Forging Machinery Safety Operation and Maintenance Procedures
1. Scope and Application
These procedures define risk identification, safety responsibilities, operating procedures, and emergency measures for forging machinery operations. They apply to all mechanical manufacturing forging equipment used in production.
2. Personal Protective Equipment (PPE)
- Safety helmet must be worn at all times in the forging area
- Safety goggles or face shield to protect against flying scale and debris
- Ear plugs or earmuffs for noise protection in high-decibel environments
- Heat-resistant gloves rated for handling hot workpieces
- Safety shoes with steel toe caps and metatarsal guards
- Fire-resistant clothing or leather forging apron
- Respiratory protection if working in areas with scale dust or fumes
3. Pre-Operation Safety Checks
- Inspect the forging machine for visible damage, cracks, or loose components
- Verify all safety guards and protective devices are properly installed
- Test emergency stop buttons and safety interlocks for proper function
- Check hydraulic or pneumatic system pressure meets specifications
- Ensure the work area is clean, organized, and free of trip hazards
- Verify fire extinguishing equipment is accessible and fully charged
- Check die alignment and mounting condition before starting
- Ensure adequate lighting and ventilation in the forging area
4. Operational Standards
- Stay at the workstation and focus on equipment operation
- Do not engage in unrelated activities during machine operation
- When leaving the equipment, stop the machine and shut off all power sources
- Use equipment strictly according to manual specifications
- Never operate beyond rated capacity or load limits
- Maintain proper die temperature through preheating before forging
- Coordinate with manipulator operators for safe material handling
5. Maintenance Schedule
5.1 Daily Maintenance
- Clean the machine and work area after each shift
- Lubricate all moving parts according to the lubrication chart
- Check hydraulic fluid levels and top up as needed
- Inspect hammers, dies, and anvils for wear or cracking
- Check all fluid lines for leaks
5.2 Weekly Maintenance
- Tighten all bolts and fasteners, especially on dies and guide rails
- Check belt tension and overall belt condition
- Inspect electrical connections for tightness and heat damage
- Clean or replace air and hydraulic filters
- Check foundation bolts and anchor points
5.3 Monthly Maintenance
- Check alignment of slides, guides, and rams
- Inspect clutch and brake systems for wear and adjustment
- Test all safety devices and interlocks
- Change hydraulic oil and filters if contamination is detected
- Check flywheel bearings and lubrication
6. Emergency Response
- Know the location of all emergency stops and fire extinguishers
- If equipment malfunctions, stop immediately and report to supervisor
- For injuries, follow first aid procedures and seek medical attention
- Maintain clear evacuation routes at all times
- Document all incidents and near-misses for investigation
