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LCD production equipments are featured by large scale, high speed, and automation. As larger and more complex equipments continue to become available, there are various hazard sources that may cause serious damages. Analysis on serious casualties occurred in the TFT-LCD industry and the occupational injury types of a photoelectric plant indicated that, mechanical injury is the primary cause. The main reason is insufficient safety protections, such as failure of intrinsic safety on the mechanical equipment and safety interlock, followed by improper operation.
However, it is inevitable for machines to encounter malfunctioning and for personnel to make mistakes. Hence, this study applied intrinsically safe strengthening, substitution, attenuation, limitation of effects, simplification, avoidance of domino effect, foolproof design, clear status, tolerance, easy to control, and software. These strategies were combined with the optimum design of safety interlock, in the forms of electromagnetic type, tongue type, diversification of power sources, and safe optical grating. There fore, once personnel enter into the danger zone of energy operation space, the energy operation will stop, and the personnel are guaranteed to be out of the danger zone once the energy operation restarts. Meanwhile, a case study was conducted to verify the protection safety. To ensure the operators’ safety, comprehensive trainings could be provided for newly-hired and in-service staffs on the operating safety and hazard recognition of the equipments. Moreover, a reward and penalty system could be implemented to reinforce the staffs’ understanding of the machinery hazards and the safety standards. The code for practice against different operating hazards needs to be established to ensure the operators to operate in accordance with the standard procedures in order to prevent the unacceptable risk of production interruption caused by occupational hazards.
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