Contents |
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Page last reviewed: 08/04/2009
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Highlights |
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- Machine Guarding.
OSHA eTool. Focuses on recognizing and controlling common amputation hazards associated with the operation and use of
certain types of machines.
- Plastics
Machinery. Discusses guidelines and safety measures for horizontal
injection molding machines. A virtual tour of a horizontal injection molding machine is also available.
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Plastics Industry
Employing over 1.1 million workers in the United States, the plastics industry represents a substantial portion of the American workforce. Various safety and health concerns exist throughout the plastics industry, ranging from raw material manufacturing to plastics processing.
This page was developed as a product of OSHA's former Alliance with the Society of the Plastics Industry, Inc. (SPI).
OSHA's mission is to prevent work-related injuries, illnesses, and deaths. Since the agency was created in 1971, occupational deaths
have been cut by 62% and injuries have declined by 42%. One way OSHA accomplishes this mission is by the development and enforcement of standards
that address hazards in the workplace.
Standards
This section highlights OSHA standards, directives (instructions for compliance officers), state standards, and national consensus standards related to the plastics industry.
OSHA
Note: Twenty-five states, Puerto Rico and the Virgin Islands have OSHA-approved State Plans and have adopted their own standards and enforcement policies. For the most part, these States adopt standards that are identical to Federal OSHA. However, some States have adopted different standards applicable to this industry or may have different enforcement policies. State standards that differ from Federal standards are listed in the State section below.
Frequently Cited Standards
The following standards, in order, were the most frequently cited by Federal OSHA from October 2010 through September 2011, in Miscellaneous
Plastics Products Industry Group (SIC
code 308). A comparison of SIC and NAICS codes for the plastics industry is also available.
- 1910.147, The control of hazardous energy (lockout/tagout) [related topic page]
- 1910.212,
General requirements for all machines [related topic page]
- 1910.305,
Wiring methods, components, and equipment for general use
- 1910.1200,
Hazard communication [related topic page]
- 1910.178,
Powered industrial trucks [related topic page]
- 1910.303, General requirements (Electrical)
[related topic page]
- 1910.134,
Respiratory protection [related topic page]
- 1910.95,
Occupational noise exposure [related topic page]
- 1910.215, Abrasive wheel machinery
- 1904.29, Forms [related topic page]
Directives
- National Emphasis Program on Amputations. CPL 03-00-003, (2006, October 27). Describes policies and procedures for implementing a National Emphasis Program (NEP) to identify and reduce the workplace machinery and equipment hazards which are causing or are likely to cause amputations. This directive applies to general industry workplaces where saws, shears, slicers, press brakes, and power presses of all types are present.
- Inspection Procedures for the Hazard Communication Standard. CPL 02-02-038 [CPL 2-2.38D], (1998, March 20). Provides clarifications and guidance to comply with this performance-oriented standard. The appendices include sample hazard communication programs, hazard evaluation procedures, and clarifications and interpretations of the standards.
- Search all available directives.
State
Note: These are NOT OSHA regulations. However, they do provide guidance from their originating organizations related to worker
protection.
- Part 62, Plastic Molding [31 KB PDF, 7 pages]. Michigan Department of Labor & Economic Growth (DL&EG), General Industry Safety Standards, (2000, January 24).
National Consensus
Note: These are NOT OSHA regulations. However, they do provide guidance from their originating organizations related to worker
protection.
American National Standards Institute (ANSI)/Society of the Plastics Industry, Inc. (SPI)
- Injection
- B151.1-2007, Horizontal injection molding machines - safety requirements
for manufacture, care and use. Applies to horizontal injection molding machines that are used in the rubber and
plastics industries.
- B151.21-2003, Injection blowmolding machinery - safety requirements for manufacture, care and use.
Applies to all IBMMs (including Injection Stretch Blow) that process plastic
materials and produce and/or deliver a preform which is then blown into the shape of a mold held together by a
vertically or horizontally acting clamp(s).
- B151.27-2003, Safety requirements for the integration, care and use of robots used with horizontal & vertical injection molding machines.
- B151.29-2002, Safety requirements for the manufacture, care and use of vertical clamp injection molding
machines. Identifies and addresses known hazards to personnel working on or with the specified machinery.
- Extrusion
- B151.15-2003, Extrusion blowmolding machines - safety requirements for the manufacture care and use.
Minimizes hazards to personnel associated with machine activity by establishing requirements for the manufacture, care, and
use of these machines.
- B151.5-2000, Plastic film and sheet winding machinery - manufacture, care, and use. Identifies and addresses
known hazards to personnel working on or adjacent to the machinery.
- B151.2-1999, Film casting machines - construction, care, and use (revision and redesignation of ANSI
B151.2-1982 (R1988)). Identifies and addresses known hazards to personnel working on or adjacent to the machinery.
- B151.4-1999, Blown film take-off and auxiliary equipment - construction, care, and use (revision
and redesignation of ANSI B151.4-1982 (R1988)). Identifies and addresses known hazards to personnel working on or adjacent to the machinery.
- B151.20-1999, American national standard for plastic sheet production machinery - manufacture,
care and use. Identifies and addresses known hazards to personnel working on or with the machinery.
- Lockout/Tagout
- Z244.1-2003 (R2008), Control of hazardous energy - lockout/tagout and alternative methods. Cited in OSHA interpretations and private
sector materials, the Z244.1 Standard is used as a resource for addressing control of hazardous energy and lockout/tagout. The scope and purpose of the standard is to establish requirements for the control of hazardous energy associated with machines, equipment, or processes that could cause injury to personnel. The purpose of this standard is to establish requirements and performance objectives for procedures, techniques, designs and methods that protect personnel where injury can occur as a result of the unexpected release of hazardous energy. Unexpected release of hazardous energy can include any unintended motion, energization, start-up or release of stored energy, deliberate or otherwise, from the perspective of the person(s) at risk.
- Z244 Subcommittee Information. American Society of Safety Engineers (ASSE).
Hazards and Solutions
Many workers are unaware of the potential hazards in their work environments, making them more vulnerable to injury. The following references aid in recognizing and controlling workplace hazards that may be present in the plastics industry.
General
Electrical
Ergonomics
- A Primer Based on Workplace Evaluations of Musculoskeletal Disorders. US Department of Health and Human Services (DHHS), National Institute for Occupational Safety and Health (NIOSH) Publication No. 97-117 (Elements of Ergonomics Programs), (1997, March). Links to NIOSH investigations where certain work settings were found to contribute to work-related musculoskeletal disorders (WMSDs). Lists disorders and recommendations for avoiding injury. The following are relevant to the plastics industry:
- 3070: Manufacturing (Plastics, metal products)
- Bennett Industries, Peotone, Illinois [172 KB PDF, 20 pages]. National Institute for Occupational Safety and Health (NIOSH) Health Hazard Evaluation and Technical Assistance (HETA) Report No. HETA 89–146–2049, (1990, June).
- 3089: Manufacturing (Plastic products)
- Scott Molders, Inc., Kent, Ohio [180 KB
PDF, 20 pages]. National Institute for Occupational Safety and Health (NIOSH) Health Hazard Evaluation and Technical Assistance (HETA) Report No. HETA 91–0003–2232, (1992, July).
- Ergonomics
FAQs for Plastics Processors. Society of the Plastics Industry (SPI). Answers commonly asked questions regarding ergonomics for plastic processors.
- For additional information, see OSHA's Ergonomics Safety and Health Topics Page.
Hazard Communication
Isocyanates
- A Summary of Health Hazard Evaluations: Issues Related to
Occupational Exposure to Isocyanates, 1989 to 2002 [1 MB PDF, 42 pages]. US Department of Health and Human Services (DHHS), National Institute for Occupational Safety and Health (NIOSH) Publication No. 2004-116, (2004, January).
- TDI User Guidelines for Protective Clothing Selection [126 KB PDF, 6 pages]. Alliance for the Polyurethanes Industry (API) Technical Bulletin AX179, (2001, July). Presents guidelines for selecting the appropriate chemical protective clothing for working with toluene diisocyanate (TDI) and TDI-based foam systems.
- PMDI User Guidelines for Protective Clothing Selection [245 KB PDF, 6 pages]. Alliance for the Polyurethanes Industry (API) Technical Bulletin AX178, (2002, January). Presents guidelines for selecting the appropriate personal protective equipment (PPE) for working with methylene diphenyl diisocyanate (PMDI) and PMDI-based foam systems.
- For additional information, see OSHA's Isocyanates
Safety and Health Topics Page.
Legionnaires' Disease
Lockout/Tagout
Machine Guarding
Noise
Personal Protective Equipment (PPE)
Powered Industrial Trucks
Respiratory Protection
Walking/Working Surfaces
- Slips and Falls Caused by Plastic Pellets and Beads
- Slips and falls are one of the major causes of plastics industry accidents. They occur frequently and happen when you least expect it. Walking
surfaces that have spilled resin pellets or beads provide minimal traction due to the slippery nature of the pellets or beads, and subject workers to slips
and falls. The occurrence of slips and falls and the extent of injuries from them can be minimized through proper safety and good housekeeping practices.
It is important to identify and correct unsafe conditions to prevent slips and falls from spilled resin pellets or beads. An all around program that will
help you is called "Operation Clean Sweep". This free program shows you how to ensure that your worksite is properly set up to prevent pellet loss and to assist you in cleaning up your facility.
- For additional information, see OSHA's Walking/Working Surfaces Safety and Health Topics Page.
Additional Information
Other Resources
- SPI. Society of the Plastics Industry,
Inc. (SPI). SPI represents one of the largest manufacturing industries in the United States. SPI members
represent the entire plastics industry supply chain, including processors,
machinery and equipment manufacturers, and raw materials suppliers.
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