Machine Safety

Department of Labor and Employment
OCCUPATIONAL SAFETY AND HEALTH CENTER
MACHINE SAFETY
BASIC OCCUPATIONAL SAFETY AND HEALTH TRAINING
SAFETY CONTROL DIVISION
OBJECTIVES
1. Identify causes and effects of

machine related accidents
2. Enumerate ways of machine
safeguarding
3. Explain the LOTO system
WHAT IS A MACHINE?
• An assemblage
of parts that
transmit forces,
motion and
energy in a
predetermined
manner.
• Can be simple or
compound
Department of Labor and Employment 3
MACHINE SAFETY
Safeguarding any machine part that may

cause injury. It is the prevention of
accidents when working with machines.
IMPORTANCE OF MACHINE
SAFETY
Prevents:
• Loss of life
• Severe accidents or serious injury
• Loss of production
• Equipment damage and repairs
• Possible litigation
• Having time spent on accident investigation
and other statutory requirements.
CAUSES OF MACHINE RELATED
ACCIDENTS
1. An individual making unwanted contact

with a moving part of a machine
2. Something flying from the machine
3. A machine malfunction, including
mechanical and electrical energy sources
failure.
4. Workpiece movement during a forming or
cutting process
EFFECTS OF MACHINE
RELATED ACCIDENTS
• Can result to severe

injuries
• Loss of trained and
skilled employee
• Loss in productivity
• Damaged equipment
WHERE MECHANICAL
HAZARDS OCCUR
WHERE MECHANICAL
HAZARDS OCCUR
Power transmission apparatus:
• All components of the mechanical
system that transmit energy to the
part of the machine performing the
work.
• These components include flywheels,
pulleys, belts, connecting rods,
couplings, cams, spindles, chains,
sprockets, cranks, and gears.
WHERE MECHANICAL
HAZARDS OCCUR
The point of operation:
• That point where work is performed on
the material, such as cutting, shaping,
boring, or forming.
Other moving parts:

• All parts of the machine which move
while the machine is working.
HAZARDOUS MECHANICAL
MOTIONS
• Rotating – turning around
on an axis or center
• Reciprocating – the back
and forth movements of a
machine part
• Transversing –
continuous straight line
motion of a machine
element in either direction
HAZARDS ASSOCIATED WITH
ROTATING MOTIONS
Rotating shaft and

Rotating coupling with pulley with projecting
projecting bolt key and set screw
Rotating pulley with

spokes and projecting
burr
3 TYPES OF IN‐RUNNING NIP POINTS
• Parallel axes ‐ Parts can rotate in
opposite directions while their axes
are parallel to each other.
• Tangential ‐ Nip points are also NIP POINT
created between rotating and NIP POINT
tangentially moving parts such as belt
and pulley and chains and sprocket.
• Rotating and Fixed Part ‐ Such as
screw conveyor, flywheels, abrasive FIXED PART
(grinding) wheel.
NIP POINT
PINCH POINT/NIP POINT HAZARDS
(EXAMPLES)
Rotating Parts in Opposite
Direction
Between Rotating Part and

Tangentially Moving Part
Between a Rotating Part

and Fixed Parts
HAZARDS ASSOCIATED WITH
ROTATING MOTIONS
Other Hazards from Rotating Parts
• “caught by”
• flying particles
• sparks
HAZARDOUS MECHANICAL MOTIONS
Reciprocating Motions
• Punching - The danger of
this type of action occurs at
the point of operation where
stock is inserted, held and
withdrawn by hand.
OCCUPATIONAL SAFETY AND HEALTH CENTER 16
• Shearing - involves applying

power to a slide or knife in
order to trim or shear metal or
other materials.
• Bending - Bending action

results when power is applied
to a slide in order to draw
stamp metal or materials.
Hazards of Reciprocating
Parts of Machines
Cutting - May involve

rotating, reciprocating,
or transverse motions
such as milling and
lathe machines.
MACHINE GUARDS
• Guards are barriers that prevent

entry of an individual’s hands or
other body parts into a hazard
area.
• Installed to minimize the risk of
injury to machine operators or
other persons from hazardous
machine parts, materials being
processed, or scrap.
REQUIREMENTS FOR MACHINE
GUARDS
• Prevent employee contact with
hazardous moving parts
• Secured and durable
• Prevent falling materials into
moving parts
• Create no new hazards
• Must not interfere with worker
productivity
• Should allow for proper and safe
maintenance and lubrication
CATEGORY OF MACHINE
GUARDS
• Preventing Access • Preventing
– Fixed enclosing Dangerous Motion
guards – Photoelectric light
– Movable Guards with curtains/Presence
interlocking switches sensing device
– Adjustable Guards – Two hand controls
• Manually adjustable – Pullback devices
• Self-adjusting – Restraint device
PREVENTING ACCESS
Fixed enclosing guards

• This type of guard is attached to a
fixed surface and encloses the
hazard. When in place, it prevents
anyone from going over, around,
under or through it to the hazard.
• The principal advantage of the fixed

enclosing guard is that it always
prevents access to the hazard area.
PREVENTING ACCESS
Movable guards w/ interlocking switches
Prevents machine motion until the guard is moved into
place. The interlocking method may be mechanical,
electrical, pneumatic, or a combination of these.
To be effective, interlocking guards must:
1.Enclose the point of operation before the machine
can be operated.
2. Keep the point of operation enclosed before the
hazardous part of the machine motion ceases.
3. Prevent operation of the machine if the interlock
fails.
PREVENTING ACCESS
Adjustable Guards
• This type of guard can be positioned to
accommodate a variety of operations or work
and when properly adjusted provides
adequate protection from the hazard at the
point of operation.
• Adjustment of the guard should only be
performed during setup.
Self-Adjusting Guard
• Provides a barrier which moves according to
the size of the stock entering the danger area.
PREVENTING DANGEROUS
MOTION
Safety Device - Any mechanical or electrical
devices designed to protect a worker’s hands
or other body parts from coming into contact
with a hazardous motion of a machine.
Presence Sensing Device – A safety device

which is designed, constructed, and arranged
to create a sensing field, area, or plane that
will detect in its field the presence of an
opaque object.
MOTION
Photo Electric Light Curtain
• These devices emit a
“curtain” of harmless infrared
light beams in front of the
hazard area.
•When any of the beams are
blocked the light curtain
control circuit sends a stop
signal to the guarded
machine.
MOTION
MOTION
• Pressure sensitive • Pressure sensitive
safety mats edges
MOTION
Two-Hand Controls
• Two- hand controls are
operator controls that
require an operator to
hold both controls down
during the hazardous
portion of the machine’s
stroke.
MOTION
Restraint devices
•Uses cables or straps
attached to the
operator’s hands and a
fixed point
•Must be adjusted to let
the operator’s hands
travel within a
predetermined safe
area.
MOTION
Pullback devices
•Holdout and restraint devices
are cable and wristlet systems
that attach to an operator’s
hands and to the machine’s
moving slide or ram, or to a
fixed object away from the point
of operation. They are usually
used on machines having
reciprocating motions.
EMERGENCY STOPS
• Emergency stop buttons
• Grabwire switches
PROTECTIVE SHIELDS
• Provides some protection from flying particles,

splashing cutting oils or coolants
HOLDER, JIGS, PUSH STICKS
THE HIERARCHY OF CONTROL
MEASURES
ENGINEERING CONTROL
• Fixed enclosing guards
• Movable (interlocked) guards or protection
devices
• Protection appliances/other safety devices.
ADMINISTRATIVE CONTROLS
• Provision of information, procedure, instruction,
training & supervision
• Lockout/Tagout Procedure
• Signs
PERSONAL PROTECTIVE EQUIPMENT
CONTROL OF ALL ENERGY
SOURCES THROUGH
LOCKOUT/TAGOUT SYSTEM
MAIN CAUSES OF MAINTENANCE
INJURIES “FATAL FIVE”
• Failure to stop equipment

• Failure to disconnect from
power source
• Failure to dissipate (bleed,
neutralize) residual energy
• Accidental restarting of
equipment
• Failure to clear work areas
before restarting
SOURCE OF HAZARDOUS ENERGY
• Electrical – the uncontrolled current

and voltage in electrical circuits
• Mechanical – exposed crushing or
cutting parts of equipment or loose
parts
• Thermal – such as steam or due to
chemical reaction
• Potential - stored energy that may
be due to gravity, hydraulics,
pneumatics, vacuum or springs
ISOLATION OF HAZARDOUS
ENERGY
BASIC CONCEPT
• Each worker who can be
exposed to unexpected
energization or start-up of
equipment, or release of
stored energy is protected
by an isolation device which
is under his personal
control.
LOCK-OUT/TAG-OUT SYSTEM
(LOTO)
• The standard for the
control of hazardous
energy sources which
covers maintenance
of machines in which
the unexpected start
up of machines or
release of stored
energy could cause
injury to employees.
LOCK-OUT DEVICES
• Lockout device
– device that utilizes a
positive means such as a
lock to hold an energy
isolating device in the safe
position and prevents the
energizing of an
equipment.
– Included are blank flanges
TYPES OF LOCK-OUT DEVICES
• Plug Locks
• Ball Valve Lock-out
• Gate Valve Lock-out
• Group Lock-out or
Hasp
• Circuit Breaker Lockout
• Blanks for Hydraulic,
pneumatic and other
pressurized systems
TAG-OUT DEVICES
Tagout device
– A warning device, such as a tag and
a means of attachment
– Can be securely fastened to an
energy isolating device in
accordance with an established
procedure to indicate that the energy
isolating device and the equipment
being controlled can not be operated
until the tag is removed.
WHO ARE INVOLVED IN LOTO
PROCEDURE?
Authorized Employee
• An employee who locks or tags machines or
equipment to perform maintenance or
servicing.
Affected Employee
•An employee whose job requires him/her to
operate or work in an area where servicing is
being performed under Lockout/Tagout.
TYPICAL LOTO PROCEDURE
1. NOTIFY:
Notify all affected employees that
servicing or maintenance is required
on an equipment and that it must be
shut down and locked out.
2. IDENTIFY:
The authorized employee shall
identify the type, sources and
magnitude of the energy that the
equipment utilizes, shall understand
the hazards of the energy, and shall
know the methods to control the
energy.
3. SHUT-DOWN:
If the equipment is operating, shut it down by the
normal stopping procedure.
4. ISOLATE:
De-activate the energy isolating device(s) so that the
equipment is isolated from the energy source(s).
5. LOCK-OUT:
Lock out the energy isolating device(s) with assigned
individual lock(s) . Place a tag-out.
6. VERIFY:
Stored or residual energy (such as that in
capacitors, springs, elevated machine
members, rotating flywheels, hydraulic
systems, and air, gas, steam, or water
pressure, etc.) must be dissipated or
restrained.
Verify the isolation of the equipment by

operating the push button or other normal
operating control(s) or by testing to make
certain the equipment will not operate.
APPLICATION OF THE LOCK-OUT
• For multiple energy

sources, apply one padlock
for each safety disconnect
device.
• One padlock per person

per equipment.No one is
authorized to remove
another’s padlock while the
person who owns the pad-
lock is on site.
CONCLUSION
 0% energy, 100% safety.

 A twist of the key could keep you accident
free.
 Play it safe from head to toe;
Off for fixing, on for go.
 A machine will bite with all its might.
So put a lock on its appetite.
Thank you for listening!
MACHINE SAFETY PROGRAM
An effective Machine Safety Program must have the
following:
• Equipment/Machine inspection and maintenance program.
• Installation of safety devices (guards, relief valves, provision
for LOTO, interlocks, limit switches, etc)
• Compliance to regulatory requirements and standards (e.g.
mechanical permits, OSHS, etc)
• Implementation of LOTO system.
• Having a machine operation and safety procedures.
• Machine alarm and warning signal system.
• Equipment/machine safety signages.
• Application of Job hazard Analysis
SUMMARY
• Machine safety is preventing access to

dangerous motions or preventing dangerous
motions to access.
• Machine safeguarding is generally

accomplished by the use of machine guards
and safety devices.
• The lockout/tagout system is an effective safety

program when performing maintenance activity.
BASIC OCCUPATIONAL SAFETY AND HEALTH TRAINING
SAFETY CONTROL DIVISION

Machine Safety

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Department of Labor and Employment

1. Identify causes and effects of

Safeguarding any machine part that may

1. An individual making unwanted contact

• Can result to severe

Other moving parts:

Rotating shaft and

Rotating pulley with

created between rotating and NIP POINT

Between Rotating Part and

Between a Rotating Part

• Shearing - involves applying

• Bending - Bending action

Cutting - May involve

• Guards are barriers that prevent

Fixed enclosing guards

• The principal advantage of the fixed

Presence Sensing Device – A safety device

• Emergency stop buttons

• Provides some protection from flying particles,

• Failure to stop equipment

• Electrical – the uncontrolled current

Verify the isolation of the equipment by

• For multiple energy

• One padlock per person

 0% energy, 100% safety.

• Machine safety is preventing access to

• Machine safeguarding is generally

• The lockout/tagout system is an effective safety

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