# Standardized Safe Operation Guidelines for Hollow Molding Processes in Dalian

As an important industrial base in Northeast China, Dalian has a wide application of plastic hollow molding (such as blow molding and injection-molded hollow products) in packaging, building materials, auto parts and other fields. Standardized safe operation is not only the core of protecting employees' life and health, but also the cornerstone of sustainable enterprise development. Combined with the industrial characteristics and work safety requirements in Dalian, the key points of standardized safe operation for hollow molding are systematically sorted out from the aspects of personnel management, equipment maintenance, operation procedures, protective measures and emergency response.

## I. Personnel Qualifications and Training: Prerequisites for Safe Operation

Hollow molding equipment falls within the scope of special equipment, and operators must hold corresponding qualifications:

1. **Certified Posting**: Operators must pass training and assessment organized by Dalian work safety supervision authorities or industry associations, and obtain a *Special Equipment Operator Certificate* or industry-specific operation certificate. Uncertified operation is strictly prohibited.

2. **Pre-job Training**: New employees shall receive no less than 40 hours of theoretical and practical training covering equipment principles, safety regulations, emergency response and other contents; veteran employees shall take retraining every six months to update safety knowledge and operational skills.

3. **Safety Awareness Cultivation**: Regular case analysis meetings shall be held to strengthen employees' safety awareness and eliminate fluke mentality through local or industrial accident cases (such as injuries caused by mold falling and high-temperature scalds).

## II. Daily Equipment Inspection and Maintenance: Key to Eliminating Hidden Dangers

Equipment failure is one of the main causes of safety accidents, so a system of "daily inspection + regular maintenance" shall be established:

1. **Pre-start Inspection**:

   - Confirm that molds are firmly installed and clamping force meets requirements to prevent mold displacement or cracking during molding;

   - Check whether heating systems (such as heating coils and thermocouples) function normally and temperature sensors are accurate to avoid fires caused by overheating;

   - Verify safety devices: ensure emergency stop buttons, protective fences and photoelectric sensors are sensitive and effective for immediate shutdown in case of equipment abnormalities;

   - Inspect the hydraulic system: check for oil pipe leaks and whether pressure is within the specified range to prevent injuries from hydraulic oil spraying.

2. **Regular Maintenance**:

   - Clean dust on and inside the equipment weekly, and check whether the lubrication system (such as gears and guide rails) is short of oil;

   - Conduct insulation testing on electrical circuits and grounding devices monthly to prevent electric leakage;

   - Maintain molds quarterly, clean residues and apply anti-rust oil to extend service life;

   - Establish equipment maintenance logs to record fault handling and provide a basis for subsequent improvements.

## III. Standardized Operation Procedures: Core of Standardized Work

Strict adherence to operation procedures is critical to avoiding human errors:

1. **Start-up Preparation**:

   - Confirm that raw material dryness meets requirements (e.g., moisture content of PET raw materials shall be lower than 0.02%) to prevent bubbles or bursts during molding;

   - Wear complete personal protective equipment: safety helmets, goggles, heat-resistant gloves and anti-slip shoes; dust masks shall be worn when handling dusty raw materials.

2. **Molding Operation**:

   - Operate strictly in accordance with process parameters (temperature, pressure, time) without unauthorized modification;

   - When the equipment is running, it is forbidden to put hands or tools into the mold area, heating chamber or discharge outlet to prevent mechanical injuries;

   - Monitor equipment operation: immediately press the emergency stop button if abnormal noise, vibration or odor is detected, and troubleshoot only after the equipment stops stably.

3. **Shutdown and Cleaning**:

   - Turn off the heating system before shutdown, and cut off the power supply only after the temperature drops to a safe range;

   - Use special tools (such as copper bars and brushes) when cleaning molds to avoid scratching molds or damaging equipment;

   - Stack raw materials and finished products by category, keep work area passages clear, and stay away from heat sources and electrical equipment.

## IV. Safety Protection and Site Management: Building a Strong Safety Line

1. **Personal Protection**: Employees are mandatory to wear protective equipment. Loose clothing and long hair (which must be tied up) are prohibited to prevent entanglement by equipment.

2. **Site Environment**:

   - The work area shall be equipped with sufficient fire-fighting facilities (fire extinguishers, fire hydrants) with regular validity checks;

   - Raw material warehouses shall be ventilated and dry, kept away from fire sources, and marked with "No Smoking" signs;

   - Electrical equipment shall be well grounded, and operating switches with wet hands is prohibited to prevent electric shock.

3. **Mold Replacement Safety**:

   - Shut down and cut off power before mold replacement, and hang a "Under Maintenance" warning sign;

   - Clarify division of labor for multi-person collaboration; when lifting molds with hoisting equipment (such as cranes), check whether lifting gear is firm to avoid mold falling.

## V. Emergency Response Plans: Guarantee for Rapid Response

1. **Plan Formulation**: Develop detailed emergency response procedures for common accidents such as fires, mechanical injuries and electric shocks, and clarify responsible persons and contact information.

2. **Regular Drills**: Organize emergency drills quarterly, such as fire evacuation and casualty first aid (hemostasis, bandaging), to ensure employees master relevant skills proficiently.

3. **Emergency Supplies**: Equip first-aid kits (including bandages, disinfectants, painkillers, etc.), fire-fighting equipment and insulating gloves in conspicuous and accessible locations.

## Conclusion

The standardized safe operation of Dalian's hollow molding industry requires joint efforts of enterprises, employees and regulatory authorities. Enterprises shall establish and improve safety management systems, employees shall strictly abide by operation procedures, and regulatory authorities shall strengthen supervision and inspection. Only by integrating safety into every link of production can accidents be effectively prevented, employees' rights and interests be protected, and the healthy and sustainable development of Dalian's hollow molding industry be promoted.