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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
AUR21920 CERTIFICATE II IN TYRE SERVICING TECHNOLOGY
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
Table of Contents INTRODUCTION ........................................................................................................................................... 3 TRAINING AND ASSESSMENT ...................................................................................................................... 4 PRACTICAL ASSESSMENTS ........................................................................................................................... 4 THEORY ASSESSMENTS ............................................................................................................................... 4 ONSITE EVIDENCE PORTFOLIO .................................................................................................................... 4 HOW TO USE THIS LEARNER GUIDE ............................................................................................................. 5 SAFETY / LEGISLATION AND YOU ................................................................................................................ 7 LEGISLATION ............................................................................................................................................... 9 REGULATIONS THAT SUPPORT THE ACTS ............................................................................................................................ 9
EMPLOYER RESPONSIBILITIES ....................................................................................................................10 PERSONAL PROTECTIVE EQUIPMENT .........................................................................................................11 WORKPLACE SAFETY FORUMS ...................................................................................................................12 ASSESSING HAZARDS AND RISKS IN THE WORKPLACE ...............................................................................12 RISK MANAGEMENT...................................................................................................................................13 HAZARD IDENTIFICATION: ..........................................................................................................................13 RISK ASSESSMENT: .....................................................................................................................................13 RESOURCES ................................................................................................................................................14 PERSONNEL ................................................................................................................................................14 THE OVERALL PROCESS ..............................................................................................................................14 PERSONAL RISK MANAGEMENT TOOL .......................................................................................................15 JOB HAZARD ANALYSIS (JHA) – OPERATIONAL RISK MANAGEMENT TOOL ................................................15 PROCESS STEPS TO FOLLOW WHEN WRITING UP A JHA.............................................................................16 WORKPLACE HEALTH & SAFETY COMMITTEES ...........................................................................................17 HAZARDS IN THE WORKPLACE ...................................................................................................................17 RISK MATRIX ..............................................................................................................................................18 RISK CONTROL IN THE WORKPLACE ...........................................................................................................20 RISK CONTROL: ..........................................................................................................................................................20 RISK TREATMENT ........................................................................................................................................................21 IMPLEMENTING CONTROL MEASURES ...............................................................................................................................21
WORKPLACE EMERGENCIES .......................................................................................................................22 EMERGENCY COMMUNICATIONS...............................................................................................................23 AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace FIRE AWARENESS .......................................................................................................................................23 FIRE HAZARDS MAY INCLUDE: ........................................................................................................................................23 PREVENTION MEASURES MAY INCLUDE: ............................................................................................................................23 FIRE EVACUATION PROCEDURES ......................................................................................................................................24 FIRE EXTINGUISHER TYPES AND APPLICATIONS FOR FIRE CLASSES ............................................................................................25
HAZARDOUS SUBSTANCES .........................................................................................................................26 MANUAL HANDLING ..................................................................................................................................27 HAND INJURIES ..........................................................................................................................................28 HYDRAULIC INJECTION INJURIES ................................................................................................................28 SAFETY SIGNAGE ........................................................................................................................................29 ELECTRICAL SAFETY ....................................................................................................................................31 MACHINE SAFETY GUARDING ....................................................................................................................31 COMPRESSED AIR.......................................................................................................................................31 VEHICLE SAFETY .........................................................................................................................................33 VEHICLE HOISTS HAZARDS/RISKS ...............................................................................................................35 EXAMPLES OF VEHICLE HOISTS ..................................................................................................................36 JACK STANDS..............................................................................................................................................36 HYDRAULIC JACKS ......................................................................................................................................37 PNEUMATIC JACKS .....................................................................................................................................37 LIFTING CAPACITIES FOR JACKS AND STANDS .......................................................................................................................38
WORKING AROUND BATTERIES..................................................................................................................38 FUEL ...........................................................................................................................................................38 HIGH VOLTAGE IN BATTERY ELECTRICAL AND HYBRID VEHICLES ...............................................................39 SAFETY CONSIDERATIONS FOR WORKPLACE VEHICLE SAFETY: ..................................................................39 SAFELY WORKING IN AUTOMOTIVE PITS ...................................................................................................41
COPYRIGHT STATEMENT All rights reserved. Apart from any fair dealing or other statutory use permitted under the Copyright Act 1968, No part of this material may be reproduced, distributed or transmitted in any form or by any means, including photocopying, recording or any other electronic or methods without the written permission of the owner Otraco International Pty Ltd.
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
Introduction Welcome to the Otraco Training Centre!! The Otraco Training Centre is a Registered Training Organisation (RTO) within Australia; we have a range of tyre servicing and maintenance training programs to meet current Tyre Industry requirements. Our Nationally accredited training solutions build stronger safety awareness while developing skilled personnel to provide efficient servicing, maintenance and management of tyres across all industries. For those who work with heavy machinery, training for heavy vehicle maintenance and tyre care is essential. Proper training and qualifications can reduce tyre operation costs and maximise tyre life, which is vital for the smooth running of any worksite and can reduce running costs, in turn improving profits. Training also ensures safety on the worksite and guarantees everyone is working to the same standard. Otraco’s AUR21920 Certificate II in Automotive Tyre Servicing Technology program has been specifically designed to prepare new employees to the organisation to gain the necessary skills to service and repair automotive tyres within the mining industry. The units of competency within the qualification has been clustered to reflect current industry work roles including maintenance and repair on light vehicles, heavy vehicles and earthmover/off-the-road vehicles. The following units have been chosen based on extensive industry consultation. UNIT CODE
CORE/ELECTIVE UNIT
UNIT TITLE
Safety, Tools and the Environment Unit Title AURAEA002
Follow environmental and sustainability best practice in an automotive workplace
Core
AURASA102
Follow safe working practices in an automotive workplace
Core
AURTTK102
Use and maintain tools and equipment in an automotive workplace
Core
Light Vehicle Skill Set AURLTJ011
Select light vehicle tyres and wheels for specific applications
Elective
AURLTJ102
Remove, inspect, repair and refit light vehicle tyres and tubes
Elective
AURLTJ113
Remove, inspect and refit light vehicle wheel and tyre assemblies
Elective
AURATA001
Identify basic automotive faults using troubleshooting processes
AURTTJ011
Balance Wheels and Tyres
Core Elective
Heavy Vehicle Skill Set AURHTJ102 Select heavy vehicle tyres, wheels and rims for specific applications
Elective
AURHTJ103
Remove, inspect and refit heavy vehicle wheel and tyre assemblies
Elective
AURHTJ106
Remove, inspect, repair and refit heavy vehicle tyres and tubes
Elective
Earthmoving and Off-the-Road Skill Set AURKTJ011 Remove, inspect and fit earthmoving and off-the-road tyres
Elective
AURKTJ012
Remove, inspect and fit earthmoving and off-the-road wheel and rim assemblies
Elective
AURKTJ015
Select earthmoving and off-the-road tyres, wheels and rim assemblies for specific applications
Elective
AURKTJ016
Use earthmoving and off-the-road tyre handlers
Elective
If you would like more information in regard to the AUR21920 Certificate II in Tyre Servicing Qualification, please click on the following link: https://training.gov.au/Training/Details/AUR21920 AURASA102 Learning Guide 1 Vs1.05 [LG1]
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Training and Assessment
The Otraco Training Centre provides competency-based training and assessment, which comprises of classroom, workshop and on-the-job components. Training reflects (as far as practically possible) mine site conditions and practices. Assessment involves gathering evidence and making judgement on whether a person has achieved the skills and knowledge required. Learners who successfully complete all assessment to the required standard will be issued with the appropriate qualification or statement of attainment. Assessments will consist of a combination of theory and practical components based directly on the performance evidence and knowledge evidence requirements for each unit of competency.
PRACTICAL ASSESSMENTS Practical assessments will either be conducted at the Training Centre or on-site where direct observation of the learner’s skills occurs whilst completing realistic workplace tasks.
THEORY ASSESSMENTS Online theory assessments will be completed by the learner outside the formal workshop/class attendance times. Approximately 1.5 – 2 hours per unit is required to research and complete theory assessments. Please remember to read all questions carefully.
ONSITE EVIDENCE PORTFOLIO To confirm ongoing consistency of skills and knowledge, a workplace evidence portfolio will also need to be collected and submitted once you have completed the formal training and assessment processes. This could take between 4-8 month depending on your site and your ability to perform various workplace tasks. You would have been provided will additional information regarding this at the start of the course. If additional evidence or information is required, your Trainer /Assessor will discuss this with you personally. All training and assessment materials have been contextualized to reflect Otraco Best Practice Procedures as well as industry and regulatory requirements. Learners must complete all the assessments to the required standard in order to successfully complete the units of competency.
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How to use this Learner Guide
This Learner Guide has been developed specifically for new employees in the tyre industry to provide the necessary knowledge and foster the skills required to safely work with light vehicle, heavy vehicle and earth moving tyres. The learner guide includes is broken down into sections which contain information on the following aspects of the tyre service industry. Learner Guide #
Unit/s Linked to Guide
1
AURASA102 - Follow safe Working Practices in an Automotive Workplace
2
AURAEA002 - Follow Environmentally & Sustainability Best Practice in an Automotive Workplace
3
AURTTK102 - Use and Maintain Tools & Equipment in an Automotive Workplace
Light Vehicle Skill Set 4
AURLTJ011 - Select light vehicle tyres and wheels for specific applications AURLTJ102 - Remove, inspect, repair and refit light vehicle tyres and tubes AURLTJ113 - Remove, inspect and refit light vehicle wheel and tyre assemblies AURATA001 - Identify basic automotive faults using troubleshooting processes AURTTJ011 - Balance wheels and tyres
Heavy Vehicle Skill Set 5
AURHTJ102 - Select heavy vehicle tyres, wheels and rims for specific applications AURHTJ103 - Remove, inspect and refit heavy vehicle wheel and tyre assemblies AURHTJ106- Remove, inspect, repair and refit agricultural equipment tyres and tubes
Earth Mover / OTR Skill Set 6
AURKTJ011 - Remove, inspect and fit earthmoving and off-the-road tyres AURKTJ012 - Remove, inspect and fit earthmoving and off-the-road wheel and rim assemblies AURKTJ015 - Select earthmoving and off-the-road tyres, wheels and rim assemblies for specific applications AURKTJ016 - Use earthmoving and off-the-road tyre handlers
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace This learner guide supports your learning as you embark on your learning journey at The Otraco Training Centre. This information also links to the units of competency in the AUR21920 Certificate II in Tyre Servicing Technology qualification. You will need to do additional research on these aspects as well and this may take the form of:
Watching video tutorials and/or guides
Prescribed reading of technical journals, standards and workplace policies
Completing online activities
Networking with fellow learners Please keep a look out for these icons throughout your training. These will prompt you complete various activities as part of this process.
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SAFETY / LEGISLATION AND YOU SAFETY is our TOP PRIORITY Otraco’s tyre technicians are not only equipped with technical training, they are also fully equipped with safety training, making our teams some of the safest in the industry. You will be required to perform various safety tasks as part of your training and assessment and will receive additional information regarding this throughout your time with the training centre.
Figure 1 Otraco Training Centre – Pre-Start Information Meeting
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace Otraco have several specific “rules” that MUST be followed to keep you and your colleagues safe whilst performing tasks.
These are the mandatory rules that all tyre fitters MUST follow when conducting tyre maintenance activities. They have been developed over a period of time, based on serious incidents and fatalities that have occurred when performing tyre maintenance tasks in workplaces around the globe.
Figure 2 - Otraco Golden Rules
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LEGISLATION
The law in the workplace The workplace is a heavily regulated environment. Acts and Regulations impose duties and responsibilities on employers and employees aimed at reducing the incidence of workplace injury and work-related disease backed up by criminal offences and financial penalties for non-compliance.
Acts that govern safety in the workplace Work Health and Safety Act 2020 (WA) The main object of this Act is to provide for a balanced and nationally consistent framework to secure the health and safety of workers and workplaces Mines safety inspection Act 1994 The principle objective of the Mines Safety Inspection Act is to promote and secure the safety and health of persons engaged in mining operations. Work Health and Safety Act 2011 (NSW, ACT, QLD, NT) This act provides a framework to protect the health, safety and welfare of all workers at work. It also protects the health and safety of all other people who might be affected by the work.
Regulations that support the Acts • • •
Work Health and Safety Regulations 2022 (WA) Mines safety and inspection regulations 1995 Work Health and Safety Regulations 2011(NSW, ACT, QLD, NT)
An Act is legislation that has been passed by the Australian Parliament. Regulations support these Acts are the guidelines that dictate how the provisions of the Act are applied. In these Acts and regulations, there are legislative terms that specify whether something is mandatory or recommended. The term SHALL, indicates a statement that is mandatory. An example of this is “hearing protection shall be worn in this area”. This statement means that all employees must wear hearing protection in the specified area. The term SHOULD, indicates a statement that is a recommendation. An example of this is “hearing protection should be worn in this area”. This statement means that employees may choose to wear hearing protection in the specified area. It is important to understand the legislation that governs your workplace and to follow the correct procedures which support these laws. You don’t need to know these acts and regulations off by heart, but you will need to be able to access and navigate around these documents should you need this information moving forward. AURASA102 Learning Guide 1 Vs1.05 [LG1]
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EMPLOYER RESPONSIBILITIES
The law requires employers to provide a high standard of safety and health at their workplaces and ensure, as far as practicable, that employees are not injured or harmed because of their work. Some of these responsibilities are: An employer SHALL as for as practicable: • •
• • • •
Provide and maintain safe Workplaces, Plant and Systems of work Provide information, instructions and training to enable employees to complete their work safely Provide adequate level of supervision Consult and co-operate with employees regarding WHS matters in the workplace Provide employees with adequate personal protective clothing (PPE) and equipment Make arrangements to ensure the use, cleaning, maintenance, transportation and disposal of plant and the use, handling, processing, storage, transportation and disposal of substances is carried out without exposing employees to hazards
It is an employer’s ‘duty of care’ to provide and maintain a safe work environment for their workers. Employees Responsibilities Whilst it is the responsibility of your employer to provide a safe work environment, you have a responsibility to work safely. Some of these responsibilities are: An employee SHALL, take reasonable care, • • • • • • • •
To ensure his or her own safety and health at work To avoid adversely affecting the safety or health of any other person at work To not misuse or damage any equipment provided To report fit for work each day Co-operate with their employer and follow instructions Use the personal protective clothing (PPE) provided correctly Report any hazards, incidents, accidents or near misses in the workplace Participate in forums the employer has established
Many workplaces have various hazards that place workers at risk of injury or harm to health. Managing workplace health and safety is a team effort. For further information, you can access site/company documents through: • Company intranet e.g., DoneSafe, Open Text • Company Inductions • Site/client inductions • Ask your supervisor AURASA102 Learning Guide 1 Vs1.05 [LG1]
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PERSONAL PROTECTIVE EQUIPMENT
Personal protective equipment (PPE) is clothing or equipment designed to be worn by someone to protect them from the risk of injury or illness. Types of PPE can include: • • • • • • •
Respiratory protection i.e., disposable, cartridge, airline, half or full face Eye Protection i.e., spectacles/goggles, shields, visors Hearing protection i.e., earmuffs, ear plugs Hand protection i.e., gloves, barrier cream Foot protection i.e., shoes, safety boots Head protection i.e., helmets, hats, hoods, caps Skin protection i.e., hats, sunscreen, long-sleeved shirts, long pants
PPE requirements may vary based on workplace and conditions The use of personal protective equipment is lowest on the list of control priorities. These controls should not be relied on as the primary means of risk control until the options higher in the list of control priorities have been exhausted. The training centre attempts to replicate the workplace as closely as possible. See the picture below for details of what these PPE requirements are:
Figure 3 – Otraco Training Centre PPE Requirements
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WORKPLACE SAFETY FORUMS
Participating in safety and health at the workplace is a way of having a say on the safety and health of your job and that of your co-workers. Employees are often best placed to know about safety and health because they know how the work is done and may have seen near misses and incidents in the past. Employees can participate in forums such as safety meetings, toolbox talks, Pre-Shift Information meetings (PSI) or through direct consultation with their supervisor. Safety forums are usually attended by Supervisors, Health and Safety representatives, co-workers and Managers or Superintendents.
Figure 4 – Safety Forum
During these forums’ employees can discuss topics like • • • • •
Hazards Incidents & Accidents Suggestions for improvement Safety shares from other industry Any other general workplace business
Forums facilitate meaningful and constructive communication between employees and management about how hazards and risks can best be managed.
ASSESSING HAZARDS AND RISKS IN THE WORKPLACE
Figure 5 – Definition of risk vs Hazard AURASA102 Learning Guide 1 Vs1.05 [LG1]
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RISK MANAGEMENT
Is defined as; The coordinated activities used to direct and control an organization with regards to risk. These activities include the process of identifying risks, assessing risks and developing planned strategies to manage risks. According to the AS ISO 31000:2018: Risk management — Guidelines. The standard provides a set of principles, a framework and a process for managing risk. Using AS ISO 31000:2018 can help organizations of all sizes increase the likelihood of achieving their objectives, improve the identification of opportunities and threats, and effectively allocate and use resources for risk treatment. Mining operations are often fundamentally hazardous, and their projects and operational costs are significant. Therefore, risk management should be a core process and skill in this sector. Constantly and systematically assess your surroundings through the following three steps 1. Hazard identification 2. Risk assessment 3. Risk control
HAZARD IDENTIFICATION:
Identifying in your task area any sources or situation with potential for harm, including human injury or ill health, damage to property, damage to environment, or a combination.
RISK ASSESSMENT:
Risk is the possibility that harm (death, injury or illness) might occur when exposed to a hazard. Assessing risks - understand the nature of the harm that could be caused by the hazard, how serious the harm could be and the likelihood of it happening. Every organisation will have a systematic process for risk assessment. Personal task risk assessments & JHA’s provide a systematic approach to safe work practices, focusing on • Planning • Resources • Personnel Planning – Detailed planning must be undertaken to plan for the safety of the task to be completed Question - What might influence your planning? Pressure or influence from areas such as production to decrease downtime. Cost involved with replacement parts, or resources required to complete the task, personal experience on the task. However, planning must remain focused on safety and efficiency. Consequences of uncontrolled or poorly planned work may include: • Personal Injury AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace • Equipment Damage • Production Loss • Environmental Damage • Re-work This can result in increasing the overall downtime or cost more than taking time to correctly plan.
RESOURCES
Resources are linked to the detailed planning of the task to be completed. A thorough assessment is required to determine what resources are available or required for the task. The correct resources are important to control or mitigate risk.
Figure 6 – Mandatory Signage
PERSONNEL Our personnel are the key to reducing risks involved in any task. During the planning stage we need to consider our people and their:
• • • •
Knowledge, Skills, Attributes Focus on safety and efficiency
THE OVERALL PROCESS
Assessing risk involves considering what could happen if someone is exposed to a hazard and the likelihood of it happening. Carrying out a risk assessment can help you evaluate the potential risks that may be involved in an activity or task. The process to manage risk as outline in AS ISO 31000:2018 Below are listed various workplace process and documents that you could be used to reduce hazards in the workplace. (i.e. personal injury risks / equipment damage, housekeeping issues) : •
Workplace procedures
•
Personal task risk assessments – Take 5, Slam, Star
•
Operational level risk assessment – JHA, JSA
•
Hazards log and Incident reports
•
Daily Area Tyre Bay Inspection
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PERSONAL RISK MANAGEMENT TOOL A personal Risk Assessment that is to be used in conjunction with workplace procedures / OBP’s (Otraco Best Practice) and requires the user to think through the task they are about to complete to identify and Hazards and or Critical Risks they may be exposed to. When used correctly personal task risk assessments will assist the user in implementing control measures to manage the hazards.
Figure 7 – PTA Example
When used correctly: • Personal task risk assessments are a process used by the individual to identify and control risks associated with their daily tasks. • Personal task risk assessments promote an assessment process, focusing on risk. • Personal task risk assessments must be completed prior to the commencement of any task or if the task changes. Steps to follow when completing your personal task risk assessments Stop, look and walk around, assess for potential hazards
Think through the task that you are about to undertake
Identify the hazards, make the changes and control
Complete the task safely
Figure 8 – Risk Assessment Flow Chart
If the job steps change or further hazards are identified, reassess the job and control the hazards identified. Communicate this with others in the work group.
JOB HAZARD ANALYSIS (JHA) – OPERATIONAL RISK MANAGEMENT TOOL A JHA is an operational level risk assessment completed by one or more persons that are required to complete a task were a procedure / OBP (Otraco Best Practice) does not exist or the physical task requires deviation from the written procedure AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace When writing up a JHA the steps must be laid out in logical order to complete the task, for each step hazards are identified and control measures are put in place to minimise the risk to people, property, plant, equipment, facilities and the environment using the Hierarchy of Controls A JHA can be a benefit to an organization by: • Helping to uncover existing and potential hazards and consequence of exposure of the associated to work steps. • Helping to outline appropriate control measures to prevent and eliminate hazards • Standardizing work processes based on acceptable safe practices and Personal Protective Equipment. • Helping to reduce risks and prevent injuries and incidents at workplaces. • Identify and develop absent procedures required by an organization or site.
PROCESS STEPS TO FOLLOW WHEN WRITING UP A JHA
Figure 9 – JHA Example
Figure 10 – Flow Chart JHA Process AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace The JHA is a team activity, conducted by the persons undertaking the task & should include: • Team leader/Supervisor • All persons working on the job • Any persons who can positively contribute All persons involved in the job or wish to enter the job site are required to sign onto the JHA. The following process SHALL involve the persons carrying out the task: • Confirm if a JHA completed previously • Identify the key steps • Identify the hazards at each step • Assess the risk • Control the risk associated with the hazards • Reassess the risk
A JHA MUST be constructed in a manner that is: legible, concise, accurate and easy to understand.
WORKPLACE HEALTH & SAFETY COMMITTEES Roles of workplace personnel • • • • •
Provide a forum for committee members to discuss WHS issues. Develop plans or procedures to resolve the identified issues. Recommend corrective actions to reduce hazards. Address any additional health and safety issues. Evaluate reports submitted by the HSRs.
You can find information on work health and safety (WHS) representatives as well as emergency wardens, first aiders and those staff with cardiopulmonary resuscitation (CPR) and first aid qualifications in the work health and safety (WHS) Policy/Procedure policy. This information should also be displayed throughout your workplace environment on various posters/lists.
HAZARDS IN THE WORKPLACE
Health and safety hazards exist in every workplace. Some are easily identified and corrected, while others create extremely dangerous situations that could be a threat to your life or long-term health. Some categories that hazards may come under and examples of the types of hazards are: AURASA102 Learning Guide 1 Vs1.05 [LG1]
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Psychological – Heights, loud sounds, bright lights Physical – Wet floors, protruding objects, uneven ground, stairs, ladders Ergonomic – Lifting heavy objects, stretching the body, twisting the body, poor posture Environmental – Temperatures, ventilation, airborne contaminants, waste Radiation – electric, welding flashes, sunburn Biological – Bacteria, viruses, parasites, hepatitis B, influenza, food contamination Hazardous substances – Alkalis, acids, solvents
A part of risk management is, identifying the category and in turn the hazard which then ensures the correct preventive measures are in place to prevent a near miss or incident from occurring.
RISK MATRIX
In Risk Management, a process is followed where the risks are assessed against the Risk Assessment Matrix to evaluate Risks, Opportunities and Consequences Using a Risk Assessment Matrix allows us to determine the likelihood and potential consequence of an event giving it a score level with required actions for each outcome The Downer Risk Matrix Heatmap is divided in two halves one for Opportunities and one for Risks
Figure 11 - Example of Risk and Opportunity Heatmap / Risk – Likelihood / Consequence
A system for assessing the severity of a risk, requires three components: • a multi-level scale for rating the likelihood of a risk, • a multi-level scale for rating the consequences of a risk, and • a matrix for scoring the severity of each possible combination of likelihood and consequences. Consequence – What would be the outcome if it did occur? AURASA102 Learning Guide 1 Vs1.05 [LG1]
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Figure 12 - Example of a risk consequence matrix
Likelihood – how likely is it to occur?
Figure 13 - Example of a Likelihood Rating matrix AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace Assessing risk involves considering what could happen if someone is exposed to a hazard and the likelihood of it happening. Carrying out a risk assessment can help you evaluate the potential risks that may be involved in an activity or undertaking. Once the likelihood and consequence has been determined the risk Heatmap will indicate a severity score level out of A, B, C, D in the table in either Opportunity or Risk and provide required action steps that need to be implemented
Figure 14 - Example of a Risk Heatmap
A risk assessment can help determine: • how severe a risk is • whether any existing control measures are effective • what action you should take to control the risk • how urgently the action needs to be taken Taking a risk without proper assessment can have negative results.
RISK CONTROL IN THE WORKPLACE Risk control: Risk control means taking action to eliminate health and safety risks so far as is reasonably practicable, and if that is not possible, minimising them so far as is reasonably practicable. Eliminating a hazard will also eliminate any risks associated with that hazard. Controlling risks—implement the most effective control measure that is reasonably practicable in the circumstances. All workplaces must manage work health and safety risks that may affect workers and other people. If you identify a faulty piece of equipment/ machinery • Make the equipment/ machinery safe (if safe to do so) • Isolate the equipment • Attach out of service tag • Report to supervisor If you’re involved or other workers are in an incident, accident or have an injury/illness. • Stop task, render assistance if safe to do so • Make the area safe and preserve the scene (if safe to do so) • Report the incident/accident or injury/illness to the supervisor • Complete incident/accident report AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace An employee’s duty of care is to report all Hazards, Near misses, Incidents and Accident to your supervisor immediately. Once the hazards and their risks are identified, controls need to be put in place. The ways of controlling risks are guided by the hierarchy of control. Using the type of controls listed in the hierarchy as a measure to deal with the hazard.
Risk Treatment – AS ISO 31000:2018 The purpose of risk treatment is to select and implement options for addressing risk Actions taken to lessen the likelihood, negative consequences, or both, associated with a risk. Risk treatment involves developing a range of options for mitigating the risk, assessing those options, and then preparing and implementing action plans. The highest rated risks should be addressed as a matter of urgency.
The hierarchy of controls ranks control measures in order of their effectiveness in removing hazards, and describes the order that MUST be followed when choosing options for controlling hazards Figure 15 - Hierarchy of Controls
Implementing control measures 1. 2. 3. 4.
Which of your options is feasible? Have you identified and considered all possible options to reduce risks? Identify resource requirements for feasible options Note and action most appropriate controls
Some hazards can be easily fixed and should be done straight away, while others with require more effort and planning to resolve. Prioritise the areas of action while focusing on the highest level of risk. Residual Risk If the risk is still deemed too high, STOP the task consult and communicate with your supervisor. Monitor- supervise and check whether expected performance levels are being achieved, and Review hazards and risks with the job, process conditions or equipment and implement appropriate controls to bring the risk down to an acceptable level.
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
WORKPLACE EMERGENCIES
A workplace emergency is an unforeseen situation that threatens your employees, clients, or the public; disrupts or shuts down your operations; or causes physical or environmental damage. In the event of a workplace emergency, you are required to follow instructions as per your emergency procedures. Every workplace will have an emergency procedure specific to their site requirements. Emergency events that may result in an evacuation could be: • • • • • • • • •
Flood Fire Cyclones Terrorist threat Toxic gas releases Explosions Chemical spills Loss of services Weather events – lightning
The best way to protect yourself is to expect the unexpected and become familiar with your workplace emergency procedure and evacuation plans.
Figure 16 – Kewdale Facility Emergency Map AURASA102 Learning Guide 1 Vs1.05 [LG1]
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EMERGENCY COMMUNICATIONS
Successful communication is critical during an emergency. Information about the situation affects the initial response and defines the first moments of an incident. In addition, both technical and interpersonal communications play a central role in the first critical moments of a mine emergency response. If you are involved in an emergency, you are required to contact your site Emergency Response Team (ERT) as soon as possible Radios are the preferred method on most mine sites and provide to alert all staff that an emergency event is in progress – Refer to site inductions for information and procedures You will need to provide the following information: Your Name/call sign Your Exact Location Description of the incident/type of emergency How many people are involved? Remember to remain calm and send clear information to reduce potential time delays, confusion for response crews and un-needed panic at the scene. DO NOT use name of the person/s involved in the emergency as this can create stress or panic for friends or family on the site.
FIRE AWARENESS Fire tetrahedron There are four components needed to start a fire: fuel, oxygen, heat and a chemical chain reaction. This is commonly referred to as the fire tetrahedron. Removing any of these elements will prevent, suppress or control the fire. A fire in the workplace can be a dangerous and costly event resulting in lost revenue, equipment/ building damages or even personal injuries or fatalities, being prepared and putting control measures in place is key to reducing the likelihood of a fire.
Fire Hazards may include: • • • • • • • •
Damaged or faulty electrical equipment Overloading of power sockets Objects that generate heat Discarded cigarette butts Overflowing waste bins Dust builds up Human error or negligence Flammable liquids and vapours
Prevention measures may include: • • • •
Tagged and inspected electrical equipment quarterly Daily workshop inspections Store flammable liquids in correct storage cabinet Workplace auditing
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace • • • • •
Training (fire hazard awareness) Good housekeeping practices e.g. Empty bins regularly Clearly marked locations for firefighting equipment Designated smoking areas MUST be 5 metres from doorways / buildingentrances Designated smoking areas MUST be away from flammable goods storage
Fire evacuation procedures
In the event of a fire in the workplace: • • • • • •
Follow your workplace evacuation procedures Raise the alarm Notify emergency services Only if safe to do so put out fire with correct firefighting equipment Evacuate to the muster point and await further instruction from warden Never re-enter the building once evacuated until all clear is given
To determine where firefighting equipment in your workplace look for: • • • •
Signage Area Inductions Designated areas Site emergency management plans and procedures (these include locations types and applications for each extinguisher)
Operating a fire extinguisher You should only operate a fire extinguisher if you are TRAINED to do so. Use the PASS method.
Figure 17 - How to correctly use a fire extinguisher
You may like to view a video on the correct way to operate a fire extinguisher AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace Fire Extinguisher Types and Applications for Fire Classes Name of the type of fire extinguishers
Band colours and their meaning
Class A Wood, paper, wood, textile, solid material
Class B
Class C
Class E
Liquids
Gas fires
Electrical fires
Water
Red / Red band
Foam
Red / Blue band
Powder
Red / White band
Carbon Dioxide
Red / Black band
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
HAZARDOUS SUBSTANCES
A substance which has the potential, through being used at work, to harm the health or safety of persons in the workplace. Information on hazardous substances can be found by referring to the substances Safety Data Sheet (SDS). Below is link to example and an explanation of an SDS.
Please take the time to read some additional information on Safety Data Sheets https://www.safeworkaustralia.gov.au/sds
The SDS is a detailed document that provides information about the • • • •
substances first aid measures physical and chemical properties handling and storage, firefighting measures and any other specific safety information relative to the product.
Substances you may be exposed to in an automotive workplace oil, brake fluid, brake dust, chemicals, cleaning products these substances need to be handled with the appropriate PPE and stored in the appropriate location as per SDS. In any workplace required to use hazardous substances, the employer must ensure the SDS is readily available for each substance, which should be located at the chemical storage cabinet or in the workplace office with the registered files. Workplaces can use electronic versions provided ALL employees have access to these documents [Chemwatch/Chemalert or similar].. In the event you replaced a product you were using and does not look or meet the physical properties of the product you used previously or meet the SDS description, • • •
Stop using the product immediately Quarantine the product Report to the Supervisor
Storage Precautions for Hazardous Substances 1. 2. 3. 4.
Only store compatible chemical within the SDS cabinet Ensure cabinet has self-closing doors Cabinet MUST be away from sources of ignition Cabinet MUST be in a well-ventilated area
Further precautions are found in the individual product SDS
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
MANUAL HANDLING
Manual Handling is any activity requiring the use of force exerted by a person to lift, lower, push, pull, carry or otherwise move, hold or restrain a person, animal or thing. Also including any activity involving repetitive and/ or forceful movements, any activity where the person must maintain constrained or awkward postures. Manual handling is the most common cause of injury in workplaces across Australia. One (1) in three (3) injuries to Australian workers are caused by manual handling tasks.
Correct Manual Handling
Figure 18 - Correct manual handling technique
1. 2. 3. 4. 5. 6. 7. 8.
Assess the weight Bend your knees Keep your back straight Keep the load close to your body Lift with legs Turn your body, don’t twist If required, use two (2) person lift or use mechanical lifting aids Wherever possible, heavier or frequently used items should be stored at waist level to avoid unnecessary bending and twisting during the lift.
Please take the time to view the video on correct manual handling techniques Manually handling wheel assemblies When conducting tyre maintenance activities daily there are lots of repetitive motions and are handled in various conditions e.g., flat tyres, rough terrain, cramped spaces on trailers, with wheel assemblies varying weight from a few kilograms to hundreds of kilograms this can lead to long term severe bodily injuries, if incorrect manual handling practices are not followed. List below gives you ways to make the right choice when working with wheel assemblies. •
Determine the weight of the assembly – refer to Otraco’s component weight chart LV tyres and rims, manufacturers data weights Figure 19 - Example of correct manual handling or use scales to determine the weight. technique
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace • • •
Use correct manual handling techniques - knees bent, back straight, turn don’t twist Use mechanical aids – use tyre machine to strip and fit tyres, use clever lever/wheel dolly to take wheels of the hub, use forklift to transport tyres. Ask for help – two-person lift
HAND INJURIES
Every day we use our hands to conduct tyre maintenance tasks, where there are many hazards’ hands and fingers can be injured. In some cases, injuries can be superficial with minimal impact and quick recovery in other unfortunate instances injuries can be life changing to your career and everyday life from ligament and nerve damage, bone fractures to amputations. • • •
• •
Plan and remain focused on task. Watch for pinch/crush points or clarify where pinch/crush points are. Wear adequate personal protection, this is not 100% guarantee that you will be protected from every type of hand injury though this will limit the impact when used for Figure 20 - Xray of actual hand injury sustained the correct task. Use correct tooling when conducting tyre maintenance activities. Otraco specific tooling hazard – using torque multipliers tools and extensions
(reference material located in LG3 & LG)
Please take the time to view the video on protecting your hands
HYDRAULIC INJECTION INJURIES
The injection fluid often does not cause any immediate reaction, however hydraulic injection directly into your blood vessel can spread rapidly through your circulatory system and can result in permanent injury or death.
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Safety Signage
Safety signs draw your attention to objects or situations that could affect your health and safety. Safety signs are placed in strategic locations as close as possible to the hazardous area.
If a safety sign displays a distinct safety message, it will carry the same authority as a direct instruction from your supervisor. Mandatory Signs (Blue and White) Mandatory signs indicate an instruction that MUST be carried out.
Prohibitory Signs (Red Circle with a slash) Prohibitory signs indicate an action or activity that is NOT PERMITTED.
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace Caution Signs Caution signs indicate a hazard or hazardous condition that is NOT LIKELY TO BE LIFE THREATINING.
Danger Signs Danger signs warn of a hazard or hazardous condition that is LIKELY TO BE LIFE THREATINING.
Emergency Signs Emergency information signs indicate the location of, or direction to, emergency related facilities such as exits, safety equipment or first aid facilities.
Fire Signs Fire related signs indicate the location of fire alarms and firefighting equipment and facilities.
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ELECTRICAL SAFETY Tools in the workplace
When using electrical tools in the workplace the following checks must be conducted. • • • • •
Check the cable is in good condition Check the voltage capacity for the tool Check the tool is in good working order and free from damage Check for damaged or faulty switches and safety trigger locks Inspect the plug for damaged or missing prongs
Any faulty electrical tools must be removed from service immediately and clearly tagged for repair or disposal. Electrical tools and water don’t mix When using electrical tools in damp or wet conditions it increases the likelihood of personal injuries or death due to electrification as a result of arching. Remember if you need to use electrical equipment in wet conditions • Always use a tested safety cut out switch • Ensure the tool is kept out of the water unless designed to be submerged • Ensure extension leads are secured up out of wet conditions Electricity will always follow the path of less resistance water is a perfect conductor of electricity.
MACHINE SAFETY GUARDING
Safety guarding on machines and equipment prevent or reduce access to dangerous areas of the machine. All machine guarding must be of a solid construction and securely mounted to the plant, to resist impact or shock from operation. Automotive workshop equipment that requires guarding includes wheel balancers, disc grinders and bench grinders. Equipment that is designed to have guarding in place should never be operated with missing or damaged guards.
COMPRESSED AIR
Compressed air systems are widely used in automotive workshops due to the large number of application abilities from small handheld tools to workshop pumps and lifting equipment with relatively low operating costs. Hazards of compressed air and compressed air equipment: AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace • • • •
Flying particles and debris – can result in eye injuries, cuts/scrapes or other significant injuries to almost any body part. High pressure air – can result in air injection into the body leading to potential injuries such as air embolism, ruptured ear drums or organs, and dislodged eyeballs. High noise – can result in temporary or permanent hearing loss. Flailing air hoses due to coupling disconnection.
Before using any equipment using compressed air it is important to check the following: • Air hose condition • Fittings for condition and compatibility • Pressure ratings for equipment – pressure setting on supply line • Safety clips (where required must be fitted and secure) • General condition of the equipment • Location of safety shut off valves
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
VEHICLE SAFETY
Running Vehicles in the Workplace Working in and around vehicles can expose you to many hazards and risks. It is important to be aware of these and take appropriate preventative and protective steps to control these risks. One of the main hazards associated with running vehicles in a workshop is the production of exhaust fumes and gases which can lead to poisoning and asphyxiation. You can reduce this risk by the following: • Operate in a well ventilated area and reduce idling of vehicle • Use roof ventilation and /or extraction fans • When doing long running and testing of vehicles conduct the work outside whenever possible Another high risk hazard while working on running vehicle is: Operational stored energy. e.g PTO systems/braking systems You must be aware that stored energy will be present when working on live vehicles and additional risk assesments will be required to be put in place when conducting this work. E.g. testing and commissioning tags.
Please refer to original OEM BEFORE conducting live works.
Figure 29 - Example of Working with a Vehicle Hoist
Other risks hazards when working on vehicles include: AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace Engine moving parts Engines have so many moving parts that it can become easy to overlook obvious hazards that can have catastrophic outcomes. Hazards may include: • Pinch points • Crushing points • Rotating parts • Stored energies
Hot components Many automotive components (i.e. brakes) become very hot during their normal operation and pose significant hazards if not identified prior to working on the equipment Hazards may include: • Burns • Scolds • Increased pressure within systems • Fires
High voltage ignition systems Vehicle ignition systems generate a spark or heat an electrode to a high temperature to ignite a fuel air mixture in an internal combustion engine using a coil to increase the voltage (typically 20,000 to 50,000 volts) working on running ignition systems can be extremely hazardous Hazards may include: • Electrification • Heart complications or death • Electrical arcing or shorting out of other vehicle systems
Basic mechanical ignition system
Figure 30 - Mechanics of an Ignition System
•
The coil is the heart of the ignition system. As current flows through the coil a strong magnetic field is built up. When the current is shut off, the collapse of this magnetic field to the secondary windings induces a high voltage which is released through the large center terminal. This voltage is then directed to the spark plugs through the distributor.
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace Wearing jewellery while working around high current wiring systems Although it is the current that will be main danger, wearing jewellery while working on any wiring system even 12volts increases the likely hood of a shock as the metal increases the conductivity for electricity to travel to the body. Hazards may include: • Electrification • Skin burns • Electrical arcing or shorting out of other vehicle systems
VEHICLE HOISTS HAZARDS/RISKS
Failure of lifting equipment can cause crush injuries or fatalities. Moving vehicles on and off hoists also presents potential hazards. Safety solutions to train operators in the safe use of hoists and ensure they do not work under a suspended load without checking that safety features are engaged and operating correctly. Prominently display Figure 31- Example 4 post hoist equipment operating and maintenance instructions, as well as the safe working load. Ensure hoists have a valid design registration number issued by a work health and safety regulator in Australia. To avoid worker entrapment, ensure that moving parts of the hoist or its load are located at least 600mm away from any other fixed structure or equipment that moves. Ensure that operator controls are undamaged, clearly marked and positioned for effective, safe use. Check that the dropper bar (safety prop) is fitted to any in-ground, hydraulic, ram-type hoist. Conduct pre-operational inspections daily (e.g., look for leaks in hydraulic and pneumatic components). Inspect and maintain the hoist at least every 3 months. Arrange for a comprehensive annual inspection to be carried out by an independent, qualified, competent person. Undertake hoist inspections in accordance with the manufacturer’s instructions, and with reference to Australian Standards: • AS/NZS 2550.9: Cranes – Safe use. Part 9: Vehicle hoists • AS/NZS 1418.9: Cranes (including hoists and winches). Part 9: Vehicle hoists. Ensure electrical hoists and wiring are tested with reference to Australian Standard AS/NZS 3000: Australian Wiring Rules. Record all inspections, servicing and maintenance in a logbook which is available for all users, maintenance or inspection personnel. AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
EXAMPLES OF VEHICLE HOISTS
There are various types of lifiting and supporting equipment in the automotive industry that have certain capabilities with varing Safe Work Load (S.W.L.) or Work Load Limits (W.L.L.) which would be identify with a stamping, placard or sticker labelled on the equipment clearly. Vehicle hoist are common in most automotive workshops which vary in designs from 2 post to 4 post and with various lift capacities which are mainly driven by 3 phase power/hydraulic system with lock out latch features to prevent the vehicle for coming down suddenly. A vehicle hoist has its limitations such as: they are not transportable, limited by size of the vehicle (height, length and width), require dedicated workshop space and require a power supply (usually three phase). Knowing the basic functions a. Adjustable arm assembly to be positioned under the vehicle lift points b. Controls to ope rate the arms to be raised or lowered c. Hydraulics to raise the vehicle to the desired height
Figure 32- Example of 4 and 2 post vehicle lifting hoists
JACK STANDS
Jack stands are used to support the weight of the vehicle once it has been raised from the ground by the jack to reduce the likelihood of crushing injuries resulting from un-expected jacking equipment failure. Jack stands are usually very versatile as they are easily transportable, adjustable and have a range of heights and weights available. Their limitations are that they are unable to lift the vehicle and are weight restricted. Pin type
Threaded type
Ratchet type
Figure 33 - Types of Jack Stands AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
HYDRAULIC JACKS
Hydraulic trolley jacks are commonly used in light vehicle workshops rather than the vehicles supplied screw jack. A hydraulic trolley jack uses an incompressible liquid that is forced into the cylinder by manually operating the handle up and down which pumps plunger raising the saddle up lifting the vehicle to it desired height. This allows the user to lift heavier loads with minimal physical exertion. To lower the saddle the handle will need to be rotated anticlockwise that will allow the hydraulic pressure to release in the pump and lower the saddle. A hydraulic trolley jack has limited lift heights by cylinder size, trolley jacks need to be used on smooth stable ground and can be too high to fit under some vehicles. Trolley jack are mobile design for different range of conditions made from steel or alloy. that is linked to a hydrualic pump that will build pressure to the hydrualic oil and push the piston out and
Figure 34 - Photo examples of Hydraulic Jacks
PNEUMATIC JACKS
Pneumatic jacks operate like a standard hydraulic jack but use air pressure to actuate the hydraulic pump instead of physical exertion. Using air pressure to operate the pump can potentially increase the operation speeds and the lifting capacity and allows the operator to be further away from the jack while in operation. Pneumatic jacks’ limitations are limited lift heights by cylinder size, trolley jacks need to be used on smooth stable ground, can be too high to fit under some vehicles and requires air to be operated (some can use manual pump as back up).
Figure 35 - Photo examples of Pneumatic Jacks AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace Lifting capacities for jacks and stands
When using any type of jacks or stands in the workplace it is critical that the safe workload is not exceeded. All equipment used for lifting and supporting equipment MUST have a legible sticker or certification placard displaying their Working Load Limits (WLL) or Safe Work Load (SWL). Never use an un-certified jack or stand to support a vehicle. Remove from service any jacks or stands that do not clearly display their WLL or SWL.
Figure 36 - WLL examples
WORKING AROUND BATTERIES
An automotive battery is a rechargeable battery that supplies electrical energy to start the vehicles motor, its main purpose is to start the engine, once the engine is running the cars electric system is supplied by the alternator, lead acid batteries contain sulphuric acid and can produce hydrogenoxygen gases when charging Hazards may include: • Severe burns/ skin irritation • Flammable/ explosive gas concentration – during recharging • Object weight
FUEL
All vehicles that use a combustion engine require a form of flammable fuel to run on (diesel, petrol LPG), this creates a hazardous condition when working on them. Hazards may include: • Severe burns • Flammability • Personal health effects – nausea, skin irritations, asphyxiation • Slippery surfaces • Contamination
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
HIGH VOLTAGE IN BATTERY ELECTRICAL AND HYBRID VEHICLES
Hybrid vehicles are becoming more common sight on roads today thanks to the popularity of their gas saving powertrains however Hybrids equal high voltage – the voltage in most hybrid storage cells can deliver a lethal shock like an electric chair. High voltage cables are usually color-coded to warn you of their potential danger. Hazards may include: • Electrocution • Electrical arching or shorting out of other vehicle systems • Fire hazard All hybrid batteries have a safety switch or disconnect mechanism to disconnect the storage cell from the vehicles electrical system, the location of the switch will vary from manufactures so always refer to the service manuals for the relevant vehicle. Most hybrids have a ready indicator on the dash to indicate when the system is on, however this should never be relied upon for positive isolation to undertake mechanical work on the vehicle.
The correct method for isolating the battery system will be clearly detailed in the service manuals including written and picture instructions
Figure 37 - Example of hybrid vehicle isolation
SAFETY CONSIDERATIONS FOR WORKPLACE VEHICLE SAFETY: • • • • • • •
Correct isolation/removal of the power source will stop the engine from -- operating during maintenance activities. Wearing correct PPE, having machine guarding, and allowing equipment adequate time to cool down after operation, will reduce the likelihood of these hazards. Remember to always adhere to the manufacturer safety precautions when working on or around the ignition system, isolate the power source and wear adequate PPE (rubber insulated gloves). Remember you should always remove jewellery when working on high current wiring systems. Always use correct handling and safety procedures when working with automotive batteries. Always store and charge batteries in a well-ventilated area. Always use correct handling and safety procedures when working with fuels, remove any potential sources of ignition.
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace • • •
Always use correct PPE (refer to SDS) and work in a well-ventilated area. Always follow vehicle manufacturer safety procedures when working high voltage electrical and hybrid systems, always use correct shock resistant PPE and isolate the power source. Always isolate the power source before completing any mechanical work.
Sometimes the risks associated with a work task may be obvious, such as using dangerous machinery or chemicals. Other times the risks are not so obvious, such as unloading goods or packing boxes. Safe work procedures make workers aware of risks in their work tasks and tell them how to avoid injury or illness while doing those tasks. Safety is everyone’s responsibility!!
You must be aware of your site emergency management procedure and plan. This includes information on roles and responsibilities of personnel including: • • • • •
First aid Cardio-pulmonary resuscitation (CPR) Fire warden Emergency evacuation Work health and safety representatives
To obtain a copy of your site emergency plan you can either access this through your site Intranet webpage or ask your supervisor for a copy. You may also find this on a site safety board.
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
SAFELY WORKING IN AUTOMOTIVE PITS Service pits Hazards/risks
The hazards of working in or around vehicle service pits can include falls into an unguarded or uncovered pit, asphyxiation, explosion or fire. Some fuel vapours from vehicles and gaseous byproducts of combustion have a tendency to settle in low areas, such as vehicle service pits. Service pits have poor ventilation which can allow hazardous atmospheres to develop. Risk control measures should be based on fall prevention, ventilation, and fire safety. Read more about working in confined spaces on page 52. Read more about fire and explosion on page 54 of the Automotive Workshop Safety Guidebook. Safety solutions Provide multi-purpose hoists and elevated ramps for overhead work, rather than the conventional service pit. Paint the pit interior white and outline the edges for at least 600mm in a conspicuous colour (e.g., safety yellow). Install sectionalised guard railing designed to fit into prepared floor sockets or suspend chain barriers from removable steel uprights to prevent people walking into open pits. Cover pits when not in use with either traditional hardwood covers, or the better solution of heavy interlocked steel plates designed to run through guide rails (much like a roller shutter). Use ventilation systems with vents in the side walls of the pit to vent vapours and fumes. Ensure all portable or permanent lighting and/or electrical equipment within the hazardous zone of the pit is intrinsically safe. Never drain a petrol tank or service LPG-powered vehicles over or next to a service pit. Avoid work involving welding or oxy cutting inside or adjacent to service pits.
Figure 38 - Workshop pit example
Inspection pits are still commonly found in automotive tyre workshop premises and an assessment of workplace risks may well show that they are the safest option when working on diesel-fuelled vehicles. But they present particular hazards and are a common cause of accidents, not only to those unfamiliar with the premises but also to employees who momentarily forget the presence of an unfenced pit, or who slip or trip, and fall into them. When working on petrol-fuelled vehicles, a lift is usually a safer alternative. The principal hazards are: • • • • •
falling into the pit (the Work at Height Regulations will apply). slipping on access steps. fire or asphyxiation from an accumulation of gases or vapours that are heavier than air, or fuel release. a vehicle or other objects falling on an employee in the pit. head injuries from contact with the vehicle over the pit.
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace Preventing falls into pits When deciding on the precautions, the employer needs to consider a number of options. The best solution is likely to depend on the particular work undertaken, • • • •
Health and safety in motor vehicle repair and associated industries Health and Safety Executive Layout of the premises and management and supervision in the workplace Limiting access to the area
The more people working or walking around the pit area, the greater the risk of falls, probably because they become familiar with the risk and are concentrating on other tasks. Restrict access to people who need to be there. Where possible, physically segregate the pit or group of pits or modify the layout of the workplace to keep non-authorised people away from the pit area (for example by making clearly defined pedestrian routes and using barriers and partitions). • • •
Provide enough signs and supervision to enforce this segregation. Covering pit openings Where practical, cover pit openings when they are not in use. Also cover areas of the pit that are left exposed when the vehicle being worked on is shorter than the length of the pit. A number of proprietary systems are available that allow all or parts of the pit to be covered.
Ideally, any cover should: • • • •
be quick to install and remove (for example if a pit worker needs to get out in an emergency); be robust enough to withstand a falling person and any other load likely to be imposed on them fit securely in place be compatible with other pit equipment
Installation and removal of covers may itself create a small risk, due to handling and proximity to the opening, and this should be weighed against the time that the pit is left uncovered and other precautions in place.
Safe access across the pit
Given the length of many pits, people take short cuts across the opening even where there are ‘official’ instructions not to. It may be a better solution to provide a proprietary moveable bridge across the pit with handrails on the open sides (see Figure 63). Such a bridge can also be used as a safe platform for work that would otherwise be impractical to carry out due to the open pit, for example on the rear engine of a bus or coach.
Other types of barriers
Guard rails, chains or extendible barriers can provide flexible protection for workers near the pit edge. They allow access to the side of a vehicle over a pit (as the vehicle covers the pit at this point) while providing a warning of the open pit not covered by the vehicle. They need to be sufficiently high, stable, and clearly visible so that they do not create a tripping hazard. Extendible barriers are not designed to withstand the weight of a falling person, but act as a physical reminder of an open edge.
Improving visibility
It is important that the pit opening can be seen easily. Use pit lighting during working hours and clearly mark pit edges, for example by black and yellow bands of slip-resistant paint. Ensure the pit
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace lights are kept clean and replace failed bulbs immediately. White painted walls help reflect light and increase the efficiency of the lighting system but need to be cleaned regularly. Reducing the risk of slips and trips Ensure the surface around the pit is slip-resistant, either by using anti-slip materials or by having an effective cleaning regime As far as possible, keep the area clear from obstructions and deal with spillages immediately. Similarly, keep the area inside the pit free from obstructions – this will improve access for pit workers.
Access to pits
Figure 39 - Sample of barricading over workshop pit
Pits require safe means of entry and exit. Provide at least one fixed entry/exit point with additional, separate, usable means of escape where the risk assessment identifies the need (for example, where escape may be blocked off by the parked vehicle or for pits over 9 m long). A significant number of injuries occur from people slipping on the access steps. Provide a handrail where possible, for example a permanent handrail may be appropriate on sunken pits or low-level handrails below floor level. Removable handrails may be an option for other installations. Use slip-resistant coatings on the steps and keep them free from contamination. The Health and Safety Laboratory (HSL) have carried out extensive research on tread patterns for footwear, which shows large variations in performance even for those designated ‘slip-resistant’. When specifying footwear, remember that ‘oil-resistant’ does not mean ‘slip-resistant’.
Preventing fire and asphyxiation
Pits are likely to have poor natural ventilation so the release of any low flashpoint substance or heavier-than-air gas above or near a pit can create fire/explosion and asphyxiation risks. To reduce these risks: AURASA102 Learning Guide 1 Vs1.05 [LG1]
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace • • • • • • • •
do not carry out pit work on non-diesel tanks or associated fuel lines where there is a risk of release. do not carry out any hot work on or near any tank or fuel line, including diesel systems. do not store portable LPG heaters, or other LPG-fuelled devices, in or near pits in case they leak. before carrying out pit work on air-conditioning units, empty the refrigerant with a proprietary system well away from the pit area. do not weld in a pit unless effective local exhaust ventilation is provided. use fixed lighting in the pit that is suitable for potentially explosive atmospheres and conforms to a suitable standard. use handlamps of special construction, that have been designed and tested to prevent ignition in flammable atmospheres. do not leave vehicles idling over pits unless there is dedicated exhaust extraction.
Preventing vehicles or other objects falling into the pit Highlighted pit edges (approximately 150 mm wide) are a useful guide when driving vehicles on and off the pit but may need supplementing with mirrors. It may be necessary to authorise a competent marshal to assist manoeuvring (and watch out for moving vehicles or pedestrians). Only competent and authorised drivers should be allowed to manoeuvre vehicles on and off the pit. For narrow-wheelbase, twin-wheeled vehicles (where the inner tyre may be hanging over the pit edge), ensure that the outer tyres are correctly inflated and in a satisfactory condition to reduce the risk of vehicles tipping or sliding into the pit. Also ensure that outer tyres will not be loaded more than their carrying capacity (load index rating). Remove discarded or replaced parts as soon as possible and do not leave tools or other items around the pit apron, working platforms etc. Preventing other injuries Provide suitable head protection for pit workers where there is a risk of injury from contact with the vehicle overhead or from falling objects. The ultimate strength of the head protection is probably less important than the ability to wear it. For example, baseball-style, short-peak bump caps provide a degree of protection, stay in place and allow reasonable upward vision. They may be more appropriate than traditional, constructiontype helmets. 1. Eye protection may be required to guard against displaced dust, rust or other debris and especially materials ejected under pressure, e.g., hydraulic fluids. 2. Ear defenders may be necessary for noisy processes such as engine running
Figure 40 - Working underneath a vehicle raised on hoist AURASA102 Learning Guide 1 Vs1.05 [LG1]
2022-09-21
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LEARNER GUIDE - 1 AURASA102 – Follow safe working practices in an automotive workplace
GENERALLY, CONSIDER: Once safe systems and procedures are in place, they need to be maintained through an ongoing focus on health and safety. Maintain a safe workplace by: • • • • •
• • •
carrying out regular workplace inspections ensuring equipment and tools are safe to use and maintained fixing high risks immediately and others as soon as possible in order of level of risk discussing common injuries, work practices and procedures with workers keeping up-to-date knowledge of product labels, Safety Data Sheets and manufacturer’s instruction manuals having an easy-to-use hazard, near miss and injury reporting process as well as reviewing incident reports planning and regularly testing of emergency procedures (e.g., for fire, medical, chemical leaks) keeping workers informed of any changes and providing training opportunities when anything new at work is introduced.
Figure 41 - Example safety checklist
Record keeping Document what you’re doing to maintain and improve your work health and safety. Keeping records will help you to monitor the health and safety performance of your business as well as meet your legal requirements. You will need to keep the following records: • • • •
all incident/hazard reports hazardous chemicals and asbestos registers (if those substances are in your workplace) plant registration documents tests, maintenance, inspection and repairs for specific items of plant.
It’s also useful to keep records of: • •
maintenance of all items of plant and equipment workers’ induction and training.
You now have all the knowledge required to complete the online knowledge assessment
AURASA102 Learning Guide 1 Vs1.05 [LG1]
2022-09-21
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