Machine Guarding (Subpart O) and Lockout/Tagout

The words on each slide as the author wrote them, read from the file by software so they can be searched. Layout, pictures and tables are not shown here: the slides above and the download are the original.

1. Slide 1

   Subpart O -

   • Machine Guarding
2. Slide 2

   Disclaimer

   • This material was produced under grant number SH-29660-SH6 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government.
3. Slide 3

   What are your biggest machine guarding challenges?

4. Slide 4

   We Will Cover:

   • Machine Guarding Principles
   • Subpart O – Highlights
   • 1910.147 – Lockout/Tagout Highlights
5. Slide 5

   Machine Guarding Requirements

   • Prevent contact
   • Be secure
   • Protect from falling objects
   • Create no new hazards
   • No interference
   • Maintainability and accessibility
6. Slide 6

   Where machine hazards occur:

   • Point of operation
   • Mechanical power transmission
   • Other moving parts
7. Slide 7

   Machine Guarding

8. Slide 8

   Machine Guarding Hazardous Actions

   • Cutting
   • Shearing
   • Bending
   • Punching
9. Slide 9

   Methods of machine safeguarding

   • Physical guards
   • Devices
   • Location/Distance
10. Slide 10

    Guards

    • Fixed
    • Interlocked
    • Adjustable
    • Self-adjusting
11. Slide 11

    Fixed Guard

    • Provides a barrier - a permanent part of the machine, preferable to all other types of guards.
12. Slide 12

    Interlocked Guard

    • When this type of guard is opened or removed, the tripping mechanism and/or power automatically shuts off or disengages, and the machine cannot cycle or be started until the guard is back in place.
    • Interlocked guard on revolving drum
13. Slide 13

    Adjustable Guard

    • Provides a barrier which may be adjusted to facilitate a variety of production operations.
    • Bandsaw blade adjustable guard
14. Slide 14

    Self-Adjusting Guard

    • Provides a barrier which moves according to the size of the stock entering the danger area.
    • Circular table saw self-adjusting guard
15. Slide 15

    Gotcha Stick illustration

16. Slide 16

    Guard Distance Table

17. Slide 17

    Safeguarding devices

    • Presence sensing
    • Pullback
    • Restraint
    • Safety controls and trips
    • Gates
18. Slide 18

    Some Examples of Guards/Safeguards

19. Slide 19

    Light Curtain

20. Slide 20

    Pullback Restraints

21. Slide 21

    Pullback Device (cont’d)

    • Hands in die, feeding
    • Point of operation exposed
    • Pullback device attached and properly adjusted
    • Die closed
    • Hands withdrawn from point of operation by pullback device
22. Slide 22

    Two-Hand Controls

23. Slide 23

    Gate

    • Movable barrier device which protects the operator at the point of operation before the machine cycle can be started
    • If the gate does not fully close, machine will not function
    • Gate Closed
    • Gate Open
24. Slide 24

    Safety Tripwire Cables

    • Device located around the perimeter of or near the danger area
    • Operator must be able to reach the cable to stop the machine
25. Slide 25

    Safeguarding by Location/Distance

    • Locate the machine or its dangerous moving parts so that they are not accessible or do not present a hazard to a worker during normal operation
    • Maintain a safe distance from the danger area
26. Slide 26

    Holding Tools

    • Used to place and remove stock in the danger area
    • Not to be used instead of other machine safeguards, but as a supplement
27. Slide 27

    Pressure-

    • Sensitive
    • Mats
28. Slide 28

    Robots

    • Machines that load and unload stock, assemble parts, transfer objects, or perform other tasks
    • Best used in high-production processes requiring repeated routines where they prevent other hazards to employees
29. Slide 29

    Protective Shields

    • These do not give complete protection from machine hazards, but do provide some protection from flying particles, splashing cutting oils, or coolants.
30. Slide 30

    Subpart O - Machinery and Machine Guarding

    • 211 - Definitions
    • 212 - General requirements
    • 213 - Woodworking machinery
    • 215 - Abrasive wheel machinery
    • 216 - Mills and calendars
    • 217 - Mechanical power presses
    • 218 - Forging machines
    • 219 - Mechanical power transmission
31. Slide 31
    • 1910.212
    • General Requirements for all Machines
32. Slide 32

    1910.212(a)(1)

    • One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by the point of operation, in-going nip points, rotating parts, flying chips and sparks.
33. Slide 33

    1910.212(a)(3)(ii)

    • The point of operation of machines whose operation exposes an employee to injury, shall be guarded.
34. Slide 34

    Point of Operation Guarded??

35. Slide 35

    Point of Operation Guarding

36. Slide 36

    Hand Tools

37. Slide 37

    1910.212(a)(5)

    • When the periphery of the blades of a fan is less than seven (7) feet above the floor or working level, the blades shall be guarded. The guard shall have openings no larger than 1/2 inch.
38. Slide 38

    1910.212(b)

    • Machines designed for a fixed location shall be securely anchored to prevent walking or moving.
39. Slide 39
    • 1910.213
    • Woodworking Machinery Requirements
40. Slide 40

    Table Saws

41. Slide 41

    1910.213(c)(1)

    • Each circular hand-fed ripsaw shall be guarded by a hood which shall completely enclose that portion of the saw above the table and that portion of the saw above the material being cut. The hood and mounting shall be arranged so that the hood will automatically adjust itself to the thickness of and remain in contact with the material being cut without considerable resistance.
42. Slide 42

    Table Saw

43. Slide 43

    1910.213(c)(2)

    • Each hand-fed circular ripsaw shall be furnished with a spreader to prevent material from squeezing the saw or being thrown back on the operator.
44. Slide 44

    Table Saw

45. Slide 45

    1910.213(c)(3)

    • Each hand-fed circular ripsaw shall be provided with non-kickback fingers or dogs so located as to oppose the thrust or tendency of the saw to pick up the material or throw it back toward the operator.
46. Slide 46

    Dogs

47. Slide 47

    1910.213(d)(1)

    • Each circular crosscut table saw shall be guarded by a hood which shall meet all the requirements of 1910.213(c)(1) for hoods for circular resaws.
48. Slide 48

    Radial Arm Saws

49. Slide 49

    Partial guarding

50. Slide 50

    Radial arm saw

51. Slide 51

    1910.213(i)(1)

    • All portions of the saw blade (bandsaws) shall be enclosed or guarded, except for the working portion of the blade between the bottom of the guide rolls and the table.
52. Slide 52

    Bank saw

53. Slide 53

    Metal cutting band saw

54. Slide 54
    • 1910.215
    • Abrasive-Wheel Machinery
55. Slide 55

    1910.215(a)(4)

    • Work rests shall be adjusted closely to the wheel with a maximum opening of one-eighth inch to prevent the work from being jammed between the wheel and the rest, which may cause wheel breakage.
    • Work Rest
56. Slide 56

    1910.215(b)(9)

    • The distance between the wheel periphery and the adjustable tongue or the end of the peripheral member at the top shall never exceed one-fourth inch.
    • Tongue Guard
57. Slide 57

    1910.215(d)(1)

    • Immediately before mounting, all wheels shall be closely inspected and sounded by the user (ring test) to make sure they have not been damaged.
58. Slide 58

    Grinder

59. Slide 59

    Unguarded grinder & other issues

60. Slide 60

    Tech Guide available @ www.oshainfo.gatech.edu

61. Slide 61
    • 1910.219
    • Mechanical Power-Transmission Apparatus
62. Slide 62

    Back guard

63. Slide 63
    • Missing Guard
64. Slide 64

    1910.219(b)(1)

    • Flywheels located so that any part is 7 feet or less above the floor or platform shall be guarded.
    • Wherever flywheels are above working areas, guards shall be installed having sufficient strength to hold the weight of the flywheel in the event of a shaft or wheel mounting failure.
65. Slide 65

    1910.219(c)

    • Horizontal, vertical, and inclined shafting must be enclosed.
    • Projecting shaft ends shall present a smooth edge and end and shall not project more than 1/2 the diameter of the shaft unless guarded by non rotating cap or safety sleeves.
66. Slide 66

    Unguarded coupling

67. Slide 67

    Unguarded coupling

68. Slide 68

    Result of hair getting caught in rotating parts.

69. Slide 69

    1910.219(d)

    • Pulleys 7ft. or less above the floor or platform must be guarded.
    • Pulleys with cracks or pieces broken out of rims shall not be used.
70. Slide 70

    Gears need guarding

71. Slide 71

    Unguarded Chain/Sprocket

72. Slide 73

    Lockout/Tagout - What is covered?

    • Servicing and maintenance
    • Normal production operations where:
    • Employees by-pass guard(s)
    • Employees place any part of their body in a hazardous area
73. Slide 74

    What is not covered?

    • Construction, agriculture, and maritime
    • Normal production operations (subpart O)
    • Cord-and-plug under the control of employee (written procedure still required)
    • Exposure to electrical conductors (subpart S and electrical safety-related work practices)
74. Slide 75

    Locked Out?????????

75. Slide 76

    Lockout vs. Tagout

    • If capable of being locked out:
    • Prefer lockout
    • Tags allowed, if employer can demonstrate FULL EMPLOYEE PROTECTION
    • Machine Modifications
76. Slide 77

    Full employee protection?

    • Tags attached at the same location as locks
    • Full compliance with all tagout provisions in 29 CFR 1910.147
    • Additional means when necessary (e.g. removal of a valve handle)
77. Slide 78

    Energy control procedure

    • Notification of employees
    • Preparation for shutdown
    • Machine or equipment shutdown
    • Machine or equipment isolation
    • Lockout/tagout device application
    • Stored energy
    • Verification of isolation
    • Release from lockout/tagout
78. Slide 79

    Periodic Inspection

    • Performed at least annually
    • Lockout – include review with authorized employees
    • Tagout – include review with authorized and affected employees
    • Certification record kept:
    • Identify machine or equipment
    • Date of inspection
    • Employees performing and included in inspection
79. Slide 80

    Training and re-training

    • Authorized employees
    • Recognition of hazardous energy
    • Type and magnitude of hazardous energy
    • Methods of isolating energy
    • How to verify isolation
    • Affected – Purpose and use of procedure
    • Other – Procedure and Prohibition from tampering
    • Tagout provisions
80. Slide 81

    Re-training is required when:

    • Change in job assignment
    • Change in machine or process
    • Change in lockout/tagout procedure
    • Inadequacies revealed in periodic review
81. Slide 82

    Training certification

    • Certify that the training has been conducted and kept up to date:
    • Employee names
    • Date(s) of training
82. Slide 83

    Testing or positioning machines

    • Clear the machine of tools and materials
    • Remove employees from the area
    • Remove lockout/tagout devices
    • Energize and proceed with testing/positioning
    • De-energize and re-apply energy control measures
83. Slide 84

    Group lockout

    • Personal lock or tag (usually)
    • Lockbox or master tag system with principal authorized employee
    • “Shall utilize a procedure which affords a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device”
84. Slide 85

    Minor Servicing Exemption

    • Activities which are routine, repetitive, and integral to the use of the equipment for production are not covered by this standard if alternative measures provide effective protection.
    • Activity must be conducted during normal production operations
    • Activity must be routine (regular course of procedure in accordance with established practices), repetitive (regularly repeated as part of production), and integral (essential to the production process).
85. Slide 86
    • Machine Guarding etool