Schedule XIX

FORGING, FORMING, HEAT TREATMENT AND INCIDENTAL

PROCESSES

1. Application

The schedule shall apply to all types of operations involved in Forging,

Forming, Heat Treatment and other incidental processes.

2. Definition

For the purpose of this Schedule,

(a) "approved"means approved by the Chief Inspector-cum-facilitator;

(b) “Forming” includes all kinds of manufacturing processes involving the

application of force by power press, rollers etc.,

(c) “Heat treatment” includes annealing, normalizing, hardening, tempering,

marquenching, ausforming, carburizing, nitriding etc.,

(d) "fixed fencing “means fencing provided for the tools of a power press being

fencing which has no moving part associated with or dependent upon the

mechanism of a power press and includes that part of a closed tool which

acts as a guard;

(e) "power press" means a machine used for moulding, pressing, blanking,

raising, drawing and similar purposes;

3. Starting and stopping mechanism

(1) The starting and stopping mechanism shall be provided with a safety stop

so as to prevent over running of the press.

(2) Suitable arrangements shall be made to arrest the movement of ram

during power failure, changing of dies, tool setting and other maintenance

work etc.

4. Safety provisions on power press

(1) Each power press shall be provided with suitable fixed fencing on all sides

so as to safeguard the workers engaged nearby.

(2) The design, construction and mutual position of the safeguards referred to

in sub paragraph (1) shall be such as to preclude the possibility of the

workers hand or fingers reaching the danger zone.

(3) The machine shall be fed through suitable means so as to ensure the

safety of the workers.

(4) Notwithstanding anything contained in sub-paragraph (1) an automatic or

an inter-locked guard with photo-electric sensors, proximity sensors etc.,

may be used in place of a fixed guard, but where such guards are used

they shall be maintained in an efficient working condition and if any guard

develops a defect, the power press shall not be operated unless the defect

of the guard is removed.

5. Appointment of persons to prepare power presses for use

(1) Except as provided in paragraph6,noperson shall set,re-set,adjust or try

out the tools on a power press or install or adjust any safety device

thereon, being installation or adjustment preparatory to production of (to

proving, or carry out an inspection and test of any safety device thereon

required by paragraph 8 unless he –

(a) Has attained the age eighteen;

(b) Has been trained in accordance with the sub-paragraph(2);and

(c) has been appointed by the Occupier of the Factory to carry out those

duties in respect of the class or description of power press or the class or

description of safety device to which the power press or the safety device

(as the case may be) belongs;

(2) The training shall include suitable and sufficient practical instruction in the

matters in relation to each type of power press and safety device in respect

of which it is proposed to appoint the person being trained.

6. Examination and testing of power-presses and safety devices

(1) No power press or safety device shall he taken into use in any Factory for

the first time in that factory or in case of a safety device for the first time

on any power press, unless it has been thoroughly examined and tested, in

the case of a power press, after installation in the factory, or in the ease of

a safety device, when in position on the power press in connection with

which it is to be used.

(2) No power press shall be used unless it has been thoroughly examined and

tested by a competent person, within the immediately preceding period of

twelve months.

(3) No power press shall be used unless every safety device (other than fixed

fencing) thereon has within the immediately preceding six months when in

position on that power press been thoroughly examined and tested by a

competent person.

(4) The competent person carrying out an examination and test under the

foregoing provisions shall make a report of the examination and test

containing the following particulars and every such report shall be kept

readily available for inspection, namely:

(a) Name of the occupier of the Factory;

(b) Address of the Factory;

(c) identification number or mark sufficient to identify the power press or the

safety device;

(d) date on which the power press or the safe device was first taken into use

in the Factory;

(e) the date of each periodical thorough examination carried out as per

requirements of sub-paragraph (2) above;

(f) particulars of any defects affecting the safe working of the power pressor

the safety device found at any such thorough examination and steps taken

to remedy such defects.

7. Defects disclosed during a thorough examination and tests

(1) Where any defect is disclosed in any power press or in any safety device by

any examination and test under paragraph 6 and in the opinion of the

competent person carrying out the examination and test, either

(a) the said defect is a cause of danger to workers and in consequence the

power press or safely device (as the case may be) ought not to be used

until the said defect has been remedied ; or

(b) the said defect may become a cause of danger to workers and in

consequence the power press or the safety device (as the case

maybe)ought not to be used after the expiration of a specified period

unless the said defect has been remedied; such defect shall, as soon as

possible after the completion of the examination and test, be notified in

writing by the competent person to the occupier of the Factory and, in the

case of a defect falling within clause(b) of this paragraph such notification

shall include the period within which, in the opinion of the competent

person, the defect ought to be remedied.

(2) In every case where notification has been given under this paragraph, a

copy of the report made under sub-paragraph (4) of paragraph 6 shall be

sent by the competent person to the Inspector-cum-facilitator for the area

within fourteen days of the completion of the examination and test.

(3) Where any such defect is notified to the Occupier in accordance with the

foregoing provisions of this paragraph the power press or safety device (as

the case may be) having the said defect shall not be used

(a) In the case of a defect falling within clause(a)of sub-paragraph

(1) Until the said defect has been remedied; and

(b) In the case of defect falling within clause (b) of sub-paragraph (1), after

the expiration of the said defect has been remedied.

(4) As soon as is practicable after any defect of which notification has been

given under sub-paragraph (1) has been remedied, are cord shall be made

by or on behalf of the occupier stating the measures by which and the date

on which the defect was remedied.

8. Inspection and test of safety devices

(1) No power press shall be used after the setting, resetting or adjustment of

the tools thereon unless a person appointed or authorized for the purpose

under paragraph 5 has inspected and tested every safety device thereon

whack is in position on the said power press;

Provided that an inspection, test and certificate as aforesaid shall not be

required where any adjustment of the tools has not caused or resulted in

any alteration to or disturbance of any safety device on the power press

and if, after the adjustment of the tools, the safety devices remain, in the

opinion of such a person as aforesaid, in efficient working order.

(2) Every power press and every safety device thereon while it is in position on

the said power press shall be inspected and tested by a trained person

every day.

9. Defects disclosed during an inspection and test

(1) Where it appears to any person as a result of any inspection and test

carried out by him under paragraph 8 that any necessary safety device is

not in position or is not properly in position on a power press or that any

safety device which is in position on a power press is not in his opinion

suitable, he shall notify the occupier forthwith.

(2) Except as provided in sub-paragraph (3) of this paragraph where any

defect is disclosed in a safety device by any inspection and test under

paragraph 8, the person carrying out the inspection and test shall notify

the Occupier forthwith.

(3) Where any defect in a safety device is the subject of a notification in

writing under paragraph 7 by virtue of which the use of the safety device

may be continued during a specified period without the said defect having

been remedied, the requirement in sub-paragraph (2) of this paragraph

shall not apply to the said defect until the said period has expired.

10. Identification of power presses and safety devices

For the purpose of identification every power press and every safety device

provided for the same shall be distinctively and plainly marked.

11. Safety precautions in forging and rolling operations:

(1) Workers shall be provided with suitable personal protective equipment

to prevent burns from contact with hot surfaces or splatters of hot

material.

(2) Material handling equipment’s involved in forging and rolling operations

shall be of adequate strength, size and suitable shape.

(3) Substantial safeguards shall be provided to ensure the safety of the

persons employed in forging and rolling operations from the flying

scales, splatter and other materials.

(4) No process or work shall be carried on in such a manner as to cause

risk of bodily injury to the persons employed.

12. Precautions against ignition

Wherever there is danger of fire from accumulation of flammable or

explosive dust, fumes or vapors or any combustible materials in air:-

(a) all electrical apparatus shall either be excluded from the area of risk or

they shall be of such construction and so installed and maintained as to

prevent the danger of their being a source of ignition;

(b) effective measures shall be adopted for prevention of accumulation of

static charges to a dangerous extent; and

(c) all other precautions as are reasonably practicable, shall be taken to

prevent initiation of ignition from all other possible sources such as

open flames, frictional sparks, overheated surfaces etc.,

(d) safe level of quenching medium shall be ensured in the heat treatment

furnaces.

(e) alternate power supply arrangements shall be made and interlocked

with the normal power supply system so as to ensure constant supply

of power during quenching operations.

13. Training and Instructions to operators

The operators shall be trained and instructed in the safe method of work

before starting work on any power press.

14. Ventilation

Efficient ventilation shall be provided by mechanical means and shall

operate on the dust, fumes or smoke given off in the process as near as

may be at the point of origin. The ventilation system shall be so

constructed, arranged and maintained as to prevent the dust, fumes or

smoke entering into any room or place in which work is carried on.

15. Testing and examination of ventilating systems:-

(1) All ventilating systems used for the purpose of extracting or suppressing

fumes as required by this schedule shall be as per the relevant standard

prescribed by the Bureau of Indian Standards. It shall be thoroughly

examined and tested by a competent person once in every period of twelve

months. Any defects found by such examinations or test shall be rectified

forthwith.

(2) A register containing particulars of such examination and tests and the

state of the plant and the repairs or alterations, if any, found to be

necessary shall be kept and shall be available for inspection by an

Inspector-cum-Facilitator.

16. Medical facilities and records of examinations and tests

(1) The occupier of every factory to which the schedule applies, shall

a. employ a Health Surveillance Officer for medical surveillance of the

workers employed therein.

b. provide to the said Health Surveillance Officer all the necessary facilities for

the purpose referred to in clause (a).

(2) Workers employed in this scheduled process / operation shall be medically

examined by the Health Surveillance Officer-

i. Once before employment, to ascertain the physical fitness of the person to

do the particular job:

ii. Once in a period of six months, to ascertain the health status of all the

workers in respect of occupational health hazards to which they are

exposed; and in cases where in the opinion of the Health Surveillance

officer it is necessary to do so at a shorter interval in respect of any

workers.

(3) The record of the examinations referred to in sub-paragraph (2) shall be

maintained in health register in Form: HR which shall be kept readily

available for inspection by the Inspector-cum-Facilitator.

(4) No person shall be employed for the first time without a Certificate of

Fitness in Form: XVII granted by the Health Surveillance officer. If the

Health Surveillance officer declares a person unfit for being employed in

any process covered under sub-rule(1),such a person shall have the right

to appeal to the Inspector-cum-Facilitator who shall refer the matter to the

Medical Officer whose opinion shall be final in this regard. If the Inspector-

cum-Facilitator is also a Medical Officer, he may dispose of the application

himself.

(5) Any findings of the Health Surveillance officer revealing any abnormality or

unsuitability of any person employed in the process shall immediately be

reported to the Medical Officer who shall in turn, examine the concerned

worker and communicate his findings to the occupier within thirty days. If

the Medical Officer is of the opinion that the workers examined is required

to be taken away from the process for health protection, he will direct the

occupier accordingly, who shall not employ the said worker in the same

process. However, the worker so taken away shall be provided with

alternate placement unless she is in the opinion of the Medical Officer, fully

incapacitated in which case the worker affected shall he suitably

rehabilitated.

(6) A Medical Officer on his own motion or on a reference from an Inspector-

cum- Facilitator may conduct medical examination of a worker to ascertain

the suitability of his employment in the scheduled Process/operation or for

ascertaining his health status. The opinion of the Medical Officer in such a

case shall be final. The fee required for this medical examination shall be

paid by the occupier.

(7) The worker taken away from employment in any process under sub-rule

(2) may be employed again in the same process only after obtaining the

Fitness Certificate from the Medical Officer and after making entries to that

effect in the Health Register.