Basics of Machine Guarding

Hazards and Solutions

March, 2020
 Basics of Machine Safeguarding
Hazards and Solutions
Crushed hands and arms, severed fingers, blindness -the list of possible
machinery related injuries is as long as it is horrifying. There seems to be as
many hazards created by moving machine parts as there are types of machines.
Safeguards are essential for protecting workers from needless and preventable
injuries such as crushed hands and arms, severed fingers, and blindness.

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 Topics Covered

• Identify dangerous parts of machinery

• Identify hazardous actions and motions

of machinery
• Identify methods of safeguarding

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 Where Dangerous Mechanical Hazards Occur

Dangerous moving parts in these basic areas require safeguarding:

1.Point of operation
2.In running nip points
3.Pinch points
4.Power transmission
5.Other moving parts

Safeguarding can be accomplished by either machine guards or machine devices.

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 Steps of Machine Guarding
1. Recognize the hazards by identifying hazardous actions and
motions.
2. Analyze the workplace and prioritize safeguarding efforts based
on the most predictable injury, the probability of occurrence and
vailable resources.
3. Develop and implement a systematic safeguarding program
which includes identifying safeguarding methods, selection and
installation.
4. Ensure use of safeguarding and reinforce program by training,
education and enforcement.

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 Types of Mechanical Motions and Actions
The basic types of hazardous mechanical motions are rotating
motions, reciprocating motions and transverse motions.

Rotating motion - spinning

Reciprocating motion – back & forth

Transverse motion – one way

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What are the hazards of rotating motion?

Rotating Coupling with Rotating Shaft and Pulleys with

Projecting Bolt Heads Projecting Key and Set Screw

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 Rotating Parts
In-running nip point hazards

Parts rotating in opposite direction

Rotating and tangentially

moving parts

Point of contact
between a chain and a
sprocket
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 Rotating Parts
Nip Points Between Rotating and Fixed Parts
Nip points can occur between rotating and fixed parts which create a shearing, crushing, or abrading
action. Examples include: spoked handwheels or flywheels, screw conveyors, or the periphery of an
abrasive wheel and an incorrectly adjusted work rest and tongue.

Spoked flywheel Nip point between rotating screw conveyor Rotating abrasive wheel on
and fixed trough a grinder

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 Reciprocating motions
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.

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 Transverse Motion
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.

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Examples of 3 Types of Motion

Rotating and fixed parts

Transverse motion

Rotating and tangential motion

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Hazardous Machine Actions
Cutting

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Hazardous Machine Actions
Shearing

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Hazardous Machine Actions
Punching

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Hazardous Machine Actions
Bending

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 Methods of Safeguarding

There are many ways to safeguard machinery, and that

means any method of preventing employee contact with the
moving part.

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Develop & Implement Program

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 Develop & Implement Program
Safeguarding strategies are grouped under these general classifications:

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 Effective Guards

An effective guard must . . .

1. Prevent contact
2.Secured and well constructed
3.Protect from falling objects/contain the hazard
4. Create no new hazards
5.Create no interference
6.Allow safe lubrication

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 Machine Guards/Guarding

A “guard” prevents entry into the danger area.

There are four types of machine guards:
1.Fixed
2.Interlocked
3.Adjustable
4.Self-adjusting

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 First Choice – Guards
(barriers that prevent access)
Fixed guards are usually a permanent part of the machine that prevent access to
the danger area.
Fixed Guards
Permanent part of the machine
Not dependent upon moving parts to perform its intended
function
Constructed of sheet metal, screen,
wire cloth, bars, plastic or other substantial
material.
Usually preferable to all other types because
of its relative simplicity and permanence. Metal mesh guards

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Interlocked Guards

When this type of guard is opened or

removed, the tripping mechanism and/or
power automatically shuts off or disengages,
and the machine cannot cycle or be started
until the guard is back in place.

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 Adjustable Guards
Self-Adjusting Guard: The openings of these
barriers are determined by the movement of the
stock. As the operator moves the stock into the
danger area, the guard is pushed away,
providing an opening which is only large enough
to admit the stock. After the stock is removed,
the guard returns to the rest position. This guard
protects the operator by placing a barrier
between the danger area and the operator.

Adjustable guards allow flexibility in accommodating

various sizes of stock.
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 Placing guards at a safe distance
Table 200-1

Distance of opening from point of

operation Maximum width of opening (inches)
Hazard (inches) POO

* 1/2 to 1-1/2 1/4

Over 1-1/2 to 2-1/2 3/8
Over 2-1/2 to 3-1/2 1/2
Over 3-1/2 to 5-1/2 5/8
Over 5-1/2 to 6-1/2 3/4
Over 6-1/2 to 7-1/2 7/8

Over 7-1/2 to 12-1/2 1-1/4

Over 12-1/2 to 15-1/2 1-1/2

Over 15-1/2 to 17-1/2 1-7/8

Over 17-1/2 to 31-1/2 2-1/8

Over Over 31-1/2 6

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Placing guards at a safe distance

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 Second Choice – Devices (control access)
Devices control access to the point of operation and may replace or supplement
guards. To qualify as a device, it may perform one of several functions.

 Stop the machine if a hand or any part of the body is inadvertently placed in the danger area
 Restrain or withdraw the operator's hands from the danger area during operation.
 Require the operator to use both hands on machine controls, thus keeping both hands and
body out of danger.
 Provide a barrier which is synchronized with the operating cycle of the machine in order to
prevent entry to the danger area during the hazardous part of the cycle.
 Allow safe lubrication and maintenance and not create hazards or interfere with normal
machine operation.
 7/9Be secure, tamper-resistant and durable. I3EMNJ]\

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 Machine Guarding Devices

A “device” controls entry into the danger area.

Six types of Machine Devices:
1.Presence sensing device
2.Two hand control
3.Pullbacks/restraints
4.Moveable barriers (gates)
5.Safety trip controls

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 Presence Sensing Devices
These devices either stop the machine, or will not start the cycle, if a hand or any
part of the body is inadvertently placed in the danger area. There are 4 types of presence
sensing devices.
The light curtain (photoelectric-optical) presence
sensing device uses a system of light sources and
controls that can interrupt the machine's operating cycle.
If the light field is broken, the machine stops and will not
cycle. This device must be used only on machines
which can be stopped before the worker can reach the
danger area. The light curtain must be positioned at a
minimum safe distance from the machine’s point of
operation. If the light curtain is too close to the point of
operation, the workers hand could reach a danger zone
before the machine has time to stop.

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 Presence sensing devices

Radiofrequency
presence-sensing
device

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 Presence sensing devices

Electro-mechanical
sensing device

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 Presence sensing devices
The safety mat is a pressure sensitive safeguarding
product that is designed to detect the presence of
people on its sensing surface. Picture shows guarding
application using pressure sensitive floor mats. It can
be used to detect the presence of someone or
something within the protected area and can be used to
Safety Mat safeguard a floor area around a machine or robot.
A matrix of interconnected mats (safety mat system)
can be laid around the hazardous area and any
pressure (e.g. an operator’s footstep) will cause the
controller unit to send a stop signal to the machine.
They can also be used as a point of entry alert method.
Other safeguarding devices such as pressure sensitive
Source: Omron Industrial Automation safety edges and bumpers also fall into this family of
devices.
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 Guarding Devices – Pullback/Restraints
Uses a series of cables attached to the operator’s hands, wrists,
and/or arms and to a moving or fixed point.
The pullback is primarily used on machines with stroking action.
When the slide/ram is up, the operator is allowed access to the
point of operation. When the slide/ram begins to descend, a
mechanical linkage automatically assures withdrawal of the hands
from the point of operation.
The restraint (holdout) device uses cables or straps that are
attached to the operator's hands and a fixed point. The cables or
straps must be adjusted to let the operator's hands travel within a
predetermined safe area. There is no extending or retracting action
involved. Consequently, hand-feeding tools are often necessary if
the operation involves placing material into the danger area.
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 Guarding Devices – Safety Trip Controls
These devices provide a quick means for deactivating the machine in an emergency
situation.
A pressure-sensitive body bar, when depressed, will deactivate the machine. If the
operator or anyone trips, loses balance, or is drawn toward the machine, applying pressure to
the bar will stop the operation. The positioning of the bar, therefore, is critical. It must stop the
machine before a part of the employee's body reaches the danger area.
When pressed by hand, the safety trip-rod deactivates the machine. Because it has to be
actuated by the operator during an emergency situation, its proper position is also critical.
Safety tripwire cables are located around the perimeter
of or near the danger area. The operator must be able to
reach the cable with either hand to stop the machine.
All of these tripwires, rods or other safety devices
must be manually reset to restart the machine.

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 Guarding Devices – gates & moveable barriers
A gate is a moveable barrier which protects the operator at the point of operation
before the machine cycle can be started.
Gates are, in many instances, designed to be operated with each
machine cycle. If the gate is not permitted to descend to the fully
closed position, the press will not function. Another potential
application of this type of guard is where the gate is a component
of a perimeter safeguarding system. Here the gate may provide
protection not only to the operator but to pedestrian traffic as well.
There are two types of gate functions:

A type “A” gate remains closed during the entire cycle of the machine.
Use for full or part revolution clutches.
A type “B” gate opens after the die closing portion of the machine
cycle has been completed. Use for part revolution clutch only.
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Guarding Devices – Two hand controls/trips
These devices prevent the operator from reaching into the point of operation
when the machine cycles by requiring the hands to be on palm buttons or levers.
The two-hand control requires constant, concurrent pressure by the operator to activate the
machine. This kind of control requires a part-revolution clutch, brake, and brake monitor if used
on a power press as shown. With this type of device, the operator's hands are required to be at a
safe location (on control buttons) and at a minimum safe distance from the danger area while the
machine completes its closing cycle.
The two-hand trip requires concurrent application of both of the operator's control buttons to
activate the machine cycle, after which the hands are free. This device is usually used with
machines equipped with full-revolution clutches. The trips must be placed far enough from the
point of operation to make it impossible for the operator to move
his or her hands from the trip buttons or handles into the point
of operation before the first half of the cycle is completed. Thus
the operator's hands are kept far enough away to prevent them
from being accidentally placed in the danger area prior to the
slide/ram or blade reaching the full "down“ position.

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 Third Choice -Other Methods

When guards or devices cannot be used, “Other Methods” can be selected. These
other methods (safe distance, safe holding, safe opening, safe position of controls)
are methods of safeguarding that can be applied to machines with unique
safeguarding problems.
Other methods do not provide the protection of guards or devices. These methods
require placement or adjustment for each operation. They depend upon specific
procedures, work rules, extensive training and supervision to prevent the tendency
to circumvent the method used.

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 Other Methods
Safe Holding
This method is one that is designed and constructed so when the operator is
required to hold or support the work piece, the operator is prevented from
inadvertently reaching into the hazard area.

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 Other Methods
Safe Opening
This method is one that provides small opening to the hazardous area. It meets one of the
following conditions:
1.The opening, when no work piece is in place is small enough to prevent any part of operator’s
body from entering the area (1/4 inch or less opening); or
2.When part is in place, opening is only 1/4 inch to prevent any part of the operator’s body from
entering the hazardous area. The machine cannot cycle unless the work piece is in place.
Openings for two-dimensional work pieces meet the following conditions:
 Maximum area of any guard opening should be 7 square inches
(example: opening 2-1/2 inches by 2-1/2 inches has an area
of 6-1/4 inches);
 Longest dimension of a rectangular opening should be 3.5 inches;
 The maximum shorter dimension of the rectangular opening should
be 2 inches;
 The minimum distance from the guard to any point of operation is 4 inches.
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 Other Methods
Safe Position of Controls
Operating controls are properly positioned by one of these
methods:
1.Controls that require continuous actuation to complete the
hazardous portion of the cycle positioned so that no part of the
operator’s body can reach the hazardous area during the
hazardous portion of the cycle or until cessation of hazardous
motion; or
2.Controls for single-cycle machines located far enough from
the hazardous area that no part of the operator’s body can
enter before the machine completes the hazardous portion of
its cycle or until
cessation of motion. Remote controls cannot be easily
moved or are securely fixed in position.
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 Other Methods
Safe Distance
Eliminates the need for operator’s hands or other parts of the body to be in or near
the hazardous area during the hazardous portion of the cycle by one of the
following:
1.Work practice;
2.Size and location of work piece; or
3.Operator location where the operator is not required to place any part of body
within the established safe distance during
hazardous portion of cycle, nor is the operator
required to enter the safe distance for the
purpose of loading, unloading, adjusting,
measuring, cleaning.
Link to Table 200-2 – safe distance for fixed barricades
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Managing the Safeguarding Program

There is more to machine safeguarding than just guarding

machines. The employer must:
Ensure that employees are trained to do the job,
Ensure that employees wears personal protective
equipment to protect against other hazards,
Establish safe operating procedures,
Supervise to ensure compliance with company rules.

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 Managing the Safeguarding Program
Even the most elaborate safeguarding system cannot offer effective protection unless the worker
knows how to use it and why. Specific and detailed training is therefore a crucial part of any effort to
provide safeguarding against machine-related hazards. Thorough operator training should involve
instruction or hands-on training in the following key areas:
1.Parts and functions of the machine
2.Basic operator controls
3.Operator Responsibilities
4.Safeguarding
A description and identification of the hazards associated with particular
How to use the safeguards and why
How and under what circumstances safeguards can be removed, and by whom (in most cases,
repairs or maintenance personnel only).
What to do (e.g., contact the supervisor) if a safeguard is damaged, missing, or unable to provide
adequate protection.
This training is necessary for new operators and maintenance or setup personnel, when any new or
altered safeguards are put in service, or when workers are assigned to a new machine or operation.
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 Further Information
Oregon OSHA – Machine Safeguarding at the Point of Operation

U.S. Dep.t of Health and Humane Services –

Preventing Scalping and Other Severe Injuries from Farm Machinery

OSHA – Safeguarding Equipment and Protecting Workers from Amputations

OSHA – Guide for Protecting Workers from Woodworking Hazards

WorkSafe BC – Safeguarding in Metal Products Manufacturing

WorkSafe BC – Safeguarding in Food Products Manufacturing

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