⚠️ SOP 18 — Safety and Machine Danger Zone

SOP Name:         Safety and Machine Danger Zone
Process Code:     MACHINE_SAFETY_V1
Version:          V1
Owner:            Factory Supervisor
Applies To:       All factory staff
Frequency:        Daily
Last Updated:     2026-06-25
Review Frequency: Monthly

1. Purpose

Prevent accidents near the machine and production area.

2. Who Is Responsible

Factory Supervisor — enforces safety rules daily.
Machine operator — only trained staff operate the machine.

3. When To Use This SOP

Every production day, and whenever the machine is running.

4. Visual Process Flow

flowchart TD
A[Before machine start] --> B[Clear danger zone]
B --> C[Only trained operator runs machine]
C --> D[Keep visitors/children away]
D --> E{Abnormal sound/vibration?}
E -- Yes --> F[Stop + inform Ram/Srinivasan]
E -- No --> G[Continue safely]

Safety Rules

1. No hand inside danger zone during machine operation.
2. Only trained operator should handle the machine.
3. Keep children/visitors away from the machine.
4. Do not clean the machine while it is running.
5. Report abnormal sound/vibration immediately.
6. Keep the walkway clear.
7. Use basic PPE where required.

[PHOTO: Danger zone marking] [PHOTO: Correct PPE]

6. Do / Don't

✅ Do	❌ Don't
Stop the machine before cleaning	Clear jams with the machine running
Keep the danger zone clear	Reach in during operation
Report odd sound/vibration at once	Run a machine that sounds wrong

7. Checklist

[ ] Machine area clear
[ ] Operator available
[ ] No unsafe handling
[ ] Walkway clear
[ ] Cleaning done safely
[ ] Issue reported if any

8. Records To Update

🔵 Safety check note
🔵 Telegram report on any incident or near-miss

9. Escalation Rule

Inform Ram/Srinivasan immediately on any safety incident, near-miss, or abnormal machine behaviour. Stop the machine first.

10. Common Mistakes

Cleaning/clearing a jam without stopping the machine.
Letting untrained staff or visitors near the machine.
Ignoring abnormal sound or vibration.

11. Improvement Suggestion

If you find a better way to do this process, add a comment below or submit an improvement request in the SOP Improvement Register.

Automation Readiness

Telegram command: /safety
n8n workflow:     wf_machine_safety_v1
Odoo object:      maintenance.request (if incident)
Approval role:    Factory Supervisor
Supabase table:   safety_incidents
Status:           Future automation