1. Machine Guarding Slide Show Notes
Welcome to the training session on machine guarding.
Image credit: OSHA

2. Session Objectives You will be able to:
Understand the hazardous actions of different types of machinery
Identify the hazards of working with machinery
Identify machine safeguards and know how they work
Properly operate machines with guards
Slide Show Notes
By the end of this training session, you will be able to:
Understand the hazardous actions of different types of machinery.
Identify the hazards of working with machinery.
Identify machine safeguards and know how they work.
Properly operate machines with guards.
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3. Why Machines Must Be Properly Guarded
Point of operation hazards
Power transmission apparatus hazards
800 deaths each year
High injury rates
Amputations, fractures, lacerations, and crushing
Electric shock and burns
Slide Show Notes
Thousands of workplace injuries each year are caused when workers are exposed to point of operation hazards. The point of operation is where the machine part (e.g., drill bit, cutting blade) contacts material that is being worked on.
According to the Occupational Safety and Health Administration (OSHA), workers who operate and maintain machinery suffer over 800 deaths per year.
Injury rates are high. According to federal statistics, workers in the U.S. experience 92,000 injuries annually from unguarded machine parts, each resulting in one or more days away from work.
Approximately 18,000 amputations, fractures, lacerations, crushing injuries. Amputation is one of the most severe and crippling types of injuries in the occupational workplace, and often results in permanent disability.
Electric shocks and burns are experienced by workers every year from unprotected machine parts.
Ask trainees to provide examples of machine-related injuries that have occurred or potential injuries that can occur in their work area.
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4. Unsafe Machines Cause Injuries
Poorly designed machines
Poorly maintained machines
Machines being used for unintended purposes
Machine not properly installed
Inadequate safeguarding
Objects discharged from the machine
Slide Show Notes
Some common unsafe conditions of machines that can cause injuries include:
Poorly designed machines
Poorly maintained machines
Machines being used for unintended purposes
Machine not properly installed
Inadequate safeguarding
Objects discharged from the machine
Discuss specific potential causes of injuries at your company’s workplace.
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5. Unsafe Actions Cause Injuries
Reach around, under, over or through guards into hazardous areas
Remove or bypass guards
Reach into equipment to remove stuck or jammed material
Not use electrical safety procedures
Not wear appropriate protective equipment
Not know how to properly service or repair machines
Slide Show Notes
Injuries can result from actions, or the lack of proper actions, on the part of the machine operator, including:
Reaching around, under, over or through guards into hazardous areas
Removing or bypassing guards
Reaching into equipment to remove stuck or jammed material
Not using electrical safety or lockout/tagout procedures
Not wearing appropriate protective equipment
Not knowing how to properly service or repair machines
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6. Regulatory Requirements
29 CFR 1910, Subpart O
Applies to specific types of equipment
Training
Slide Show Notes
The OSHA regulations for machine guarding (Code of Federal Regulations Title 29, Section 1910, Subpart O) apply to many types of machines.
The rules provide specific requirements for various types of machines, including power presses, woodworking equipment, and forges. But whether or not there are specifics in the standard, simply keep in mind that if there are movements or actions that can affect you when operating the machine, then it must be guarded in some way.
The rules require that machine operators and service personnel must be trained in the proper operation and maintenance of the machines that they use.
Add any state or company-specific requirements that may apply.
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7. Where Machine Hazards Occur
Point of operation
Drill bit cutting wood
In-running nip points
Power transmission apparatus
Operating controls and moving parts
Slide Show Notes
Machine hazards occur most commonly in three areas of a machine or operating equipment with moving parts:
The point of operation is where the work is actually performed on the material.
A drill bit cutting into wood or metal is an example of the point of operation.
In-running nip points is another example. They occur when machine parts move toward each other or when one part moves past a stationary object.
The power transmission apparatus includes 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, cranks, and gears.
Operating controls and other moving parts include all parts of the machine that move while the machine is working.
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8. Types of Rotating Machine Parts
Collars, couplings, and cams
Clutches, gears, and pulleys
Flywheels
Shafts, including shaft ends
Slide Show Notes
Rotating action is hazardous regardless of the speed, size, or surface finish of the moving part. Rotating parts and shafts can catch hair or clothing and seriously mangle or crush the operator. Rotating parts and stock can also force an arm or hand into a dangerous position, breaking bones and lacerating or severing a hand or other parts of a limb. Bolts, projecting keys, or screws on rotating parts increase the danger of getting caught by the rotary part. Operators can also be struck by a projecting bolt or key. Common types of rotating mechanisms include:
Collars, couplings, and cams
Clutches, gears, and pulleys
Flywheels
Shafts, including shaft ends
Modify this slide or add slides to describe or picture rotating mechanisms, if any, at your facility.
Image credit: OSHA
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9. Nip Points Hazard—Hands, arms, or whole body get caught in nip
Causes lacerations, crushing, amputation, and death
Created by:
Two parts rotating in opposite directions
Parts rotating tangentially
Parts rotating close to a fixed part
Slide Show Notes
Nips points are often easy to identify but sometimes difficult to safeguard.
Nip point injuries are caused when hands, arms, or the whole body get caught in a nip.
Injuries include lacerations, crushing of body parts, amputations, and even death.
Nip points are created by:
Two or more parts rotating in opposite directions
Parts rotating tangentially
Parts rotating close to a fixed part
Show trainees examples of nip points on machinery in your workplace.
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10. Point of Operation Functions
Cutting
Punching
Shearing
Bending
Compressing
Slide Show Notes
Hazardous actions are most generally within the point of operation. The farther away the operator is from the point of operation, the less hazard created by these motions. Common point of operations include:
Cutting wood, metal, or other materials
Punching metal, wood, or plastic
Shearing
Bending
Compressing actions
Modify, add, or delete the next series of slides that describe types and actions of machines to reflect the types of machines and equipment used at your facility. Where possible, show the hazardous actions of machines and equipment in your facility.
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11. Cutting Machines and Actions
Hazard—Cutting action, flying chips or scrap material cut fingers or strike the head or body
Machines
Band and circular saws
Boring or drilling
Lathes and milling
Actions
Rotating, reciprocating, or transverse motion
Slide Show Notes
Equipment used for cutting is extremely common in industry. Because operators are so accustomed to using these pieces of equipment, it is easier to overlook the hazard or eliminate the safeguard.
Cutting hazards occur where finger, arm and body parts are exposed to cutting actions, and where flying chips or scrap material can strike the head, particularly in the area of the eyes or face.
Cutting machines include:
Band and circular saws
Boring or drilling machines
Lathes and milling machines
Cutting actions include:
Rotating, reciprocating, or transverse motion
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12. Punching Machines and Actions
Hazard—Fingers can be crushed where material is inserted, held, or withdrawn
Machines
Power presses
Ironworking equipment
Action of ram mechanism
Blanking, drawing, or stamping
Slide Show Notes
Punching actions require an incredible amount of force. Therefore, the point of operation guarding is very important. You must be extremely careful not to place any part of your body in harm’s way.
Punching hazards occur where fingers can be crushed while material is inserted, held, and withdrawn by hand.
Punching equipment includes:
Power presses
Ironworking equipment
Bending actions occur when a ram mechanism is used on metal or other materials for:
Blanking, drawing, or stamping
Image credit: OSHA
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13. Shearing Machines and Actions
Hazard—Crush or tear body parts where material is inserted, held, and withdrawn
Machines:
Hydraulic shears
Mechanical shears
Pneumatic shears
Actions
Powered slide or knife to trim or shear metal or other materials
Slide Show Notes
Shearing actions can crush or tear body parts where material is actually inserted, held, and withdrawn
Shearing machines are powered by:
Hydraulic energy
Mechanical energy
Pneumatic energy
Shearing actions include:
The use of a powered slide or knife to trim or shear metal and other materials.
Image credit: OSHA
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14. Bending Machines and Actions
Hazard—Crushing body parts where material is inserted, held, or withdrawn
Machines
Power presses and press brakes
Tubing benders
Actions
Draw and stamp
Slide Show Notes
Bending operational hazards occur at the point of operation where stock is inserted, held, or withdrawn.
Bending actions can crush body parts where material is inserted, held, and withdrawn.
Bending equipment includes:
Power presses and press brakes
Tubing benders
As with shearing, the force required to bend materials such as metal is extreme, and the human body is no match for it.
Bending actions are where power is applied to draw or stamp metal or other materials.
Image credit: OSHA
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15. Compressing Machines and Actions
Hazard—Compression crushes body parts
Machines
Compactor
Molding
Concrete
Actions
Squeezing, extruding, and pressing
Slide Show Notes
Compressing actions can crush body parts, sometimes resulting in amputation.
Machines that compress include:
Compactors
Molding, including injection molding
Concrete
Compressing actions include:
Squeezing, extruding, and pressing
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16. Power Transmission Apparatus
Hazard—Grab, nip, cut, or strike body parts
Machines and parts
Power transmission belts and pulleys, gears, sprockets and chains, shafts, collars, couplings, flywheels, clutches, and other power transmission apparatus
Action
Grabbing, nipping, cutting, flying and falling objects, reciprocating motions, transverse motions, or a combination of these
Slide Show Notes
Power transmission parts are the mechanical components of a piece of equipment that, together with a source of power (sometimes referred to as a prime mover), provide the motion to a part of that machine or equipment. The power from the prime mover is transferred through the use of gears, flywheels, cranks, shafts, chains, sprockets, belts, pulleys, pistons, couplings, connecting rods, etc., to the various machines found in the workplace. The power from the prime mover can come from mechanical, pneumatic, hydraulic, steam, or electrical sources.
Power transmission apparatus hazards include grabbing clothes, nipping, cutting, or striking body parts from the operation of machines, equipment, or systems that are stationary in their use, other than the point operation.
This applies to machines with:
Power transmission belts and pulleys, gears, sprockets and chains, shafts, collars, couplings, flywheels, clutches, and other power transmission apparatus
Machine actions that can cause hazards include:
Grabbing, nip points, cutting, reciprocating motions, transverse motions, or a combination of these
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17. Types of Machines and Hazards—Any Questions?
Are there any questions about the types of machines or equipment used at our facility?
Any questions about the hazards associated with the operation of the machinery? Power transmission apparatus?
Any questions about machine and equipment hazards in general?
Slide Show Notes
Are there any questions about the types of machines or equipment used at at out facility?
Any questions about the hazards associated with the operation of the machinery or power transmission apparatus?
Any questions about machine and equipment hazards in general?
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18. Purpose of Machine Safeguarding
Prevent access to point of operation and power transmission apparatus
Prevent objects from being ejected toward people
Slide Show Notes
Now we’ll discuss safeguards to protect you from machine-related injuries. You should always make sure that safeguards:
Prevent limbs or any part of our body from contacting the point of operation or power transmission apparatus
Prevent objects from being ejected toward people
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19. Safeguarding Best Practices
Never remove or defeat safeguards
Don’t create new hazards
Ensure no interference with the production process
Lubricate parts without removing the safeguard, or turn off the machine
Slide Show Notes
In order to make sure that the safeguards work effectively and don’t create their own hazards, make sure the guards:
Are secure, and not easy to remove or defeat.
Do not create additional hazards, such as allowing objects to fall into moving parts, or create an additional hazard such as a pinch point. If so, they are basically defeating their own purpose.
Do not interfere with the typical production process; otherwise, some operators may have a tendency to remove them. This is a warning that design of the safeguard may need to be reviewed for effectiveness.
Have lubrication points built in so that equipment can be serviced without having to remove the guard; if not, turn off the machine in order to lubricate.
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20. Safeguarding Best Practices (cont.)
Remove guards only when machine is locked and tagged out
Report problems immediately
Operate equipment only when guards are in place and properly adjusted
Don’t use unauthorized or damaged guards
Never leave machines unattended with parts still moving
No loose clothing, long hair, or jewelry
Slide Show Notes
Here are a few safe work practices to use when working with machines with moving parts:
Do not remove guards unless the machine is locked and tagged out.
Immediately report any machine guard problems or failures to supervisors.
Operate equipment only when the proper machine guards are in place.
Do not use unauthorized or damaged guards.
Never leave machines unattended with parts still moving. Even after the machine is turned off, some parts may still be moving.
Do not wear loose clothing, long hair, or loose jewelry around machines.
Discuss any additional safe work practices employed at your facility. Modify this slide or add another slide to include any additional safe work practices.
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21. Classifications of Safeguards
Safeguard or barrier
Device
Location and distance
Automatic stock feed and ejection method
Miscellaneous aids
Slide Show Notes
There are many ways to safeguard machinery. There are five basic classes of safeguards:
A guard or barrier ensures you cannot reach the moving parts.
A device stops the motion of the machine or apparatus before a worker can come into contact with it, and prevent restart until the operator manually resets the device.
Location places the machine or power transmission apparatus in a locked mechanical room, or more than 7 feet above the work surface, and distance places the hazardous machinery in locked cages, or protects worker with proximity light curtains.
Automatic or semiautomatic stock feeding and ejection methods.
Miscellaneous aids, such as push sticks or other tools to place or remove stock.
Modify, add, or delete the next series of slides that describe machine safeguards to reflect the guards and devices used at your facility.
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22. Fixed Safeguards Permanent part of the machine or apparatus
Best guard protection
Power transmission apparatuses are best protected by fixed guards or barriers that enclose the danger area
Slide Show Notes
Fixed guards are permanent part of the machine.
They provide the best guard protection.
As a general rule, power transmission apparatuses are best protected by fixed guards that enclose the danger are.
Image credit: OSHA
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23. Interlocked Safeguards
Automatically shut off and quickly stop the machine or apparatus
Slide Show Notes
Interlocked guards automatically shut off and quickly stop the machine when they are opened. Interlocks must never be defeated.
Image credit: OSHA
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24. Adjustable or Self-Adjusting Safeguards
Adjustable to accommodate varying sizes of material placed at the point of operation
Self-adjusting types move according to the size of the stock
Slide Show Notes
Adjustable and self-adjusting guards accommodate varying sizes of material placed at the point of operation.
Self-adjusting types provide a barrier that moves according to the size of the stock entering the danger area.
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25. Safeguarding Devices
Presence sensing automatically shut down equipment
Photoelectrical, radio frequency, and electromechanical
Pullbacks or Restraints
Gates around robots and large areas
Interlocked
Other
Slide Show Notes
There are several types of safety devices that provide the same amount of protection as guards.
Presence-sensing devices automatically shut down equipment when the worker gets too close to moving parts.
Photoelectrical devices use light to detect the presence of an operator, while radio frequency devices use capacitance.
Pullbacks and restraints are not used as commonly anymore; however, some old equipment may still incorporate these methods. A restraint device is pictured here (top picture).
Gates are commonly found around robots and other operations where the operation of the equipment encompasses a fairly large area and, therefore, requires perimeter guarding. A closed gate (with window) is pictured here.
Gates can be used across openings in a piece of equipment. Perimeter “distance” gates around equipment should be interlocked.
Show examples of safety devices used at your facility.
Image credit: OSHA
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26. Safeguarding Devices (cont.)
Safety trip control
Pressure-sensitive body bar
Safety tripod
Safety tripwire cable
Two-hand safety control or two-hand safety trip
Slide Show Notes
Other types of devices include:
Safety trip controls typically rely on the force of the operator leaning against them to trip a microswitch that shuts down the equipment, eliminating the hazard.
A pressure-sensitive body bar is an example
A safety tripod is another example
Others, like the tripwire cable pictured here, are placed around the danger area and are immediately reachable by the operator.
Two-hand control devices eliminate the possibility of freeing up one hand while operating the equipment with the other. Operators who try to defeat the two-hand control by using what is called a “cheater bar” will face disciplinary action.
Image credit: OSHA
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27. Two-Hand Devices
Two-hand controls require constant two-hand pressure during the entire machine cycle
Two-hand trips activate the machine, then allow hands to be free while machine completes its cycle
Slide Show Notes
“Two Hand Controls” require constant 2 hand pressure during the entire machine cycle
“Two Hand Trips” activate the machine, and then allow the hands to be free while the machine completes the cycle. The placement of the two hand trips need to be far enough away from the hazard so that the operator cannot reach the hazard. OSHA has a formula based on a hand speed of 63 inches per second.
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28. Location and Distance Separates operators from the equipment
Makes it virtually impossible to contact moving parts
Limited by the available workspace
Slide Show Notes
Keeping distance between you and the machinery is about as safe as you can get from exposure to moving machinery parts.
Distance virtually eliminates the risk of injury.
This very effective method is limited by the amount of space available in the work area.
Describe or show trainees examples of machines that are operated from a distance, if applicable.
Image credit: OSHA
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29. Feeding and Ejection Methods
Automatic feed
Semiautomatic feed
Automatic and semiautomatic ejection
Robot
Slide Show Notes
Automatic feeding and ejection methods do not require you to place your hands in the danger area. In some cases, no operator involvement is necessary after the machine is set up.
With semiautomatic feeds, operators can manually feed the stock with the assistance of a feeding mechanism.
Properly designed ejection methods do not require any operator involvement after the machine starts to function.
A robot is a good method of automatic feeding and ejection.
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30. Miscellaneous Aids Awareness barriers Protective shields
Hand-feeding tools and holding fixtures
Slide Show Notes
Miscellaneous aids do not give complete protection from machine hazards. They may, however, provide you with an extra margin of safety. Sound judgment is needed in their application and usage. They include:
Awareness barriers
Protective shields, such as the one pictured here around a drill press.
Holding tools or fixtures, such as hand-held clamps used to insert or remove material from the point of operation.
Show trainees examples of miscellaneous aids used at your facility.
Image credit: OSHA
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31. Rule of Thumb
Guard any machine part, function, or process that may cause injury
Follow manufacturer’s specifications
Slide Show Notes
If you can contact the moving parts on a machine, the machine must be guarded. Because the OSHA standards are performance-oriented with regard to machine guarding, companies have the freedom to design their own guards.
Most machines built today include guards designed and installed by the manufacturer. Follow the manufacturer’s specifications for the guarding of machines, unless another safe procedure or process has been implemented by our company.
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32. Machine Safeguarding— Any Questions?
Any questions about safeguarding best practices?
Questions about any particular type of safeguard?
Slide Show Notes
Any questions about safeguarding best practices?
Questions about any particular type of safeguard?
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33. Key Points to Remember
All point of operation and power transmission apparatus hazards must be safeguarded
Do not operate machines without proper guards in place
Remove guards or protective devices only when machine is not operating
Immediately report problems with safeguards
Slide Show Notes
To protect yourself from injury from machinery or equipment, remember these key points:
All point of operation and power transmission apparatus hazards must be safeguarded.
Do not operate machines without proper guards in place.
Remove guards or protective devices only when the machine is locked out following a formal lockout/tagout program.
Report problems with machine guards or protective devices immediately.
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