Practice of Safety Production Management in Precision Casting Industry

Practice of Safety Production Management in Precision Casting Industry

Analyze the major hazards, hidden dangers, and points in the precision casting industry, establish practical and feasible effective control (monitoring) measures, control unsafe behavior of people, unsafe state of controlled objects, control the working environment, and strengthen safety management. Today, precision casting manufacturer Tianyao Metal will talk to you about how to implement safety production management in the casting industry.

1、 Measures for controlling unsafe behavior of individuals

Foundry worker:

1. Only personnel who have received specialized training in casting can operate independently after passing the exam and obtaining an operation certificate.

2. During operation, wear protective equipment and prohibit bare chest, arms, and feet.

3. In places with ventilation equipment, the ventilation equipment should be activated before work.

4. The workplace should be kept clean, and sandboxes, models, tools, etc. should not be stacked randomly, and the passage should be kept unobstructed.

5. Waste and garbage should be disposed of at designated locations and regularly eliminated. The voltage of the running lights used should not exceed 36V.

6. When using equipment or cranes, safety technical operating procedures should be followed.

Pouring worker:

1. Remove all obstacles from the passage and venue.

2. All tools in contact with molten steel must be preheated to standard temperature before use, otherwise they are not allowed to be used.

3. The amount of molten steel should not exceed 80% of the volume, and it should be walked steadily and slowly with consistent steps to prevent splashing and injuring people.

4. Strictly implement the six no pouring measures:

① Do not pour if the temperature of the molten steel is not enough;

② Do not pour if the steel grade is incorrect;

③ Do not block slag or pour;

④ Do not pour the sand box until it is dry;

⑤ Do not pour outside the gate;

⑥ If there is not enough molten steel, do not pour it.

5. During casting, it should be accurate and stable, and it is not allowed to pour molten steel inward from the riser.

6. The remaining molten steel should be poured into the prepared sand pit and not onto the sand pile or the ground to prevent it from exploding and injuring people. The molten steel flowing on the ground due to running fire or other reasons should not be covered with sand before it solidifies, and should be removed in a timely manner after solidification.

7. All equipment should be checked for safety and reliability before use, and cleaned thoroughly after use.

Metal melting chemical industry:

1. Before starting work, it is necessary to carefully inspect the machinery, electrical appliances, water cooling, hydraulic (or air pressure) they belong to, and confirm that they are normal before melting.

2. When working, one should wear work clothes, protective shoes, protective goggles, protective helmets, etc. Do not shirtless to prevent burns.

3. The front of the furnace and the workplace should be kept clean and tidy regularly. Various materials and tools should be placed in designated locations.

4. The furnace material should be dry and inspected by someone. It is strictly prohibited to put explosive materials (such as bullets, detonators, etc.), sealed containers, and furnace materials with water (or snow) into the furnace.

5. Spoons, molds, and sample plates should be kept dry and clean. The remaining molten liquid should be poured into a dry place or a dry ingot mold.

6. Before opening the furnace, all obstacles around the furnace pit must be removed, and no explosive materials are allowed within 5m. There must be no accumulated water on the furnace pit and the ground in front of the furnace.

7. When adding powdered materials, they should be fed sideways to prevent splashing and injuring people.

8. Before discharging the molten metal, the tools and pouring bags used must be baked and dried. The pouring bags must be placed upright and stable to prevent splashing and injuring people.

9. When opening the furnace, adhere to the work position according to the division of labor and shall not leave the job without permission.

2、 Measures to control the unsafe state of objects have been identified through hazard identification of explosions, fires, and toxic gases

1. Melting and pouring process (explosion hazard). The intermediate frequency electric furnace melting itself constitutes a major danger "hidden danger point", and the characteristic of the integrated working principle of "water, fire, and electricity" in the production environment determines the inspection of each process link, and no small errors are allowed.

2. In the production process, if a furnace leakage accident occurs, effective emergency measures should be taken immediately.

3. Management of alcohol based coatings, paints, and wooden molds (fire hazards). There are many types of flammable and explosive chemicals used by casting enterprises, and fire prevention cannot be ignored. Smoking and fire are strictly prohibited within 10 meters of flammable materials. It is particularly important to post no fire signs, strengthen fire source management, and carry out emergency management. The size of the stock of flammable and explosive materials in the warehouse and on site determines the level of "hazard sources", and the warehouse reports the purchase and inventory levels once a week. Implement strict management, such as locking the warehouse, signing by the recipient, returning remaining materials to the warehouse before leaving work, supervising the warehouse, and confirming with both parties.

3、 Measures for controlling the working environment: The casting working environment is dusty, noisy (toxic and harmful), with high temperatures. Improper control of the working environment can easily lead to occupational diseases such as silicosis, noise induced deafness, and heatstroke. The focus is on "prevention first", implementing the "Occupational Disease Prevention and Control Law", informing of hazardous factors, evaluating the current situation of occupational diseases, conducting physical examinations of employees, and strengthening individual protection. Dust removal measures such as retractable polishing rooms and paint spraying rooms are adopted, greatly reducing dust and paint mist pollution in the polishing room, with good results. 4、 Security management measures

1. Safety production management includes inspection, closure, inspection, and punishment. Strengthening the continuous repetition of "inspection, investigation, punishment", and making the mandatory full coverage and zero tolerance throughout the entire process the focus and main direction of work, to achieve the goal of "zero safety production accidents".

2. Breaking through the Difficulties of Safety Production Management in the Foundry Industry

3.Human thoughts and behaviors. Outstanding personnel mobility, shortage of technical talents, and weak cultural foundation of frontline employees; Backward production processes, primitive operating methods, and deep-rooted bad behaviors bring difficulties to management. By adopting a spiritual and natural guidance approach, the safety management goals of enterprises and employees are consistent, both aimed at ensuring the physical and mental health of employees. Therefore, from their respective perspectives, management should be strengthened to prevent and correct habitual violations;

4.The root cause of safety hazards lies in the analysis of outdated work methods and insufficient investment in technological transformation from the perspective of changing work methods and investment in technological transformation. China needs entrepreneurs to boldly innovate and use intelligent robots to replace workers in dangerous, repetitive, and simple physical labor in order to move from a manufacturing powerhouse to a manufacturing powerhouse. This can not only improve work efficiency but also ensure essential safety production Security management is meticulous and meticulous. From the process of safety production management in the casting industry, it can be seen that the prevention characteristics of "hot explosion and smashing, powder noise and fire" are highlighted. Starting from the source and micro links, regardless of the type of "hidden danger", the five elements analysis of "human machine material method environment" should be followed to obtain safety methods and measures. We must adhere to classification, sub items, grading, layering, grouping, and dividing into the smallest units, using the most meticulous thinking method, not letting go of the predictive content of small hidden dangers, to achieve the goal of 100% safety with "zero accidents".

5.Pay attention to training without relaxing. There is generally a strong dependence, with one level pressing down on the other, and when faced with a tense situation for a period of time, there is a need for continuous inspection and rectification. After the "tense period", it bounces back to the starting point and habitual violations and risky operations occur. We will not relax our focus on training and pay attention to "repetitive" training. We will provide step-by-step, graded, and planned training on people's ideological awareness, laws and regulations, operating procedures, major hazard management, and safety standardization management systems. We will use new stimulation methods to stimulate employees' brains and receive knowledge of safety production. Control the changing patterns of "dynamic management" factors, take effective measures to control unsafe behaviors of people, unsafe conditions of objects, and working environment, strengthen safety management, improve the enterprise production performance management platform, and at the same time, curb the occurrence of production accidents.

The above practices for safety production management in the casting industry are hoped to be helpful to everyone.

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