Machine Guarding

Machine Guarding
OSHA 10-hour Outreach Training

General Industry
1
PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
Introduction
Possible machinery-related injuries include:
• Crushed fingers or hands
• Amputations
• Burns
• Blindness
A good rule to remember is:

Any machine part, function, or process which may
cause injury must be safeguarded.
2
Introduction
Lesson objectives:
1. Identify the main causes of machinery accidents.
2. Recognize basic machinery parts that expose
workers to hazards.
3. Recognize workplace situations involving
machinery that requires guarding.
4. Identify the requirements for safeguards.
5. Identify types of machine guards including types
of devices used to safeguard machines.
3
Machinery Accidents
Examples of how machine accidents

can occur:
• Reaching-in to “clear” equipment
• Not using Lockout/Tagout
• Unauthorized persons doing maintenance
or using the machines
• Missing or loose machine guards
4
Machinery Accidents
Amputations:
• Unguarded/inadequately
safeguarded machinery
• Materials handling activities Source: OSHA
• Activities involving
stationary machines
Source: OSHA
5
Basic Machinery Parts and Hazards
Three fundamental machine areas:

• Point of operation
• Power transmission device
• Operating controls – mechanical or electric
power control
Source: OSHA
6
Point of operation:
• Where work is performed on material
• Examples
– Cutting
– Shaping
– Boring
– Forming
Source: OSHA DTE
7
Power transmission device:
• Parts that transmit energy to the part of the
machine performing work
• Examples
– Flywheels – Cams
– Pulleys – Spindles
– Belts – Chains
– Connecting rods – Cranks
– Couplings – Gears
8
Hazardous motions and actions:

• Motions
– How the machine part moves
– Examples: rotating, in-running nip points,
reciprocating, and transversing
• Actions
– Operation that the machine part performs
– Examples: cutting, punching, shearing, bending
9
• Rotating parts with hazardous projections
Source of graphics: OSHA
10
• Common nip points on
rotating parts
11
• Nip points between rotating elements and
parts with longitudinal motions
12
• Nip points between rotating
machine components
13
• Reciprocating motions:
– Back-and-forth
– Up-and-down
Source: OSHA
14
• Transverse motion – movement in straight,
continuous line
15
• Cutting action – may involve rotating,
reciprocating, or transverse motion
Source: OSHA
16
• Punching action – power applied to a slide
(ram) for purpose of blanking, drawing, or
stamping metal or other materials
Source: OSHA
17
• Shearing action – applying power to a
slide or knife in order to trim or shear metal
or other materials.
Source: OSHA
18
• Bending action – applying power to draw
or stamp metal or other materials
Source: OSHA
19
Machinery That Requires Guarding
Machines that require point of operation guarding:
• Guillotine cutters
• Shears
• Alligator shears
• Power presses
• Milling machines
• Power saws
• Jointers
• Portable power tools
• Forming rolls and calenders
20
• Exposure of fan blades:

– Guard when periphery of
blades is less than 7’ above
the floor or working level
– Guards with openings no
larger than ½”
21
• Abrasive wheel machinery:

– Adjustable tongue guard to
within ¼” of wheel
– Work rest with maximum
opening of 1/8”
– Cover spindle end, nut, flange
projections
22
Revolving barrels, containers, and drums:

• Guard by an enclosure which is interlocked
with drive mechanism
• Guards with openings no larger than ½”
Source: OSHA
23
Power-transmission Unguarded belt

and pulley
apparatus:
• Shafting, flywheels,
pulleys, belts, chain
drives, etc.
• Less than 7 feet from the
floor or working platform
must be guarded
Source: OSHA
24
Machinery associated with amputations – examples:
1. Mechanical power 7. Food slicers
presses 8. Meat grinders
2. Power press breaks 9. Meat-cutting
3. Powered and non- band saws
powered conveyors 10. Drill presses
4. Printing presses 11. Milling machines
5. Roll-forming and 12. Grinding machines
roll-bending 13. Slitters
machines
6. Shearing machines
25
Requirements for Safeguards
Safeguards must meet these minimum
general requirements:
• Prevent contact
• Be secured
• Protect from falling objects
• Create no new hazards
• Create no interference
• Allow safe lubrication
Source: OSHA
26
Types of Machine Safe Guards
Safeguarding machinery:
• Primary methods
– Guards
– Devices
• Ensure employee protection
– Properly designed, constructed, and installed
– Used and maintained in good operating
condition
27
• Secondary methods
– Probe detection and safety edge devices
– Awareness devices
– Safeguarding methods
• Safe distance
• Safe holding
• Safe opening
– Safe work practices
• Safe work procedures
• Complementary equipment
28
Guards:
• Preferable to other control methods
• Provide physical barrier that prevents
contact with dangerous machine parts
• Four general types
– Fixed
– Interlocked
– Adjustable
– Self-adjusting
Source: OSHA
29
Fixed guard:
• Provides a barrier
• Permanent part of the machine, preferable
to all other types of guards.
Source of photos: OSHA
30
Interlocked guards:
• Shuts off or disengages power, stops
moving parts, and prevents starting of
machine when guard is open
• May use electrical, mechanical, hydraulic,
or pneumatic power, or combination
Source: OSHA
31
Adjustable guards:
• Shuts off or disengages power
• Stops moving parts
• Prevents starting of machine when
guard is open
Source: OSHA
32
Self-adjusting guards:
• Openings of barriers determined by
movement of the stock
• Places barrier between danger area
and operator
Source: OSHA
33
Devices:
• Controls or attachments that prevent inadvertent
access by employees to hazardous machine areas
• Examples
– Presence sensing – Safety trip controls
• Photoelectric – Two-hand control
• Radiofrequency
– Two-hand trip
• Electromechanical
– Gate
– Pullback
– Restraint
34
Presence-sensing devices:
• Photoelectric
• Radiofrequency
• Electromechanical
Source: OSHA
35
Pullback devices:
• Utilize a series of cables
attached to operator
• Automatically withdraws
hands from point of
operation when slide/ram
begins to descend
Source: OSHA
36
Source: OSHA Source: OSHA
• Hands in die, feeding • Die closed

• Point of operation exposed • Hands withdrawn from
point of operation by
• Pullback device attached and
pullback device
properly adjusted
37
Restraint devices:
• Utilize cables/straps
attached to operator’s
hands and a fixed point
• No extending/retracting
action involved
• Hand-feeding tools may
be necessary
38
Safety trip controls:
• Deactivates the machine
in an emergency situation
• Examples
– Pressure-sensitive bar
– Safety tripod
– Safety tripwire
• Positioning is critical;
must stop machine before
body reaches danger area
39
Two-hand controls:
• Deactivates the machine
in an emergency situation
• Pressure-sensitive
• Positioning is critical;
must stop machine before
body reaches danger area
40
Gate devices:
• Moveable barrier that protects operator at
point of operation before machine cycle can
be started
• Must be interlocked so machine cannot begin
cycle unless gate guard is in place
• Must be closed before machine can function
• Types
– “A” Gate
– “B” Gate
41
Gate Open
Gate devices:
• Moveable barrier that protects
operator at point of operation
before machine cycle can be
started
• Must be interlocked so Gate Closed
machine cannot begin cycle
unless gate guard is in place
• Must be closed before
machine can function
42
Type “A” Gate Operation Type “B” Gate Operation
43
Additional Safeguarding
Location/distance:
• The dangerous moving part of a machine
must be so positioned that those areas are
not accessible or do not present a hazard
• Feeding process safeguarded
by maintaining safe distance
to protect worker
• Operator’s controls located
safe distance from machine
Source: OSHA
44
Transparent
Enclosure
Guard
Feeding and ejection Stock Feed

Roll
methods:
• Automatic/
semi-automatic feed
Completed Work
• Automatic/
semi-automatic ejection
• Robots
45
Miscellaneous aids:
• Awareness barriers
• Protective shields
• Hand-feeding tools
46
Identify the Hazard
Unguarded lower blade and

arbor end of radial saw.
47
Identify the Hazard
Guard removed from chain rail exposing pins on

the spiked chain and sprocket mechanism.
48
Summary
• Safeguards are essential for protecting
workers from needless and preventable
machinery-related injuries
• The point of operation, as well as all parts
of the machine that move while the
machine is working, must be safeguarded
• A good rule to remember is:
Any machine part, function, or
process which may cause injury
must be safeguarded
49
Knowledge Check
1. All machines consist of three fundamental areas,
including __.
a. Flywheels, connecting rods, and transverse moving
parts
b. Point of operation, power transmission device, and
operating controls
c. Reciprocating parts, rotating parts, and on/off switch
d. Feed mechanisms, auxiliary machine parts, and nip
points
Answer: b. point of operation, power transmission device,

and operating controls
50
Knowledge Check
2. Rotating, in-running nip points,

reciprocating, and transversing are
types of hazardous ___.
a. motions
b. actions
c. guards
d. devices
Answer: a. motions
51
Knowledge Check
3. Cutting, punching, shearing, and

bending are types of hazardous ___.
a. motions
b. actions
c. guards
d. devices
Answer: b. actions
52
Knowledge Check
4. Which of the following explains how a guard
protects workers?
a. Stops the machine when a worker enters the
danger area
b. Restrains the worker from entering the danger
area
c. Creates distance to keep the worker from
entering the danger area
d. Provides a barrier to prevent access to the
danger area
Answer: d. Provides a barrier to prevent
access to the danger area
53
Knowledge Check
5. Which of the following is an example of

a safeguarding device?
a. Protective shield
b. Hand-feeding tool
c. Safety trip control
d. Awareness barrier
Answer: c. Safety trip control
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Machine Guarding

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Machine Guarding

OSHA 10-hour Outreach Training

A good rule to remember is:

Examples of how machine accidents

Three fundamental machine areas:

Source: OSHA DTE

Hazardous motions and actions:

Source of graphics: OSHA

Source of graphics: OSHA

Source of graphics: OSHA

Source of graphics: OSHA

Source of graphics: OSHA

Source of graphics: OSHA

• Exposure of fan blades:

Source of graphics: OSHA

• Abrasive wheel machinery:

Source of graphics: OSHA

Revolving barrels, containers, and drums:

Power-transmission Unguarded belt

Source of graphics: OSHA

Source of photos: OSHA

Source: OSHA Source: OSHA

• Hands in die, feeding • Die closed

Source of graphics: OSHA

Source of graphics: OSHA

Type “A” Gate Operation Type “B” Gate Operation

Source of graphics: OSHA

Feeding and ejection Stock Feed

Source of graphics: OSHA

Source of graphics: OSHA

Unguarded lower blade and

Guard removed from chain rail exposing pins on

Answer: b. point of operation, power transmission device,

2. Rotating, in-running nip points,

3. Cutting, punching, shearing, and

5. Which of the following is an example of

Answer: c. Safety trip control

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