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Production The job position is the most fundamental unit of safe production, the most critical focus of the “Three Fundamentals” (foundation, grassroots, and basics) initiative for safe production, and the most basic building block for risk control in enterprise safety production. The casting industry is a high-risk sector characterized by harsh working conditions, high temperatures, and a propensity for accidents such as explosions and burns during production. Trade unions are the defenders of the broad masses’ interests; they serve as a bridge and link between employees and enterprises, representing workers’ interests. They bear significant responsibility for safeguarding workers’ safety and health during the production process. Therefore, workshop trade unions have organized production backbones to study and develop the “1+4 Work Method for Safe Production with Medium-Frequency Induction Furnaces,” taking into account the unique characteristics of the casting industry, the actual conditions of the workshop, and years of production experience. This approach has effectively ensured safe and healthy casting production and vividly demonstrates the positive contributions that trade unions have made to enterprise safety production and stable operations.

Safety Technical Operation Procedures for Intermediate-Frequency Furnace Operators

The procedure provides detailed instructions on items that must be carefully observed during operation. For example, it stipulates that flammable, explosive, low-melting-point materials, seals, tubular objects, hollow components, and other suspicious substances must be carefully removed from the charge. The surface of the charge must be free of severe rust, oil stains, water marks, or dampness to prevent the molten metal in the furnace from boiling and splashing during charging. All such details are fully incorporated into the procedure. Before and after each shift, the shift supervisor or safety officer will conduct briefings and training sessions for team members, explaining and demonstrating the key points of the safe production operating procedures, ensuring that all operators thoroughly understand and skillfully apply them.

4 specific measures

First, we have developed effective hand signals for crane lifting operations based on the actual conditions on site. Because... Foundry workshop The site is characterized by loud noise and heavy dust, making it necessary to rely on large-amplitude gestures to direct the overhead crane during lifting operations. Therefore, commands such as “lift,” “lower,” and “move” have been standardized into fixed, wide-ranging gestures, and overhead crane operators have undergone training in visual memory techniques to ensure safety throughout the production process.

Second, we have equipped ourselves with three auxiliary tools for safe production: a voltage detector, a long-range infrared thermometer, and a furnace lining thickness alarm. During the production process, we are required to inspect key areas—such as critical distribution boxes—every two hours to check for any signs of electrical leakage. Additionally, after each batch of molten iron is tapped, we conduct temperature checks on the furnace coil and copper busbar connections to promptly identify any abnormal temperature readings. We’ve also installed a furnace lining thickness alarm; when the furnace lining thins down to a critical threshold, the alarm will automatically activate. Team members will immediately prepare to clean the furnace and reline it. This measure has effectively prevented serious accidents such as furnace breaches caused by excessive thinning of the furnace lining.

Third, ensure that all seven pieces of personal protective equipment—namely, a safety helmet, flame-retardant clothing, furnace boots, goggles, dust mask, earplugs, and gloves—are fully equipped. Provide employees with detailed training on how to properly wear these protective items and set forth stringent requirements. Before each shift, designated personnel will conduct thorough inspections to prevent safety accidents and occupational health hazards.

Fourth, 51 key safety inspection items were summarized based on the production process, and all these items were listed in an inspection checklist. Every day, the shift leader and the assistant shift leader conduct inspections according to the items on the checklist and keep detailed records for future reference.

By implementing the “1+4 Work Method for Medium-Frequency Induction Furnaces,” a simple-to-learn, practical, and effective approach developed by the trade union organization, we have ensured the safety and health of on-site workers. At the same time, this method has enabled comprehensive, systematic, and scientifically grounded prevention and control of safety risks in the casting industry, further highlighting the indispensable and positive role played by trade unions in ensuring safe production. Since adopting this method, the workshop has experienced no safety incidents over the past two years. This approach can be widely promoted and applied within the casting industry, with remarkable results.