MACHINE GUARDING
CORPORATE SAFETY TRAINING
29 CFR 1910.211-222
WELCOME
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BASIS FOR THIS COURSE
 Proper Machine Guarding Results in Accident Reduction
 Elimination of Workplace Injuries & Illnesses Where Possible
 Reduction of Workplace Injuries & Illnesses Where Possible
 Development of Efficient Machine Guarding Techniques
 OSHA Safety Standards Require:
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Machines Be Properly Guarded
Training Be Conducted
Hazards and Precautions Be Explained
A “Safety” Program Be Established
Job Hazards Be Assessed and Controlled
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REGULATORY STANDARD
THE GENERAL DUTY CLAUSE
FEDERAL - 29 CFR 1903.1
EMPLOYERS MUST: Furnish a place of employment
free of recognized hazards that are causing or are likely
to cause death or serious physical harm to employees.
Employers must comply with occupational safety and
health standards promulgated under the WilliamsSteiger Occupational Safety and Health Act of 1970.
OSHA ACT OF 1970
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INDUSTRY CONSENSUS STANDARDS
ANSI - B11.2 Hydraulic presses
B11.3 Power Press Brakes
B11.10 Metal Sawing Machines
B11.11 Gear Cutting Machines
B11.12 Roll-Forming and Bending Machines
B11.14 Coil Slitting Machines
B11.15 Pipe, Tube, and Shape Bending
B11.16 Metal Powder Compacting Presses
B11.17 Horizontal Hydraulic Extrusion
B11.18 Coiled Steel Processing
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INDUSTRY CONSENSUS STANDARDS
ANSI - B11.19 Machine Tools, Safeguarding
B11.20 Manufacturing Systems/Cells
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PROGRAM REQUIREMENTS
ALL EMPLOYERS MUST:
 Install Machine Safeguards
MACHINE
GUARDING
PROGRAM
 Review Job Specific Hazards
 Implement Corrective Actions
 Conduct Hazard Assessments
 Conduct Accident Investigations
 Provide Training to All Required Employees
 Control Workplace Hazards Using PPE As a Last Resort
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BASICS OF MACHINE GUARDING
Where Mechanical Hazards Occur
 The Point of Operation:
 Power Transmission Apparatus:
 Other Moving Parts:
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BASICS OF MACHINE GUARDING
Where Mechanical Hazards Occur
 The Point of Operation: Where work is performed
on the material, such as:
 Cutting
 Shaping
 Boring
 Forming of stock
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LATHE
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BASICS OF MACHINE GUARDING
Where Mechanical Hazards Occur
 Power Transmission Apparatus: All components
of the mechanical system which transmit energy
to the part of the machine performing the work.
300 RPM
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BASICS OF MACHINE GUARDING
Where Mechanical Hazards Occur
 Other Moving Parts: Any part of the machine
which moves while the machine is working.
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Rotating parts
Feed mechanisms
Reciprocating parts
Transverse moving parts
Auxiliary parts of the machine
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions and Actions
A wide variety of mechanical motions and actions
may present hazards to the worker:
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Rotating members
Reciprocating arms
Moving belts
Meshing gears
Cutting teeth
Any parts that impact or shear
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions and Actions
Recognition of these hazards is the first step
toward protecting workers from the danger
they present.
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
Motions
 Rotating
 Reciprocating
 Transversing
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NIP POINT
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Actions
Actions
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Cutting
Punching
Shearing
Bending
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SHEARITE
CUTTING BLADES
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
 Rotating Motions
- Collars
- Couplings
- Cams
- Clutches
- Flywheels
- Shaft ends
- Spindles
- Meshing gears - Horizontal shafts
- Vertical shafts
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
 Rotating Motions
Rotating motions can grip clothing, and through
mere skin contact force a limb into a dangerous
position. The danger increases when projections
such as set screws, bolts, nicks, abrasions, and
projecting keys or set screws are exposed on
rotating parts.
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
 Reciprocating Motions
NIP POINT
NIP POINT
RECIPROCATING
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MOTION
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
 Reciprocating Motions
RECIPROCATING
MOTION
CAUGHT “IN-BETWEEN”
OR “STRUCK-BY”
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
 Transversing Motions
TRAVEL
IN-RUNNING NIP POINTS
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
 Rotating Motions
NIP POINTS
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Actions
 Cutting Actions
- Rotating motions
- Reciprocating motions
- Transversing motions
The danger of cutting action exists at the point of
operation where finger, arm and bodily injuries can
occur and where flying chips or scrap material can
strike the head, particularly in the area of the eyes or
face.
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Actions
 Cutting Actions
 Bandsaws
 Circular saws
 Boring machines
 Drilling machines
 Turning machines (lathes)
 Milling machines
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Actions
 Punching Actions
20 TON
 Power presses
 Iron workers
 The principle hazard occurs
at the point of operation
where stock is inserted, held
or withdrawn.
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PRESS
ACME
PRESSES
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PRESS
BASICS OF MACHINE GUARDING
Hazardous Mechanical Actions
 Shearing/Bending Actions
 Mechanical shears
 Hydraulic shears
 Pneumatic shears
 The principle hazard occurs
at the point of operation
where stock is inserted, held
or withdrawn.
DANGER
CUTTING EDGE
PRESS
PRESS
SHEARITE
POWER SHEARS
SHEAR TERROR
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BASICS OF MACHINE GUARDING
 Requirements for Safeguards
 Be securely attached
 Create no new hazards
 Withstand operational conditions
 Allow for safe routine maintenance
 Allow for safe operator adjustments
 Withstand environmental conditions
 Provide protection from falling objects
 Prevent contact with hazardous conditions
 Create no interference in the conduct of work
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BASICS OF MACHINE GUARDING
 Nonmechanical Hazard Considerations:
 Power sources are potential sources of danger
 How will guarding affect equipment operation?
 Ensure proper grounding of systems
 Replace frayed, exposed , or old wiring
 Consider effects of - High pressure systems
- Extreme temp. conditions
- Pulsation, vibration, or leaks
- Noise or unwanted sounds
- Cutting fluids and coolants
HOT SURFACE
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BASICS OF MACHINE GUARDING
 Operator Training Considerations:
 Provide instruction and or hands-on training
 Discuss the purpose of safeguards
 Cover associated hazards thoroughly
 Involve guard designers in the training
 Describe how to properly use safeguards
 Describe how safeguards provide protection
 Describe circumstances for safeguard removal
 Explain what to do if safeguards are damaged
 Explain what to do if safeguards are missing
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BASICS OF MACHINE GUARDING
 Operator Training Considerations:
Defeating, altering, or removing safeguards
can cause injury to co-workers and can leave
the person performing such actions liable
under the OSHA Act of 1970.
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BASICS OF MACHINE GUARDING
 Protective Clothing and Equipment Considerations:
ENGINEERING CONTROLS
 Work Station Design
 Process Modification
 Tool Selection and Design
 Mechanical Assist
 ADMINISTRATIVE CONTROLS
 Training Programs
 Pacing
 FIRST CHOICE
 SECOND CHOICE
 Job Rotation/Enlargement
 Policy and Procedures
 PERSONNEL PROTECTIVE EQUIPMENT LAST CHOICE
 Gloves
 Shields
 Non-Slip Shoes
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 Wraps
 Eye Protection
 Aprons
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BASICS OF MACHINE GUARDING
 Protective Clothing and Equipment Considerations:
 Appropriate for the particular hazard(s)
 Maintained in good condition
 Properly stored when not in use
 Kept clean, fully functional, and sanitary
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METHODS OF MACHINE GUARDING
 Guarding Method Dependant on:
 Type of material
 Type of operation
 Method of handling
 Size or shape of stock
 Physical layout of the work area
 Production requirements or limitations
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METHODS OF MACHINE GUARDING
 Manufacturers Recommendation:
Before beginning the process of guard
procurement, design, or installation, the
equipment
manufacturer
should
be
consulted for advice.
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METHODS OF MACHINE GUARDING
 Generally:
 Power transmission apparatus is best protected
by fixed guards that enclose the danger areas
 Point of operation hazard guarding will vary
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METHODS OF MACHINE GUARDING
 Safeguards Are Grouped Under 5 Classifications:
 Guards
 Devices
 Locations/Distance
 Feeding and ejection methods
 Miscellaneous aids
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METHODS OF MACHINE GUARDING
GUARDS
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METHODS OF MACHINE GUARDING
 Guards:
 Guards are barriers which prevent access to
danger areas, there are four general types:
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Fixed guards
Interlocked guards
Adjustable guards
Self-Adjusting guards
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METHODS OF MACHINE GUARDING
 Fixed Guards:
 Fixed guards are a permanent part of the
machine and not dependent upon moving parts
to perform its intended function.
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METHODS OF MACHINE GUARDING
 Fixed Guards:
ADVANTAGES
 Can be constructed to suit many different applications
 In-plant construction is often possible
 Can provide maximum protection
 Usually requires minimum maintenance
 Can be suitable to high production operations
 Can be suitable to high repetition operations
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METHODS OF MACHINE GUARDING
 Fixed Guards:
LIMITATIONS
 May interfere with visibility
 Can be limited to specific operations
 Machine adjustments and repair often require guard
removal, thereby necessitating other means of protection
for maintenance personnel
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METHODS OF MACHINE GUARDING
 Interlocked Guards:
 Interlocked guards are designed to automatically
shut off or disengage the machine if the guard is
opened or removed
AUTOMATIC
VISUAL ALARM
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AUTOMATIC
AUDIBLE ALARM
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METHODS OF MACHINE GUARDING
 Interlocked Guards:
 Interlocked guards may use:
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Electrical power
Mechanical power
Hydraulic power
Pneumatic power
OR ANY COMBINATION OF POWER SOURCES
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METHODS OF MACHINE GUARDING
 Interlocked Guards:
 Interlocks should not prevent “inching” by
remote control if required
 Replacing guards should
restart the machine
not
automatically
IMPORTANT
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METHODS OF MACHINE GUARDING
 Interlocked Guards:
ADVANTAGES
 Can provide maximum protection
 Allows access to machine for removing jams without time
consuming removal of fixed guards
LIMITATIONS
 Requires careful adjustment and maintenance
 May be easy to disengage jams
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METHODS OF MACHINE GUARDING
 Adjustable Guards:
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Typically adjusted by the operator
Accommodate various sizes of stock
May require additional operator training
Adjustable guards are typically used on:
 Bandsaws
 Tablesaws
 Power presses
 Routers
 Similar equipment
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METHODS OF MACHINE GUARDING
 Adjustable Guards:
ADVANTAGES
 Can be constructed to suit many specific applications
 Can be adjusted to admit varying sizes of stock
LIMITATIONS
 Hands may enter danger area
 Protection may not be complete at all times
 May require frequent maintenance and or adjustment
 The guard can be defeated by the operator
 May interfere with visibility
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METHODS OF MACHINE GUARDING
 Self-Adjusting Guards:
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Adjusts automatically to the work
Accommodate various sizes of stock
May require additional operator training
Self-Adjusting guards are typically used on:
 Radial arm saws
 Tablesaws
 Circular saws
 Routers
 Jointers
 Similar equipment
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METHODS OF MACHINE GUARDING
 Self-Adjusting Guards:
ADVANTAGES
 Off-the-shelf guards are often commercially available
LIMITATIONS
 Protection may not be complete at all times
 May require frequent maintenance and or adjustment
 May interfere with visibility
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METHODS OF MACHINE GUARDING
DEVICES
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METHODS OF MACHINE GUARDING
 Devices:
 Devices fall into four general types:
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Presence-Sensing devices
Pullback devices
Restraint devices
Safety trip controls
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METHODS OF MACHINE GUARDING
 Devices:
 Devices may perform one of several function:
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Stop a machine if a body part is in danger
Restrain or withdraw a hand if it is in danger
Require activation by the use of both hands
Provide a barrier synchronized to the operation
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METHODS OF MACHINE GUARDING
 Presence-Sensing:
 Photoelectric
 Radiofrequency
 Electromechanical
PRESS
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ACME
PRESSES
PRESS
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METHODS OF MACHINE GUARDING
 Presence-Sensing:
Before beginning the process of
procurement, design, or installation, the
equipment manufacturer should be
consulted for advice.
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METHODS OF MACHINE GUARDING
 Presence-Sensing:
 Photoelectric
 Radiofrequency
 Electromechanical
20 TON
PRESS
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ACME
PRESSES
PRESS
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METHODS OF MACHINE GUARDING
 Pullback Devices:
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Attached to Wrists
Positioning Critical
Adjustment Critical
Maintenance Critical
Training Critical
Must Stop Machine
Immediately!
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NYLON
PULLBACK
STRAPS
ATTACHED TO
WRISTBANDS
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METHODS OF MACHINE GUARDING
 Restraint Devices:
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Uses Cables or Straps
Affixes to Hands
May Need Feeding Tools
Adjustment Critical
Positioning Critical
Maintenance Critical
Training Critical
Must Restrain Body Part
From Hazard!
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METHODS OF MACHINE GUARDING
 Safety Trip Controls:
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Body Trip Bars
Hand/Arm Trip Bars
Tripwire Cables
Positioning Critical
Adjustment Critical
Maintenance Critical
Training Critical
Manual Reset Needed
Must Stop Machine
Immediately!
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METHODS OF MACHINE GUARDING
 Two-Hand Control:
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Needs Constant Pressure
Needs Concurrent Pressure
Positioning Critical
Adjustment Critical
Maintenance Critical
Training Important
Must Stop Machine
Immediately!
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20 TON
PRESS
ACME
PRESSES
PRESS
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METHODS OF MACHINE GUARDING
 Location/Distance Safeguarding:
 Position Dangerous Areas of Machines So That They Are
Not Assessable During Normal Operations. Examples
Include:
 Position Hazard Areas Against a Wall
 Locate Hazards Out of Reach of Operators
 Add Enclosures or Fences to Restrict Access
 Design Stock Feeding Openings Away From Hazards
 Position the Operators Control Station Away From Hazards
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METHODS OF MACHINE GUARDING
 Feeding and Ejection Methods:
 Automatic Feeds - Fed From Rolls, Indexed by Machine
 Semiautomatic Feeds - Fed by Chutes, Movable Dies, Dial
Feed, Plungers, or Sliding Bolsters
 Automatic Ejection - Air or Mechanical Ejection
 Semiautomatic Ejection - Air or Mechanical Ejection Initiated
by The Operator
 Robotics - Perform Work Usually Performed by Operator
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METHODS OF MACHINE GUARDING
 Feeding and Ejection Methods:
 Manufacturers Should Be Consulted to Determine:
 Feeding and Ejection Add-on Options
 Latest Technology Available
 Best Available Technology
 Operator Training Requirements
 Maintenance Staff Training Requirements
 Cost Estimates for Upgrades
 Feasibility Assessment Information
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METHODS OF MACHINE GUARDING
 Miscellaneous Aids:
 Examples of Possible Applications:
 Awareness Barriers - (Not adequate for continuous hazards)
 Color coding of hazard areas
 Signage
 Shields (i.e. splash, eye protective, thermal etc.)
 Holding and Positioning Tools
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METHODS OF MACHINE GUARDING
 Guard Construction:
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Many Machines Come With Safeguards
Many Older Machines Now Have Safeguards Available
Manufacturers Are Increasingly More Concerned With Liability
Companies Not Specialized in Guarding Issues
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METHODS OF MACHINE GUARDING
 Builder Designed and Installed Guards:
 Usually Conform to Design and Function of Machine Better
 Can Be Designed to Strengthen the Machine in Some Way or
to Serve Some Additional Functional Purposes
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METHODS OF MACHINE GUARDING
 User Designed and Installed Guards:
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Often the Only Practical Solution for Older Equipment
Can Be Designed and Built to Fit Unique & Changing Situations
Can Be Installed on Individual Dies and Feeding Mechanisms
Can Help Promote Safety Consciousness in the Workplace
Sometimes Do Not Conform As Well As “Builder Designed”
Depending on Talent and Resources May Be Poorly Designed
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METHODS OF MACHINE GUARDING
 Point-of-Operations Guards :
Defined as: “The area on a machine where work is actually
performed upon the material being processed.”
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Complicated by the Number and Complexity of Machines in Use
Must Fully Safeguard the Employee
Must Allow Production to Continue
Hazard Analysis Is Usually Required
If Poorly Designed, Built, or Installed Guards May Create a
Hazard Rather Than Eliminating One.
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METHODS OF MACHINE GUARDING
 Mechanical Power Transmission Apparatus Guards:
 The only openings usually needed are for:
 Lubrication
 Adjustment
 Repair
 Inspection
300 RPM
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METHODS OF MACHINE GUARDING
 Guard Material:
 Under Many Circumstances, Metal Is the Best Material for
Guards.
Guard Framework Is Usually Made From
Structural Shapes, Pipe, Bar, or Rod Stock. Filler Material
Generally Is Expanded or Perforated or Solid Sheet Metal or
Wire Mesh. It May Be Feasible to Use Plastic or Safety
Glass Where Visibility Is Required.
 Guards Made of Wood Generally Are Not Recommended
Because of Their Flammability and Lack of Durability and
Strength. However, in Areas Where Corrosive Materials Are
Present, Wooden Guards May Be the Better Choice.
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LOCKOUT TAGOUT OVERVIEW
29CFR - 1910 - 147
29CFR - SAFETY AND HEALTH STANDARDS
1910 - GENERAL INDUSTRY
147 - LOCKOUT TAGOUT STANDARD
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LOCKOUT TAGOUT OVERVIEW
 TITLE - CONTROL OF HAZARDOUS ENERGY
 SEPTEMBER 1, 1989 - FINAL RULE ISSUED
 JANUARY 2, 1990 - FINAL RULE TOOK EFFECT
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LOCKOUT TAGOUT OVERVIEW
 Authorized Employee
The Person Who Locks or Tags Out Machines To Perform Servicing
or Maintenance.
 Affected Employee
An Employee Whose Job Requires Him or Her To Operate or Use a
Machine or Piece of Equipment On Which Servicing or Maintenance
Is Being Performed.
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LOCKOUT TAGOUT OVERVIEW
DANGER
LOCKED
OUT
DO NOT OPERATE
This Lock/Tag may
only be removed by
NAME: _______________
DEPT : _______________
EXPECTED COMPLETION
DATE: ________________
TIME: _________________
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LOCKOUT TAGOUT OVERVIEW
 Normal Operations
1. Covered If an Employee Must Remove or Bypass Guards
or Devices
2. Covered Where Employees Are Required to Put A Body
Part in a Machine Process Area
3. Covered Where Employees Are Required to Put A Body
Part in a Machine Having a Danger Zone
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TIPS FOR USING CONTRACTORS
 REMEMBER, YOU CONTROL YOUR FACILITY OR AREA!
 REVIEW THEIR PROCEDURES WITH THEM BEFORE
STARTING THE JOB!
 DETERMINE THEIR SAFETY PERFORMANCE RECORD!
 DETERMINE WHO IS IN CHARGE OF THEIR PEOPLE!
 DETERMINE HOW THEY WILL AFFECT YOUR EMPLOYEES!
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MACHINE GAURDING
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MACHINERY AND MACHINE GUARDING
SAFETY
•MECHANICAL POWER PRESSES AND BENCH
GRINDERS
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MECHANICAL POWER PRESSES
TWO TYPES: FULL REVOLUTION OR
PART REVOLUTION (CLUTCH DRIVEN).
NO GUARDS OR SWEEPS ALLOWED FOR
HANDFEEDING.
PRESENCE SENSING DEVICES ALLOWED ON
PART REVOLUTION ONLY.
PULLBACKS MAY BE USED, BUT REQUIRES
INSPECTION FOR EACH SHIFT, OPERATOR
OR DIE SETUP.
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Workforce Development Institute
POWER PRESSES
•GATES ARE RECOMMENDED FOR HANDFEEDING:
TYPE A FOR BOTH PART OR FULL REV PRESSES.
TYPE B NOT RECOMMENDED FOR FULL REV.
• ALL PRESSES REQUIRE POINT OF OPERATION
SAFEGUARDING.
•FOR NON-HANDFEED OPERATIONS, GUARDS MAY BE
USED.
•GUARD OPENINGS MUST CONFORM TO 1910.217,
TABLE O-10
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Workforce Development Institute
BENCH GRINDERS
WORK REST GAP MUST BE WITHIN 1/8 INCH OF WHEEL.
TONGUE GUARD GAP MUST BE WITHIN
1/4 INCH OF WHEEL.
WHEEL GUARD MUST COVER SPINDLE, END NUT
AND FLANGE.
INSPECT BLOTTER, WHEEL MOUNTING HOLE,
FLANGES, COLLET BEFORE USE.
MAKE
SURE SPINDLE SPEED DOES NOT EXCEED
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WHEEL
RPMInstitute
RATING.