Machine Guarding: Prevent Injuries and Ensure Compliance

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Unguarded machines present serious safety hazards in numerous industrial environments. Whether on the assembly lines of the automotive industry or in the confines of metalworking shops, workers face daily risks interacting with hazardous machinery. The U.S. Occupational Safety and Health Administration (OSHA) reports approximately 18,000 severe injuries&#;including burns, crushed hands or fingers, lacerations, amputations and blindness&#;due to inadequate machine guarding every year. These mostly preventable incidents also result in over 800 fatalities annually.

Machine guarding consistently appears on OSHA&#;s Top 10 Most Frequently Cited Standards list, with 1,635 violations recorded in alone. This blog explores the critical role of machine guarding, the hazards it mitigates, different methods for implementation and Intelex&#;s role in enhancing safeguarding practices.

Machine Guarding: What Is It and How Is It Regulated?

Machine guarding involves the use of safety barriers and protective devices to shield workers from hazardous parts and functions of machinery during operation and maintenance activities. These include methods such as fixed guards, interlocking guards and two-hand operating devices, designed to reduce the risk of severe injuries and fatalities.

Compliance with regulatory requirements is essential for ensuring proper worker protection. In the U.S., specific machinery standards are outlined under OSHA&#;s 29 CFR Subpart O. In Canada, provincial laws and guidelines, including those from the Canadian Centre for Occupational Health and Safety (CCOHS), govern machine guarding. In Europe, the European Union&#;s Machinery Directive /42/EC specifies health and safety standards for machinery, while in the UK, post-Brexit, the Health and Safety Executive (HSE) ensures compliance with both national and relevant EU regulations. On a global scale, the International Organization for Standardization (ISO) and the International Electrotechnical Commission (IEC) provide standards that promote consistency in machine safety practices worldwide.

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Not adhering to regulations can result in severe penalties and significant operational risks. A notable example is the case of an Ohio aluminum parts manufacturer fined $1.7 million by OSHA after a fatal incident involving a machine&#;s barrier door. Clearly, beyond the financial impact, such violations can also seriously compromise the sustainability and reputation of non-compliant organizations.

Common Machine Guarding Hazards

Each piece of machinery, from table saws and mechanical power presses to conveyor belts and robotic arms, poses unique mechanical and non-mechanical hazards. To address these risks, machine guarding serves as a critical line of defense for workers in a wide range of industries such as construction, energy, mining and metals, agriculture, manufacturing and food and beverage. Common hazards include:

1. Hazardous Mechanical Motions:
   • Rotating Parts: Rotating parts such as gears and rollers can catch hair and clothing, pulling hands and arms into hazardous positions and causing severe injuries.
   • In-running Nip Points: These occur where two parts move together, for example between a belt and roller, risking entrapment of body parts.
   • Reciprocating Motions: Found in presses and shapers, these back-and-forth movements can trap and injure body parts.
   • Transverse Motions: These involve continuous movement of materials that can pull in nearby objects, including body parts.
2. Hazardous Actions at Points of Operation:
   • Cutting: Machines such as saws and cutting discs perform sharp cuts that can pose severe risks.
   • Punching: Punch presses create holes in materials through a downstroke motion that can be hazardous to operators.
   • Shearing: Shearing machines apply force to cut materials like metal, which require rigorous safeguards to prevent amputation risks.
   • Bending: Machines that bend metal or other materials can create pinch points and other hazardous interactions.
3. Non-Mechanical Hazards:
   • Flying Chips and Sparks: Operations such as grinding or welding can eject particles or sparks, posing risks to eyes and skin, which require protective guards and barriers.
   • Thermal Hazards: Machinery operating at high temperatures can cause burns or scalds. Heat shields and other barriers are crucial to protect workers from heat-related injuries.
   • Electrical Hazards: Electrical machines can cause shocks, arc flashes or burns, with effective guarding involving insulation and grounding.
   • Noise Hazards: High noise levels from machinery can lead to hearing loss that can be mitigated by noise-reducing enclosures or barriers.
   • Chemical Exposures: Hazardous emissions from industrial processes necessitate the use of specialized guards designed to shield workers from harmful exposure.

Key Methods of Machine Guarding

Effective machine guards must meet several critical requirements. They should prevent contact with hazardous parts, remain securely in place and must not create additional hazards or interfere with machine operations. The five key safeguarding methods include:

• Guards: Physical barriers preventing contact, including fixed guards that permanently enclose hazards, interlocked guards that halt operation if altered, adjustable guards for varying material sizes and self-adjusting guards that adapt automatically.
• Devices: Tools that restrict access to hazardous areas, featuring sensors like photoelectric and radiofrequency that detect intrusions, electromechanical devices that stop machines when triggered and safety features such as pullback devices and trip controls.
• Automated Feeding and Ejection Mechanisms: Systems that automatically handle materials and reduce direct exposure to hazards.
• Machine Location or Distance: Placing machinery at a safe distance from operators to reduce risks of contact.
• Miscellaneous Aids: These include shields to contain debris, holding tools for safer material handling and awareness barriers that highlight hazardous areas.

Additionally, effective lockout/tagout (LOTO) procedures remain a critical safety measure in many industries. These procedures ensure that machines are properly shut off and unable to energize or start up during maintenance or servicing. By incorporating machine guards along with safety measures like LOTO, organizations can significantly improve workplace safety and protect employees from serious injuries or fatalities.

Advantages of Machine Guarding

Machine guarding is an essential safety measure in high-risk industries, effectively preventing accidental contact with hazardous machine parts. It not only reduces the risk of severe injuries but also demonstrates an organization&#;s commitment to prioritizing employee well-being.

In industries that depend heavily on machinery, safety&#;especially through machine guarding&#; directly correlates with productivity by minimizing accidents and ensuring continuous operations. For example, in the aerospace sector, machine guarding protects workers during the precise assembly and testing of components. In the food and beverage industry, it helps maintain smooth production lines, adhering to strict health standards and preventing safety breaches.

The financial impact of machine guarding is significant. According to the National Safety Council, workplace injuries cost the U.S. economy $167 billion in , including medical expenses, lost wages and productivity losses. Demonstrating the effectiveness of preventive measures, a randomized study involving 40 small metal-fabrication businesses showed that machine-guarding measures improved safety scores by 13% to 23%. This improvement not only enhances safety but also translates into financial savings by reducing the costs associated with workplace injuries and operational disruptions.

Challenges in Implementing Machine Guarding

Although the advantages of machine guarding are clear, implementation faces challenges such as insufficient understanding of standards, lack of safeguarding processes and limited resources. Many organizations fail to fully comply with OSHA&#;s requirements, leading to inadequate protection. Effective safety protocols need input from operators, maintenance personnel, supervisors, engineers and safety professionals. Without robust processes, such as design reviews and risk assessments, identifying and mitigating risks are difficult. Additionally, safeguarding can be costly, averaging $2,500 per machine and another $2,500 per day for assessment labor. Improper design, installation and non-compliance of older machines with modern safety regulations further complicate the implementation process. Regular inspections and maintenance, along with retrofitting guards, are crucial to bring older machines up to current safety standards.

Organizational culture also impacts the effectiveness of machine guarding initiatives. Without the support and engagement of workers, these initiatives can never truly succeed. Engaging employees requires management to lead cultural changes, offer thorough training and establish direct processes for incident investigation and prevention to cultivate a safety-first mindset across the entire organization.

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How Can Intelex Help with Machine Guarding?

Intelex offers a comprehensive suite of Environment, Health and Safety (EHS) management solutions that help organizations effectively implement and manage machine guarding. Key features include:

• Identifying and Assessing Machine Guarding Needs: Intelex&#;s Job Safety Analysis application conducts thorough risk assessments to identify areas requiring machine guarding. Integrated with the Incident Reporting application, it ensures all potential hazards are promptly addressed.
• Tracking and Managing Machine Guards: The Audit Management application schedules regular inspections and maintenance of machine guards, proactively preventing accidents.
• Ensuring Compliance with Relevant Standards: Automated updates and alerts keep organizations compliant with the latest machine guarding standards and regulations.
• Documentation and Reporting Capabilities: Intelex&#;s Incident Reporting and Document Control offer robust documentation and reporting capabilities, supporting audits and inspections and maintaining clear records of machine guarding practices and compliance efforts.
• Training and Awareness: Intelex&#;s Training Management application provides extensive training solutions, covering standards review, understanding machine guards, reporting procedures for damaged or missing guards and the organization&#;s lockout/tagout program, helping employees stay informed and proactive in workplace safety.

Integrating these advanced tools allows organizations to take a holistic approach to managing machine guarding and overall safety, helping to safeguard workers and enhance operational efficiency.

Conclusion

Machine guarding is a crucial aspect of workplace safety, protecting workers from incidents and ensuring regulatory compliance. Effective measures can drastically reduce typical machinery-related injuries, such as crushed hands, severed limbs, lacerations, abrasions and amputations. Injuries as severe as these can lead to permanent disability, profoundly affecting workers&#; lives and livelihoods.

Achieving zero accidents and injuries should be a top priority in any workplace. Advanced EHS software solutions support this goal by enhancing the management of machine guarding protocols through risk assessment, real-time monitoring and compliance tracking. By prioritizing effective safeguarding and utilizing modern EHS applications, organizations can create safer work environments and advance toward the ultimate goal of zero harm.

Experience how Intelex can transform your EHS processes with a Custom Demo Tour. Select the features you need and see how our solutions align with your goals. Start now!

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Safeguards or machine guards are designed to prevent you from accidentally coming into contact with dangerous machine parts. Motors, gearboxes, presses, laminator and cutters all have safeguards to protect you and your employees from being injured. A safeguard is designed to create a barrier between an operator and a dangerous moving part that could seriously injure a finger, hand or other body party.

There are six types of machinery hazards typically found in printing operation:

• Pinch or Nip Points
• Rotating Motion
• Cutting Action
• Transverse Motion
• Punching Action
• Impact Hazard

There are several different types of safeguards used on equipment and they include fixed guards such as nip guards or barrier guards, adjustable and self-adjusting guards, interlocks, devices such as light curtains, controls such as two handed controls, and guarding by distance. The use of a particular type of machine guard will depend upon the configuration of the equipment and the hazard that requires guarding.

Older Equipment

One of the most common misperceptions with OSHA&#;s machine guarding standard is that equipment that was built prior to OSHA is exempt or &#;grandfathered&#; from the machine guarding standard. OSHA does not have a grandfather clause for machine guarding. This means that any existing equipment that has unguarded hazard areas must be guarded and it is the equipment owner&#;s responsibility to ensure all hazard areas are guarded.

New Equipment

Another misconception with OSHA&#;s regulations is that original equipment manufacturers are required to provide equipment in compliance with OSHA&#;s machine guarding requirements. In the United States, original equipment manufacturers are not required to sell machinery with guards that meet OSHA&#;s regulations. Equipment manufacturers have an incentive to provide guarded equipment as they are subject to being sued by injured workers, but there are no mandatory requirements. As with existing equipment, OSHA requires the employer to ensure that new equipment is properly guarded to protect the operators.

Types of Safeguards

Safeguards can be grouped under five general classifications: guards, devices, safety controls, gates and location/distance.

Guards

Fixed guards are permanent parts of a machine. These guards are preferable because they&#;re simple and permanent.

Interlocked guards automatically shut off or disengage a machine through a tripping mechanism or power when the guard is opened or removed. The machine cannot cycle or start until the guard is replaced.

Adjustable guards are useful because they accommodate various sizes of stock.

Self-adjusting guards allow the opening of the barrier to be determined by the stock. As the operator moves the stock into the danger area, the guard is pushed away, providing an opening that only is large enough for the stock.

Devices

Presence-sensing devices are divided into two groups. Photoelectrical devices use light sources and controls that can interrupt the machine. Radio frequency or capacitance devices use a radio beam that is part of the machine circuit. When the capacitance field is broken, the machine will stop.

Safety Controls

Safety trip controls, such as safety tripwire cables, can quickly deactivate a machine.

Two-hand controls require both hands and constant pressure on the controls for the machine to operate.

Gates

Gates are movable barriers that protect the operator at the point of operation before the machine cycle starts.

Location/Distance

Though not actual guards, location and distance can keep employees safe. You can place a machine in an infrequently traveled area or where it&#;s dangerous moving parts are not accessible.

Machine Safeguards must be constructed or designed to withstand the forces that will be placed against it and meet minimum general requirements that include the following:

1. Prevent contact&#;The safeguard must prevent hands, arms or any other part of a worker&#;s body from making contact with dangerous moving parts.
   
2. Be secure - Workers should not be able to easily remove or tamper with the safeguard. Guards and safety devices should be made of durable materials that will withstand normal use. They must be firmly secured to the machine where possible or secured elsewhere if attachment to the machine is not possible.
   
3. Protect from falling objects - The safeguard should ensure that no objects can fall into moving parts.
   
4. Create no new hazards - A safeguard defeats its own purpose if it creates a hazard such as a shear point, a jagged edge or an unfinished surface.
   
5. Create no interference - Any safeguard that impedes a worker from performing a job quickly and comfortably might soon be bypassed or disregarded.
   

Common Hazards that Require Safeguarding in the Screen Printing Process

• Screen stretching areas: Screens that are stretched and held in place for drying with pressurized clamps can cause a hazard if one of the clamps break loose.
  Solution: A method of safeguarding the clamps is to place a 2 x 4 or other board behind each bank of clamps on all four sides of the table. Then, if the screen rips, the board will keep the clamp from flying backward.
• Ink mixing: Using a rotating shaft to mix ink should be guarded to protect technicians from possibly catching loose clothing or a finger.
  Solution: A plexiglass cover that fits over the mixing container with an opening for the shaft would work to provide protection.
• In line press (feed end): The drive rollers on an automatic feed mechanism creates a pinch point where the substrate enters the machine.
  Solution: A nip guard should be positioned that allows the substrate to pass under it but narrow enough that a finger cannot be pinched between the two drive rollers. If the operator is exposed to the in-going nip or could be exposed, OSHA&#;s requirements is that the nip guard needs to be adjusted to within a ¼ inch of nip.
• Carousel press: The printing beds on a carousel press present an impact hazard.
  Solution: Safeguarding would entail screening or gating off the areas where an operator could be caught when the beds are automatically rotated.
• Flatbed press: The printing bed presents a pinch and crushing hazard.
  

  Solution: Interlocked guards around the perimeter of printing unit prevent the unit from contacting the bed if tripped. The printing unit returns to the starting position.

Common Hazards that Require Safeguarding in the Digital Printing Process

• Digital press: The primary hazard with digital presses is found on those that have an exposed printing area, so that when the printhead moves toward the user interface, a pinch point is formed between the printhead and the interface.

Solution: A simple safeguard can be a piece of plexiglass permanently attached to the press. Many presses are equipped with a safety hood that covers the printhead thus eliminating the pinch point hazard. These safety hoods are usually interlocked, which means the machine stops printing when it is lifted. It is important to ensure that interlocks are present, and they are maintained and not overridden or otherwise defeated.

• Eyelet/grommet machine: If the machine has a foot pedal, then it must be safeguarded against being accidentally pressed.
  Solution: All machines with a foot pedal must have a cover over the foot pedal. In addition, a telescoping cage at the point of operation is required to safeguard against the punching hazard.
• Laminator: The feed mechanism on the laminator forms a pinch point.
  Solution: Laminators should be guarded with a nip guard.

Training Requirements

Any safeguarding system by itself is not enough to provide protection to an operator. Many machine guards and other safety features may be unfamiliar to their operators, especially new operators. They may not understand all the hazards of the machine, and might not realize that long hair, rings, watches, jewelry or loose clothing could get caught in the moving parts.

Employees need to be trained in the hazards associated with the equipment they will be operating along with the safeguards that are present to protect them from the hazards. Training on how to operate equipment must address all the hazards associated with each machine and the activities they are required to perform.

The topics include the following:

1. A description and identification of the hazards associated with the equipment they will be operating. The hazard identification needs to include all of all the hazards where there is potential exposure during normal operation, setup or make ready, and other activities such as maintenance.
   
2. The safeguards themselves, how they work and provide protection and the hazards they are designed to protect against.
   
3. How to use the safeguards.
   
4. How and under what circumstances the safeguards can be removed or bypassed, by whom, and what protective measures need to be taken.
   
5. How to safely clear jams, especially if a safeguard needs to be removed or bypassed.
   
6. What to do if a safeguard is damaged, missing or becomes inoperable.
   
7. Not to touch moving parts.
   
8. Not to operate equipment if long hair is not contained and wearing rings, watches, jewelry or loose clothing.
   

Training helps workers understand how each safeguard protects them from harm.

Training also needs to be extended to maintenance personnel and when any new or modified safeguards are put into service. Most importantly, all training needs to be documented to demonstrate that it actually was provided.

PRINTING United Alliance's OSHA Compliance Resource Center provides technical assistance and services designed to allow printing operations to manage compliance and stay informed. For more information on Machine Guarding or PRINTING United Alliance&#;s EHS services,  or call 888-385-.

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