Machine Guarding (OSHA 10-Hour General Industry Outreach)

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1. Slide 1

   Machine Guarding

   • OSHA 10-hour Outreach Training
   • General Industry
2. Slide 2

   Introduction

   • Possible machinery-related injuries include:
   • Crushed fingers or hands
   • Amputations
   • Burns
   • Blindness
   • A good rule to remember is:
   • Any machine part, function, or process which may cause injury must be safeguarded.
3. Slide 3

   Introduction

   • Lesson objectives:
   • 1. Identify the main causes of machinery accidents.
   • 2. Recognize basic machinery parts that expose workers to hazards.
   • 3. Recognize workplace situations involving machinery that requires guarding.
   • 4. Identify the requirements for safeguards.
   • 5. Identify types of machine guards including types of devices used to safeguard machines.
4. Slide 4

   Machinery Accidents

   • Examples of how machine accidents can occur:
   • Reaching-in to “clear” equipment
   • Not using Lockout/Tagout
   • Unauthorized persons doing maintenance or using the machines
   • Missing or loose machine guards
5. Slide 5

   Machinery Accidents

   • Amputations:
   • Unguarded/inadequately safeguarded machinery
   • Materials handling activities
   • Activities involving stationary machines
   • Source: OSHA
6. Slide 6

   Basic Machinery Parts and Hazards

   • Three fundamental machine areas:
   • Point of operation
   • Power transmission device
   • Operating controls – mechanical or electric power control
   • Source: OSHA
7. Slide 7

   Basic Machinery Parts and Hazards

   • Point of operation:
   • Where work is performed on material
   • Examples
   • Cutting
   • Shaping
   • Boring
   • Forming
   • Source: OSHA DTE
8. Slide 8

   Basic Machinery Parts and Hazards

   • Power transmission device:
   • Parts that transmit energy to the part of the machine performing work
   • Examples
   • Flywheels
   • Pulleys
   • Belts
   • Connecting rods
   • Couplings
   • Cams
   • Spindles
   • Chains
   • Cranks
   • Gears
9. Slide 9

   Basic Machinery Parts and Hazards

   • Hazardous motions and actions:
   • Motions
   • How the machine part moves
   • Examples: rotating, in-running nip points, reciprocating, and transversing
   • Actions
   • Operation that the machine part performs
   • Examples: cutting, punching, shearing, bending
10. Slide 10

    Basic Machinery Parts and Hazards

    • Rotating parts with hazardous projections
    • Source of graphics: OSHA
11. Slide 11

    Basic Machinery Parts and Hazards

    • Common nip points on rotating parts
    • Source of graphics: OSHA
12. Slide 12

    Basic Machinery Parts and Hazards

    • Nip points between rotating elements and parts with longitudinal motions
    • Source of graphics: OSHA
13. Slide 13

    Basic Machinery Parts and Hazards

    • Nip points between rotating machine components
    • Source of graphics: OSHA
14. Slide 14

    Basic Machinery Parts and Hazards

    • Reciprocating motions:
    • Back-and-forth
    • Up-and-down
    • Source: OSHA
15. Slide 15

    Basic Machinery Parts and Hazards

    • Transverse motion – movement in straight, continuous line
    • Source of graphics: OSHA
16. Slide 16

    Basic Machinery Parts and Hazards

    • Cutting action – may involve rotating, reciprocating, or transverse motion
17. Slide 17

    Basic Machinery Parts and Hazards

    • Punching action – power applied to a slide (ram) for purpose of blanking, drawing, or stamping metal or other materials
18. Slide 18

    Basic Machinery Parts and Hazards

    • Shearing action – applying power to a slide or knife in order to trim or shear metal or other materials.
19. Slide 19

    Basic Machinery Parts and Hazards

    • Bending action – applying power to draw or stamp metal or other materials
    • Source: OSHA
20. Slide 20

    Machinery That Requires Guarding

    • Machines that require point of operation guarding:
    • Guillotine cutters
    • Shears
    • Alligator shears
    • Power presses
    • Milling machines
    • Power saws
    • Jointers
    • Portable power tools
    • Forming rolls and calenders
    • Source of graphics: OSHA
21. Slide 21

    Machinery That Requires Guarding

    • Exposure of fan blades:
    • Guard when periphery of blades is less than 7’ above the floor or working level
    • Guards with openings no larger than ½”
    • Source of graphics: OSHA
22. Slide 22

    Machinery That Requires Guarding

    • Abrasive wheel machinery:
    • Adjustable tongue guard to within ¼” of wheel
    • Work rest with maximum opening of 1/8”
    • Cover spindle end, nut, flange projections
    • Source of graphics: OSHA
23. Slide 23

    Machinery That Requires Guarding

    • Revolving barrels, containers, and drums:
    • Guard by an enclosure which is interlocked with drive mechanism
    • Guards with openings no larger than ½”
24. Slide 24

    Machinery That Requires Guarding

    • Power-transmission apparatus:
    • Unguarded belt and pulley
    • Shafting, flywheels, pulleys, belts, chain drives, etc.
    • Less than 7 feet from the floor or working platform must be guarded
    • Source: OSHA
25. Slide 25

    Machinery That Requires Guarding

    • Machinery associated with amputations – examples:
    • 1. Mechanical power presses
    • 2. Power press breaks
    • 3. Powered and non-powered conveyors
    • 4. Printing presses
    • 5. Roll-forming and roll-bending machines
    • 6. Shearing machines
    • 7. Food slicers
    • 8. Meat grinders
    • 9. Meat-cutting band saws
    • 10. Drill presses
    • 11. Milling machines
    • 12. Grinding machines
    • 13. Slitters
    • Source of graphics: OSHA
26. Slide 26

    Requirements for Safeguards

    • Safeguards must meet these minimum general requirements:
    • Prevent contact
    • Be secured
    • Protect from falling objects Create no new hazards Create no interference Allow safe lubrication
    • Source: OSHA
27. Slide 27

    Types of Machine Safe Guards

    • Safeguarding machinery:
    • Primary methods
    • Guards
    • Devices
    • Ensure employee protection
    • Properly designed, constructed, and installed
    • Used and maintained in good operating condition
28. Slide 28

    Types of Machine Safe Guards

    • Secondary methods
    • Probe detection and safety edge devices
    • Awareness devices
    • Safeguarding methods
    • Safe distance
    • Safe holding
    • Safe opening
    • Safe work practices
    • Safe work procedures
    • Complementary equipment
29. Slide 29

    Types of Machine Safe Guards

    • Guards:
    • Preferable to other control methods
    • Provide physical barrier that prevents contact with dangerous machine parts
    • Four general types
    • Fixed
    • Interlocked
    • Adjustable
    • Self-adjusting
    • Source: OSHA
30. Slide 30

    Types of Machine Safe Guards

    • Fixed guard:
    • Provides a barrier
    • Permanent part of the machine, preferable to all other types of guards.
    • Source of photos: OSHA
31. Slide 31

    Types of Machine Safe Guards

    • Interlocked guards:
    • Shuts off or disengages power, stops moving parts, and prevents starting of machine when guard is open
    • May use electrical, mechanical, hydraulic, or pneumatic power, or combination
    • Source: OSHA
32. Slide 32

    Types of Machine Safe Guards

    • Adjustable guards:
    • Shuts off or disengages power
    • Stops moving parts
    • Prevents starting of machine when guard is open
33. Slide 33

    Types of Machine Safe Guards

    • Self-adjusting guards:
    • Openings of barriers determined by movement of the stock
    • Places barrier between danger area and operator
    • Source: OSHA
34. Slide 34

    Types of Machine Safe Guards

    • Devices:
    • Controls or attachments that prevent inadvertent access by employees to hazardous machine areas
    • Examples
    • Safety trip controls
    • Presence sensing
    • Photoelectric
    • Radiofrequency
    • Electromechanical
    • Two-hand control
    • Two-hand trip
    • Gate
    • Pullback
    • Restraint
35. Slide 35

    Types of Machine Safe Guards

    • Presence-sensing devices:
    • Photoelectric
    • Radiofrequency
    • Electromechanical
36. Slide 36

    Types of Machine Safe Guards

    • Pullback devices:
    • Utilize a series of cables attached to operator
    • Automatically withdraws hands from point of operation when slide/ram begins to descend
    • Source: OSHA
37. Slide 37

    Types of Machine Safe Guards

    • Source: OSHA
    • 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
38. Slide 38

    Types of Machine Safe Guards

    • Restraint devices:
    • Utilize cables/straps attached to operator’s hands and a fixed point
    • No extending/retracting action involved
    • Hand-feeding tools may be necessary
    • Source of graphics: OSHA
39. Slide 39

    Types of Machine Safe Guards

    • Safety trip controls:
    • Deactivates the machine in an emergency situation
    • Examples
    • Pressure-sensitive bar
    • Safety tripod
    • Safety tripwire
    • Positioning is critical; must stop machine before body reaches danger area
    • Source of graphics: OSHA
40. Slide 40

    Types of Machine Safe Guards

    • Two-hand controls:
    • Deactivates the machine in an emergency situation
    • Pressure-sensitive
    • Positioning is critical; must stop machine before body reaches danger area
    • Source of graphics: OSHA
41. Slide 41

    Types of Machine Safe Guards

    • Gate devices:
    • Moveable barrier that protects operator at point of operation before machine cycle can be started
    • Must be interlocked so machine cannot begin cycle unless gate guard is in place
    • Must be closed before machine can function
    • Types
    • “A” Gate
    • “B” Gate
42. Slide 42

    Types of Machine Safe Guards

    • Gate Open
    • Gate devices:
    • Moveable barrier that protects operator at point of operation before machine cycle can be started
    • Must be interlocked so machine cannot begin cycle unless gate guard is in place
    • Must be closed before machine can function
    • Gate Closed
    • Source of graphics: OSHA
43. Slide 43

    Types of Machine Safe Guards

    • Type “A” Gate Operation
    • Type “B” Gate Operation
    • Source of graphics: OSHA
44. Slide 44

    Additional Safeguarding

    • Location/distance:
    • The dangerous moving part of a machine must be so positioned that those areas are not accessible or do not present a hazard
    • Feeding process safeguarded by maintaining safe distance to protect worker
    • Operator’s controls located safe distance from machine
    • Source: OSHA
45. Slide 45

    Additional Safeguarding

    • Feeding and ejection methods:
    • Automatic/ semi-automatic feed
    • Automatic/ semi-automatic ejection
    • Robots
    • Transp arent
    • Enclos
    • ure
    • Stock
    • Feed
    • Guard
    • Roll
    • Complete d Work
    • Source of graphics: OSHA
46. Slide 46

    Additional Safeguarding

    • Miscellaneous aids:
    • Awareness barriers
    • Protective shields
    • Hand-feeding tools
    • Source of graphics: OSHA
47. Slide 47

    Identify the Hazard

    • Unguarded lower blade and arbor end of radial saw.
48. Slide 48

    Identify the Hazard

    • Guard removed from chain rail exposing pins on the spiked chain and sprocket mechanism.
49. Slide 49

    Summary

    • Safeguards are essential for protecting workers from needless and preventable machinery-related injuries
    • The point of operation, as well as all parts of the machine that move while the machine is working, must be safeguarded
    • A good rule to remember is:
    • Any machine part, function, or process which may cause injury must be safeguarded
50. Slide 50

    Knowledge Check

    • 1. All machines consist of three fundamental areas, including __.
    • a. Flywheels, connecting rods, and transverse moving parts
    • b. Point of operation, power transmission device, and operating controls
    • c. Reciprocating parts, rotating parts, and on/off switch
    • d. Feed mechanisms, auxiliary machine parts, and nip points
    • Answer: b. point of operation, power transmission device, and operating controls
51. Slide 51

    Knowledge Check

    • 2. Rotating, in-running nip points, reciprocating, and transversing are types of hazardous ___.
    • a. motions
    • b. actions
    • c. guards
    • d. devices
    • Answer: a. motions
52. Slide 52

    Knowledge Check

    • 3. Cutting, punching, shearing, and bending are types of hazardous ___.
    • a. motions
    • b. actions
    • c. guards
    • d. devices
    • Answer: b. actions
53. Slide 53

    Knowledge Check

    • 4. Which of the following explains how a guard protects workers?
    • a. Stops the machine when a worker enters the danger area
    • b. Restrains the worker from entering the danger area
    • c. Creates distance to keep the worker from entering the danger area
    • d. Provides a barrier to prevent access to the danger area
    • Answer: d. Provides a barrier to prevent access to the danger area
54. Slide 54

    Knowledge Check

    • 5. Which of the following is an example of a safeguarding device?
    • a. Protective shield
    • b. Hand-feeding tool
    • c. Safety trip control
    • d. Awareness barrier
    • Answer: c. Safety trip control