Login to Members Only to request a cd-rom or download software

• Safety Audit Checklist (pdf)

Introduction to NADCA Machine Safety Requirement Audit

In 1999 the NADCA Safety committee started the development of Safety Requirements for the Design, Manufacture, Maintenance, and Operation of Die Casting Machines.  The first version of the standard was approved for use in 2000.  As technology changed and feedback was provided the standard was revised.  In 2006 the standard was updated as NADCA B152.1-2006.  The standard applies to die machines, dies and there integration with metal delivery systems, die lubrication systems, and casting extraction systems.  The purpose of this standard is to minimize safety hazards to employees operating die casting machines.  Installing and maintaining proper safety equipment should be a top priority in every die casting facility.  However, safety devices alone cannot guarantee safety.  In order to maintain safe conditions employees must be trained in safe practices.  Employees should also be encouraged to think safe.  

A checklist has been created to assist in the compliance with the B152.1 standards.  The checklist can be found on the NADCA website.  This checklist addresses clauses 4-6, and 8-10 in the standard.  The uncovered sections provide definitions and added information.  For clarifying information the Safety Requirements for the Design, Manufacture, and Operation of Die Casting Machine book also contains Annex information.  Many illustrations are contained in these annexes.  The purpose is to clarify the standards with a pictorial reference. 

Many of the clauses in the checklist have multiple questions that apply.  The purpose of multiple questions is to confirm the proper installation and use of safety devices.  Keep in mind that safety devices found on a die casting machine can be hazardous if not used properly.  Therefore, if full compliance is not established the die casting machine remains unsafe.  All applicable questions must be answered affirmatively in order to effectively use safety equipment.

Fulfilling all applicable die casting machine safety standards may appear to be a daunting task.  To assist in this task NADCA has developed the machine safety audit tool.  Its purpose is to quickly highlight areas of the die casting machines that are not compliant with the 2006 standards.  The tool is an audit that reflects the current checklist.  At the start of this audit the auditor is allowed to add, remove, and select machines.  Once a machine has been selected the audit record is created or opened for editing.  The questions listed in the checklist should be answered by selecting a Yes, No, or N/A response.  Ideally the response to every question will be Yes or N/A.  If the response is, “No” then a hazardous state has been identified. 

Reports generated by the software provide information on current compliance levels and how to achieve complete compliance.  On the start page the level of compliance in each section for the selected machine are reported.  This provides a quick identifier of the level of compliance a given machine has achieved.  This software can also report statistics based on all the machines.  This report will indicates the level of compliance for each machine in each section. 

Figure 1: Example of Plant Status report

It also indicates the section of greatest compliance, least compliance, average compliance, safest machine, and least safe machine.  This information can be used to attack safety issues on a plant wide basis or machine specific. 

To achieve complete compliance the violated standards must be brought into conformance.  During the audit, reports can be generated that display these violations.  This report applies to the machine that is currently being audited.  The figure below is an example of such a report.

Figure 2: Example of section report.

These reports use a two column format identical to the printed standards.  The left side is the standard requirement.  This column provides the requirements of the standard.  The right side is reserved for explanatory information.  This information is not part of the standard and is intended to clarify its associated standard. 

For interpretations and clarifications regarding specific clauses in the standards, consult NADCA’s website (http://www.diecasting.org/safety/interpretation.htm).  Here some clarification is already provided, or a form can be filled out to request more interpretations.  Comments and suggested improvements of this audit are welcome.  These should be sent to the Secretary of the NADCA Safety Committee, North American Die Casting Association, 241 Holbrook Drive, Wheeling, Illinois 60090.

* CD-ROM request is only valid for members in the United States Only.