Machine Guarding: Lesson Plan (OSHA 10-Hour General Industry Outreach)

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1. Page 1

   IDENTIFICATION

   • TOPIC T ITLE: _Machine Guarding
   • MINIMUM TIME: __30 minutes
   • OBJECTIVES
   • Terminal Objective:
   • Given current OSHA and industry information regarding general industry worksite illnesses, injuries, and/or fatalities, the student will be able to recognize hazards associated with machinery that has improper or missing guard.
   • Enabling 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.
   • INSTRUCTOR MATERIALS AND RESOURCES
   • PowerPoint presentation: Machine Guarding
   • Knowledge Check Answer Key: Machine Guarding
   • STUDENT MATERIALS
   • OSHA Fact Sheet: Amputations
   • Knowledge Check: Machine Guarding
   • NOTE: This lesson plan contains more content than what can likely be covered in a 30-minute presentation. Adjust coverage of specific machinery to the needs of the audience.
2. Page 2

   Crushed fingers or hands

   • TEACHING PROCEDURES ---Preparation, Presentation, Application, Evaluation
   • Anticipatory Set (Focus Attention/ Gain I nterest)
   • Estim ated Tim e: 5 m inutes
   • Key Points
   • Methods
   • Moving machine parts can cause severe injuries
   • Amputations
   • Burns
   • Blindness
   • Safeguards are essential
   • Any machine part, function, or process that may cause injury must be safeguarded
   • OSHA has a special emphasis program to identify and reduce workplace machinery and equipment hazards which are causing or likely to cause amputations.
   • Review learning objectives
   • Introduction
   • Slides #1- #3
   • National Emphasis Program on Amputations*. CPL 03-00-019, (August 13, 2015).
   • P resentation (I nstruction)___
   • Estim ated Tim e: ?? hours
   • I.
   • Main causes of machinery accidents
   • Instructor-led discussion
   • A. Examples of ways machine accidents could occur
   • Slides #4 - #5
   • Key Points
   • Methods
   • 1. Reaching-in to “clear” equipment
   • 2. Not using LOTO
   • 3. Unauthorized persons performing maintenance or using the machines
   • 4. Missing or loose machine guards.
   • B. Amputations occur most often in the following situations
   • 1. Operating unguarded or inadequately safeguarded machinery https://www.osha.gov/Publications/amputationsqc.html
   • 2. Materials handling, including during use of forklifts, compactors, powered and non-powered hand tools
3. Page 3
   • 3. During activities involving stationary machines
   • a. Setting-up
   • b. Threading
   • c. Preparing
   • d. Adjusting
   • e. Cleaning
   • f. Lubricating
   • g. Maintaining
   • h. Clearing jams
   • II. Basic machinery parts and hazards
   • Slides #6 - #19
   • A. All machines consist of three fundamental areas
   • 1. Point of operation
   • a. Where work is performed on material https://www.osha.gov/SLTC/etools/machineguarding/intro.html
   • b. Examples – cutting, shaping, boring, forming
   • 2. Power transmission device
   • a. Parts that transmit energy to the part of the machine performing work
   • b. Examples – flywheels, pulleys, belts, connecting rods, couplings, cams, spindles, chains, cranks, gears
   • 3. Operating controls
   • B. Other moving parts
   • 1. All parts of the machine which move while the machine is working
   • 2. Examples
   • a. Reciprocating, rotating, and transverse moving parts
   • b. Feed mechanisms and auxiliary machine parts
   • C. Hazardous motions and actions
   • 1. Motions
   • https://www.osha.gov/SLTC/etools/machineguarding/motions_actions.html
   • a. Rotating
   • b. In-running nip points
   • c. Reciprocating
   • d. Transversing
4. Page 4
   • 2. Actions
   • a. Cutting
   • b. Punching
   • c. Shearing
   • d. Bending
   • III. Workplace situations with machinery that requires guarding
   • Slide #20 - #25
   • A. Machinery requiring point of operation guarding
   • 1. Guillotine cutters
   • 2. Shears
   • 3. Alligator shears
   • 4. Power presses
   • 5. Milling machines
   • 6. Power saws
   • 7. Jointers
   • 8. Portable power tools
   • 9. Forming rolls and calenders
   • B. Guarding requirements for machinery
   • 1. Fan blades
   • 2. Abrasive wheels – 29 CFR 1910.215
   • 3. Revolving barrels, containers, and drums
   • 4. Power-transmission apparatus
   • C. Sources of amputations
   • 1. Machinery ranked from those with most amputations to fewer:
   • a. Mechanical power presses
   • b. Power press breaks
   • c. Powered and non-powered conveyors
   • d. Printing presses
   • e. Roll-forming and roll-bending machines
   • f. Shearing machines
   • g. Food slicers
5. Page 5
   • h. Meat grinders
   • i. Meat-cutting band saws
   • j. Drill presses
   • k. Milling machines
   • l. Grinding machines
   • m. Slitters
   • 2. Targeted industries with high amputation rates – see list in CPL 03-00-019
   • IV. Requirements for safeguards
   • Slide #26
   • A. Prevent contact
   • B. Secure
   • C. Protect from falling objects
   • D. Create no new hazards
   • E. Create no interference
   • F. Allow safe lubrication
   • V. Types of machine guards
   • Slides #27 - #46
   • A. Guards
   • 1. Barriers which prevent access to danger areas
   • 2. Four general types
   • https://www.osha.gov/SLTC/etools/machineguarding/guards.html
   • a. Fixed
   • b. Interlocked
   • c. Adjustable
   • d. Self-adjusting
   • B. Devices
   • 1. Perform one of several functions:
   • a. Stop the machine if a hand or any part of the body is inadvertently placed in the danger area;
   • https://www.osha.gov/SLTC/etools/machineguarding/devices.html
   • b. Restrain or withdraw the operator’s hands from the danger area during operation;
   • c. Require the operator to use both hands on machine controls, thus keeping both hands and body out of danger; or
6. Page 6
   • d. Provide a barrier which is synchronized with the operating cycle of the machine in order to prevent entry to the danger area during the hazardous part of the cycle.
   • 2. Examples of devices
   • a. Presence-sensing device
   • i. Photoelectric (optical)
   • ii. Radiofrequency (capacitance)
   • iii. Electromechanical
   • b. Pullback
   • c. Restraint (holdback)
   • d. Safety trip controls (pressure-sensitive body bar, safety tripod, safety tripwire)
   • e. Two-hand control
   • f. Two-hand trip
   • g. Gate
   • C. Additional Safeguarding
   • 1. Location/distance
   • 2. Feeding and ejection methods
   • 3. Miscellaneous aids
   • a. Awareness barriers
   • b. Protective shields
   • c. Hand-feeding tools
   • Application (How students apply w hat they learn) __
   • Estim ated Tim e: ?? hours
   • View slides so that students can identify hazards being illustrated.
   • Slides #47 - #48
   • Key Points
   • Methods
7. Page 7

   Evaluation/ Sum m ary

   • Key Points
   • Methods
   • Summarize key points
   • Slide #49
   • Knowledge check
   • Slides #50 - #54
   • R eferences
   • OSHA Standard
   • 1910 Subpart O - Machinery and Machine Guarding
   • 1910.211 - Definitions.
   • 1910.212 - General requirements for all machines.
   • 1910.213 - Woodworking machinery requirements.
   • 1910.214 - Cooperage machinery. [Reserved]
   • 1910.215 - Abrasive wheel machinery.
   • 1910.216 - Mills and calenders in the rubber and plastics industries.
   • 1910.217 - Mechanical power presses.
   • 1910.217 App A - Mandatory requirements for certification/validation of safety systems for presence sensing device initiation of mechanical power presses
   • 1910.217 App B - Nonmandatory guidelines for certification/validation of safety systems for presence sensing device initiation of mechanical power presses
   • 1910.217 App C - Mandatory requirements for OSHA recognition of third-party validation organizations for the PSDI standard
   • 1910.217 App D - Nonmandatory supplementary information
   • 1910.218 - Forging machines.
   • 1910.219 - Mechanical power-transmission apparatus.
   • OSHA Publications
   • Amputation Fact Sheet (2002) (English: PDF*)
   • Amputation: Preventing Cuts and Amputations from Food Slicers and Meat Grinders Fact Sheet
   • (OSHA FS 3794 - 2015) (English: PDF*)
   • Amputations QuickCard ™ (OSHA 3204 - 2015) (English: PDF*)
   • Amputations: Safeguarding Equipment and Protecting Employees from Amputations
   • (OSHA 3170 - 2007) (English: HTML PDF*)
   • Hazards Associated with Hand-Feeding Bar Straightening Machines
   • (2004, May 20) (English: HTML PDF*)
   • Hazards Associated with the "Unintended (Double) Cycling" of Mechanical Power Presses
   • (2010, February 2) (English: HTML PDF*)
8. Page 8

   Limitations of Radiofrequency Presence Sensing Devices

   • (1987, September 21) (English: HTML)
   • Potential Hazards Associated with the Use of Replacement Materials for Machine Guarding
   • (2000, June 23) (English: HTML HTML)
   • OSHA References/Resources
   • Machine Guarding eTool (2007) https://www.osha.gov/SLTC/etools/machineguarding/index.html
   • Workbench Grinder Wheel Explodes , video (2005) https://www.osha.gov/video/shipyard_accidents/07_improper_equipment_use.html