetesterisrunningautomaticoperations,andwhichanoperatorcanclearlyacknowledge.
•Iftherearetwooperatorsinthepit,installtwooperationpanelsinlocationswherethepanels
cannotbeoperatedbyonlyoneperson.Theworkcompletioninstructionshouldnotbegiven
unlessbothoperatorsoperatethepush-buttonsatthesametime.
SafetyOperations
•Theoperationbuttonsusedduringaninspectionshouldbeprovidedinlocationswherean
operatorcaneasilyoperatethem.
WorkEnvironment
•Thecompletedvehicleandlightreceptorshouldhaveasufficientclearanceinorderto
enableanoperatortoperformtheinspection.
7.2 Highlight Tester
96
Highlight Tester Illustration
Illustration 1

97. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 7–Inspection and Testing System
SafetyGuards
•Thestructureshouldnotimpactthemachineprecision,consideringthevehicleweightofthe
completedvehicle.
•Eachoperatingsectionalwaysoperatessmoothly,andhasasufficientlydurablestructure
•Thestructureshouldbesuchthatitalwayspreventsthecompletedvehiclefromjerkingoutor
shakingsideways.
•Thestructureshouldbesuchthatitcanfixtherollersinasafeandsecurefashionforthecompleted
vehicletoenterorleavethepit.
•Thestructureshouldbesuchthatitminimizesthegapsthatexposetheoperating(up/down,rotation)
partsandinflictsnoharmonanoperator.
•Thestructureshouldbesuchthatitmakesprecisionmaintenanceinspectioneasyandsafe.
•Thestructureshouldallowfortheeasyremovalofoil,water,greaseandsuchthatdrippedfroma
completedvehicle.
•Theopeningforthecoolingfanshouldhaveastructure,suchasametalnet,thatpreventsthe
dischargeofforeignobjectswithoutinterferingwiththeair-blowing.
•Equipmentusingwatershouldbeprovidedwithameansofpreventingelectricalshocks.
SafetyFunctions
•Installaguiderollerandsuchthatitmakestheentryofacompletedvehicleeasy.
•Thetestershouldhaveafunctionthatdisablesthecompletedvehiclefromleavingthepitwhilethe
rotationrollersarerotating.
•Therotationrollersshouldnotbeamechanismthatlocksorcrashstopsincaseofemergencystop
orpoweroutage.Iftheleftandrightdrivesourcesarenotthesame,whenonestopsitsoperationthe
othershouldsimilarlystop,ensuringsafety.
•Theliftershouldnotbeamechanismthatrisesinthecaseofemergencystopsorpoweroutages.
SafetyOperations
•Theoperationbuttonsusedduringaninspectionshouldbeprovidedinlocationswhereanoperator
caneasilyoperatethem.
•Inaninspectionandtestingsystemwheretheoperationpanelisinstalledeitherleftorright
dependingonthetypeofcompletedvehicle,suchoperationpanelsmustbefixed.
WorkEnvironment
•Provideaventilationsystemthatexpelstheexhaustfromacompletedvehicle.
7.3 Driving Tester
97

98. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 7–Inspection and Testing System
SafetyGuards
•Thestructureshouldnotimpactthemachineprecision,consideringthevehicleweightofthecompleted
vehicle.
•Eachoperatingsectionalwaysoperatessmoothly,andhasasufficientlydurablestructure.
•Thestructureshouldbesuchthatitalwayspreventsthecompletedvehiclefromjerkingoutorshaking
sideways.
•Thetestershouldincludeastructuresuchasanintermediatelifterthatfacilitatesthecompletedvehicle's
entrytoandleavingfromthepit.
•Thestructureshouldbesuchthatitminimizesthegapsthatexposetheoperating(up/down,rotation)
partsandinflictsnoharmonanoperator.
•Thestructureshouldbesuchthatmakesprecisionmaintenanceinspectioneasyandsafe.
•Thestructureshouldallowfortheeasyremovalofoil,water,greaseandsuchthatdrippedfroma
completedvehicle.
SafetyFunctions
•Provideamechanismthatcanpreventthesidewaysshakingofthecompletedvehicle.
•Thetestershouldhaveafunctionthatimmediatelystopsthetesterinanomalouscasesincludingpower
SafetyOperations
•Theoperationbuttonsusedduringaninspectionshouldbeprovidedinlocationswhereanoperatorcan
easilyoperatethem.
•Inaninspectionandtestingsystemwheretheoperationpanelisinstalledeitherleftorrightdependingon
thetypeofcompletedvehicle,suchoperationpanelsmustbefixed.
WorkEnvironment
•Provideaventilationsystemthatexpelstheexhaustfromacompletedvehicle.
7.4 Brake Tester
7.5 Sideslip Tester
SafetyGuards
•Thestructureshouldnotimpactthemachineprecision,consideringthevehicleweightofthecompleted
vehicle.
•Eachoperatingsectionalwaysoperatessmoothly,andhasasufficientlydurablestructure.
•Thedevicesshouldadoptastructurethatdoesnotprotrudefromthefloorsurface.
•Thestructureshouldbesuchthatmakesprecisionmaintenanceinspectioneasyandsafe.
•Thestructureshouldallowfortheeasyremovalofoil,water,greaseandsuchthatdrippedfroma
completedvehicle.
SafetyFunctions
•Themechanismshouldbesuchthatallowsthefixingoftreadsatalltimesexceptforduringmeasurement.
Brake Tester Illustration
Illustration 1
Side Slip Tester Illustration
Illustration 1
98

99. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Production Machine
Section 7–Inspection and Testing System
SafetyFunctions
•Themechanismshouldundernocircumstancesdisengagetheclampswhilethevehicleisbeing
driven,eveninthecaseofpoweroutages.
•Thetestershouldsoundawarningusingabuzzerorsuchwhentheexitgateistobeopened.
7.6 Test Stand for Completion Inspection
7.7 Two-Post Lift
SafetyGuards
•Fallpreventionshouldbeimplementedbyfixingthevehiclewithanchorboltsorsimilardevicesthat
havesufficientstrength.
•Theperipheryoftheliftshouldbemarkedandsurroundedbyazoningline,identifyingtherangeof
movement.
SafetyFunctions
•Whenraisingthelift,alwayschecktheconditionoftheloweringpreventionsystem(lockclawor
safetybar,etc.).
•Settheswingarmwithintheeffectiverangeofthelockclaw.
Safety-RelatedIndicationsandAlarmSystem
•Provideratedloadindications.
7.8 Inspection Lift
SafetyGuards
•Whenraisingthelifterwithapersonworkingonit,provideafallpreventionguard(safetyfence).
SafetyFunctions
•Whilethelifterismovingupwardordownward,aninstalledalarmbuzzerorchimeshouldwarnthe
peripheraloperators.
•Theequipmentshouldhaveawheellocksystemforfixingthevehiclebodytothelift.
•Iftherearetwooperatorsinthepit,installtwooperationpanelsinlocationswherethepanelscannot
beoperatedbyonlyoneperson.Theliftshouldnotgoupordownunlessbothoperatorsoperatethe
push-buttonsatthesametime.
Safety-RelatedIndicationsandAlarmSystem
•Provideratedloadindications.
Two-Post Lifter Illustration
99

100. PT Honda Prospect Motor
100
Occupational Health & Safety Department
PT Honda Prospect Motor
AccidentCaseRelatedSafetyGuard
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialsMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedSensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

101. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Accident Case Related Sensor
101

102. PT Honda Prospect Motor
102
Occupational Health & Safety Department
PT Honda Prospect Motor
AccidentCaseRelatedSafetyGuard
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
MachineTools
IndustrialsMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
AccidentCaseRelatedSensor
ProductionMachine
Definition
GoodImplementationBasedOnGreenBook
HPM
Implementation

103. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Accident Case Related Guard
103

104. PT Honda Prospect Motor
104
Occupational Health & Safety Department
PT Honda Prospect Motor
AccidentCaseRelatedSafetyGuard
SafetyDistance
SafetyGuard
SafetyOperation
WorkEnvironment
Safety-RelatedIndicationsandAlarmSystem
GoodImplementationBasedOnGreenBook
MachineTools
IndustrialsMachine
SafetyFunction
Background,PurposeandTargetPreface
Training
Content
Case Study
HPM
Implementation
AccidentCaseRelatedSensor
ProductionMachine
Definition

105. PT Honda Prospect Motor
Occupational Health & Safety Department
PT Honda Prospect Motor
Good Implementation
No Good Implementation
Item
Check
Standard
1
Status and
Indication
Alarm
2
Safety switch
of the door
3 Safety Guard
Illustration
Green Book “Honda Standard”
Standard B.
Chapter 4 : Operation
Section 5 : Status and Indication Alarm
Illustration
Green Book “Honda Standard”
Standard B.
Chapter 2 : Guard
Section 1 : Guard (Safety Partition)
Safety Door Guard With Interlock
Green Book “Honda Standard”
Standard B.
Chapter 2 : Guard
Section 1 : Guard (Safety Partition)
Surrounding Guard
Illustration
105

106. PT Honda Prospect Motor
106
Occupational Health & Safety Department
PT Honda Prospect Motor
Terima Kasih
Semoga Bermanfaat