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INTRODUCTION
This course covers OSHAs machine
guarding requirements. We will begin with a
discussion of the general principles of
machine guarding. Next, we will cover some
of the requirements of OSHAs machine
guarding regulations. We will examine
moving parts, hazardous motions, and types
of machine guarding. We will look at some
important OSHA directives for specific
machine guarding issues. Finally, we will
look at OSHAs new initiative to reduce and
eliminate hazards on machines that cause,
or are likely to cause, amputations.
LEARNING OBJECTIVES
KEY TERMS
Push stick:
means a narrow strip of wood or other soft
material with a notch cut into one end and
which is used to push short pieces of material
through saws.
KEY TERMS
Abrasive wheel:
means a cutting tool consisting of abrasive grains
held together by organic or inorganic bonds.
Diamond and reinforced wheels are included.
Inorganic wheels:
means wheels which are bonded by means of
inorganic material such as clay, glass, porcelain,
sodium silicate, magnesium oxychloride, or
metal. Wheels bonded with clay, glass, porcelain,
or related ceramic materials are characterized as
"vitrified bonded wheels.
Bolster plate:
means the plate attached to the top of the bed of
the press having drilled holes or T-slots for
attaching the lower die or die shoe.
KEY TERMS
Pinch point:
means any point other than the point of
operation at which it is possible for a part of the
body to be caught between the moving parts of
a press or auxiliary equipment
Press:
means a mechanically powered machine that
shears, punches, forms or assembles metal or
other material by means of cutting, shaping, or
combination dies attached to slides.
Slide:
means the main reciprocating press member. A
slide is also called a ram, plunger, or platen.
LESSON 1
PRINCIPLES OF
MACHINE GUARDING
This lesson focuses on the following topics:
Requirements of safeguarding
Employee training
LESSON 1
PRINCIPLES OF
MACHINE GUARDING
Crushed hands and arms, severed fingers,
blindness -- the list of possible machinery-related
injuries is as long as it is horrifying.
There seem to be as many hazards created by
moving machine parts as there are types of
machines. Safety guards are essential for
protecting workers from needless and
preventable injuries.
This man lost his finger when a machine in a
foundry cut it off. There was no safety guard in
place, as required by federal law, to keep his
hand out of the point of operation.
LESSON 1
PRINCIPLES OF MACHINE
GUARDING
Where Mechanical Hazards Occur
Dangerous moving parts require safeguarding. Scroll over each area to find
out more about:
The point of operation
Power transmission apparatus
Other moving parts
LESSON 1
PRINCIPLES OF
MACHINE GUARDING
The point of operation:
that point where work is performed on the material, such as cutting, shaping,
boring, or forming of stock.
Power transmission apparatus:
all components of the mechanical system which transmit energy to the part
of the machine performing the work. These components include flywheels,
pulleys, belts, connecting rods, couplings, cams, spindles, chains, cranks,
and gears.
Other moving parts:
all parts of the machine that move while the machine is working. These can
include reciprocating, rotating, and transverse moving parts, as well as feed
mechanisms and auxiliary parts of the machine.
LESSON 1
HAZARDOUS MOTIONS
AND ACTIONS
A variety of mechanical motions and actions may present hazards to the
worker. These can include the movement of rotating members, reciprocating
arms, moving belts, meshing gears, cutting teeth, and any parts that impact
or shear. The basic types of hazardous mechanical motions and actions are
the following:
Motions
rotating (including in-running nip points)
reciprocating
transversing
LESSON 1
HAZARDOUS MOTIONS
AND ACTIONS
Actions
Cutting
Punching
shearing
bending
LESSON 1
HAZARDOUS MOTIONS
AND ACTIONS
Motions
Rotating motion can be dangerous. Even
smooth, slowly rotating shafts can grip clothing,
and through mere skin contact, force an arm or
hand into a dangerous position. Some examples
of common rotating mechanisms which may be
hazardous are:
Collars
Couplings
Cams
Clutches
Flywheels
LESSON 1
HAZARDOUS MOTIONS
AND ACTIONS
Shaft ends
Spindles
Meshing gears
Horizontal or vertical shafting
LESSON 1
HAZARDOUS MOTIONS
AND ACTIONS
Nip Points
Nip points are also created between rotating and
tangentially moving parts. Some examples would
be: the point of contact between a power
transmission belt and its pulley, a chain and a
sprocket, and a rack and pinion
Nip points can also occur between rotating and
fixed parts which create a shearing, crushing, or
abrading action. Examples are: spooked handwheels or flywheels, screw conveyors, or the
periphery of an abrasive wheel and an incorrectly
adjusted work rest.
LESSON 1
HAZARDOUS MOTIONS
AND ACTIONS
Cutting Action
Cutting action may involve rotating,
reciprocating, or transverse motion. The danger
of cutting action exists at the point of operation
where finger, arm and body injuries can occur
and where flying chips or scrap material can
strike the head, particularly in the area of the
eyes or face. Such hazards are present at the
point of operation in cutting wood, metal, or other
materials.
Examples of mechanisms involving cutting
hazards include band saws, circular saws, boring
or drilling machines, turning machines (lathes),
or milling machines.
LESSON 1
HAZARDOUS MOTIONS
AND ACTIONS
Punching Action
Punching action results when power is applied to a slide (ram) for
blanking, drawing, or stamping metal or other materials. The danger of
this type of action occurs at the point of operation where stock is
inserted, held, and withdrawn by hand. Typical machines used for
punching operations are power presses.
LESSON 1
HAZARDOUS MOTIONS
AND ACTIONS
Shearing Action
LESSON 1
HAZARDOUS MOTIONS
AND ACTIONS
Bending Action
LESSON 1
REQUIREMENTS OF
SAFEGUARDING
What must a safety guard do to protect workers against mechanical hazards?
Safety guards must meet minimum general requirements. Scroll over each
requirement below to find out more:
Prevent contact
Be secure
Protect from falling objects
Create no new hazards
Create no interference
Allow safe lubrication
LESSON 1
REQUIREMENTS OF
SAFEGUARDING
Prevent contact:
The safety guard must prevent hands, arms, and any other part of a
worker's body from making contact with dangerous moving parts.
Be secure:
Workers should not be able to easily remove or tamper with the
safety guard, because a safety guard that can easily be made
ineffective is no safety guard at all. Guards and safety devices
should be made of durable material that will withstand the conditions
of normal use. They must be firmly secured to the machine.
LESSON 1
REQUIREMENTS OF
SAFEGUARDING
Create no interference:
Any safety guard which impedes a worker from performing the job
quickly and comfortably might soon be overridden or disregarded.
Proper safety guarding can actually enhance efficiency since it can
relieve the worker's apprehensions about injury.
LESSON 1
EMPLOYEE TRAINING
Training
Even the most elaborate safety guarding 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 safety
guarding against machine-related hazards.
LESSON 1
EMPLOYEE TRAINING
Thorough operator training should involve instruction and/or hands-on
training in the following:
LESSON 1
EMPLOYEE TRAINING
LESSON 2
OSHA MACHINE
GUARDING REQUIREMENTS
This lesson focuses on the following topics:
LESSON 2
GENERAL
REQUIREMENTS
FOR ALL MACHINES
LESSON 2
GENERAL
REQUIREMENTS
FOR ALL MACHINES
LESSON 2
GENERAL
REQUIREMENTS
FOR ALL MACHINES
OSHA encourages the use of special hand tools such as push sticks
to allow for easy handling of material without the operator having to
put his hand in the danger zone.
Safety committees or an individual (s) with responsibility for plant safety should
perform regular safety audits of machine areas to ensure guards have not been
removed, discarded, or are in need of repair or replacement. Machines generally
should not be operated unless all the guards are securely in place.
LESSON 2
GENERAL
REQUIREMENTS
FOR ALL MACHINES
When the periphery of the blades of a fan is less than 7 feet above the
floor or working level, the blades shall be guarded.
The use of concentric rings with spacing between them not exceeding a
1/2 inch are acceptable provided that sufficient radial spokes and firm
mountings are used to make the guard rigid enough to prevent it from
being pushed into the fan blade during normal use.
LESSON 2
WOODWORKING
MACHINERY REQUIREMENTS
Many of the woodworking
requirements apply to specific
types of equipment such as cut-off
saws and circular saws. One of
the first requirements of the
section (1910.213 (a)(4)) covers
automatic cutoff saws. On October
30, 1978 OSHA issued a directive
(OSHA Instruction STD 1-12.15)
that clarified its position on
automatic cutoff saws.
LESSON 2
WOODWORKING
MACHINERY REQUIREMENTS
In work situations where employees
are not exposed to any hazards
involving automatic cut-off saws,
such saws that stroke continuously
without the operator being able to
control each stroke, may be used.
In work situations where employees
are exposed to any hazards
involving automatic cut-off saw,
(e.g., load, clamp, cut-off, unload,
etc.) such saws that stroke
continuously without the operator
being able to control each stroke are
in violation of 29 CFR 1910.213(a)
(4) and shall be cited.
LESSON 2
WOODWORKING
MACHINERY REQUIREMENTS
One on the most hazardous
situations involving woodworking
machinery is the re-starting of a
machine after the power has been
cut. Any time injury to the operator
might result if motors were to restart
after power failures, a safety guard
must be implemented to prevent
machines from automatically
restarting upon restoration of power
(usually an in-line anti restart cord
with a built-in reset button).
LESSON 2
WOODWORKING
MACHINERY REQUIREMENTS
It is important that machine operators can
cut power to the machine anytime it is
necessary, and as soon as possible. To
accomplish this, OSHA has another
requirement: A mechanical or electrical
power control shall be provided on each
machine so the operator can cut off the
power from each machine without leaving
his position at the point of operation.
Safety and practicality are important
consideration when setting up
woodworking machines for operator use.
Power controls and operating controls
should be located within easy reach of the
operator while he is at his regular work
location, making it unnecessary for him to
reach over the cutter to make adjustments.
LESSON 2
WOODWORKING
MACHINERY REQUIREMENTS
For circular saws where there is a
possibility of contact with the portion of the
saw either beneath or behind the table,
that portion of the saw shall be covered
with an exhaust hood, or, if no exhaust
system is required, with a guard that shall
be so arranged as to prevent accidental
contact with the saw.
Each circular hand-fed ripsaw shall be
guarded by a hood which completely
encloses that portion of the saw above the
table and above the material being cut.
LESSON 2
WOODWORKING
MACHINERY REQUIREMENTS
LESSON 2
WOODWORKING
MACHINERY REQUIREMENTS
Radial saws must be equipped with
special safety features to protect
operators. These include:
a guard that encloses the upper
portion of the blade
an adjustable guard for the sides
and lower portion of the blade, to
the full diameter of the blade, by a
device that will automatically adjust
itself to the thickness of the stock
LESSON 2
WOODWORKING
MACHINERY REQUIREMENTS
Non-kickback fingers or dogs located on
both sides of the saw so as to oppose the
thrust or tendency of the saw to pick up
the material, or to throw it back toward the
operator; an adjustable stop shall be
provided to prevent the forward travel of
the blade beyond the position necessary
to complete the cut in repetitive
operations; and a retracting device to
automatically bring the saw back to the
starting position are other required safety
guards.
LESSON 2
LESSON 2
LESSON 2
The rpm rating on the grinding wheel must be rated at or higher than
the rpm rating of the grinding machine it is being installed on. If the rpm
rating is lower than that of the grinder the wheel could break apart
causing possible serious injury to the operator.
LESSON 2
LESSON 2
LESSON 2
LESSON 3
LESSON 3
MECHANICAL POWER
PRESS SAFETY
Point of operation guards are required that prevent entry into the
point of operation during the operating cycle. It is the responsibility of
the employer to provide and insure the usage of point of operation
guards
LESSON 3
MECHANICAL POWER
PRESS SAFETY
LESSON 3
MECHANICAL POWER
PRESS SAFETY
LESSON 3
MECHANICAL POWER
PRESS SAFETY
They must prevent and/or stop normal stroking of the press if the
operator's hands are inadvertently placed in the point of
operation, and they must be interlocked into the control circuit to
prevent or stop slide motion if the operator's hand, or other part
of his body, is within the sensing field of the device during the
down stroke of the press slide.
LESSON 3
MECHANICAL POWER
PRESS SAFETY
Pull-out devices are another method of
protecting hands form press point of
operations. The requirements for
pullbacks include the following:
Each pull-out device in use shall
be visually inspected and checked
for proper adjustment at the start of
each operator shift, following a new
die set-up, and when operators are
changed.
Necessary maintenance or repair,
or both, shall be performed and
completed before the press is
operated.
LESSON 3
MECHANICAL POWER
PRESS SAFETY
A record of the inspection must be
kept including the date of the
inspection, the signature of the
person performing the inspection,
and an identifier of the press that
was inspected.
LESSON 3
MECHANICAL POWER
PRESS SAFETY
LESSON 3
MECHANICAL POWER
PRESS SAFETY
Where the operator feeds or removes parts by placing one or both hands in
the point of operation, then a two hand control, presence sensing device of
Type B gate or movable barrier (on a part revolution clutch) is used for
safeguarding.
A brake monitor is required so that a failure within the system does not
prevent the normal stopping action from being applied to the press when
required, but does prevent initiation of a successive stroke until the failure is
corrected.
LESSON 3
LESSON 3
LESSON 3
LESSON 3
Belts, pulleys, chains, rotating shafts, gears, pinions, and sprockets can all be
potentially hazardous to work near or around. Workers can get hands caught
in pinch or nip points, or can be drawn into the moving parts of machines. All
moving parts of machines that could injure employees should be guarded.
LESSON 3
LESSON 3
All exposed parts of horizontal, vertical, and inclined shafting seven (7)
feet or less from floor or working platform (excepting runways used
exclusively for oiling, or running adjustments), must be protected by a
stationary casing enclosing shafting completely, or by a trough enclosing
sides and top or sides and bottom of shafting as location requires.
Projecting shaft ends shall present a smooth edge and end and shall not
project more than one-half the diameter of the shaft unless guarded by
non-rotating caps or safety sleeves. Unused keyways shall be filled up or
covered.
LESSON 3
All belts, pulleys, gears, chains and sprockets must all be guarded if
they are lower than seven feet from the floor or working platform.
Horizontal belts higher than seven feet must be guarded if located over
passages or work location and traveling over 1800 feet per minute, if the
center to center distance between pulleys is over ten feet, or if the belt is
8 inches or more in width.
Hand operated gears are exempt from the requirement for guarding, but
it is highly recommended that they also be guarded.
LESSON 4
TYPES OF MACHINE
GUARDS AND THEIR
APPLICATIONS
Guard Materials
LESSON 4
GUARD MATERIALS
LESSON 4
Fixed Guards
Interlocked Guards
Adjustable Guards
Self-Adjusting Guards
LESSON 4
Interlocked guards:
Removing or opening the guard
trips the interlock.
LESSON 4
Self-adjusting guards:
Have the added advantage of
adjusting automatically. When
stock is removed, the guard
returns to original position.
LESSON 4
Devices
Electromechanical
Safety Gates
LESSON 4
Devices:
Includes presence sensing, pullbacks and holdouts, body bars, tripwires,
safety gates, and two-hand controls and trips. Of these, presence
sensing devices are the most sophisticated. One type is a photo electric
beam of light that runs across the entrance to a point of operation. If the
plane of the beam is broken by any object, the machine will not cycle.
Electromechanical:
This type of guard can be a probe or a contact bar. Any obstruction will
prevent the machine from cycling. They are excellent for sewing or
riveting operations. An example of an electromagnetic guard is a ring
guard
LESSON 4
Safety Gates:
Are removable barriers that protect the operator before the machine
cycle starts. Usually they are interlocked so if the gate is opened the
machine will stop, and a cycle will not initiate until the gate is closed.