Adapting PPE to a particular workplace requires a very careful analysis of the working environment, the type of equipment to be operated and the type of tasks to be performed. It is not enough to reach for generic protective equipment - it must be selected precisely for the real risks that workers, especially fitters responsible for installing and relocating machinery, may face.
Each stage - from assembly to machine relocation - carries unique risks that must be anticipated and effectively mitigated. With the right choice of protective equipment for machine fitters and regular health and safety training, accidents can be significantly reduced and working comfort improved, resulting in better efficiency throughout the process.
How to adapt personal protective equipment to the type of machine?
Each machine, depending on its design and function, carries different potential risks. The assembly and dismantling of heavy industrial equipment can involve the risk of mechanical injury, electric shock, contact with chemicals, as well as noise, vibration or working at height. Every possible measure should be taken to reduce these risks as much as possible. In practice personal protective equipment for the assembly of machinery can include a wide range of solutions. Below are some examples tailored to specific types of machinery:
- Cutting and grinding machines - require the use of safety goggles or visors to protect against metal splatter. Cut-off gloves are a must for any fitter working on such equipment.
- High-voltage electrical machinery - dielectric gloves, anti-static clothing and electro-insulating footwear are essential here. When working on switchgear or assembling control cabinets, such equipment minimises the risk of electrocution.
- Hydraulic and pneumatic machinery - can cause sudden leaks of pressurised fluids. Therefore, protective overalls, goggles with side shields and oil- and grease-resistant gloves are recommended.
- Heavy industrial machinery (e.g. presses, injection moulding machines) - installation often involves working at height, so safety harnesses, helmets with a chin strap and shoes with a metal toecap to protect against foot injuries are used.
Also relocation of machinery require additional safeguards. Moving large equipment involves the risk of crushing, slipping, losing balance or coming into contact with moving parts. In such cases, safety helmets, reinforced gloves and reflective waistcoats are essential, especially if the work takes place in a space shared with other crews. Those in charge of relocation often also use hearing protection - transport machinery generates considerable noise, especially in enclosed halls.
Protective equipment for machine fitters must be tailored to the worker's specific role. For example, a person responsible for electrical connections requires a different protective kit than a forklift operator transporting machine components. For this reason, it is worth equipping workers with individual sets of protective equipment and providing training in their correct use.
Ergonomics in assembly and disassembly - how to avoid injury?
Assembly and disassembly of industrial machinery covers work that can directly affect the health and safety of workers. In this industry, musculoskeletal strains, overloading, as well as injuries resulting from organisational errors or improper working techniques occur on a daily basis. It is worth taking care of both the technical and organisational conditions of the process to eliminate the most common risks when working with machinery.
The aim of ergonomics is to create conditions that allow workers to perform tasks efficiently and safely, minimising strain on the body.
Among the main hazards associated with working in the assembly and disassembly of machinery are:
- Back and spinal injuries caused by lifting heavy items.
- Bumping and crushing, especially when machines or their components are not correctly positioned.
- Overloading of muscles and joints resulting from prolonged work in a forced body position.
- Vibration and noise, which can lead to micro-trauma and permanent hearing damage.
- Falls from height, especially when installing equipment on platforms or support structures.
Awareness of these risks is the first step to answering the question, How to protect yourself against accidents when assembling machinery.
Principles of ergonomic assembly and disassembly:
1. limit manual lifting - use trolleys, hoists, cranes or manipulators. Remember that the permissible standards for lifting by one person are predetermined. Exceeding them leads to chronic health problems.
2. working in natural positions - as far as possible, work with raised arms, twisting of the torso or prolonged kneeling should be avoided. Machine components should be positioned so that access to them is easy and does not require excessive effort. Work should take place at a height between the hips and chest - this is the safest range for the arms and spine.
3. breaks and task variation - continuous, repetitive work leads to overload of the same muscle groups. It is a good idea to introduce task rotation - for example, alternate activities that require precision and physical strength.
4. proper lighting and organisation of the workplace - a well-lit workplace helps to reduce unnecessary movements that often lead to injury. All tools should be within easy reach and the workplace should be tidy to avoid tripping and accidental collisions.
In addition to ergonomics, the use of personal protective equipment and compliance with safety procedures are of paramount importance. Proper training of employees in health and safety rules and knowledge of assembly instructions is also crucial. A well-prepared employee knows what to avoid and how to react in emergency situations.
How to train workers on safety when working with machinery?
Safety training for employees when working with machinery is the cornerstone of protecting health and life in an industrial environment. Whether dealing with a new employee or an experienced fitter, regular, well-planned training raises awareness of risks and teaches, for example, that, How to avoid injury when dismantling equipment.
Why is training essential?
Accidents at work with machinery often result from routine, inattention or lack of knowledge. It is not uncommon for workers to underestimate the risks, especially when they have been performing the same activities for years. However, each assembly or disassembly can be different. Conditions change, as does the type of equipment, the location, and also the people involved in the process. Training helps to organise knowledge, update information and remind people of basic safety rules. This makes it easier to avoid injuries when dismantling equipment and reduces the number of dangerous situations.
How to train effectively?
1. training based on real risks
The best results come from learning based on practice. Rather than limiting yourself to theory, it is useful to show employees what risks they may encounter on a daily basis. For example, by discussing health and safety principles during assembly and dismantling machines, it is a good idea to use photos, videos of real installations, and preferably to carry out training at the site where these works take place.
2. taking account of different positions and roles
Each team member has different responsibilities. A person in charge of mechanics requires different training than an electrician or an overhead crane operator. Therefore, the training programme should be differentiated and tailored to specific responsibilities. Only the general principles of conduct, communication and emergency response should be common.
3. simulation of dangerous situations
Practical exercises are an effective way to show how to avoid injuries when dismantling equipment. Simulations of malfunctions, dropped loads or incorrect wiring allow learning to take place under controlled conditions. Employees remember more when they experience difficult situations themselves and learn from their mistakes - without real consequences.
4. clear and simple message
Not every employee has a technical background. Therefore, jargon and complicated language should be avoided. Training should be specific, understandable and convey unambiguous instructions. Short messages such as 'Always disconnect the power before starting disassembly' or 'Do not work alone with heavy components' are more effective than complex definitions.
5. consolidation of knowledge
One-off training is not enough. It needs to be repeated periodically - at least once a year, and preferably after any major change in work organisation, the arrival of new equipment or after a safety incident.
What should the training include?
The following elements are worth including in the training programme:
- Basic health and safety principles during the assembly and disassembly of machinery.
- Identifying the risks associated with a specific type of equipment.
- Rules for the use of personal protective equipment.
- How to communicate within the team when working with machinery.
- Dealing with accidents or equipment failure.
- Safe disassembly techniques - e.g. disconnection sequence, markings, locks.
Working safely with machinery does not happen by chance. It is the result of conscious, regular and well-prepared training. Health and safety principles during assembly and disassembly should not only be known, but also applied in practice.
