Machinery

Safety
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Machine Guarding for Warehouse and

Maintenance Workers
This material was produced and revised
(using information from OSHAs website, publications and CDC website) under grant
[SH20856SH0] 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
 The Problem
Workers who operate and maintain
machinery each year suffer
approximately
18,000 amputations, lacerations, crushing
injuries, and abrasions
800 deaths

OSHA 7100
2
 The Problem: Machinery
Associated with Amputations
1. Mechanical power presses
2. Power press brakes
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
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 Causes of Machine Incidents
Reaching in to clear equipment
Not using Lockout/Tagout
Unauthorized person doing
maintenance or using the machines
Missing or loose machine guards
Lack of training

4
 Prevention
Any machine part, function, or process
which may cause injury must be
safeguarded.
Where the operation of a machine can
injure the operator or other workers, the
hazard must be controlled or eliminated

5
 OSHA Citations
Fiscal Year 2010
Machines, general requirements
(1910.212)
10th most frequently cited standard
5th ranked standard in assessed penalties
Lockout/Tagout (1910.147)
5th most frequently cited standard
4th ranked standard in assessed penalties

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Machine Guarding

OSHAs 1910 Subpart O

 Objectives
Explain the general requirements for
guarding the hazards of machines
Describe precautions to be taken
around machinery
Identify important terms associated with
guarding machinery

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Machine Guarding

Group Worksheet

9
 3 Basic Areas To Be
Safeguarded
Point of Operation
Power Transmission Apparatus
Other Moving Parts

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 Hazard Identification
Motions Actions
Rotating (including in- Cutting
running nip points) Punching
Transverse Shearing
Reciprocating Bending

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 Rotating Motion
Hazard Danger increases
Machinery grips when projections
and moves are present
clothing, hair and Screws, bolts,
body parts into nicks, abrasions,
danger area etc.

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Rotating Parts with Projections

BURR Rotating shaft and pulleys with

projecting key and set screw

Rotating pulley with spokes and

projecting burr on face of pulley Rotating coupling with
projecting bolt heads
OSHA 3067
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 In-Running Nip Points
Nip Point

Nip Point

Nip Point

Nip Point
Nip Point Nip Point

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OSHA 3067
In-Running Nip Points

Nip Points

Nip Point
Nip Point

Nip Point OSHA 3067 15

 Transverse Motion
Movement in a straight, continuous line
around rotating component
Hazard may strike or catch employee a
pinch or shear point

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OSHA 3067
 Reciprocating Motion
Back and forth / up and down
Hazard - Caught between moving part
and stationary object

OSHA 3067 17
 Bending Actions
Power applied to
slide to draw or
stamp metal or other
materials in a
bending motion
Example: Press
Brake, Tube
Benders

OSHA 3067 18
Bending Actions
Press Brake

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 Punching Actions
Power applied to
slide ram for
purpose of blanking,
drawing or stamping
Example: Power
press

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 Shearing Actions
Apply power to slide or knife to trim or
cut

OSHA 3067
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 Shearing Actions
Sheet Metal Shear

OSHA 7100

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 Cutting Actions
Rotating,
reciprocating or
transverse
motion
Examples: Band
saw, circular
saws, lathes,
drills OSHA 3067
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 Classification of Safeguards
Guards
Devices
Location/distance
Automatic/semiautomatic feed or
ejection
Miscellaneous

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 Types of Guards
Fixed
Provide secure barrier
Interlocked
Cuts off power when guard opened or removed
Adjustable
Barrier manually moved to accommodate stock or
operation
Self-adjusting
Barrier automatically moves to accommodate
operation
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 Fixed Guards
Advantages Disadvantages
Maximum Poor visibility
protection Must remove for repairs
Variety of requiring LOTO
applications OSHA 3067

In-house
fabrication
Low cost &
maintenance
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 Interlocked Guards
Switch that when opened stops power
Advantage
Maximum protection
Portion of guard easily removed for access
Disadvantage
Can be overridden by employee
High cost
Maintenance required
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 Adjustable Guards
Advantage
Flexibility
In-house fabrication
Bandsaw blade
Disadvantage adjustable guard
Not maximum
protection
Rely on worker to
properly position
May prohibit easy
access OSHA 3067
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 Self-adjusting Guards
Advantage
Employee not
involved in positioning
Readily available
Disadvantage
Not maximum
protection
May need frequent
fine tuning
OSHA 3067

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 Self-adjusting Guard
Table Circular Saw

OSHA 10 Hour GI Presentation

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 Devices
Presence sensing Safety Controls
Photoelectrical Safety trip control
Radiofrequency Two-hand control/trip
Electromechanical Gates

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Presence-Sensing Device

www.osha.gov/SLTC/etools/machineguarding/presses/psd.html
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 Two-Hand Control
Requires constant,
concurrent pressure to
activate the machine
The operators hands are
required to be at a safe
location (on control
buttons) and at a safe
distance from the danger
area while the machine
OSHA 10 hour
completes its closing cycle

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 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

OSHA 10 hour
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 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 Open Gate Closed 35

OSHA 10 hour
 Gate
Vertical Downstroke Baler

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www.cdc.gov/niosh/hc14.html
 Safeguard by
location/distance
Position dangerous parts
of machine in
inaccessible areas during
normal operation
Moving parts more
than 7 feet above floor
Controlled access
room
Control station at safe
distance from machine
OSHA 10 hour
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Feeding and Ejection Methods
Automatic / semiautomatic feed
Automatic / semiautomatic ejection
Robots

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 Automatic Feed
(shown on power press)

Transparent
Enclosure
Guard

Stock Feed
Roll

Dang
er
Area

Completed Work

OSHA 3170 39
 Robots
Machines that load and
unload stock, assemble Press
Robot
parts, transfer objects,
or perform other tasks
Best used in high- Stock
Conveyor
production processes
requiring repeated
routines where they
prevent other hazards Fixed
to employees Barrier

OSHA 3170

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 Miscellaneous
Awareness Barriers
Protective Shields
Hand tools

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 Awareness Devices
Alert employees to
hazard
Signs
Awareness signals (audible
or visual)
Awareness barriers (allows access to
machine danger areas, but is designed to
contact employee, creating an awareness that
employee is close to danger point)

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

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 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
OSHA 3067

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 Requirements for Safeguards
Prevent contact
Secure, tamper-resistant, and durable
Protect from falling objects
Create no new hazards
Create no interference
Allow safe lubrication and maintenance

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 Requirements of Safeguards
Fixed guards should used whenever
possible
Machines designed for fixed location
shall be secured to prevent movement
Conform to ANSI and OSHA
requirements

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 Machine Safety
Responsibilities
Management
ensure all machinery is properly guarded
Supervisors
train employees on specific guard rules in their
areas
ensure machine guards remain in place and are
functional
immediately correct machine guard deficiencies

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 Machine Safety
Responsibilities
Employees
do not remove guards unless machine is
locked and tagged
report machine guard problems to
supervisors immediately
do not operate equipment unless guards are
in place

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 Employee Training
Hazards associated with particular machines
How the safeguards provide protection and the
hazards for which they are intended
How and why to use the safeguards
How and when safeguards can be removed and by
whom
What to do if a safeguard is damaged, missing, or
unable to provide adequate protection

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Some Examples of Machine
Guarding

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Abrasive Wheel Machinery
Improper Work Rest and Tongue

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 Abrasive Wheel Machinery
Work rests on offhand grinding machines must be kept
adjusted closely to the wheel with a maximum opening
of 1/8-inch to prevent the work from being jammed
between the wheel and the rest, which may result in
wheel breakage.

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OSHA 3067
 Abrasive Wheel Machinery
The distance between the wheel periphery and the
adjustable tongue must never exceed 1/4-inch.

OSHA 10 hour 53
 Abrasive Wheel Machinery
When installing new abrasive wheel
Inspect for condition and compatibility
Conduct ring test

Click on picture
for video

OSHA 7100

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Abrasive Wheel Machinery

Checklist

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 Power-Transmission Apparatus

Power-transmission Unguarded belt

apparatus (shafting, and pulley
flywheels, pulleys,
belts, chain drives, etc.)
less than 7 feet from
the floor or working
platform must be
guarded.

OSHA 10 hour
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Portable Circular Saws

Guard Retracted

Stock

Blade

Guard
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OSHA 3067
 Table Saw

On/off switch should be

Guard located at knee height
-- so you can turn off
machine while your
hands are on the
material
Blade must be guarded
Automatic brake a
good safety feature

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www.osha.gov/SLTC/etools/machineguarding/saws/tablesaws.htm
 Table Saw -- Kickback
Back of the blade, as it rises out of
table, is the critical kickback zone
Material tends to be lifted off of the table
If wood moves sideways at this point, it
will be caught by the rotational motion
and will be flung back toward the
operator!

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 Preventing Kickbacks
Use a splitter or wedge inserted into the
saw kerf to separate material
Make sure rip fence is perfectly parallel
to the blade

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 Table Saw - Splitters
Metal fins, secured behind and in line with the
blade -- must move freely & not stick open
Anti-kickback pawls also attached

Splitter & anti-

kickback pawls

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www.orosha.org/pdf/pubs/2980.pdf
Table Saw - Push Sticks

Push stick

www.osha.gov/SLTC/etools/machineguarding/saws/tablesaws.html
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 Radial Arm Saw

Anti-
Kickback
Device

Lower Blade Guard 63

 Machinery: General Safety
Principles
Securely fasten equipment to eliminate
movement or walking
No loose clothing, long hair, jewelry, or
gloves around rotating machine parts
Respect machine guards
Keep electrical cords and plugs intact
Inspect machinery before each use
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 Machinery: General Safety
Principles
Do not leave machines running and
unattended
Never attend to brush debris from the
table surface while the machine is
running
An active brake mechanism adds
greatly to safety
Easily reached off switch increases
safety 65
Machine Guarding

Checklist

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Case Studies
Quiz
 Resources
OSHA Machine Guarding Website
http://www.osha.gov/SLTC/machineguarding/index.html

OSHA Machine Guarding eTool

http://www.osha.gov/SLTC/etools/machineguarding/index.html

OSHA Amputation Fact Sheet

http://www.osha.gov/OshDoc/data_General_Facts/amputation-
factsheet.pdf

Safeguarding Equipment and Protecting

Employees from Amputations
http://www.osha.gov/Publications/osha3170.pdf

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