1. Preventing Amputations
Slide Show Notes
Amputation injuries are a serious workplace hazard for those who work with or around machinery. Failure to use proper safeguards can mean the loss of a finger, the loss of a hand, or even death.
OSHA regulations require our company to ensure that machines are properly guarded to protect your safety. We also use other safety devices to prevent amputation injuries.
But we need your help to make sure our machine safety program is 100 percent successful. During this training session, you’ll learn about how you can help prevent amputations and other machine-related injuries.

2. Session Objectives You will be able to:
Identify the amputation hazards of different types of machinery
Understand OSHA’s machine safety requirements
Recognize different types of guards and safety devices
Take proper precautions to prevent injuries
Slide Show Notes
The main objective of this session is to talk about amputation hazards on the job and the precautions we all need to take to prevent these terrible injuries. By the time this session is over, you should be able to:
Identify the amputation hazards of different types of machinery in the workplace;
Understand OSHA’s machine safety requirements designed to prevent amputations;
Recognize the function of different types of guards and safety devices; and
Take proper precautions to prevent injuries.

3. What You Need to Know Types of machines with amputation hazards
Specific machine hazards
Guarding requirements
Safe work practices
Maintenance and repair rules
Inspection procedures
Slide Show Notes
During the session, we’ll discuss:
Types of machines with amputation hazards;
Specific machine hazards;
Guarding requirements;
Safe work practices;
Maintenance and repair rules; and
Inspection procedures.

4. OSHA Requirements OSHA standards
National Emphasis Program on Amputations
Machine safety stressed with citations from OSHA for noncompliance
Slide Show Notes
OSHA has comprehensive regulations to help protect you from machinery hazards and help reduce amputations. The standards are:
Machinery and Machine Guarding, 29 CFR 1910 Subpart O;
Hand and Portable Power Tools, 29 CFR 1910 Subpart P; and
Lockout/Tagout, 29 CFR
These standards describe general machine guarding requirements and safety measures as well as specific requirements for certain kinds of equipment. The Lockout/Tagout standard describes procedures for preventing amputations and other injuries caused by unexpected start-up when machines are being serviced or repaired.
Because OSHA found that compliance with its machine guarding standards was frequently not achieved, the agency developed a National Emphasis Program, or NEP, on amputations in 2002, revised in The NEP provides additional information on how to identify hazards and how to use guarding measures more effectively to prevent amputations.
OSHA has always stressed the importance of machine safety by issuing citations to companies that are not in compliance. In fact, machine guarding violations usually rank among the top 10 OSHA citations issued each year, and fines can run into tens of thousands of dollars.

5. Four Primary Types of Machines
Power presses and saws
Shears
Slicers
Slide Show Notes
Many thousands of amputations occur each year in U.S. workplaces. When OSHA studied some of these amputation injuries, it found that the types of machines that cause the most amputations are power presses, saws, shears, and slicers.
Power presses and saws consistently account for the top two types of machines that present hazards of amputations.
Shears are also ranked high as machines with hazards of amputations in manufacturing.
Slicers are classified under “food and beverage processing machinery,” and many amputations from their misuse have occurred in these industries.
Think about the machines used in our workplace that fit one of these four categories of machines.
Bring pictures to the session of machines in your workplace that fit one of the four categories of machines with hazards for amputations, or add the pictures to this PowerPoint presentation. Pictures should identify equipment hazards and guarding.

6. Other Machines Bending, rolling, shaping machinery
Boring, drilling, milling, planing machinery
Conveyors
Food processing and packaging machinery
Grinding and polishing machinery
Printing machinery
Slide Show Notes
There are other machines that also present amputation hazards. They include:
Bending, rolling, and shaping machinery;
Boring, drilling, milling, and planing machinery;
Conveyors—both gravity and powered;
Food and beverage processing and packaging machinery;
Grinding and polishing machinery; and
Printing machinery.
Think about the other machines used in our workplace that also present amputation risks.
Bring pictures to the session of other machines in your workplace that also present amputation hazards, or add the pictures to this PowerPoint presentation. Pictures should identify equipment hazards and guarding.

7. Point of Operation
Most dangerous area where work is done on the material
Cutting
Punching
Shearing
Bending
Slide Show Notes
Now let’s talk about the point of operation, which is the area on a machine where the work is performed on the material. This is the most dangerous area on most machinery. Proper guarding at the point of operation is always required to prevent amputations.
Cutting is one of the primary actions conducted by machinery at the point of operation. Examples of cutting equipment include band and circular saws, drills, lathes, and mills. Amputations are a main concern when working with machines that cut at the point of operation.
Punching action occurs when a powered ram is used to blank, draw, or stamp material such as metal. Power presses are a prime example. Amputations can occur if the operator’s hands are in the point of operation when the punching action occurs.
Shearing action occurs when a powered knife or slide is used to cut materials. Many shears require the material to be manually inserted into the point of operation, which creates an amputation hazard.
Bending action involves a powered slide that is used to draw or stamp materials such as sheet metal. Examples of machinery that uses bending action includes power presses, tube benders, and press brakes. Operators are exposed to amputation hazards when inserting, holding, and ejecting the material.

8. Mechanical Motion Reciprocating Transverse Rotation Nip points
Slide Show Notes
Almost every machine has moving components that, if not properly guarded, can injure you. For example, reciprocating motions include back and forth or up and down motions of machine components. An example is the motion of the ram on a power press.
Transverse motion in a straight or continuous line could drag you into a pinch point or shear point—for instance, the motion of a powered belt.
Rotating motion can be found on almost every machine. Every form of rotation can be hazardous. Even slowly rotating smooth shafts can grab clothing or hair, or push a hand into a more dangerous area. Rotating motions are even more dangerous when the rotating shaft has exposed keys, set screws, bolts, nicks, or spokes. Examples of rotating machine components include collars, couplings, cams, clutches, flywheels, shaft ends, spindles, meshing gears, and horizontal or vertical shafts.
Nip points are created when parts with parallel axes rotate in opposite directions. Examples include rollers and sprockets. Another type of nip point occurs between a rotating component and a tangentially moving part—for example, the nip point between a chain and sprocket or a belt and pulley. Nip points are also created between rotating objects and stationary objects, such as screw conveyors, abrasive wheels with incorrectly set work rests, and spoked flywheels.

9. Guarding Requirements
Prevent contact
Be secured to machinery
Protect from falling objects
Create no additional hazards
Allow for safe lubrication
Cause no interference with production
Slide Show Notes
OSHA regulations require that any machine part that could cause injury must be properly guarded. Safeguards must meet the following requirements:
Guards must prevent bodily contact with dangerous areas.
They must be made of durable materials and secured to the machinery so that they can’t be easily removed or tampered with.
Guards must also ensure that small objects such as tools, nuts, or bolts can’t fall into the guarded area.
Guards should be designed so that they do not present a hazard—for example, they should not have sharp edges or nip points that could injure your hands.
Ideally, maintenance workers should be able to lubricate parts without removing guards. If not, machines must be locked out when moving parts are exposed during lubrication.
Guards should also be designed not to interfere with production. Guards that interfere with production are more likely to be removed or circumvented by workers in a hurry. And that, of course, could create a potential amputation hazard.

10. Guarding Types Fixed guards Interlocked guards Adjustable guards
Self-adjusting guards
Image Credit: OSHA
Slide Show Notes
There are four basic types of machine guards. Fixed guards are probably the most common because of their simplicity and effectiveness. Fixed guards are attached permanently to equipment and can only be removed with considerable effort. They usually cover power transmission units and can also be found on band saws.
Interlocked guards are designed to be removed or opened to allow access to the hazard zone—for example, to insert or remove material from the point of operation. Once the guard is opened, however, the machine shuts down automatically, effectively eliminating the hazard.
Adjustable guards allow a machine to handle a wide variety of material sizes while still protecting the unused portion of the blade or the point of operation. These guards must be adjusted manually. An example is the guard over the point of operation on a band saw.
Self-adjusting guards, typically found on saws, are pushed away from the point of operation when material is fed into the machine. But they only open enough to allow the material into the cutting zone, thus keeping the remainder of the blade covered.
Think about the types of guards on the machinery you use on the job.
Discuss the types of guards on the machines in your workplace.

11. Safety Devices Light curtains Two-hand controls
Pressure-sensitive devices
Restraints and pull-back devices
Slide Show Notes
Some machines are also equipped with safety devices to prevent injuries. Photoelectric presence-sensing devices, also known as light curtains, use light beams in front of the point of operation. When beams are broken by an object, like a hand placed into the machine, the machine shuts down and can’t be reactivated until the object is withdrawn.
Two-hand controls are used to make sure that both your hands are required to start the machine so one hand can’t be in danger while the other hand starts the machine. This is a common device on punch presses.
Pressure-sensitive devices such as mats, bars, and trip wires all act as emergency stops when activated. For example, pressure-sensitive mats may be placed on the floor near a danger zone. If you step on the mat, the machine shuts down and won’t restart until the mat is manually reset, thus preventing start-up when you step off the mat.
Restraints and pull-back devices use a wire, cable, or strap attached to your hand, wrist, or arm. Restraints prevent you from putting your hand in the danger zone. Pull-back devices allow you access to the point of operation but pull your hands away once the machine starts.
Think about the types of safety devices on the machinery you use.
Discuss the types of safety devices on the machines in your workplace.

12. Distance Guarding Barrier guards
Automatic feeding and ejection systems
Manual feed systems
Mechanical ejectors
Slide Show Notes
Distance guarding is another type of machine safeguard. For example, barrier railings and fences can be used around some machines to keep people away from danger zones when a machine is operating.
For some machines, automatic feeding and ejection systems are an effective way to keep hands away from the point of operation. Even if this type of system is used, however, the point of operation must still be guarded to prevent people from placing their hands in the danger zone while monitoring the equipment.
When manual feed systems are used, guarding is required to ensure that you can feed materials into the machine without putting hands at risk. Manual feed methods include chute systems and plunger systems.
Mechanical ejection methods also help prevent amputations, since they eliminate the need for putting your hands into the point of operation to remove parts and scrap. Examples of these ejection methods include compressed air to blow the part out of the point of operation, shuttles that mechanically remove parts, mechanical ejectors that push the part out, and robotics.
Think about distance guarding methods used in the workplace.
Discuss distance guarding methods used in your workplace.

13. Amputations: General Hazards and Guarding
Do you understand the information presented in the previous slides?
Slide Show Notes
Now it’s time to ask yourself if you understand the information presented so far. Do you understand what we’ve discussed about applicable OSHA standards? Can you identify the four primary types of machines that present the most amputation hazards? Do you understand the general hazards of these and other hazardous machinery? Do you understand what we’ve discussed about types of guarding and safety devices as well as OSHA’s guarding requirements?
Preventing amputations depends on your knowledge of safety hazards and precautions. Lack of knowledge could cost you a finger, a hand, or even your life.
Answer any questions trainees have about the material presented in the previous slides.
Conduct an exercise, if appropriate.
Now let’s continue to the next slide and discuss the hazards of saws.

14. Saws—Hazards Table and radial arm saws
Handheld, chop, miter, and band saws
Point of operation— blade
Power transmitting unit—nip points
Slide Show Notes
The two types of saws most frequently associated with amputations are table saws and radial arm saws.
Other saws that present the hazard of amputations include handheld saws, chop saws, miter saws, and band saws.
The point of operation, which is the blade used for cutting, is the primary hazard associated with amputation injuries.
The power transmitting unit, from the motor that drives the blade motion, also contributes to amputation injuries. This might include a belt and pulley system with nip points or a rotating shaft.
Think about the hazards of the saws you use on the job or at home and the guarding that is necessary to protect against amputations.
Discuss hazards of any saws used in your workplace. Then, after presenting the information in the next slide, talk about the types of guarding used on your equipment to prevent amputations.

15. Saws—Guards Self-adjusting guards for the blade
Push sticks or other tools
Alternate fixed blade guards
Spreaders or antikickback fingers
Additional fixed guards for moving parts
Slide Show Notes
The guards normally used on saws are self-adjusting to the thickness of the material being cut. When material is not going through the blade, the guard completely covers the blade. However, when material is pushed through, the guard is pushed out of the way.
Since these guards do not completely eliminate the risk of contact with the blade, they should be supplemented with push sticks or push blocks to minimize the risk of amputation injuries.
For repetitive sawing operations or for jobs when standard guards can’t be used, jigs can minimize or eliminate amputation risks.
Alternate fixed guards can be used when self-adjusting guards can’t be used. Fixed guards might include a fixed enclosure, a fixed barrier guard, or a manually adjusted guard that allows material access to the blade while preventing you from touching the blade with your hand.
When saws are used for ripping, additional safeguards such as spreaders or antikickback fingers are required to prevent the material from pinching the blade or kicking back at you.
Additional guarding is required over moving parts such as a belt and pulley system or a rotating shaft. These guards should be fixed guards.

16. Shears—Hazards Mechanically driven ram moves the blade
Squaring shears cut sheet metal
Alligator shears cut metal stock
Guillotine shears cut paper, plastic
Primary hazard is point of operation
Other areas hazardous also
Slide Show Notes
Mechanical power shears are self-contained machines that use a mechanically driven ram for the shearing action. The ram moves a nonrotary blade at a constant rate past the edge of a fixed blade. The machine components generally consist of the frame, ram, blades, hold-downs, guards, drive, clutch, brake, motor, and controls. Shears can be mechanical, hydraulic, or pneumatic. OSHA says shear-associated amputation injuries occur primarily on three types of equipment:
Squaring shears used to cut sheets of metal;
Alligator shears used to cut metal stock; and
Guillotine shears used to trim, cut, or slice rolls and slabs of paper, plastic, film, and other materials.
The primary hazard of shears is the point of operation. Material is inserted into the point of operation, held, and ejected. If you insert and eject material manually, you are exposed to amputation hazards at the dangerous point of operation.
Be careful around all moving parts and pinch points.
Think about hazards and guarding for any shears used on the job.
Discuss hazards of any shears used in your workplace. Then, after presenting the information in the next slide, talk about the types of guarding used on your equipment to prevent amputations.

17. Shears—Guards Feed/eject systems Feeding tools Interlocked guards
Presence-sensing devices
Two-hand controls
Restraints or pull-back devices
Slide Show Notes
There are many guarding options for shears. The primary goal is to keep your hands out of the point of operation.
For example, feed/eject systems make it unnecessary for you to put your hands in or near the point of operation.
Feeding tools can also be used to place the material into the shear instead of your hand.
Interlocked guards can also be used. On shears, these guards are often doors that must be opened to insert material. When the door is opened, the machine shuts down and prevents it from shearing. Once the door closes, the machine turns back on and is able to shear the material.
Light curtains can also be used on shears to prevent machine operation when you reach through the light beams to insert the material. In addition, pressure-sensing devices such as floor mats can be used effectively to eliminate amputation risks.
Two-handed control devices are another way to prevent exposure to amputation hazards on shears.
And restraints or pull-back devices can also be used to keep your hands from going too close to the blade when inserting material.

18. Slicers—Hazards Meat and food slicers are most common
Most amputations occur in the restaurant and grocery industry
Primary hazard is point of operation
Operator pushes food through the blade
Slide Show Notes
The most common slicers are meat and food slicers.
These are powered machines that use a rotary blade to cut sections of meat, cheese, or other foods into slices. OSHA says that slicer-associated amputation injuries occur primarily on meat slicers used in restaurants and grocery stores. However, injuries occur in manufacturing plants that process food as well. And some people use slicers at home.
The primary hazard of slicers is the point of operation, where the food makes contact with the blade.
As the piece of meat or cheese gets smaller, your hand get closer to the blade. If you’re not careful, your hand can easily come in contact with the sharp, rotating blade, and you could lose part of a finger in a fraction of a second.
If you’ve ever used a slicer, you know they can be dangerous. One slip can cause a serious cut or even an amputation. Are you familiar with the hazards and required precautions for using slicers?
Discuss hazards of any slicers used in your workplace. Then, after presenting the information in the next slide, talk about the types of guarding used on your slicing equipment to prevent amputations.

19. Slicers—Guards Blade is typically unguarded
Adjust thickness to zero when slicer not in use
Use a guiding tool
Unplug when cleaning or clearing jams
Slide Show Notes
The rotary blade of a slicer is typically unguarded at the point of operation. The only time the blade is guarded is when the thickness adjustment has been moved to zero. Then the blade is set into the meat holder so that nothing can be cut off the block of food.
That’s why, when a slicer is not being used, you should always make sure the thickness is adjusted to zero so that the blade is not exposed.
Another way to protect against amputation hazards is to always use the guiding tool to hold the food in place when slicing so that your hand is kept away from the blade. Also make sure you’re aware of where your other hand—the one that’s not holding the guiding tool—is at all times. Keep it well away from the point of operation as well.
Finally, be sure to unplug a slicer before cleaning the machine or before clearing a food jam from the blade.

20. Power Presses—Hazards
Punch, shear, and form metal and other materials
Point of operation— materials manually fed
Reciprocating motion of ram
Power transmission units
Slide Show Notes
Power presses are used to work on metal or other materials by cutting or shaping, or with dies attached to plungers, platens, or slides—also called rams. The slide has a reciprocating motion toward and away from the bed surface at right angles.
Again, the point of operation is the primary hazard. If you feed material into the point of operation and hold it there while it is sheared, punched, or formed, and if your hand is caught in the point of operation during the press’s operation cycle, you could suffer a serious injury. Power presses typically have fast cycle time, and the ram closes with a lot of force.
Because of the reciprocating motion of the ram, you could be injured even if you’re not in the point of operation.
And there are other hazards as well. Power presses have a number of different types of power transmitting units such as belts and pulleys, rotating shafts, flywheels, and so on. These areas can be hazardous and require guarding.
Power presses are hazardous machines that cause many amputations every year. Think about power press hazards and required guarding.
Discuss hazards of any power presses used in your workplace. Then, after presenting the information in the next slide, talk about the types of guarding used on your power press equipment to prevent amputations.

21. Power Presses—Guards Feed/eject systems Interlocked guards
Light curtains
Two-hand controls
Pressure-sensitive devices
Fixed guards— reciprocating motion and power transmission
Slide Show Notes
Fortunately, there are many guarding options for power presses. The primary goal is to keep your hands out of the point of operation.
Feed/eject systems, for example, make it unnecessary to ever put your hands in the point of operation. When these systems are used, usually an automatic fixed or interlocked guard is put around the point of operation to prevent you from reaching in to clear a jam or make other types of adjustments.
Interlocked guards, such as doors, are also used. As with the interlocked guard on shears, when you open the door to insert material, the machine shuts down until the door is closed again.
Light curtains are also used on power presses.
And two-handed controls are frequently used to ensure you have both hands out of the point of operation before the press can be operated.
Pressure-sensitive devices, such as the mats we’ve already talked about, can also be used with power presses.
Additional guarding is necessary to protect against the reciprocating motion of the ram system. Typically, this part of the press is guarded with a fixed or barrier guard. And power transmitting units also have fixed guards over them.

22. Amputations: Specific Hazards and Guarding
Do you understand the information presented in the previous slides?
Slide Show Notes
Do you understand the information presented in the previous slides? Do you understand the hazards and guarding requirements for the four different types of machinery discussed in the slides?
Your safety depends on your understanding of this information.
Answer any questions trainees have about the material presented in the previous slides.
Conduct an exercise, if appropriate.
Now let’s continue to the next slide and talk about safe work practices to prevent amputations.

23. Safe Work Practices to Prevent Amputations
You should be able to:
Identify machine hazards
Understand the function of machine guards and safety devices
Identify personnel who are authorized to remove guards
Slide Show Notes
Machine safeguarding is a crucial part of our machine safety program. But guards alone won’t keep you safe. You have to use your knowledge and experience about machine safety every day on the job to be absolutely safe from amputation hazards. There’s a lot you need to know about safe machine work practices. For example, you should be able to:
Identify all the hazards associated with the machines you operate;
Locate the guards and safety devices on machines you operate, know what hazards they protect against, and how to use them safely; and
Identify personnel who are authorized to remove guards and understand the circumstances in which guards may be removed—for example, so that maintenance or repairs can be performed.
But there’s still more you need to know about safe work practices, as you’ll see in the next slide.

24. Safe Work Practices to Prevent Amputations (cont.)
You should also:
Know how to report damaged, missing, or inadequate guards
Understand risks of circumventing guards
Know how to inspect machines and guards before use
Know and follow machine-related safety rules
Slide Show Notes
You should also:
Know how to report damaged, missing, or inadequate guards;
Understand the potential risk of injury if you attempt to block or disable a machine guard;
Know how to inspect machines and guards before use to make sure the machine is safe; and
Know and follow all machine-related safety rules.
Do you always follow these and other safe machine work practices?
Review the specific safe work practices that apply to the machinery used by trainees. Add any other items trainees need to know to the lists on this and the previous slide.

25. Maintenance and Repair
Only remove guards for maintenance or repair
Lock out machine before removing guard
Lock out before clearing a machine jam
De-energize before changing dies or tools
Slide Show Notes
Machine guards should never be removed during normal operations. They may only be removed by authorized personnel when necessary for maintenance and repair.
OSHA-required lockout/tagout procedures must always be followed before machine guards are removed.
Lockout/tagout procedures should also be used when clearing jammed material out of a machine.
Special de-energizing procedures should be followed when changing dies or tools in machines such as power presses.
Are you familiar with the rules for machine maintenance or repair? Remember, you should never try to remove a guard or perform maintenance or repairs unless you’ve been trained and authorized.
Review your company’s rules for removing machine guards, including a brief review of lockout/tagout and de-energizing procedures, if appropriate.
Image Credit: WA State Department of Labor and Industries

26. Machine Hazard Assessment
Initial machine assessment
Annual guarding assessment
Post-injury evaluation
Daily machine inspections
Slide Show Notes
Finally, we should say a few words about machine hazard assessment.
Each machine that presents amputation hazards will be evaluated before it is used to determine if current guarding is adequate to prevent amputation injuries.
The same assessment will be conducted on an annual basis to see if guarding requirements have changed. If so, we will make the necessary adjustments to keep you safe.
We will also conduct a post-injury analysis anytime anyone is injured by a machine to determine if the guarding was adequate, whether it was used properly, and so on.
We also require you to inspect the machines you operate before each use to make sure all guards and safety devices are in place and operating properly, and that the machine is in generally safe condition.
Do you conduct daily inspections of the machines you operate? You should. It’s a simple but important step you can take to prevent amputations and other injuries.
Bring to the session copies of the daily machine inspection checklist that trainees should use for the machines they operate.

27. Key Points to Remember
Many machines in the workplace have hazards that can cause amputations
Keep hands away from the point of operation
Guard mechanical motion
Inspect all machines before use
Never use a machine without proper guarding
Follow safe work practices
Slide Show Notes
Here are the main points to remember from this session on preventing amputations:
Many machines in the workplace have hazards that can cause amputations.
Always keep your hands and other parts of your body away from the point of operation while a machine is operating. This is the most dangerous part of any machine.
Make sure all mechanical motions are properly guarded.
Inspect all machines before use to make sure guards are in place and the machine is working properly.
Never use a machine with a missing or malfunctioning guard.
And finally, always follow the safe work practices you have learned in training whenever you use any machine.
This concludes the preventing amputations training session.
Give trainees the quiz, if appropriate.