Machine Guarding

for Injection
Molding Machines
OSHA 10-Hour Outreach Training Program for the
Plastics Processing Industry
A Presentation of the SPI-OSHA Alliance
(Screen Capture of Website)
(Screen Capture of Website)
Course Objectives
Identify the types of injuries that can occur
while operating injection molding machines

Describe the possible causes of these injuries

Identify ways to safely operate injection
molding machines

Recognize the importance of a total safety
and health approach
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Reasons to Focus on Injuries in
the Injection Molding Process
High injury/illness rates

OSHA citations

National Emphasis Program

Site-Specific Targeting

High workers' compensation costs
Types of Injuries
Fatalities

Amputations

Avulsions

Fractures
Cuts and bruises

Sprains and strains

Burns

Electric shock
Some Causes of Injuries
Reaching around, under, over or through
guards into hazardous areas

Removing or bypassing guards

Reaching into equipment to remove stuck or
jammed material

Not using LOTO procedures

Machine/equipment malfunctions
Causes of Injuries (contd)
Lack of recognition of job hazards

Lack of familiarity with the equipment

Inadequate training, comprehension, or both

Operating machines with missing or
inoperable guards and improper or
inadequate machine maintenance
Injection Molding Machinery
Horizontal injection
molding machine
(HIMM)

Vertical injection
molding machine
(VIMM)
Vertical Injection Molding Machines
VIMMs
VIMMs
Combinations of vertical and
horizontal clamp and injection
configurations of machines

Regardless of the configuration
of the machine, basic machine
guarding and good safe work
practices must be applied
Point of operation
Other moving machine parts

VIMMs:
Unique Hazards and Issues
Gravity
Plastic splatter/missing insert
Flying inserts
Unexpected bystander
interventions
Horizontal Injection Molding
Machines - HIMMs
HIMMs:
Mechanical Hazards
Point of operation

Pinch points

Nip points

Rotating parts
Potential Injuries from
Mechanical Hazards
Fatalities
Amputations
Avulsions
Crushing injuries
Fractures
Safety Guards and Devices
Types of guards and devices
Movable guards with interlocks
Fixed barrier guards
Presence-sensing devices
Mechanical safety bars

Locations of guards
Over/around moving equipment
Around electrical hazards
Around thermal hazards
Operators Gate
Equipped with redundant
interlocks
Electrical
Hydraulic
Mechanical safety bar

Allows the machine to
operate only when the
gate is closed
Electrical Interlock
Allows the electrical
system to operate and
close the clamp

Actuated when the
operators gate is opened
or closed

Prevents clamp from
closing when the
operators gate is open
Electrical Interlock Operation
Hydraulic Interlock
Actuated by opening or
closing the operators
gate

Each hydraulic IMM
requires at least one

Prevents clamp from
closing when the
operators gate is open

Hydraulic Interlock Operation
Before Activation After Activation
Hydraulic Interlock Operation
Prevents clamp from
closing when the
operators gate is open

Must have at least one
mechanical device on all
IMMs

Mechanical Safety Device
Mechanical Safety Device Operation
Other Guarding
Rear guard

Top guard

Parts discharge
guard

Feed opening guard
Electrical system
guards

Purge guard

Injection barrel
cover
Rear Guard
Prevents clamp from
closing when
interlocked rear guard
is opened

Should have at least
two interlocks

Prevents access to
mold areas
Top Guard
Required if employees
can reach over the top of
the machine and into
hazardous areas

Should be interlocked if
movable
Top Guards (contd)
Parts Discharge Guard
Keeps employees
from reaching under
the operators gate
and into hazardous
areas
Purge Protection
Covers the nozzle and
purging area

In combination with PPE,
minimizes exposure to
molten plastic during purging

Window allows observation
through purge guard, if
equipped

Should be equipped with an
interlock
Purge guard
Safety
window
Barrel cover
Injection Barrel Cover
Protects from exposure
to high voltage and high
temperatures
Grinder Guarding
Guarding by:
Enclosure over moving
components
Anti-kickback flaps in
feed throat
Proximity guarding
distance from feed chute
to rotating knives
Proximity
Guarding
Abrasive Wheel Machinery
Work rests on offhand grinding machines must be kept
adjusted closely to the wheel with a maximum opening
of 1/8-inch to prevent the work piece or tool from
being jammed between the wheel and the rest, which
may result in wheel breakage or wheel explosion.
Abrasive Wheel Machinery
The distance between the wheel periphery and the
adjustable tongue must never exceed 1/4-inch.
Power-Transmission Apparatus
Power-transmission
apparatus (shafting,
flywheels, pulleys, belts,
chain drives, etc.) less
than 7 feet from the floor
or working platform must
be guarded.
Unguarded belt
and pulley
Presence Sensing Devices
Safety mat




Light curtain
Safety Guards and Devices
Light Curtain
Presence Sensing Devices
Safety Mat

How to Protect Yourself

Recognize the hazards in the job you are
doing

Understand the requirements for
guarding machines

Implement guarding solutions
Emergency Stop
Know:
Where it is located

What it controls

When to use it
Signs and Warnings
Colors used with Safety Signs
have meaning!
DANGER
White Lettering/Red Background
WARNING
Black Lettering/Orange
Background
CAUTION
Black Lettering/Yellow
Background
High Voltage
Rotating Screw
High Temperature
High Pressure
Robots
Used to automate
repetitive or
hazardous tasks

Must be guarded to
prevent workers from
entering or reaching
into hazardous areas
The Robot
References for Injection Molding Safety

ANSI/SPI B151.1- 1997 Horizontal Injection Molding
Machines - Safety Requirements for Manufacture, Care and
Use

ANSI B11.19-2003 Performance Criteria for Safeguarding

ANSI Standards are available at the following web site:
www.ansi.org

OSHA's Site-Specific Targeting (SST) Program

OSHA's Site-Specific Targeting (SST) program selects for inspection
individual worksites with the nation's highest Days Away from Work Injury
and Illness (DAFWII) Case Rate and Days Away, Restricted, or Transferred
(DART) Rates. It is based on data reported by more than 80,000
employers surveyed by the agency.
See the OSHA Web site for the
most current directive and the
rates used to target inspections.

In order to verify the reliability of
claims by establishments that
they have achieved low DART
rates, OSHA inspects a certain
percentage of employers with low
rates.

OSHA National Emphasis Program on Amputations

On October 27, 2006, the Occupational Safety and Health Administration (OSHA)
revised its national emphasis program aimed at reducing amputations in general
industry workplaces. The National Emphasis Program on Amputations targets
all types of machinery and equipment that are considered a high risk for causing
amputations. The plastics processing industry is among the industries under
scrutiny for workplace amputations.

The twenty-four states and two territories which operate their own OSHA programs
are encouraged, but not required, to adopt a similar emphasis program. State Plan
State information is available on OSHAs Web site. The OSHA directive on this
emphasis program is available on OSHA's Web site under Regulations and
Compliance, subcategory Compliance Directives, No. CPL 03-00-003.

Under this initiative, regional and area OSHA offices will continue to conduct
outreach; targeting and selection; and inspections. Area offices will obtain and use
additional data to identify and add establishments where serious injuries or fatalities
related to these machines have occurred.
The Job Safety Analysis Process

The Job Safety Analysis (JSA) process is a very
effective means of helping reduce incidents,
accidents, and injuries in the workplace. It is a
multi-step process.

Basic Job Steps

Potential Hazards

Recommended Safe Job Procedures
Summary
Injuries can occur while operating injection
molding machines
Risk areas can be protected by safety guards
and devices

Protect yourself and operate injection molding
machines safely
Recognize the importance of a total safety
and health approach
Do you have any
Questions?