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103.(I) SAFE GUARDING OF MACHINES

A.MAHANTI

(Statutory provision related to principles in machine guarding. Type of guards,

their design and selection. Guarding of different types of machinery including
special precautions of wood working, paper rubber and printing machinery,
machine tools, etc. Built-in-safety devices, maintenance and repairs of
guards, incidental safety devices and tools.)

1.0 STATUTORY PROVISION:

(FACTORIES ACT,1948 &WB FACTORIES RULES-1958)

Section 21. Fencing of machinery.-

(1) In every factory the following, namely-

(i) every moving part of a prime-mover and every flywheel

connected to a prime-mover,
(ii) the headrace and tailrace of every water-wheel and water-
turbine;
(iii) any part of a stock bar which projects beyond the head stock
of a lathe; and
(iv) unless they are in such position or of such construction as to
be safe to every person employed in the factory as they would
be if they were securely fenced, the following, namely:-
o (a) every part of an electric generator, a motor or rotary
converter;
o (b) every part of transmission machinery; and
o (c) every dangerous part of any other machinery; shall be
securely fenced by safeguards of a substantial construction
which shall be constantly maintained and kept in position
while the parts of machinery they are fencing, are in
motion or in use:

Provided that for the purpose of determining whether any part of

machinery in such position or is of such construction as to be safe as
aforesaid, account shall not be taken of any occasion when-

(i) it is necessary to make an examination of any part of the

machinery aforesaid while it is in motion or, as a result of such
examination to carry out lubrication or other adjusting operation
while the machinery is in motion, being an examination of
operation which it is necessary to be carried out while that part
of the machinery is in motion. or
(ii) in the case of any part of a transmission machinery used in
such process as may be prescribed (being a process of a
continuous nature, the carrying on of which shall be or is likely
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to be substantially interfered with by the stoppage of that part of

the machinery), it is necessary to make an examination of such
part of the machinery while it is in motion or, as a result of such
examination, to carry out any mounting or shipping of belts or
lubrication, or other adjusting operation while the machinery is
in motion, and such examination or operation is made or carried
out in accordance with the provisions of sub-section (1) of
section 22.

(2) The State Government may by rules prescribe such further

precautions as it may consider necessary in respect of any particular
machinery or part thereof or exempt, subject to such condition as may
be prescribed, for securing the safety of the workers, any particular
machinery or part thereof from the Provisions of this section.

Rule-47: Safety precautions prescribed under sub section( 2) of Sec-21-

Without prejudice to the provision under sub section (2) of section 21 in regard
to the fencing of machineries, the further precautions specified in the Schedule
annexed hereto shall apply to the machines noted in each Schedule:

SCHEDULE-I JUTE TEXTILES

SCHEDULE-II COTTON TEXTILES

SCHEDULE-I IIWOOD WORKING MACHINERIES

SCHEDULE-IV RUBBER MILLS

SCHEDULE-V POWER PRESS

SCHEDULE-VI SHEARS,SLITTERS& GUILLOTINE MACHINES

SCHEDULE-VII CENTRIFUGAL MACHINES

Section 22. Work on or near machinery in motion.-

(1) Where in any factory it becomes necessary to examine any part of

machinery referred to in section 21, while the machinery is in motion,
or, as a result of such examination, to carry out-

(a) in a case referred to in clause (i) of the proviso to sub-

section (1) of section 21, lubrication or other adjusting
operation; or
(b) in a case referred to in clause (ii) of the proviso aforesaid,
any mounting or shipping of belts or lubrication or other
adjusting operation,

while the machinery is in motion, such - examination or operation shall

be made or carried out only by a specially trained adult male worker
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wearing tight fitting clothing (which shall be supplied by the occupier)

whose name has been recorded in the register prescribed in this behalf
and who has been furnished with a certificate of his appointment, and
while he is so engaged,-

(a) such worker shall not handle a belt at a moving pulley

unless-
o (i) the belt is not more than fifteen centimetres in width;
o (ii) the pulley is normally for the purpose of drive and not
merely a fiy-wheel or balance wheel (in which case belt is
not permissible);
o (iii) the belt joint is either laced or flush with the belt;
o (iv) the belt, including the joint and the pulley rim, are in
good repair;
o (v) there is reasonable clearance between the pulley and
any fixed plant or structure;
o (vi) secure foothold and, where necessary, secure
handhold, are provided for the operator; and
o (vii) any ladder in use for carrying out any examination or
operation aforesaid is securely fixed or lashed or is firmly
held by a second person ;
(b) without prejudice to any other provision of this Act relating
to the fencing of machinery, every set screw, bolt and key on
any revolving shaft, spindle, wheel or pinions and all spur, worm
and other toothed or friction gearing in motion with which such
worker would otherwise be liable to come into contact, shall be
securely fenced to prevent such contact.

(2) No woman or young person shall be allowed to clean, lubricate or

adjust any part of a prime-mover or of any transmission machinery
while prime-mover or transmission machinery is in motion, or to clean,
lubricate or adjust any part of any machine if the cleaning, lubrication
or adjustment thereof would expose the woman or young person to
risk of injury from any moving part either of that machine or of any
adjacent machinery.

((a) "adult" means a person who has completed his eighteenth

year of age;
(b) "adolescent" means a person, who has completed his
fifteenth year of age but has not completed his eighteenth year;
(d) "young person" means a person, who is either a child or an
adolescent; )

(3) The State Government may, by notification in the Offlcial Gazette

prohibit, in any specified factory or class or description of factories, the
cleaning, lubricating or adjusting by any person of specified parts of
machinery when those parts are in motion.
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Rule- 53. Work on or near machinery in motion.-(l) One or more adult male
workers shall be appointed for the purposes of under sub-section (1) of section
22. A list of such workers shall be maintained in a register as nearly as possible
in Form No. 7.

(2) No worker shall be appointed unless he has been suitably trained for such
examination or operation and is acquainted with the dangers from moving
machinery arising in connection with such work.

(3) A worker required to wear tight fitting clothing under sub-section (1) of section
22 shall be provided by the occupier with such clothing which shall consist of at
least a pair of closely fitting shorts and a closely fitting half-sleeve shirt or vest.
Such clothing shall be returned to the occupier on termination of service or when
new clothing is provided.

Section 23. Employment of young persons on dangerous

machines.-

(1) No young person shall be required or allowed to work at any

machine to which this section applies, unless he has been fully
instructed as to the dangers arising in connection with the machine
and the precautions to be observed, and-

(a) has received sufficient training in work at the machine, or (b) is

under adequate supervision by a person who has a thorough
knowledge and experience of the machine.

(2) Sub-section (1) shall apply to such machines as may be prescribed

by the State Government, being machines which in its opinion are of
such a dangerous character that young persons ought not to work at
them unless the foregoing requirements are complied with.

54. Employment of young persons on dangerous machines.-

The following machines shall be deemed to be of such dangerous character that
young persons shall not work at them unless the provisions of sub-section (1) of
section 23 are complied with :-

Power presses other than hydraulic presses;

Milling machines used in the metal trades;

Guillotine machines

Circular saws;

Platen printing machines.

2.0 OBJECT: To prevent contact of any part of the body with the dangerous parts
of the machinery and thus to avoid accidental injury to the workers and to protect
them from operational, mechanical or electrical failure of plant and equipment.
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The dangerous parts of the machine include:

Point of operation
Transmission machinery
Other dangerous part
2.1 PRINCIPLE:
Four areas of safety should be considered with every machine:
Maintenance necessitating some part of the body not being in the path of
machine movement
Protection of the operator at the point of operation
Protection from machine movement during operation
Servicing, adjustment, maintenance and repairs which must be done with
the guards temporarily removed and other safety devices bypassed.
2.2 BASIC REQUIREMENTS FOR EFFECTIVE GUARDING MECHANISM:
An effective guard must conform to IS specifications and should be designed
constructed and used as to:
Be simple in design, robust in construction without mechanical defect and
easy to repair/maintain;
Provide positive protection;
Prevent access to the danger zone during operation;
Create no discomfort or inconvenience to the operator;
Cause no interference with production;
Operate automatically or with minimum effort;
Be suitable for the job and the machine;
Constitute a built-in feature;
Allow machine lubrication, inspection, adjustment, maintenance;
Withstand long use, normal wear and shock with minimum maintenance;
Present no potential hazard by itself;
Be resistant to fire and corrosion;
Protect against unforeseen operational condition;
Do not obstruct operators vision;
Adhere to the provisions of sec-21 of the Factories Act,1948 and rules
framed there under;
The above requirements should satisfy while designing the guard for a machine
or equipment. It should however be remembered that designing of guards calls
for experience, specification, imagination and research..

3.3 DANGEROUS PARTS OF MACHINES REQUIRING GUARDS:

PARTS EXAMPLES
ROTATING PARTS SHAFT,PULLEY, COUPLING, FLY
WHEEL
CUTTING/SHEARING PARTS MILLING, DRILLING, BAND SAW,
SHEARING MACHINE
IN-RUNNING NIP POINTS BELT DRIVERS, ROLLERS,PINIONS
SCREW MECHANISM SCREW CONVEYOR, LATHE
FORMING AND BENDING PRESS BRAKE

3.4 ZERO MECHANICAL STATE(ZMS)

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Depending upon the type of equipment, one must consider the following sources
of energy during maintenance work:
Electrical;
Hydraulic fluid under pressure;
Compressed air
Potential energy from suspended object;
: Potential energy stored in spring
Once any/all the above mentioned energies are neutralized, the machine is in a
state called Zero Mechanical State)
It affords maximum protection against unexpected movement. The concept
includes not only locking out the energy(electrical) but also requires that all
kinetic and potential are isolated, blocked, supported, retained or controlled to
the extent that such energies will not be released unexpectedly. This state
minimizes the number of accidents while doing maintenance job on machines.

4.0 TYPES OF GUARDS:

FIXED
INTERLOCKING
AUTOMATIC
DISTANCE/POSITIONAL-INCLUDING BARRIER WITHADEQUATE
HEIGHT
BUILT IN-SAFETY BY CONSTRUCTION
SAFETY BY POSITION OF THE MACHINERY
TRIP DEVICES-INCLUDING SENSITIVE SCREEN/PHOTO ELECTRIC
DEVICE

4.1 SELECTION OF SAFE GUARD:

In order of preference in selecting an appropriate safe guard for a

particular machinery, a fixed guard provides the highest standard of
protection and should be used as far as practicable where access to the
danger area is not required during normal operation;
Where access to the danger area is required:
a) Interlocking guard
b) Automatic guard
c) Adjustable guard-which may be fixed type;
d) Two way control device- may be selected

Where access to danger area is not required during normal operation, the
following type of guards may be considered:
a) Fixed guard
b) Distance guard including barrier of adequate height;
c) Trip device including a sensitive screen/photo electric
device.

SL MACHINE/MACHINE SUITABLE TYPE OF GUARD

NO PARTS
1 Band saw Adjustable guard-as change of saw is
often required.
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2 Circular saw Automatic guard

3 Drilling machine-(spindle Adjustable guard
and drill)
4 Guillotine cutter Fixed guard
5 Milling machine Adjustable guards with interlocks, gear
train- fixed guard, V-belt-adjustable guard
6 Planning machine Barrier in front and back-not adjustable in
running condition
7 Planner table Adjustable guard
8 Power brake(shearing Away from point of operation, adjustable
machine) guard, photo-sensitive guard
9 Power press Interlocking guard, photo-electric guard,
two hand control fly wheel, fixed guard
10 Pressure rolls Nip guard with brushing arrangement
11 Rack and pinion Nip guard
12 Rotating bar stock Adjustable guard
13 Rotating screw conveyor Complete enclosure with interlocking
arrangement
14 Shaper machine Barrier in front and back-not adjustable in
running condition
15 Spur gear Fixed guard

4.2 GUARDING MATERIAL:

Preferable material under most circumstances is metal, structural pipe, or

perforated or solid sheet metal or wire mesh.

Plastic or safety glass is used where visibility is required.

Wood has limited application.

Aluminium or other soft metals are also used where rust is a possible danger.

Whatever material is selected, it should be substantially strong enough to

withstand the external impact of the materials

4.3 GUARD OPENING

-
It is very much important for Point of Operation Guard but not important in case of
Transmission machinery guard.

It normal practice, the opening should not be more than 3/8 inch.

Some designers use the following formula:

Max. safe opening= + 1/8 th the distance of guard from danger zone.
( this formula, however, does not hold good where the distance from the guard
to the danger zone exceeds 12 inches.)
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4.4 DESCRIPTION OF A FEW GUARDS

4.4.1 FIXED GUARD:
It is considered preferable to all other type of guards and should be used in every
case, unless it has been definitely determined that this type of guard is not practible.
The guard at all time prevent access to the dangerous parts of the machine.
Fixed guard may be adjustable to accommodate different sets of tools or various
kind of work. Once adjusted, they should remain fixed and there should be neither
movement nor detachment of them. Some fixed guards are installed at a distance
from the danger point in association with remote feeding arrangement which makes
it unnecessary for the operator to approach the danger point.

SUITABILITY:
POWER PRESS, SHEET LEVELLING OR PLATTENING MACHINE, MILLING
MACHINE, GEAR TRAINS, DRILLING MACHINE AND GUILLOTINE CUTTER

ADVANTAGE:
Easy to install
Ideal for blanking Power press
Can be combined with automatic or semi automatic feed
Permits increased production
Both hands free
Complete enclosure
4.4.2 INTERLOCKING GUARD

If a fixed guard can not be used, an interlocking guard should be fitted as the first
alternative. The type may be mechanical, electrical, pneumatic or combination type.

This type of guards prevents operation of control that sets the machine in motion
until the guard is moved into position, so that operator can not reach the danger or
point of operation. When guard is open, permitting access to the dangerous part, the
starting mechanism is locked and a locking pin or other suitable safety device
prevents the main shaft from turning or other basic mechanism from operating.
When the machine is in motion, the guard can not be opened. It can be opened
when only when the machine has come to rest or has reached a fixed position in its
travel.

BASIC REQUIREMENT:
An effective interlocking guard must satisfy the following three requirents. It must:
Guard the dangerous part before the machine can be operated
Stay closed until the dangerous part is at rest
Prevent operation of the machine if the interlocking device fails
Mechanical interlocks may be used if fixed or interlocking guards are not practicable.

SUITABILITY:
SHORT STROKE HIGH SPEED POWER PRESS, HYDRAULIC PRESS, HYDRO
EXTRACTOR, CENTRIFUGES, MILLING MACHINE, ROTATING SCREW
CONVEYOR.

ADVANTAGE:
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Ample space in power press can be arranged for feeding the job into the
space between the dies
Wear and tear is inevitably present in the automatic guard

4.4.3 AUTOMATIC GUARD

This type of guard is used subject to its limitation that it has excessive installation
cost for short run, requires skilled maintenance and not adjustable to variation in
the stock. Where neither a fixed nor an interlocking guard is practicable
automatic guard should be considered. Such a guard must prevent the operator
from coming in contact with the dangerous part of the machine while it is in
motion or must be able to stop the machine in case of danger.

An automatic guard functions independently of the operator and its action is

repeated as long as the machine is in operation. It is usually operated by the
machine itself through a system of levers/linkages. The stock is fed by chutes,
hoppers, conveyors, movable dies etc.

ADVANTAGE:
Generally increases production,
Operator can not place hands in danger zone.

SUITABILITY:
BAKING AND CANDY MACHINE, CIRCULAR SAW, POWER PRESS, TEXTILE
PICKERS, WOOD PLANNER, WOOD SHAPER

4.4.4 A) DISTANCE OR POSITIONAL GUARD:

Distance guard is fixed type guard which by its position(distance from the
dangerous part of machine) prevents theoperatorfrom reaching dangerous part of
the machine but which will permit the movement of material. The guard should be
capable of adjustment to suit various operators such that when an arm is
stretched over or through the guard and the fingers are extended to the fullest
extent, it should be impossible to put them into danger zone. The correct
distance of bars is a matter of experiment in a particular case but it may be
acceptable that an upper horizontal bar fitting just within the arm put of a person
standing erect and which is not less than 30 inch from the point of danger is
sufficient. In conjunction with fixed fencing on the sides and below the guard is
quite effective.

B) POSITIONAL/ TWO WAY CONTROL DEVICE:

This type of safety device requires simultaneous application of both hands to

operate the controls so that the hands of the operator are kept out of point-of-
operation area while the slide is descending. These controls can be electrical,
pneumatic or mechanical.
For electric control, a solenoid should be used in the point of operation control circuit
so that press can not be actuated unless its motor is running. The two buttons or
levers should be 21 inch apart.
Two way control device installed on power presses with friction clutches must be
constant pressure type.

ADVANTAGE:
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Operator hand away from danger zone.

SUITABILITY:
DOUGH MIXER, EMBOSSING PRESS, PAPER CUTTERS, PRESS
MACHINES.

4.4.5 SAFETY BY CONSTRUCTION OR BUILT IN GUARD:

Most of the manufacturers make point of operation and power transmission

guarding standard equipment which means machine can not be purchased
without guards.
The advantage of this type of built in guards are as follows:
They are less expensive than guards which are separately purchased or
built and installed by the user,
They usually conform better to the design and operation of the machine,
They can be designed to strengthen the machine or serve other functional purpose

SUITABILITY:
ENCLOSED SPEED GEAR BOXES OF LATHE(CAPSTAN AND TURRET);
MILLING MACHINE, RADIAL DRILL; TOTALLY ENCLOSED INDIVIDUALLY
DRIVEN MILLING MACHINE.

4.4.6 SAFETY BY POSITION:

Some time safety of machine may be ensured by safe positioning of the machine
so that the dangerous part of the machine remains out of reach of the operator.
The machine remains unguarded. It is assumed that the operator need not
approach the machine and it can be operated from distance. But it can not be
ruled out that accident may occur due to careless ness or thoughtlessness of the
operator. So choice of this type of guarding is not preferred.in the safety point of
view.it is therefore preferable that fencing of the machine by efficient guard would
be safer and one should not rely on this type of guard.

4.4.7 TRIP GUARD/TRIP DEVICE:

The trip guard/device is based on the principle of stopping a machine almost

instantly should approach be made very close to the dangerous part. This requires
disconnection of the driving mechanism associated with simultaneous application of
powerful brakes. This has same effect as if the stop button is pushed. To be
effective, this type of device should be operated from a closed electric circuit so that
interruption will automatically stop the driving mechanism.

SUITABILITY:
This type of guard is particularly suitable for large presses. The photo electric cell
or electric eye should be installed far enough from the point of operation area
that it will stop the ram before the operators hand can get under it and enough
light beams must be used to cover the open area with a curtain of light.

These devices, however, can not be used in positive clutch power press. Not
effective on punch press with positive clutch because once the operating cycle of
a power press starts, no device can prevent completion of the cycle.
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These devices should always be supplemented by hand tools or feeding and

ejecting devices so that operator need not place his hand in the point of
operation zone.

5.0 SOME IMPORTANT CONSIDERATIONS IN SAFE GUARDING:

Guarding is unnecessary, if the nearest nip point between tool and dye in
a power press can be limited to inch or 6mm.
The buttons or levers of a dual control trip device shall be located at least
21 inch apart.
If the planer bed of a stock on bed being processed travel within 18 inches
(457.2 mm) of a wall or fixed object, the space between the two ends of
the travel should be closed by barrier on either side.
The guards once taken out for repair of equipment or machine must be
fitted back on its position.
All guards are to be maintained properly and inspected regularly.

6.0 GUARDING OF DIFFERENT TYPES OF MACHINERIES:

A. WOOD WORKING MACHINERIES:
CIRCULAR SAW,
HORIZONTAL SAW
VERTICAL BAND SAW
OVERHEAD PLANING MACHINE
SPINDLE MOULDING MACHINES (SHAPERS)

CIRCULAR SAWS:
HAZARDS:
Contact with saw blade-moving/stationary
Kickback.

Every circular saw shall be fenced as follows:-

(a) Riving knife or spreader- Behind and in direct line with the saw there shall
be a riving knife, which shall have a smooth surface, shall be strong, rigid and
easily adjustable, and shall also conform to the following conditions :-

(i) The edge of the knife nearer the saw shall form an arc of a circle having a
radius of the largest saw used and it shall extend upward from the bench to a
height not less than that, reached by the largest wood or timber sawn.
(ii) The knife shall be maintained as close as possible to the saw, having regard
to the nature of the work being done at the time, and at the level of the bench the
distance between the front edge of the knife and the teeth of the saw shall not
exceed half an inch.
(b) Hood or crown guard- The top of the saw shall be covered by a strong and
easily adjustable guard, with a flange at the side of the saw farthest from the
fence. The guard shall be kept so adjusted that the said flange shall extend
below the roots of the teeth of the saw. The guard shall extend from the top of
riving knife to a point as low as practicable at the cutting edge of the saw. The
hood is supported in position by an arm fixed suitably to a post fixed to the
bench. It is U or L shaped and be strong enough to protect the operator against
flying slivers or broken saw teeth.
(c) Apron guard- The part of the saw below the bench shall be protected by two
plates of metal or other suitable material one on each side of the saw; such
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plates shall not be more than six inches apart, and shall extend from the axis of
the saw outwards to a distance of not less than two inches beyond the teeth of
the saw . Metal plates, if not beaded, shall be of a thickness of at least 1/10 inch,
or if beaded be of a thickness of at least 1/20 inch.
(d) Anti kick back fingers(dogs)- they are fitted in addition to the spreaders
/riving knife to prevent accident due to kick back. They may be in the form of
seriated can allowing the wood to move forward but preventing it from being
thrown back.

(e)Push sticks.-A push stick or other suitable appliance shall be provided for use
at every circular saw and at every vertical spindle moulding machine to enable
the work to be done without unnecessary risk.

Band saws.-Every band saw shall be guarded as follows :-

(a) Both sides of the bottom pulley shall be completely encased
by sheet metal or other suitable material
(b) . The front of the top pulley shall be covered with sheet metal
or other suitable material.
(c) Al! portions of the blade shall be enclosed or otherwise
securely guarded except the portion of the blade between
the bench and the top guide.

Planing machines.-(I) A planing machine (other than a planing machine which is

mechanically fed) shall not be used for over hand planing unless it is fitted with a
cylindrical cutter block.

(2) Every planing machine used for overhand planing shall be provided with a
"bridge" guard capable of covering the full length and breadth of the cutting slot
in the bench, and so constructed as to be easily adjusted both in a vertical and
horizontal direction.

(3) The feed roller of every planing machine used for thicknessing except the
cornbined machine for overhand planing aid thicknessing, shall be provided with
an efficient guard.

Vertical spindle moulding machines.-(1) The cutter of every vertical spindle

moulding machine shall be guarded by the most efficient guard having regard to
the nature of the work being performed.
(2) The wood being moulded at a vertical spindle moulding machine shall, if
practicable, be held in a jig or holder of such construction as to reduce as far as
possible the risk of accident to the worker.

Chain mortising machines.--The chain of every chain mortising machine shall

be provided with a guard which shall enclose the cutters as far as practicable.

Adjustment and maintenance of guards.-The guards and other appliances

required under this Schedule shall be-
(a) maintained in an efficient state,
(b) Constantly kept in position while the machinery is in motion. and
(c) so adjusted as to enable the work to be done without unnecessary risk.
B. RUBBER MILLS
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Installation of machines- Mills for breaking down. cracking, grating, mixing,

refining and warming rubber or rubber compounds shall be so installed that the
top of the front roll is not less than forty-six inches above the floor or working
level : Provided that in existing installation where the top of the front roll is below
this height a strong rigid distance bar guard shall be fitted across the front of the
machine in such position that the operator cannot reach the nip of the rolls.

Safety devices.-(1) Rubber mills shall be equipped with horizontal safety-trip

rods or tight wire cables across both front and rear, which will, when pushed or
pulled, operate instantly to disconnect the power and apply the brakes, or to
reverse the rolls.

(2) Safety-trip rods or tight wire cables on rubber mills shall extend across the
entire length of the face of the rolls and shall be located not more than fifty-nine
inches above the floor or working level.

(3) Safety-trip rods and tight wire cables on all rubber mills shall be examined
and tested daily in the presence of the Manager or other responsible person and
if any defect is disclosed by such examination and test the mill shall not be used
until such defect has been remedied.

C.POWER PRESSES:

1. Definition.--For the purposes of this Schedule power press means a machine

used in metal or other industries for blanking, raising, drawing and similar
processes. Such machine usually consists of frame within which powered slide or
ram is moved in a reciprocating motion, at right angle to a stationary bed.
Attached to the ram and stationary bed there are mated dies which cut or form
material placed between them when tremendous pressure is applied by the
slide(ram) to close the dies.
TYPES:
1. Mechanical power press
2. Hydraulic and pneumatic power press
3. Power press brake or power brake
4. Shear press
2. Starting and stopping mechanism.-The starting and stopping mechanism
shall be provided with a safety stop so as to prevent overrunning of the press or
descent of the ram during tool setting. etc.

3. Protection of tool and die:

(a) Each press shall be provided with a fixed guard with a slip plate on the
underside enclosing the front and sides of the tool

(b) Each die shall be provided with a fixed guard surrounding its front and sides,
and extending to the back in the form of a tunnel through which the pressed
article falls to the rear of the press.
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(c) The design, construction and mutual position of the guards referred to in (a)
and (b) shall be such as to preclude the possibility of the worker's hand or fingers
reaching the danger zone.

(d) The machine shall be fed through a small aperture at the bottom of the die
guard, but a wider aperture may be permitted for second or subsequent
operations if feeding is done through a chute.

POINT OF OPERATION GUARDING:

Accident occurs due to
1) Mechanical or electrical malfunction
2) Inadequate guarding of point of operation.
There are several kinds of guards, devices and combination of devices which can
be used for safe guarding of presses. Ideally the best guard for all operation
should be fixed barrier guard(mounted either on press frame or on the dies)
which would keep operators hand out of danger zone. The following are various
guards/devices to safe guard the press:

DIE-ENCLOSURE GUARD- Material- pre fabricated slotted material/ metal

frame/ welded rod stock/ transparent plastic (at least inch thick)
They are attached to die shoe or stripper in fixed position. A minimum 1 inch
clearance must be provided between the top edge of the guard and the ram.

FIXED BARRIER GUARD- This type of interlocked fixed barrier guard is used on
automatic presses where the point of operation is occasionally be exposed to
clear the jam. As further safety measures, hand tools or picks are to be used to
relieve jam.

ADJUSTABLE BARRIER GUARD- They can be provided when both die-

enclosure and fixed barrier guards are functionally impracticable.
Material- rod stocks set vertically or perforated metal
The front and side sections can be adjusted for dies of almost any size. The
pivoting/sliding section should be interlocked with press control for maximum
safety.

GATE OR MOVABLE BARRIERS- These type of guards on hydraulic press are

operated by simple, dual switches or valves.
They are designed to enclose point of operation completely before the clutch can
be engaged. The clutch is tripped by the gate or barrier mechanism during the
last inch of guards downward travel. This mechanism will however not function
in case of mechanical failure of the press.

POINT OF OPERATION DEVICES- Auxiliary point of operation devices differ

from guards in that respect that they permit access to the point operation for
loading and unloading of die. Most of such devices provide limited or no
protection against press-failure. A few such devices are as follows:

TWO HAND TRIPPING DEVICES: They require simultaneous application of

both hands to operate the controls.
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When more than one operator is required in a press operation a duplicate set of
controls should be provided for each operator and press should not be
operational until all controls are energized.

PULL-BACK /PULL-OUT /PULL-AWAY DEVICES:

They remove the hands from the point of operation zone as ram descends. This
type of device is usually limited to secondary operations and jobs where the
operator can remain at the feeding position. It is very important that the pull-back
device be adjusted to fit each operator and after each die change. Where more
than one person is working on a press, pull back devices must be provided for
each.

AUTOMATIC ELECTRICAL DEVICES:

This type of device should be operated from a closed electric circuit so that
interruption of the current will automatically prevent the press from cycling.
Advantage: Absence of mechanism in front of operator.
It is particularly applicable on large presses. The photo electric cell should be
installed far enough from the point of operation area that it will stop the ram
before operators hand can get under it and enough light beam must be used to
cover the open area with curtain of light.
However these devices are not suitable on presses with positive clutches.
They can be used on presses having friction, air or other clutches which can be
held at any position of the cycle and with adequate brakes for stopping the press
at any point of ram travel.
These devices should be supplemented by hand tools or feeding and ejection
devices.

AUXILIARY DEVICES:
Foot control guard:- All presses operated by foot pressure should have guard
over the pedal or switch button. The guard may be equipped a spring-closed
shield so that when the operators foot is removed, the shield snaps shut
enclosing the switch button.
The clutch rod should be connected to the pedal lever so that the distance the
distance between clutch rod and rear pivot on the pedal will be 1/3 of the length.
The tripping pedal should travel about 3 inches, the travel of the connecting point
will be 1 inch.
The pedal lever should have no side play and the tension of the pedal should be
maintained as per manufacturers recommendation.

SWEEP DEVICES:
These devices sweep the operators hand out of the point of operation/danger
zone. However they have some disadvantages, they may be violent. They are
activated by press action.
Some sweep devices are interlocked so that the press can not be operated
unless the sweep is in the closed position.
This requirement is at par with other approved devices and may be allowed if
suitable to the operation and well maintained.
.
D. CENTRIFUGAL MACHINES:
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These machines develop centrifugal force to separate liquid from solid materials.
Most centrifugal machines comprise a revolving basket or cage surrounded by a
stationary casing.
DANGER:
Contact with the revolving element
Bursting out due to unbalanced loading of basket or cage

GUARDING:
Safe working peripheral speed of the basket shall not be exceeded.
Automatic tripping device shall be fitted so as to cut off power in the event
of either overloading or unbalanced loading in the basket.
Shall be provided with metal lids or adequate strength. The lids shall be
provided with interlocking devices which will ensure that:
a) The machine cannot be started until the lid is closed
b) The lid cannot be opened while basket is in motion
All the centrifugal machines shall have effective braking arrangements
which shall be regularly inspected,

E PAPER MAKING MACHINES:

PAPER MAKING MACHINES-

DRYING AND FELTING ROLLERS
CALENDAR STACK
WINDER&RE-WINDER MACHINES
HAZARDS
Contact with in-running nip between the rollers.

GUARDS-
Fixed or interlocking guards for the length of the in-running nips
Efficient doctor blade and feeding shall be made to prevent operators
hands approach the nip during feeding
Mechanical devices should be used to replace manual straightening/
smoothing
Automatic lubricating devices are preferred to manual lubrication,
Push buttons, for engine-stop, pull cord connected directly to the prime
mover and control clutches should also be provided,
Press rollers should be fenced by plate guards,
Felt rollers should be fenced by covering the felt rollers,
Each set of calendar rolls with the nip points at the in-running side should
be equipped with adjustable barrier guard. In addition, efficient doctor
blade, air feeder, and feeder belts should be used
Calendar machine intake roll should be fenced by fixed round bar,
FINISHING MACHINES:
REELING &SLITTING MACHINE
CUTTING MACHINE
PAPER CUTTING GUILLOTINE

REELING &SLITTING MACHINE

Brake gear wheel of Reeling and Slitting machine should be fenced by
hinged guard,
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All intakes between the rolls of Reeling and Slitting machine should be
securely fenced by automatic adjustable guard,
Slitting knives should be enclosed with guards
CUTTING MACHINE
Cutting machine brake wheels should be covered by hinged guard
Side belts, pulleys and cutter cylinder should be securely fenced.
The cutters and all the intakes between the rolls should be securely
fenced..
PAPER CUTTING GUILLOTINE
Paper cutting guillotine should be provided with automatic or interlocking
guard.