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Presencial - OSH in the Food Industry

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Occupational Health and Safety Management in the Food Industry

START

LEGISLATION

Ordinance no. 53/71

Decree-Law No. 50/2005

Law No. 102/2009

February 3rd

February 25th

September 10th

Decree-Law No. 103/2008

Law no. 7/2009

February 12th

June 24th

employer's obligations

Provide workers with appropriate information and training to prevent accidents and occupational illnesses
Establish measures to be adopted and identify the workers responsible for their implementation regarding first aid, firefighting, and building evacuation
Prevent occupational risks and illnesses, considering the protection of workers' health and safety
Ensure health and safety conditions for workers
Implement measures arising from applicable legal and contractual requirements

Employee's duties

Comply with the safety rules implemented in the workplace
Ensure their own safety and that of others
Follow established work procedures
Attend health examinations
Report malfunctions or deficiencies that may cause hazardous situations

Occupational Health

Occupational Health, also commonly known as “Occupational Medicine”, is responsible for monitoring workers' health with the aim to: This responsibility lies with the occupational physician. The performance of duties depends on certain requirements, as stated in Article 25 of the Annex to Decree-Law no. 102/2009 of September 10, amended and republished by Law no 3/2....... of January 28, Article 103 (Portuguese original version). Admission, periodic and occasional medical examinations should be conducted.
  • Assess their aptitude to perform their duties
  • Evaluate the effects that working conditions have on their health
Law no 3/2014
Admission
periodic
Admission
periodic
occasional
occasional
The (Portuguese original version) must be filled in by the occupational doctor, who assesses the worker’s medical fitness for a specific job.
Occupational Health Form

Types of medical EXAMINATIONS

Whenever there are changes in work materials that may adversely affect the worker’s health, as well as upon return to work after an absence of more than 30 days due to illness or accident.

Whenever there are changes in work materials that may adversely affect the worker’s health, as well as upon return to work after an absence of more than 30 days due to illness or accident.

Annual examinations for minors and employees over 50 years old, and every2 years for all other workers.

Annual examinations for minors and employees over 50 years old, and every2 years for all other workers.

Before starting work, or within 15 days thereafter if urgent admission is required.

Periodic exams

Occasional exams

Occasional exams

Periodic exams

Admission exams

Occupational Health and safety

The occupational health service contributes to the promotion and monitoring of workers’ health by understanding the demands of job positions and professional risks, combined with knowledge of the individual worker.
Safety at work involves a set of methodologies designed to prevent accidents, with the primary aim of controlling risks. The identification and management of risks are associated not only with work sites and environments but also with the tools, machinery, materials, substances, and agents in contact (chemical, physical, and biological).
Occupational Health
Promotion and monitoring of workers' health
Occupational Safety
Prevention of workplace accidents

Occupational diseases

An occupational disease results directly from working conditions, is listed in the Occupational Diseases List, and causes incapacity to perform the profession or death. The (Portuguese original version) of July 17 presents the current list of occupational diseases along with the coded index.
Regulatory Decree No. 76/2007
The law also considers that bodily injury, functional impairment, or diseases not included in the list may be compensable, provided it is proven that they are a necessary and direct consequence of the work performed and do not represent normal wear and tear of the body (Labor Code, Article 283, No. 3).
Examples of Occupational Diseases
Dermatitis
Tendinitis
Hearing loss

Occupational diseases

Factors that determine an occupational disease:
Disease-causing agent
Individual characteristics
Duration of exposure

Occupational diseases

What to do in the event of suspected occupational disease?
What to do in the event of suspected occupational disease?
What to do in the event of suspected occupational disease?
If the occupational physician has strong suspicions that a worker’s illness may be work-related (presumptive diagnosis), they must complete the Mandatory Occupational Disease Report and submit it to the Department for Protection Against Occupational Risks
Department
Department
for Protection Against Occupational Risks.
The DPRP is an institution belonging to the Ministry of Labor and Social Solidarity, whose mission is to ensure the prevention, treatment, and recovery of illnesses or disabilities resulting from occupational hazards, certifying illnesses.
SOCIAL SECURITY

Occupational diseases

Mandatory reporting of occupational disease (Diagnosis Presumption)

Employee

Doctor

Hierarchical Superior

Mandatory Participation

Employer

National Center for Protection against Occupational Risks (CNPRP)

Occupational disease?

Definitive Diagnosis of Occupational Disease

Common Disease

Yes

No

Accidents at Work

An accident at work...
  • Occurs at the workplace and during working hours
  • Is an unexpected event that happens suddenly
  • Interrupts the normal course of work
  • Causes injury to workers (directly or indirectly resulting in bodily harm, functional impairment, or illness that leads to death or reduced work capacity)
The term “during working time” is defined as during the course of professional activity or during periods of travel. This includes travel, transport, or traffic accidents from home to work and from work to home, as well as traffic accidents during working hours.
The term “during working time” is defined as during the course of professional activity or during periods of travel. This includes travel, transport, or traffic accidents from home to work and from work to home, as well as traffic accidents during working hours.
An acident at work may occur:

During the commute to and from the workplace, between the employee’s home and the designated work location, as determined by the employer On the way to or from the location where wages are paid During travel between the worksite and the location where meals are taken While moving between different jobs (in cases of multiple employment), with responsibility assigned to the employer of the destination worksite While seeking employment during the legally granted job-search hours for workers undergoing contract termination In attendance at a vocational training course, provided it is authorized by the employer

Law No. 98/2009

* (PT original version) of September 4, regulates the compensation system for workplace accidents and occupational diseases

Decharacterization of a Work Accident

An accident at work is not considered if...
It was intentionally caused by the injured party
It arises from an act or omission by the injured person that entails a violation, without justification, of the safety conditions established by the employer or laid down by law
It results exclusively from gross negligence on the part of the victim
It arises from a situation of force majeure
To prevent accidents at work, the risks associated with work equipment components must be identified and controlled.

CAUSes of accidents at work

The day-to-day life of a company is not risk-free. Accidents are not the result of bad luck or chance, they have one or more causes:

Fortuitous

Human

Technical

Compensation

Insurance risk aggravation

Productivity loss

Assistance to victims

direct costs

Administrative costs

indirect costs

Reinstatement of the injured worker

Discreditation of the company's reputation

ACCIDENTS AT WORK

A workplace accident may be classified either as non-lost time or lost time.It is considered a lost-time accident if the worker does not return to work on the following day.

Temporary disability

Total

Lost-time accident

Partial

Partial

Total for specific work

Permanent disability

Total for anywork

Accidents at Work

Prevention, both at work and in life, is essential:
Be aware of the RISKS
Know theRULES
Respect the SAFETY REGULATIONS
An accident at work causes damage, which can be classified as either human or material.
Human damage (injuries) refers to death, permanent or temporary disability - whether partial or total, as well as psychological effects. Material damage may result in equipment breakdowns and damaged structures.

ONLINE PARTICIPATION

HAZARD Risk

A hazard is an intrinsic property or capability of a work component that can potentially cause harm. It is inherent to an activity, material, or equipment with the potential to cause injury or death.

Risk is the probability of damage or adverse health effects depending on the conditions of exposure to the hazard. The potential effect of the hazard is measured according to the likelihood of its occurrence and its severity.

HAZARD + RISK = Damage / injury

Example

HAZARDS AND RISKS

processes to control risk

2 - Involve the risk

1 - Limit or eliminate the risk

4 - Protect the person

3 - Drive the person away

Professional Risks

Physical Risks - NOISE

Noise is any acoustic phenomenon that produces an unpleasant and disturbing auditory sensation.
It acts through the ear on the central nervous system, which can withstand sounds with frequencies ranging from 20 Hz to 20,000 Hz. Infrasound refers to sound waves with frequencies below 20 Hz, which are outside the audible range and can be harmful to health. Ultrasound refers to sounds above 20,000 Hz, also harmful to human health. When sound stimuli exceed certain limits, they can cause hearing loss.

Physical Risks - NOISE

Noise is a significant occupational risk factor, affecting workers’ physical and psychological health, as well as their safety, while also reducing work quality and productivity. It has been proven that every decibel above the permissible limit of 85 dB (A):
  • Decreases productivity by 1%
  • Increases hearing loss risk by 1.5%
  • Increases cardiovascular disease risk by 0.5%

Physical Risks - NOISE

Physical Risks - NOISE

Physical Risks - NOISE

Preventive Measures
Preventive Measures

Source control

Use of insulating and absorbing materials

Preventive measures

PHYSICAL risks – THERMAL ENVIRONMENT

Among the causes and situations associated with thermal risks are exposure to cold environments (positive or negative temperatures) in areas such as reception, storage, sorting, and cleaning; tasks performed at high temperatures (flames, vapors); handling of frozen products; and adverse weather conditions.
Changes in ambient temperature may cause the following consequences:
- Cold exposure: Hypothermia and gradual reduction of all physiological activities - Heat exposure (especially outdoor work): Thermal stress
To avoid harmful effects, preventive measures must be adopted.
preventive measures

PHYSICAL risks – THERMAL ENVIRONMENT

Preventive and protective measures
Preventive and protective measures
Ensure adequate temperature and relative humidity levels: 18–22ºC and 50–70%, respectively Guarantee continuous and well-distributed ventilation (temperature control devices) Have installations periodically inspected by specialized technicians Reduce exposure time by introducing breaks Use appropriate PPE (thermal suits, boots, protective gloves) when necessary Introduce food into hot liquids in small amounts, verifying liquid levels to avoid spills Control work pace to prevent excessive effort and sweating (wet clothing increases cold stress) Avoid frying food containing ice or excessive moisture

PHYSICAL risks – THERMAL ENVIRONMENT

Preventive and protective measures
Preventive and protective measures
Establish regular breaks in a warmer area when long periods of work are performed inside cold chambers Stay inside cold chambers only as long as necessary Allow workers to drink hot beverages (in cold environments) or plenty of water (in hot environments) Do not open dishwashers immediately after a washing cycle finishes Provide easy access to water and prohibit alcohol consumption Handle frozen products using proper gloves and containers Promote worker rotation
In contact with surfaces/products at high temperatures such as...

Handling frozen foods or hot dishes/utensils

Contact with cold surfaces: ice or frozen foods

Contact with hot surfaces: fryers, grills, pans, ovens

Splashes or spills of substances at high temperatures: oils, cooked foods, sauces, steam (e.g., pressure cookers)

Transport or contact with cooked food (e.g., soup), ice, or hot liquids (e.g., tea)

Steam from dishwashing machines

Preventive measures

Overheated water during manual washing

PHYSICAL risks – VIBRATIONS

Decree-Law 46/2006 of February 24 transposes Directive No. 2002/44/EC into national law and establishes the minimum requirements for the protection of workers’ health and safety exposed to vibrations.
Decree-La
46/2006
establishes
the minimum requirements for the protection of workers’ health and safety exposed to vibrations
Vibration is any movement executed by a body around a fixed point. Vibrations are harmful physical agents caused by the operation of motorized machines or hand-held tools. They are divided into two types:
Hand–arm transmitted vibrations: Cause neurological, muscular, vascular, and osteoarticular disorders
Whole-body transmitted vibrations: Cause lumbar pathologies, spinal injuries, lower back pain, and spinal trauma

Preventive measures

PHYSICAL risks – Radiations

Radiation is a form of energy that, depending on its capacity to interact with matter, can be divided into two categories: ionizing and non-ionizing radiation.
Ionizing radiation
Ionizing radiation has enough energy to ionize the atoms and molecules with which it interacts. The most well-known types include:
  • X-rays and gamma rays (electromagnetic radiation)
  • Alpha rays, beta rays, neutrons, protons (corpuscular radiation)
Health effects of exposure: Anemia, leukemia, mucosal lesions, carcinomas, sarcomas.

PHYSICAL risks – Radiations

Radiation is a form of energy that, depending on its capacity to interact with matter, can be divided into two categories: ionizing and non-ionizing radiation.
Non-Ionizing radiation
Non-ionizing radiation does not have sufficient energy to ionize atoms or molecules. Examples include:
  • Infrared radiation
  • Ultraviolet radiation
  • Microwave heating
  • Microwave telecommunications
  • Electric current

PHYSICAL RISKS – LIGHTING

Proper lighting in the workplace prevents both psychological and physiological strain on workers. It therefore increases productivity, motivation, and overall performance, while reducing visual fatigue. Lighting can be natural or artificial, with natural light being the ideal source whenever possible.
WARM NATURAL COOL
Kelvin Scale – Color Temperature

PHYSICAL RISKS – LIGHTING

According to ISO 8995:2002

PHYSICAL RISKS – LIGHTING control

The quality of workplace lighting depends on factors such as the type of lighting, the arrangement of luminaires, glare factor, and contrast factor. To ensure adequate lighting conditions in the workplace, it is necessary to consider the specific characteristics of the tasks being performed and the required level of visual acuity. Proper lamp distribution and harmonization of light color with the workplace colors are essential.
Good lighting should preferably be natural, diffuse, and uniform, well distributed across the work surface, without causing glare, sufficient, steady (non-flickering), and free from stroboscopic effects.
Inadequate lighting in the workplace can result in increased strain and eye fatigue, nervous tension, headaches, blurred vision, muscle contractions, poor body posture, lack of concentration, as well as anxiety or nervousness. It may also lead to reduced productivity and a consequent increase in occupational accidents.

CHEMICAL risks

Chemical contaminants are toxic substances that can be absorbed by the body and cause long-term harmful effects on health, through one or more routes of entry:
Digestive
Dermal
Respiratory

CHEMICAL risks

Chemical risks are associated with the handling of chemical products and may be present in the atmosphere in different states:
Solid (dust, fibers, and fumes)
Liquid (aerosols and mists)
Gaseous (gases and vapors)
Identification of chemical products
Identification of chemical products
- When handling chemicals, the first step is to observe and read the
instructions provided on the label:
R phrases > Risks
H phrases > Hazard
P phrases > Precaution
S phrases > Safety

CHEMICAL risks

When absorbed by the body, chemical agents may cause toxic reactions and health damage, such as:
  • Skin and eye irritation
  • Burns
  • Chronic respiratory diseases
  • Kidney and liver diseases
  • Nervous system disorders
  • Cancer
  • Fire or explosion hazards
Each chemical product has its own properties, such as flammability, toxicity, corrosiveness, or reactivity, which require specific storage conditions, labeling and ventilation. For this reason, it is essential to follow clear rules on segregation, compatibility, labeling, and quantity control.Please consult the “Study Resources” section of the course to view three examples of Safety Data Sheets.

Chemical risks

Potentially Fatal

Flammable

Hazardous

Corrosive

Product that presents a serious fire hazard when exposed to heat, sparks, or flames.

Product that causes burns to the skin and eyes and is corrosive to metals.

Product that irritates eyes and skin, harmful to the ozone layer, and with negative health effects.

Toxic product, even when used in small quantities and during brief exposure.

Labeling through symbols and texts contains essential safety precautions.

Chemical risks

Hazards
Regulation
Directive

Unstable explosivesSelf-reactive substances and mixtures, types A, BOrganic peroxides, types A, B

Gases, aerosols, flammable liquids, and solidsSelf-reactive substances and mixtures, types B, C, D, E, F Pyrophoric liquids and solids Substances and mixtures liable to self-heating Substances and mixtures which, in contact with water, release flammable gases, organic peroxides types B, C, D, E, F

F+
*Regulation CLP 2008/1272/EC *Directive 67/548/EEC

Chemical risks

Hazards
Regulation
Directive

Oxidizing gasesOxidizing liquids Oxidizing solids

Gases under pressureCompressed gases Liquefied gases Refrigerated liquefied gases Dissolved gases

Noequivalent

*Regulation CLP 2008/1272/EC *Directive 67/548/EEC

Chemical risks

Hazards
Regulation
Directive

Acute toxicity (oral, dermal, inhalation)Skin/eye irritation Skin sensitization Specific target organ toxicity (single exposure) Respiratory tract irritation Narcotic effects

Xi
*Regulation CLP 2008/1272/EC *Directive 67/548/EEC

Chemical risks

Hazards
Regulation
Directive

Respiratory sensitizationGerm cell mutagenicity Carcinogenicity Reproductive toxicity Specific target organ toxicity Aspiration hazard

Noequivalent

Hazardous to the aquatic environmentAcute or chronic hazard

*Regulation CLP 2008/1272/EC *Directive 67/548/EEC

CHEMICAL risks – SAFE STORAGE PRACTICES

The storage of chemical products represents a critical stage in safety management within any workplace where such substances are present. Improper storage may lead to fires, explosions, the release of toxic vapors, environmental contamination, or accidental exposure of workers.
Each chemical product has its own properties, such as flammability, toxicity, corrosiveness, or reactivity, which require specific storage conditions, labeling, and ventilation. For this reason, it is essential to follow clear rules on segregation, compatibility, labeling, and quantity control.

Chemical risks - Safe storage practices

Safe chemical storage requires careful attention to several factors, including the segregation of incompatible products, the use of appropriate containers, ensuring proper ventilation, and implementing spill containment systems.
It is crucial to store chemicals in appropriate locations, away from heat sources, flames, and electrical installations. Containers must be properly labeled, and workers must receive adequate training.
Insufficient ventilation may lead to the accumulation of vapors and consequent risks such as: Fire and explosion, asphyxiation, inhalation of harmful or toxic vapors.
Insufficient
ventilation
Insufficient
ventilation

CHEMICAL risks

Preventive and protective measures
Preventive and protective measures
Identify the type of hazardous substance
Assess the safety of the packaging, considering the risk of leaks or slow evaporation and consequent air contamination
Define the necessary precautions for handling
Replace hazardous substances or processes with less aggressive alternatives whenever possible
Verify the compatibility/incompatibility of different chemical products and store them according to their technical characteristics to prevent spontaneous combustion
Avoid direct exposure to sunlight
Separate agrochemical products by class: herbicides – insecticides – fungicides

CHEMICAL risks

Preventive and protective measures
Preventive and protective measures
Store liquids on lower shelves and solids on upper shelves
Clearly label storage areas, including “No Smoking,” “No Open Flames,” and “Flammable Substances” warnings
Store cleaning and disinfecting chemicals in closed cabinets, preferably with washable, resistant, and non-degradable shelving
Hazardous, toxic, or infectious substances must be stored in separate compartments, not directly connected to workplaces
Ensure proper ventilation to prevent the dangerous accumulation of gases or vapors

CHEMICAL risks

Preventive and protective measures
Preventive and protective measures
Keep containers tightly sealed to avoid the spread of odors, gases, or vapors
Workstations releasing unpleasant or hazardous products must be equipped with local exhaust systems to prevent their spread into the work environment
Equipment generating dust must be equipped with effective collection or extraction devices, installed close to the emission source

BIOLOGICAL risks

Biological agents such as bacteria, viruses, fungi, parasites (including genetically modified microorganisms, cell cultures, and human endoparasites) are capable of causing infections, allergies, or intoxications. The entry routes for biological agents include the respiratory system, digestive system, skin, and eyes. These may result in diseases such as influenza, intestinal infections, hepatitis, tuberculosis, and meningitis.
Preventive measures
Preventive measures
  • Knowledge of procedures and modification of work methods
  • Limiting the number of workers exposed
  • Implementation of collective and individual protection and hygiene measures
  • Establishment of emergency and action plans in case of accidents involving biological agents
  • Use of proper collection, storage, transport, and disposal methods for waste, ensuring no risk, along with the use of adequate signage and secure containers

ERGONOMIC risks

Ergonomic risks depend on several aspects, including load handling, adopted postures, physical effort, repetitive movements, and monotonous activities.
Manual Load Handling (MLH) refers to the operation of transporting or supporting a load, carried out by one or more workers. It includes movements such as lifting, pushing, carrying, and moving objects. The risks associated with MLH involve falling objects, overexertion, improper movements, possible cuts, crushing, or entrapment.
To correctly handle a load manually, it is necessary to know the:
Characteristics of the load – weight, shape, size, and grips
Displacement to be performed – from where and to where, duration of transport, and frequency of movements

ERGONOMIC risks

According to Decree-Law no. 330/93, of September 25 (Article 5), risk assessment must be carried out when handling loads:
30 kg for occasional handling and 20 kg for regular handling.
30 kg for occasional handling 20 kg for regular handling.
Incorrect manual load handling can cause pain and musculoskeletal disorders (affecting the musculoskeletal, peripheral nervous, or neurovascular systems), often aggravated by occupational exposure to ergonomic risks.
Errors to avoid:
Errors to avoid:
- Bending the spine - Standing too far from the load - Keeping legs fixed to the floor and twisting the torso with the load - Resting the load on the leg or knee

ERGONOMIC risks

Another ergonomic risk relates to the posture adopted in the workplace.
Seated work may cause stiff neck, tendinitis, tense and hunched shoulders, headaches and eye strain, lower back pain, tennis/golfer’s elbow, and leg swelling.
Seated work
Standing work may result in back pain, leg inflammation and swelling, as well as circulation problems.
Standing work

ERGONOMIC risks - Standing work

For safe standing work:
  • The worker should be able to stand upright, close to the work surface, with body weight evenly distributed on both feet
  • Controls and tools should be located below shoulder height
  • Appropriate footwear should be worn to reduce strain on legs and lower back
  • Alternate between sitting and moving
  • Workstations should be adjusted to proper height levels (click to see the )
  • should be used in areas where prolonged standing is required, reducing impact on joints
picture
Anti-fatigue mats

Workplace Exercise

PSYCHOSOCIAL risks

Hazards:
Hazards
  • Increased productivity demands
  • Reduction in the workforce
  • Time pressure
  • Increased task complexity
  • Unrealistic expectations
  • Work relationships marked by tension or instability
These conditions can lead to stress, fatigue and burnout

PSYCHOSOCIAL risks

Psychosocial factors can be defined as “the characteristics of working conditions, and especially their organization, that affect people’s health through psychological and physiological mechanisms, commonly referred to as stress” (ISTAS, 2002).Such factors influence individual behavior, cause psychological harm, and have repercussions at the organizational level.

Individuals

Organization

PSYCHOSOCIAL risks

Preventive measures
Preventive measures
Reduce task monotony
Ensure regular breaks
Maintain good communication and encourage reporting of difficulties
Clearly define workload, deadlines, and requirements
Motivate and engage the work team
Manage tasks and working hours effectively
Reduce overtime
Provide appropriate training

ELECTRICAL risks

Dangers

Poor maintenance of electrical equipment
Improper use of electrical equipment
Electrical overload
Risk of death
Use of adhesive tape for insulation
Moving devices with live cables
Plugs and/or sockets stepped on or left on the floor

ELECTRICAL risks

In electrical installations, the most frequent accidents result from contact with live parts of installations or equipment. Direct electrical contact occurs when there is contact with a live part. Electric shock may result from insulation failure, rupture of insulating parts, or careless handling.Indirect electrical contact occurs when there is contact with a metallic structure, casing, or conductor that accidentally becomes energized due to a fault.
Direct electrical contact
Direct electrical
contact
Indirect
electrical
contact
Indirect
electrical

DIRECT ELECTRICAL CONTACT

INDIRECT ELECTRICAL CONTACT

ELECTRICAL risks

There are two types of electrical risks:
a) Personal risks Those related to the effects of electric current passing through the human body, directly affecting individuals
b) Material risks Those related to the destruction of property, usually resulting from fires and/or explosions caused by faulty or misused installations, which may indirectly affect people

Preventive measures

Prevention to void abnormal heating and sparking:

ELECTRICAL risks

The five golden rules for electrical installations and maintenance:
five golden rules
five golden rules
Disconnect all sources of power
Lock out circuit breakers
Verify the absence of voltage
Ground and short-circuit all power sources
Delimit and signal the work area
These five principles ensure the proper and safe maintenance of installations.

ELECTRICAL risks

When using electrical tools, the following precautions must be observed: - Avoid leaving cables scattered on the floor - Prevent cables from being crushed by corners or objects during use - Store equipment properly when not in use
Well-organized tools: Are easier to locate Are safer Last longer

MECHANICAL risks

Mechanical risks are associated with the physical environment surrounding the worker and include:
Slips
Crushing
Burns
Falls
Cuts/amputations

MECHANICAL risks

When acquiring machinery, the company must:
- Require and verify that the machines purchased are “inherently safe” (compliant with legal requirements, CE marked)
- Ensure that the machine includes an instruction manual in Portuguese and English, which must always accompany the machine
- Confirm that the machine can safely perform all routine or occasional operations: adjustment, use, cleaning, and maintenance
- Draft and disseminate work procedures that enhance or optimize the safety measures to be applied during different operations

MECHANICAL risks

Worker training should focus on:
  • Machine operating procedures
  • Risks associated with machine use
  • Protection systems – Operation, maintenance, and emergency procedures
  • Basic safety rules – Avoid removing protections, Lock-out/Tag-out procedures
  • Proper clothing – Avoid loose garments that may get caught in machines
  • Use of protective tools (such as grips and handles)
  • Automatic stop devices and safety signage
Safety procedures in maintenance: Lock-Out / Tag-Out

Maintenance should always be carried out with the machine stopped whenever possible

Power supply must be disconnected (and locked if possible)

The intervention must be signaled both at the intervention site and at the power source

During maintenance, special attention must be given to machine controls – unexpected startup may cause accidents

If protections were removed for repair, they must be reinstalled immediately afterward

Safety procedures in maintenance: Lock-Out / Tag-Out

Machines must never remain without guards, not even temporarily

Lubrication should be performed with the machine stopped. When this is not possible due to technical requirements, it must be carried out with extreme caution and using appropriate methods to prevent accidents

Operators must follow the manufacturer’s instructions and all occupational health and safety regulations

At the end of the intervention, the machine should be restarted, and all signage removed

MECHANICAL risks

Dangers and risks of compressed air on the human body
Dangers and risks of compressed air on the human body
Compressed air directly on the human body can cause subcutaneous emphysema or air embolism (air in soft tissues). It must never be used to clean work clothes, arms, or hair dust due to risks such as:
Eardrum rupture
Internal bleeding from air entering skin pores
Retinal detachment
Skin infections
Inflammation of connective tissues caused by impurities in compressed air

MECHANICAL risks

Equipment Inspection
Equipment Inspection
Employers must perform extraordinary inspections of work equipment when exceptional events occur, such as modifications, accidents, natural phenomena, or prolonged inactivity that may have serious consequences.
A competent person must carry out inspections and tests to ensure proper installation and safe operation.
Start and stop devices
Start and stop devices
Start and stop devices must be easily accessible and operated, prevent unintentional startup, and allow rapid shutdown in an emergency.

MECHANICAL risks

Preventive measures
Preventive measures
Do not transport people in equipment designed for loads (elevators, cranes, forklifts, etc.)
Ensure machines cannot be inadvertently activated during cleaning or maintenance
Report and signal any detected anomalies or defects
Never remove or disable safety devices
Knives must be stored separately from other tools
When handing over a knife, hold it by the handle and present it correctly to the other person
Always use protective devices with equipment
Broken glass must be collected using a broom and dustpan

FIRE risks

A fire is defined as an uncontrolled combustion in space and time. Occupants of burning premises are exposed to two main dangers:
  • Heat (flames and hot products)
  • Smoke and gases (responsible for most fatalities)
Combustion is a chemical reaction that releases heat and/or light, altering the substance being burned.Common causes include the storage of flammable products, the use of damaged electrical equipment during operations, and unsafe behaviors.

FIRE risks

Buildings must be equipped with firefighting resources that enable immediate intervention by occupants and support a rapid response by firefighters. The most common extinguishers are:
Water
CO2
Dry Chemical Powder
ABF

FIRE risks

Another first-response tool is the fire blanket, widely used to extinguish small fires, especially in situations where fire extinguishers are not recommended.
Fire blankets are made of flame and heat-resistant material, effective in smothering the fire and preventing its spread. They are easy to use, practical, and safe for domestic, industrial, and workplace environments, especially mandatory in kitchens and laboratories.
and
flame
flame
and
heat-resistant
heat-resistant
Recommended uses:
Recommended uses:
Kitchen fires involving oil or grease (Class F) Clothes on fire on a person’s body Covering small localized fire sources

FIRE risks

Compact and easy to access, the fire blanket should be installed in visible and easily reachable places, near critical areas such as kitchens, technical areas, and workshops. It is essential that workers know when and how to use it correctly, ensuring a quick and safe response in emergency situations.

FIRE risks

Fire Triangle
Fire Triangle - For combustion (fire) to occur, three elements must be present simultaneously:

HeatSource

OxygenSource

Heat Source: Sun, Hot Surface, Sparks, Friction, Electrical energy...

Oxygen Source: A concentration of 16% is sufficient. Fuel may also contain oxygen

FuelSource

Fuel Source: Can be a solid, liquid or gas

FIRE risks

FIRE risks

PROTECTIVE EQUIPMENT

There are two types of protective equipment: Collective Protective Equipment (CPE) and Personal Protective Equipment (PPE). Their objectives are:
To design facilities, workplaces, and work processes in such a way that foreseeable risks are identified, eliminated at the source, or minimized, thereby ensuring an effective level of protection
To prioritize collective protection over individual protection
Law no. 102/2009
(Portuguese original version) - General obligations of the employer

COLLECTIVE PROTECTIVE EQUIPMENT

Collective Protective Equipment (CPE) measures benefit all workers potentially exposed to occupational risks. CPE includes all devices, systems, fixed or mobile means, signals, images, or sounds designed to collectively preserve the physical integrity and health of workers and third parties.
Exhaust systems that remove gases, vapors or dust from the workplace

COLLECTIVE PROTECTIVE EQUIPMENT

Stair and area protections
Protections in areas with slippery floors
Handrails, baseboards, and non-slip flooring
Covers for trenches or pits that may cause falls

COLLECTIVE PROTECTIVE EQUIPMENT

Firefighting equipment and systems
Fire hoses
Extinguishers
Automatic suppression devices

COLLECTIVE PROTECTIVE EQUIPMENT

Fire detection and alarm systems
Audible alarms
Alarm buttons
Smoke detectors

COLLECTIVE PROTECTIVE EQUIPMENT

Machine component guards
Used as physical barriers to ensure safety

COLLECTIVE PROTECTIVE EQUIPMENT

Main objectives of CPE use:
  • Prevent accidents involving workers or other people present in the workplace
  • Minimize losses and increase company productivity by improving working conditions
  • Eliminate or reduce risks that were previously common in a given work environment

PERSONAL PROTECTIVE EQUIPMENT

After identifying the risks present in each workstation ( version, October 6), appropriate PPE must be selected.
Annex I, Ordinance No. 988/93 - Portuguese original
Requirements for PPE:
Requirements for PPE:
Comfortable Durable Lightweight Adaptable

PERSONAL PROTECTIVE EQUIPMENT

Personal Protective Equipment (PPE) is intended to be worn by workers to protect them against one or more risks that may threaten their safety or health at work, as well as any accessories or complements designed for this purpose. PPE requires workers to exert considerable effort in performing their duties (weight, general discomfort).
Considerations when selecting PPE:
Considerations when selecting PPE:
The risks to which the worker is exposed The conditions of the work environment The part of the body to be protected (equipment is for individual use) The worker’s characteristics, considering ergonomic and health requirements When using more than one PPE simultaneously, their compatibility and effectiveness must be ensured

PERSONAL PROTECTIVE EQUIPMENT

Head
Hands and arms
Face and eyes
Feet and legs
Respiratory system
Torso and abdomen
Tronco e abdómen
Hearing

PERSONAL PROTECTIVE EQUIPMENT

Directive No. 89/686/EEC outlines the procedures that manufacturers must follow in order to obtain a CE Declaration of Conformity for their equipment.
Directive
No. 89
/686
/EEC
Decree-Law No. 118/2019 ensures compliance with
/2019
Regulation (EU) 2016/425
Decree-Law
No. 118
Thus, PPE must be used whenever risks cannot be avoided or sufficiently minimized through collective protective measures, technical solutions, or organizational methods.

PERSONAL PROTECTIVE EQUIPMENT

EMPLOYER’S DUTIES

Provide adequate PPE and ensure availability for workers
Provide information and training on the correct use, maintenance, and cleaning of PPE
Monitor compliance with proper use and maintenance
Prevent the use of defective or damaged Personal Protective Equipment
Keep records of PPE distribution

PERSONAL PROTECTIVE EQUIPMENT

Training in the use, maintenance, and cleaning of Personal Protective Equipment should include:
Indications on which PPE to use and when How to wear, adjust, and use each item of PPE Knowledge of the limitations of each PPE Guidelines on care and maintenance during the equipment’s lifespan A practical demonstration, ensuring that workers understand the instructions and are capable of using PPE correctly

SAFETY SIGNAGE

SIGNAGE BOARDS

SIGNAGE BOARDS

Prohibition signs
Prohibit certain behaviors and indicate dangerous actionsCircular shapeBlack pictogram on a white background, with a red border and diagonal stripe
Warning signs
Warn of hazards or risksTriangular shapeBlack pictogram on a yellow background with a black border

SIGNAGE BOARDS

Mandatory signs
Impose specific behaviorCircular shapeWhite pictogram on a blue background
Information signs
Provide general information and useful directionsRectangular or square shape
White pictogram on a blue background

SIGNAGE BOARDS

Firefighting signs
Indicate the location of firefighting equipmentRectangular or square shapeWhite pictogram on a red background
Emergency and rescue signs
Indicate emergency exits and first aid or rescue equipmentRectangular or squareWhite pictogram on a green background

TRAFFIC ROUTE SIGNAGE

When necessary to ensure worker safety, vehicle traffic routes must be clearly marked with continuous lines that are an integral part of the flooring.
Requirements:
Lines may be white or yellow, depending on the floor color Location of lines must consider safety distances between vehicles, workers, and nearby installations Outdoor routes may be marked with barriers or paving instead of painted lines Pedestrian routes must have adequate lighting, non-slip flooring, and distinct markings (yellow or white lines)

OBSTACLE AND HAZARDOUS AREAs SIGNAGE

Obstacles and hazardous areas must be clearly identified to avoid collisions, falling objects, or falls. Markings consist of alternating yellow and black or red and white stripes.
Requirements:
Markings consist of alternating yellow and black or red and white stripes The size of the obstacle or hazardous area must be considered Stripes must form a 45º degrees angle and have equal surface areas Electrical supply must be autonomous in illuminated signs

Road and Obstacles Signage

illuminated SIGNAge

Illuminated signals must:
Provide adequate contrast without causing glare or poor visibility Use flashing lights instead of continuous ones to indicate high danger or urgency Have an autonomous power supply

ACOUSTIC SIGNAge

Acoustic signals must be:
Intense enough to attract attention without causing pain Clearly distinguishable from background noise and other signals Easily recognizable through duration and pulse intervals
If signals vary in intensity or frequency, they indicate higher danger or urgency. Verbal signals may also be used, such as short commands: “Start,” “Forward,” “Back.”

PIPE MARKING

Substances transported through pipelines must be clearly labeled:

hand gesture signage

Hand signals result from a movement or position of the arms or hands, or any combination of them It occurs through a coded form The main objective is to guide the execution of maneuvers that pose a risk or danger to workers

Hand gesture signage

General signals:
Meaning - Start (Attention; Start of command) Description - Both arms are extended horizontally with the palms facing forwards
Meaning Description
Start
Meaning - Stop (Interruption; End of movement) Description - The right arm points upwards with the palm facing forwards
Meaning Description
Stop

Hand gesture signage

General signals:
Meaning - End of the operation Description - Both hands are clasped at chest height
Meaning Description
End
Meaning - Raise Description - The right arm points upwards with the palm facing forward and slowly makes a circle
Meaning Description
Raise

Hand gesture signage

General signals:
Meaning - Lower Description - The right arm points downwards with the palm facing inwards and slowly makes a circle
Meaning Description
Lower
Meaning - Vertical distance Description - The hands indicate the relevant distance
Meaning Description
Vertical distance

Hand gesture signage

General signals:
Meaning - Move forwards Description - Both arms are bent with the palms facing upwards, and the forearms make slow movements towards the body
Meaning Description
Move forwards
Meaning - Move backwards Description - Both arms are bent with the palms facing downwards, and the forearms make slow movements away from the body
Meaning Description
Move backwards

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Protect the person

  • Individual worker protection
  • Individual measure
  • Acts on humans

Temporary partial disability - A situation in which the injured or ill person is able to attend work but is still unable to perform their normal duties.

Temporary total disability – A condition in which the injured or ill person is temporarily unable to attend work due to being unfit to perform their normal duties.

  • Process, machine, or component substitution
  • Use of quieter equipment
  • Application of silencers and sound attenuators
  • Improved structural design
  • Proper sizing, finishing, and material selection
  • Reduced rotation speeds and impact between components
  • Isolation
  • Regular maintenance

Limit or eliminate the risk

  • Risk prevention during the project phase
  • Constructive or engineering measure
  • Acts on the working environment (space, machine, layout)
Psychosocial Risks
  • Pressure/Stress
  • Precariousness
  • Fatigue
  • Time management
  • Work-life imbalance
  • Moral and sexual harassment

Limit or eliminate the risk

  • Risk prevention in the project phase
  • Constructive or engineering measure
  • Acts on the working environment (space, machine, layout)
Physical Risks
  • Noise
  • Thermal environment (cold, heat)
  • Vibrations
  • Radiation
  • Lighting
  • Humidity
Human causes
  • Fatigue
  • Stress
  • Alcohol/drug use
  • Failure to comply with safety rules
  • Lack of attention
  • Overconfidence
  • Lack of training/information
  • Incorrect positions when performing tasks
Technical causes
  • Equipment/tools in poor condition or without safety devices
  • Breakdown
  • Inadequate storage
  • Collective Protection Equipment incorrectly assembled
  • Poor working conditions
  • Never handle frozen foods or products directly with bare hands - always use appropriate protective gloves
  • Wear long-sleeved work clothes or protective arm covers when using fryers, pans, or grills
  • Use heat-resistant protective gloves to handle hot containers
  • Avoid leaning over or reaching across hot surfaces/equipment
  • Never fill containers with liquids that will be heated
  • Place protective splash guards around fryers and pans
  • Check the fryer thermostat temperatures before inserting food
  • Always ensure food is dry and ice-free before frying
electrical risks
  • Electrical overload
  • Damaged equipment
  • Upkeep
  • Electrical installations
  • Maintenance

Solids - Coal, wood, paper, leather, plastic, sugar, grainLiquids - Gasoline, alcohol, plant, olive oil Gases - Natural gas, propane, hydrogen, carbon monoxide

Drive the person away

  • Protection against sources of risk
  • Organizational and collective measures
  • Acts on the system Man - Machine - Environment
Fortuitous causes
  • Risks not foreseeable due to factors outside the work
  • Actions by third parties
  • Weather conditions

Examples

  • Cork and cork derivatives (agglomerates, granules, linoleum)
  • Cellular glass (decorative panels, special finishing pieces)
  • Fiberglass and mineral fibers
  • Acoustic steel plates
  • Gypsum panels, wood fiber panels
  • Plastic foam insulation
  • Polyurethane-core panels and polystyrene decorative boards
  • Lightweight concrete, siporex, ytong
  • Vermiculite and expanded clay

Protect the person

  • Individual worker protection
  • Individual measures
  • Acts on humans
Negative consequences for individuals
  • Burnout (exhaustion)
  • Cognitive changes (repetitive thoughts, difficulty concentrating, difficulty making decisions)
  • Stress, anxiety, and mood instability
Mechanical risks
  • Machine operation
  • Maintenance
  • Compressed air
  • Cuts
  • Crushing injuries
  • Blows
Ergonomic Risks
  • Manual handling of loads
  • Incorrect postures
  • Use of unsuitable tools
  • Repetitive movements
  • Monotonous activities
Chemical Risks
  • Fog
  • Chemical products
  • Chemical agents
  • Dust
  • Vapors
  • Fumes
  • Mists
Frequently check electrical installations (sockets and cables)
Remove any damaged electrical material
Label all components and equipment that show signs of malfunction or failure
Ensure all electrical equipment is correctly installed
Do not make connections or modify electrical installations (always use qualified technicians)
Never clean or handle electrical equipment without first cutting off the power supply
Do not handle electrical equipment with wet or damp hands

Hazard: Electricity Risk: Probability of electrocution

  • Periodic assessments and records
  • Medical surveillance and audiometry
  • Noise source isolation and substitution
  • Worker rotation
  • Availability of adequate protective equipment
  • Training of workers exposed to noise
Negative consequences for organizations
  • Increased demand for productivity
  • Workplace tension and deterioration of work climate
  • Reduced efficiency and performance
  • Purchase machines, tools, and vehicles that comply with CE standards
  • Keep equipment and machines properly lubricated
  • Separate fixed machines from the floor using vibration-absorbing materials
  • Reduce ground irregularities
  • Properly place loads
  • Install noise and vibration-absorbing panels in the workplace
  • Alternate tasks between those exposed and not exposed to vibration risks
  • Limit the duration and intensity of exposure
  • Define appropriate work schedules with frequent rest breaks
  • Provide workers with adequate training and information
  • Ensure proper medical surveillance

Examples

  • Cork and cork derivatives (agglomerates, granules, linoleum)
  • Cellular glass (decorative panels, special finishing pieces)
  • Fiberglass and mineral fibers
  • Acoustic steel plates
  • Gypsum panels, wood fiber panels
  • Plastic foam insulation
  • Polyurethane-core panels and polystyrene decorative boards
  • Lightweight concrete, siporex, ytong
  • Vermiculite and expanded clay
Fire risks
  • Heat
  • Smoke and gases
  • Fires

Involve the risk

  • Elimination of the hazard source
  • Constructive/engineering and organizational measure
  • Acts on the working environment (machine, layout)
Biological Risks
  • Viruses
  • Bacteria
  • Protozoa
  • Fungi
  • Bacilli

Permanent partial disability – A condition that results in the permanent impairment of the worker, leading to a lasting reduction in their overall earning capacity.

Permanent total disability – A condition in which the worker is permanently unable to perform their normal duties or carry out any type of work.