The safe production management of foundry workshops has always been the focus of attention in the manufacturing industry. Casting production has multiple processes and equipment, mechanical and manual combined operation, few automated equipment, lack of safety protection devices, poor working environment, high labor intensity, and low cultural quality and knowledge level of operators. These characteristics make it more prone to work-related accidents than other industries, such as smashing, collision, crushing, cutting, electric shock, fire, suffocation, poisoning, explosion and other hazards. Therefore, it is of great significance to deeply explore the safe production management of foundry workshops.
Major risk factors in foundry workshops
(I) Explosion and burn
Foundry workshops use molten metal, natural gas, liquefied petroleum gas and dangerous chemicals. If the operator does not operate according to the regulations and neglects the storage and use of chemicals, it is very easy to cause explosion, burn and scald accidents.
(II) Mechanical injury
1. Sand mixing operation
When the sand mixer is running, the operator may get his hand caught or dragged into the machine when taking sand samples, causing injury.
2. Modeling operation
Lifting objects can easily hurt the body if they slip.
3. Manual core making
When moving sand boxes and core boxes, careless operation can easily injure hands and feet.
4. Ladle and pouring
"Hot fire" may cause fire.
5. Sand mold drying operation
Unilateral operation of loading and unloading sand cores may overturn and injure people; storing flammable and explosive items near the fire door may cause fire or explosion.
(III) Dangers of cuts, burns and poisoning
1. Ladle and pouring
Overfilling may cause overflow and burns, and may also produce harmful gases and cause poisoning.
2. Sand cleaning
Residual sticky sand cuts hands, and flying sand hurts eyes.
3. Sand mold drying operation
Adding coal or removing slag may cause scalding or burns to the face.
4. Manual core making
Nails in the sand may cut hands or pierce feet.
Analysis of the causes of personal injury
(I) Imperfect safety production management system
1. Lack of practicality
The safety management system of some foundry enterprises is mostly for coping with inspections, borrowing or plagiarizing from peers, not starting from their own reality, with single content and loopholes.
2. Lack of scientificity
Mostly formulated based on the experience of managers, lack of scientific design, no emergency measures and emergency plans, and unable to effectively deal with safety accidents.
3. Unreasonable assessment mechanism
There are no reasonable regulations for the assessment of violations of rules and regulations, no punishment for those who violate the rules and cause injuries, no reward for those who have no accidents, which dampens the enthusiasm of employees for safe production.
(II) Weak ability and awareness of workshop management cadres
1. Poor business and simple methods
Some workshop cadres are not proficient in foundry business, especially safety production management, do not know how to deal with problems such as storage of hazardous materials, lack business guidance ability, ignore employee safety education, and have simple communication methods, which arouses employee resistance.
2. Poor work style and poor information flow
Some cadres do not realize the importance of safety management, have no idea about personnel safety protection, shirk responsibility and play tricks in the face of failures and accidents, do not actively solve problems, and do not summarize experience, resulting in an increase in safety hazards; fail to implement safety measures and systems, and have a low management level.
(III) The quality of workshop operators needs to be improved
1. Lack of safety awareness
Operators have low cultural level, weak safety awareness, low enthusiasm for compliance with rules and regulations, and frequent "two violations" phenomena.
2. Weak emergency response capabilities
Workshop managers do not pay enough attention to safety education and training, operators have weak safety knowledge and self-protection capabilities, and low emergency response capabilities.
(IV) Prominent safety hazards
1. "Two violations" phenomena are repeatedly banned
Operators do not follow the rules, violate the rules, simplify the operating procedures, and lay hidden dangers for accidents.
2. Many problems with production equipment
Inspections are not detailed, maintenance and repair systems are not implemented effectively, technical problems are not solved in a timely manner, and equipment failures occur frequently; equipment updates, maintenance and overhauls are slow, and the foundation is weak.
Effective countermeasures to strengthen workshop safety management
(I) Strengthen safety skills education and training
1. Based on the actual situation of operators
Workshop-level safety education should focus on improving the safety awareness and operating skills of operators, so that they can master the essentials of safe operation, experience and lessons of job accidents, and learn to prevent and deal with emergencies.
(II) Strengthen control over the entire casting production process
1. Equipment management
Strengthen daily inspection and inspection of production equipment, focus on checking the limit and transmission parts, and eliminate safety hazards before production.
2. Personnel management
Standardize the safe operation of operators, such as checking the mold, chute, and ladle distributor before pouring, measuring temperature according to process requirements, etc., and keep records and markings after pouring.
(III) Establish safety ledgers and safety files
1. Clarify the content of safety ledgers
The safety ledger covers safety meetings, inspections, education, accidents, etc., reflecting the safety management level and work situation of the workshop.
2. Dedicated management
A dedicated person is appointed to manage separately to ensure the effective implementation of safety meetings, inspections, education, etc., and the accurate and complete records of ledger information.
(IV) Strengthen communication and contact with other enterprises
1. Learning experience
Exchange with other enterprises, learn advanced safety production management experience, combine their own actual reform and innovation, and improve management level.
(V) Strengthen the exchange and collection of safety information, and summarize and evaluate in time
1. Formulate management model
Formulate scientific management model after exchanging and collecting information, summarize and evaluate after trial, and continuously improve.
2. Commend and help
Commend the well-run teams, find out the reasons for the poor teams and help them to achieve synchronous development.
Workshop safety management is the key to enterprise safety management. Only by doing a good job in workshop safety can enterprise safety be guaranteed. Enterprises should follow the principle of "safety first, prevention first, comprehensive management", incorporate safety production into the overall plan, and take people as the core to achieve safe, efficient and high-speed development.
