1. Machine Guarding INSTRUCTOR’S NOTES:
This presentation is designed to assist trainers conducting OSHA 10-hour General Industry outreach training for youth workers. Since youth workers are the target audience, this presentation may cover hazard identification, avoidance, and control – not standards. No attempt has been made to treat the topic exhaustively. It is essential that trainers tailor their presentations to the needs and understanding of their audience.
This presentation is not a substitute for any of the provisions of the Occupational Safety and Health Act of 1970 or for any standards issued by the U.S. Department of Labor. Mention of trade names, commercial products, or organizations does not imply endorsement by the U.S. Department of Labor.
For more detailed information on machine guarding you may refer to OSHA’s eTool at the following link:

2. Machine Guarding
Machine guarding protects you and other employees from injuries such as:
Crushed hands and arms
Severed fingers
Amputated limbs
Fatal accidents
INSTRUCTOR’S NOTES:
All machines consist of three basic components: the point of operation , the power transmission device, and the operating controls. Despite all machines having these features, their safeguarding needs differ widely due to varying physical characteristics and operator involvement.
Where the operation of a machine can injure the operator or other workers, the hazard must be controlled or eliminated.
A good rule to remember is: Any machine part, function, or process which may cause injury must be safeguarded.
Causes of Machine Accidents:
Reaching in to “clear” equipment
Not using Lockout/Tagout
Unauthorized persons doing maintenance or using the machines
Missing or loose machine guards
§ General requirements for all machines
(a) Machine guarding.
(1) Types of guarding. One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks. Examples of guarding methods are-barrier guards, two-hand tripping devices, electronic safety devices, etc.
(2) General requirements for machine guards. Guards shall be affixed to the machine where possible and secured elsewhere if for any reason attachment to the machine is not possible. The guard shall be such that it does not offer an accident hazard in itself.

3. Requirements for Safeguards
OSHA requires machine safeguards to:
Prevent contact
Be secure
Protect from falling objects
Create no new hazards for the operator
INSTRUCTOR’S NOTES:
Prevent Contact - A good safeguarding system eliminates the possibility of the operator or other workers placing parts of their bodies near hazardous moving parts.
Secure - A safeguard that can easily be made ineffective is no safeguard at all. Guards and safety devices should be made of durable material that will withstand the conditions of normal use and be firmly secured to the machine.
Protect from falling objects - A small tool which is dropped into a cycling machine could easily become a projectile that could strike and injure someone.
Create no new hazards - A safeguard defeats its own purpose if it creates a hazard of its own such as a shear point, a jagged edge, or an unfinished surface which can cause a laceration. The edges of guards, for instance, should be rolled or bolted in such a way that they eliminate sharp edges.
Create no interference - Any safeguard which impedes a worker from performing a job quickly and comfortably might soon be overridden or disregarded. Proper safeguarding can actually enhance efficiency since it can relieve the worker’s apprehensions about injury.
Allow safe lubrication - Locating oil reservoirs outside the guard, with a line leading to the lubrication point, will reduce the need for the worker to enter the hazardous area.

4. Fair Labor Standards Act (FLSA)
FLSA prohibits employees younger than 18 years from operating the following machines at work:
Band saws
Circular saws
Punching and shearing machines
Meat packing, processing, or slicing machines
Paper products machines
Woodworking machines
Metal forming machines
INSTRUCTOR’S NOTES:
OSHA has regulations to protect employees from the hazards of machinery. Additionally, the Fair Labor Standards Act (FLSA) has designated certain non-farm jobs as particularly hazardous for workers under the age of 18. For example, the FLSA prohibits employees younger than 18 years from operating the following machines at work:
Band saws
Circular saws
Punching and shearing machines
Meat packing, processing, or slicing machines
Paper products machines
Woodworking machines
Metal forming machines

5. Point of Operation
A key term to understand is “point of operation.” This is the point where work is performed and where many machine hazards exists. The point of operation must be guarded.
Point of Operation
INSTRUCTOR’S NOTES:
These mechanical hazards can occur at the point of operation.
That point where work is performed on the material, such as cutting, shaping, boring, or forming of stock must be guarded.

6. Hazardous Mechanical Motions
The basic types of hazardous mechanical motions are:
Rotating
In-running nip points
Reciprocating
Transversing
All parts of the machine which move while the machine is working can cause mechanical hazards.
A wide variety of mechanical motions and actions may present hazards to the worker. These can include the movement of rotating members, reciprocating arms, moving belts, meshing gears, cutting teeth, and any parts that impact or shear. These different types of hazardous mechanical motions and actions are basic in varying combinations to nearly all machines, and recognizing them is the first step toward protecting workers from the danger they present.

7. Mechanical Motion: Rotating
Any rotating motion can be dangerous, even when the motion appears to be slow and smooth.
INSTRUCTOR’S NOTES:
Rotating motion can be dangerous; even smooth, slowly rotating shafts can grip hair and clothing, and through minor contact force the hand and arm into a dangerous position. Injuries due to contact with rotating parts can be severe. Collars, couplings, cams, clutches, flywheels, shaft ends, spindles, meshing gears, and horizontal or vertical shafting are some examples of common rotating mechanisms which may be hazardous. The danger increases when projections such as set screws, bolts, nicks, abrasions, and projecting keys are exposed on rotating parts.

8. Mechanical Motion: In-Running Nip Points
Nip points are created when rotating parts on a machine come in contact with, or are in close proximity to, each other.
INSTRUCTOR’S NOTES:
In-running nip point hazards are caused by the rotating parts on machinery. There are three main types of in-running nips. Parts can rotate in opposite directions while their axes are parallel to each other. These parts may be in contact (producing a nip point) or in close proximity. In the latter case, stock fed between two rolls produces a nip point.  As seen here, this danger is common on machines with intermeshing gears, rolling mills, and calendars.

9. Mechanical Motion: Reciprocating
This back-and-forth or up-and-down motion creates a crushing hazard between moving and stationary parts.
INSTRUCTOR’S NOTES:
Reciprocating motions may be hazardous because, during the back-and-forth or up-and-down motion, a worker may be struck by or caught between a moving and a stationary part.

10. Mechanical Motion: Transverse
Transverse motion is movement in a straight or continuous line.
INSTRUCTOR’S NOTES:
Transverse motion (movement in straight, continuous line) creates a hazard because a worker may be struck or caught in a pinch or shear point by the moving part.

11. Hazardous Mechanical Actions
The basic types of hazardous mechanical actions are:
Cutting
Punching
Shearing
Bending

12. Mechanical Action: Cutting
Cutting action may involve rotating, reciprocating or transverse motions.
The danger of cutting action exists at the point of operation.
INSTRUCTOR’S NOTES:
Cutting action may involve rotating, reciprocating, or transverse motion. The danger of cutting action exists at the point of operation where finger, arm and body injuries can occur and where flying chips or scrap material can strike the head, particularly in the area of the eyes or face. Such hazards are present at the point of operation in cutting wood, metal, and other materials. Examples of mechanisms involving cutting hazards include bandsaws, circular saws, boring and drilling machines, turning machines (lathes), or milling machines.

13. Mechanical Action: Punching
Punching action results
when power is applied to a slide in order to blank, draw or stamp metal or other materials.
The danger of punching action exists at the point of operation.
INSTRUCTOR’S NOTES:
Punching action results when power is applied to a slide (ram) for the purpose of blanking, drawing, or stamping metal or other materials. The danger of this type of action occurs at the point of operation where stock is inserted, held, and withdrawn by hand. Typical machines used for punching operations are power presses and iron workers.

14. Mechanical Action: Shearing
Shearing action applies power to a slide or a knife in order to trim or shear metal or other materials.
The danger of shearing action exists at the point of operation.
INSTRUCTOR’S NOTES:
Shearing action involves applying power to a slide or knife in order to trim or shear metal or other materials. A hazard occurs at the point of operation where stock is actually inserted, held, and withdrawn. Machines used for shearing operations are mechanically, hydraulically, or pneumatically powered shears.

15. Mechanical Action: Bending
Bending action occurs when power is applied to a slide in order to shape, draw, or stamp materials.
The danger of bending action exists at the point of operation.
INSTRUCTOR’S NOTES:
Bending action results when power is applied to a slide in order to draw or stamp metal or other materials. A hazard occurs at the point of operation where stock is inserted, held, and withdrawn. Equipment that uses bending action includes power presses, press brakes, and tubing benders.

16. Machine Guarding Methods
Common methods of machine guarding include the use of:
Guards
Devices
Location or distance
Safety aids
INSTRUCTOR’S NOTES:
In this module, the different methods of machine guarding we will discuss can be grouped into the following categories:
• Guards
• Devices
• Location or Distance
• Safety Aids

17. Guards: Fixed
A fixed guard provides a barrier and is a permanent part of the machine.
It is preferable to all other types of guards.
INSTRUCTOR’S NOTES:
Fixed guard – A guard attached to a machine that prevents the operator from making contact with a hazardous area.

18. Guards: Interlocking
When this type of guard is opened or removed, the mechanism or power automatically disengages or shuts off and cannot be reset or restarted until the guard is back in place.
Revolving Drum
INSTRUCTOR’S NOTES:
Interlocking guard – A guard that turns off the machine’s power when opened and prevents the machine from starting up when the guard is not properly placed.

19. Guards: Adjustable
Vertical Bandsaw
Provides a barrier which can be adjusted to accommodate different production operations.
INSTRUCTOR’S NOTES:
Adjustable guard – A guard that must be adjusted for each job.

20. Guards: Self-Adjusting
Provides a barrier which adjusts according to the size of stock entering the hazardous area.
INSTRUCTOR’S NOTES:
Self-adjusting guard – A guard that adjusts or moves based on the size of the material entering the machine.

21. Devices The common types of devices used on machinery include:
Presence-sensing device
Restraints
Pullback cords
Safety trip controls
Two-hand control or trip
Safety gates
INSTRUCTOR’S NOTES:
Devices control access to a hazardous area. A safety device may perform several functions. It may:
• Stop the machine if you enter the danger area.
• Restrict you from the danger area during operation.
• Require you to use both hands on the machine controls throughout operations.

22. Devices: Presence-Sensing
Stops the machine from operating when someone or something enters the sensing field or when a set amount of weight is applied.
INSTRUCTOR’S NOTES:
Presence Sensing Device – A device that stops the machine from operating when someone or something enters the sensing field or when a set amount of weight is applied to the sensing field.

23. Devices: Restraints
Uses cables or straps attached to the operator’s hands and a fixed point so that they cannot travel beyond a safe point.
INSTRUCTOR’S NOTES:
Restraints – A set of cords connected to the your wrists so you can’t reach the point of operation.

24. Devices: Pullback Cords
Allows access to the point of operation when the slide/ram is up and withdraws hands when the slide/ram begins to descend.
INSTRUCTOR’S NOTES:
Pullback Cords – A set of cords connected to your wrists designed to automatically withdraw your hands from the point of operation at a set time in the machine’s cycle.
A pullback device:
Utilizes a series of cables attached to the operator’s hands, wrists, and/or arms
Primarily used on machines with stroking action
Allows access to the point of operation when the slide/ram is up
Withdraws hands when the slide/ram begins to descend

25. Devices: Safety Trip Controls
Device located around the perimeter of or near the danger area of a machine that stops the machine when it is tripped.
INSTRUCTOR’S NOTES:
Safety trip control - A pressure-sensitive body bar, triprod, or tripwire that stops the machine when it is tripped. The trip could occur when pressure is applied or when pressure is removed, depending on the design of the device.

26. Devices: Two-Hand Controls
Machine requires constant pressure from both hands on the controls in order to operate.
INSTRUCTOR’S NOTES:
Two-hand control or trip – A device that requires constant, concurrent pressure from both hands to activate the machine. The operator’s hands are required to be at a safe location (on control buttons) and at a safe distance from the danger area while the machine completes its closing cycle

27. Devices: Safety Gates
A moveable device that provides a barrier between you and the point of operation.
INSTRUCTOR’S NOTES:
Safety Gates - A moveable 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, the machine will not function.
Another potential application of this type of device is, if the gate is a component of a perimeter safeguarding system, the gate may provide protection not only to the operator but to pedestrian traffic as well.

28. Location or Distance Guarding
Guarding can be accomplished by locating the machine or its dangerous moving parts so they are not accessible or do not present a hazard to a worker during normal operation.
Workers must maintain a safe distance from the danger area.
INSTRUCTOR’S NOTES:
This involves positioning or designing a machine so that the points of hazard are separated from areas where employees may walk or work.
One approach to safeguarding by location is shown in this photo. Operator controls may be located at a safe distance from the machine if there is no reason for the operator to tend it.

29. Safety Aids
A safety aid is anything that helps protect you from mechanical hazards.
One example would be tools that are used to feed material into or remove material from a machine.
INSTRUCTOR’S NOTES:
There are also safety aids intended to help protect you from mechanical hazards, such as tools used to feed material into a machine or remove it from a machine. Though safety aids are useful, alone they are not a sufficient means of machine guarding. The proper guards and devices should be used at all times.

30. Safety Aids: Protective Shields
These do not give complete protection from machine hazards, but do provide some protection from flying particles, splashing cutting oils, or coolants.
INSTRUCTOR’S NOTES:

31. Safety Aids: PPE
Personal Protective Equipment (PPE) can be used to help protect you from flying mechanical debris.
INSTRUCTOR’S NOTES:

32. Machine Guarding Example
What is wrong with this picture?
INSTRUCTOR’S NOTES:
Photo is an unguarded belt and pulley. All moving parts which could present a hazard must be guarded.

33. Machine Guarding Example
This picture shows an unguarded machine. Remember, all moving parts which could present a hazard must be guarded.
INSTRUCTOR’S NOTES:
Photo is an unguarded belt and pulley. All moving parts which could present a hazard must be guarded.
Mechanical power-transmission apparatus
(b) Prime-mover guards.
(1) Flywheels. Flywheels located so that any part is seven (7) feet or less above floor or platform shall be guarded in accordance with the requirements of this subparagraph:
(i) With an enclosure of sheet, perforated, or expanded metal, or woven wire
(ii) With guard rails placed not less than fifteen (15) inches nor more than twenty (20) inches from rim. When flywheel extends into pit or is within 12 inches of floor, a standard toeboard shall also be provided
(iii) When the upper rim of flywheel protrudes through a working floor, it shall be entirely enclosed or surrounded by a guardrail and toeboard.
(iv) For flywheels with smooth rims five (5) feet or less in diameter, where the preceding methods cannot be applied, the following may be used: A disk attached to the flywheel in such manner as to cover the spokes of the wheel on the exposed side and present a smooth surface and edge, at the same time providing means for periodic inspection. An open space, not exceeding four (4) inches in width, may be left between the outside edge of the disk and the rim of the wheel if desired, to facilitate turning the wheel over. Where a disk is used, the keys or other dangerous projections not covered by disk shall be cut off or covered. This subdivision does not apply to flywheels with solid web centers.
(v) Adjustable guard to be used for starting engine or for running adjustment may be provided at the flywheel of gas or oil engines. A slot opening for jack bar will be permitted.
(vi) Wherever flywheels are above working areas, guards shall be installed having sufficient strength to hold the weight of the flywheel in the event of a shaft or wheel mounting failure.
(d) Pulleys.
(1) Guarding. Pulleys, any parts of which are seven (7) feet or less from the floor or working platform, shall be guarded in accordance with the standards specified in paragraphs (m) and (o) of this section. Pulleys serving as balance wheels (e.g., punch presses) on which the point of contact between belt and pulley is more than six feet six inches (6 ft. 6 in.) from the floor or platform may be guarded with a disk covering the spokes.
Unguarded belt and pulley

34. Training
Training on machine guarding offered by employers should include the following:
Information about all potential hazards in your work area.
The correct use of workplace machines and their safeguards.
Safe operating procedures and work practices.
Personal protective equipment that may be required.
Methods for reporting unsafe conditions.
INSTRUCTOR’S NOTES:
Proper training for working with and around machinery is critical. Specific and detailed training is needed and only trained employees should operate machines in the workplace.
Training should, at least, include the following:
• Information about all potential hazards in your work area.
• The purpose of workplace machines and their safeguards.
• The correct use of workplace machines and their safeguards.
• Safe operating procedures and work practices.
• Personal protective equipment that may be required.
• Methods for reporting unsafe conditions.
It is essential that only trained employees operate potentially hazardous machinery.

35. Summary
To StartSafe and StaySafe when working around machines, you should:
Be sure you are trained on all machinery you will be using for your job.
Keep the work area free of fall hazards.
Don’t wear loose clothing or jewelry around machinery.
Always use the right tools, machines, and materials for the job.
Use safety aids when possible.
Wear the proper personal protective equipment.
INSTRUCTOR’S NOTES:
Safe work practices have an important role in controlling mechanical hazards and preventing injuries. You can stay safe around machinery by using these and other safe work practices:
• Keep the work area free of fall hazards.
• Don’t wear loose clothing or jewelry around machinery.
• Always use the right tools, machines, and materials for the job.
• Use safety aids when possible.
• Wear the proper personal protective equipment.