Introduction to principles and concepts of

Effective
Machine
Act
Guarding
Plan
Prepare
 “Education is the beginning of safety”

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Welcome
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. Safeguards are essential for protecting
workers from needless and preventable injuries.
A good rule to remember is:
Any machine part, function, or process which may cause injury must be safeguarded. Where
the operation of a machine or accidental contact with it can injure the operator or others in
the vicinity, the hazards must be either controlled or eliminated.

This workbook overviews the various hazards of mechanical motion and presents some
techniques for protecting workers from these hazards. General information covered in this
workbook includes where mechanical hazards occur, the hazards created by different kinds
of motions and the requirements for effective safeguards, as well as a brief discussion on
training guidelines.

Goals
• Describe the basic hazards involving machinery including point of operation and
power transmission devices.
• Introduce control measures through effective machine guarding principles and
methods.

© 2000-2006 OSTN. All rights reserved.

This material, or any other material used to inform employers of compliance requirements of OSHA standards through simplification of the
regulations should not be considered a substitute for any provisions of the Occupational Safety and Health Act of 1970 or for any standards
issued by OSHA. The information in this publication is intended for training purposes only.

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Part One: The Principles

The purpose of machine guarding is to protect against and prevent injury from.…

_____________ _____________ _____________ _____________

_____________ _____________ _____________ _____________

Where Mechanical Hazards Occur

Dangerous moving parts in three basic areas require safeguarding:

1. The point of operation

That point where work is performed.
Cutting Shaping
Boring Forming

2. Power transmission apparatus

All components of the mechanical system which transmit energy to the part of the machine
performing the work.
Flywheels Pulleys Belts
Couplings Cams Spindles
Chains Cranks Gears
Sprockets Shafts Rods

3. Other moving parts

All parts of the machine which move while the machine is working.
Reciprocating Rotating Transverse
Feed mechanisms Auxiliary parts

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Hazardous Mechanical Motions & Actions

A wide 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.
These different types of hazardous mechanical motions and actions are basic in varying
combinations to nearly all machines, and recognizing them is the first step toward protecting
workers from the danger they present.

Motions
1. Rotating motion

• Collars • Clutches • Spindles

• Couplings • Flywheels • Meshing gears
• Cams • Shafts • Fans

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In-running nip point hazards

There are three main types of in-running nips.
Parts rotating in opposite direction
Rotating and tangentially parts
Rotating and fixed parts

Parts rotating in opposite direction

Rotating and tangentially moving parts

Rotating and fixed parts

Rotating hazard here?

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2. Reciprocating motion

Do you have reciprocating motion in your facility? _________

3. Transverse motion

Examples
• Conveyor lines
• Lengthy belts

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Identify each in-running nip point below.

________________________________
________________________________

________________________________
________________________________

________________________________

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Hazardous Mechanical Motions & Actions

A wide 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.
These different types of hazardous mechanical motions and actions are basic in varying
combinations to nearly all machines, and recognizing them is the first step toward
protecting workers from the danger they present.

Actions
Cutting Shearing Bending Punching

Cutting

Bending

Shearing Punching

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Part Two: Methods of Machine Guarding

There are many ways to safeguard machines. The type of operation, the size or shape of
stock, the method of handling, the physical layout of the work area, the type of material,
and production requirements or limitations will help determine the appropriate safeguarding
method for the individual machine.
As a general rule, power transmission apparatus is best protected by fixed guards that
enclose the danger areas. For hazards at the point of operation, where moving parts
actually perform work on stock, several kinds of safeguarding may be possible. One must
always choose the most effective and practical means available.

Safeguarding strategies include:

1. Guards 2. Devices
 Fixed  Presence sensing
 Interlocked  Pullback
 Adjustable  Restraints
 Self-adjusting  Controls/Trips
 Gates

Other safeguarding strategies may include:

Location/Distance
Feeding/Ejection Methods
Automatic/semi-auto feed Automatic/semi-auto ejection Robotics

Miscellaneous aids can help reduce exposure

Awareness barriers Protective shields
Hand-feeding tools and holding fixtures

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What makes a guard effective?

Î Must prevent any contact to the machine hazard and installed to prevent contact
from around, over, through, or under the guard!
“…so designed and constructed as to prevent the operator from having any part
of his/her body in the danger zone during the operating cycle” [Division
2/Subdivision O 29 CFR 1910.212(a)(3)(ii)]
Î Must not present a hazard in itself
Î Must be affixed to the machine where possible
Î Conformity with other appropriate standards: ANSI, etc.

Effective?
Y N

Effective?
Y N

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First Safeguarding Strategy: Guards

Guards are physical barriers which prevent access to danger areas.

Guards

Fixed Interlocked Adjustable Self-adjusting

Fixed Guards
• Permanent part of the machine.
• Not dependent upon moving parts to perform its intended function.
• Constructed of sheet metal, screen, wire cloth, bars, plastic, or other substantial
material
• Usually preferable to all other types because of its relative simplicity and
permanence.

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Interlocked Guards
• When opened or removed, the tripping mechanism and/or power automatically
shuts off or disengages
• Machine cannot cycle or be started until the guard is back in place
• Electrical, mechanical, hydraulic, or pneumatic power
• Replacing the guard should not automatically restart the machine

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Adjustable Guards
• Allow flexibility in accommodating various sizes of stock

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Self-adjusting Guards
Openings are determined by the movement of stock
- Guard is pushed away as stock is introduced;
- Opening is only large enough to admit the stock;
- Guard returns to rest position after stock passes through.

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Second Safeguarding Strategy: Devices

A safety device may perform one of several functions.

É It may stop the machine if a hand or any part of the body is inadvertently placed
in the danger area;
É Restrain or withdraw the operator's hands from the danger area during
operation;
É Require the operator to use both hands on machine controls; or
É Provide a barrier which is synchronized with the operating cycle of the machine
in order to prevent entry to the danger area during the hazardous part of the
cycle.

Presence-Sensing Devices
Photoelectric (optical)
Uses a system of light sources and controls which can
interrupt the machine's operating cycle.

Radiofrequency (capacitance)
Uses a radio beam that is part of the machine control
circuit. When the capacitance field is broken, the machine
will stop or will not activate.

Electromechanical
Has a probe or contact bar which descends to a predetermined
distance when the operator initiates the machine cycle. If there
is an obstruction preventing it from descending its full
predetermined distance, the control circuit does not actuate
the machine cycle.

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Pullback
Pullback devices utilize a series of cables attached to the operator's hands, wrists,
and/or arms. This type of device is primarily used on machines with stroking action.
When the slide/ram is up between cycles, the operator is allowed access to the point
of operation.

Restraint
The restraint (holdout) device utilizes cables or
straps that are attached to the operator's
hands at a fixed point. The cables or straps
must be adjusted to let the operator's hands
travel within a predetermined safe area.
There is no extending or retracting action
involved. Consequently, hand-feeding tools
are often necessary if the operation involves
placing material into the danger area.

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Safety Trip Controls

Provide a quick means for deactivating the machine in an emergency situation. A
pressure-sensitive bar, when depressed, will deactivate the machine.

Safety tripwire cables may also be

located around the perimeter or near
the danger area.

Two-Hand Controls
Requires constant, concurrent pressure by the operator
to activate the machine. With this type of device, the
operator’s hands are required to be at a safe location (on
the control buttons) and at a safe distance from the
danger area.

Two-Hand Trip
This device requires concurrent application of both the
operator’s control buttons to activate the machine cycle,
after which the hands are free.

Gate
A gate is a movable barrier which
protects the operator at the point of
operation before the machine cycle
can be started. They are usually
designed to operate with each
machine cycle.
Two types: Type A & Type B

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Third Safeguarding Strategy: Location & Distance

The machine or its dangerous moving parts are positioned so that the
hazardous areas are not accessible or do not present a hazard during
normal operation

É Walls
É Barriers/Fences
É Height above worker
É Size of stock (single end feed, punching)
É Controls (positioned at a safe distance)

What are some concerns

when considering guarding by
location and/or distance?
__________________________
__________________________
__________________________
__________________________
__________________________

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Fourth Safeguarding Strategy: Feeding & Injection

Designing exposure out!

Automatic Feeding
Operator involvement is
not necessary after the Semi-Automatic Feeding
machine is set up
Manually feed without reaching
into the point of operation or other
danger zones

Automatic Ejection
Require no operator
involvement
Semiautomatic Ejection

What are some concerns

when considering
feeding/ejection methods?
__________________________
__________________________
__________________________

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Robots
Machines that load and unload stock, assemble parts, transfer objects, and perform
other tasks - otherwise done by the operator.

What are some

concerns when
considering robotics?
___________________
___________________
___________________
___________________

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Fifth safeguard strategy: Miscellaneous Aids

May not give complete protection from machine hazards, but may provide the
operator with an extra margin of safety.
Examples:
• Awareness barriers
• Ropes
• Shields
• Holding tools
• Push sticks or blocks

What are some

concerns when using
miscellaneous aids?
___________________
___________________
___________________
___________________

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Let's review!

1. Machine guarding protects operators and prevents injury from……

P____ __ _________ F______ C_______
R________ P_____ S______ N___ P_______

2. Three basic area require machine safeguarding. Circle the three:

Other danger areas Point of operation Power transmission apparatus

3. What are the three types of equipment/machine motions that present hazards to the
worker?
R_____________ R________________ T_______________

4. What are the three types of in-running nip points?

Parts rotating in o_________ direction
Rotating and t____________ moving parts
Rotating and f______ parts

5. What are the four types of equipment/machine actions that can injure the worker?
A. Cutting B. Shearing C. Punching D. Bending E. All of the above

6. List the four general types of guards.

F_____ I___________ A___________ S____ A__________

6. List at least two types of safeguard devices.

7. What are the requirements for effective guards?

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Appendix

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Placing guards at a safe distance

This diagram shows the accepted safe openings between the bottom edge of a guard and
feed table at various distances from the danger line or point of operation.
The clearance line marks the distance required to prevent contact between guard and
moving parts.
The minimum guarding line is the distance between the infeed side of the guard and the
danger line which is one-half inch from the danger line.
The various openings are such that for average size hands, an operator’s fingers won’t
reach the point of operation.
After installation of point of operation guards and before a job is released for operation a
check should be made to verify that the guard will prevent the operator’s hands from
reaching the point of operation.

Not to scale Opening Line

Danger Line
Clearance Line*
Minimum Guarding Line
1/2” Typical guard locations

1 1/2” 3 1/2” 6 1/2” 12 1/2” 17 1/2” 31 1/2”

2 1/2” 5 1/2” 7 1/2” 15 1/2”

*Guard must extend from some point on the clearance line to some point on opening line

Distance of opening from Maximum width of

point of operation hazard (inches) opening (inches)

1/2 to 1 1/2 1/4

1 1/2 to 2/12 3/8
2 1/2 to 3 1/2 1/2
3 1/2 to 5 1/2 5/8
5 1/2 to 6 1/2 3/4
6 1/2 to 7 1/2 7/8
7 1/2 to 12 1/2 1 1/4
12 1/2 to 15 1/2 1 1/2
15 1/2 to 17 1/2 1 7/8
17 1/2 to 31 1/2 2 1/8
Over 31 1/2 6

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Machine Guarding Checklist

Answers to the following questions should help the interested reader determine the
safeguarding needs of his or her own workplace, by drawing attention to hazardous
conditions or practices requiring correction.

____ ____ 1. Do the safeguards provided meet the minimum OSHA requirements?
____ ____ 2. Do the safeguards prevent workers' hands, arms, and other body parts for
making contact with dangerous moving parts?
____ ____ 3. Are the safeguards firmly secured and not easily removable?
____ ____ 4. Do the safeguards ensure that no object will fall into the moving parts?
____ ____ 5. Do the safeguards permit safe, comfortable, and relatively easy operation
of the machine?
____ ____ 6. Can the machine be oiled without removing the safeguard?
____ ____ 7. Is there a system for shutting down the machinery before safeguards are
removed?
____ ____ 8. Can the existing safeguards be improved?

Mechanical Hazards

Y N
The point of operation:
____ ____ 1. Is there a point-of-operation safeguard provided for the machine?
____ ____ 2. Does it keep the operator's hands, fingers, body out of the danger area?
____ ____ 3. Is there evidence that the safeguards have been tampered with or
removed?
____ ____ 4. Could you suggest a more practical, effective safeguard?
____ ____ 5. Could changes be made on the machine to eliminate the point-of-operation
hazard entirely?

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Requirements for all Safeguards (continued)

Yes No
Power transmission apparatus:
____ ____ 1. Are there any unguarded gears, sprockets, pulleys, or flywheels on the
apparatus?
____ ____ 2. Are there any exposed belts or chain drives?
____ ____ 3. Are there any exposed set screws, key ways, collars, etc.?
____ ____ 4. Are starting and stopping controls within easy reach of the operator?
____ ____ 5. If there is more than one operator, are separate controls provided?

Other moving parts:

____ ____ 1. Are safeguards provided for all hazardous moving parts of the machine
including auxiliary parts?

Nonmechanical Hazards
____ ____ 1. Have appropriate measures been taken to safeguard workers against
noise hazards?
____ ____ 2. Have special guards, enclosures, or personal protective equipment been
provided, where necessary, to protect workers from exposure to harmful
substances used in machine operation?

Electric Hazards
____ ____ 1. Is the machine installed in accordance with National Fire Protection
Association and National Electrical Code requirements?
____ ____ 2. Are there loose conduit fittings?
____ ____ 3. Is the machine properly grounded?
____ ____ 4. Is the power supply correctly fused and protected?
____ ____ 5. Do workers occasionally receive minor shocks while operating any of the
machines?

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Requirements for all Safeguards (continued)

Yes No
Training
____ ____ 1. Do operators and maintenance workers have the necessary training in how
to use the safeguards and why?
____ ____ 2. Have operators and maintenance workers been trained in where the
safeguards are located, how they provide protection, and what hazards
they protect against?
____ ____ 3. Have operators and maintenance workers been trained in how and under
what circumstances guards can be removed?
____ ____ 4. Have workers been trained in the procedures to follow if they notice guards
that are damaged, missing, or inadequate?

Protective Equipment and Proper Clothing

____ ____ 1. Is protective equipment required?
____ ____ 2. If protective equipment is required, is it appropriate for the job, in good
condition, kept clean and sanitary, and stored carefully when not in use?
____ ____ 3. Is the operator dressed safely for the job (i.e., no loose-fitting clothing or
jewelry)?

Machinery Maintenance and Repair

____ ____ 1. Have maintenance workers received up-to-date instruction on the machines
they service?
____ ____ 2. Do maintenance workers lock out the machine from its power sources
before beginning repairs?
____ ____ 3. Where several maintenance persons work on the same machine, are
multiple lockout devices used?
____ ____ 4. Do maintenance persons use appropriate and safe equipment in their repair
work?
____ ____ 5. Is the maintenance equipment itself properly guarded?
____ ____ 6. Are maintenance and servicing workers trained in the requirements of 29
CFR 1910.147, lockout/tagout hazard, and do the procedures for
lockout/tagout exist before they attempt their tasks?

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Managing a Machine Guarding Program

When it comes to machine guarding a good rule-of-thumb to follow is, “if you can touch a moving part, guard it.” Where
the operation of a machine or accidental contact with it can injure the operator or others in the vicinity, the hazard must be
either controlled or eliminated. This section describes some of the hazards of mechanical motion and action and presents
some techniques for protecting workers from these hazards.
If appropriate, the safety committee may want to assign a member to monitor machine guarding throughout the workplace to
make sure all machines are properly guarded.

Where Mechanical Hazards Occur

Dangerous moving parts in these three areas need safeguarding:
• The point of operation: that point where work is performed on the material, such as cutting, shaping, boring, or
forming 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 which 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.

Hazardous Mechanical Motions and Actions

A wide variety of mechanical motions and actions may present hazards to the worker. These can include rotating members,
reciprocating arms, moving belts, meshing gears, cutting teeth, and any parts that impact or shear. These different types of
hazardous mechanical motions and actions are basic to nearly all machines, and recognizing them is the first step toward
protecting workers from the danger they present.

Requirements for Safeguards

What must a safeguard to protect workers against mechanical hazards? Safeguards must meet these minimum general
requirements:
• Prevent contact: The safeguard must prevent hands, arms, or any other part of a worker’s body from making contact
with dangerous moving parts. A good safeguarding system eliminates the possibility of the operator or another
worker placing their hands near hazardous moving parts.
• Secure: Workers should not be able to easily remove or tamper with the safeguard, because a safeguard that can
easily be made ineffective is no safeguard 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.
• Protect from falling objects: The safeguard should ensure that no objects can fall into moving parts. A small tool
which is dropped into a cycling machine could easily become a projectile that could strike and injury someone.
• Create no new hazards: A safeguard defeats its own purpose if it creates a hazard of its own such as shear point, a
jagged edge, or an unfinished surface which can cause a laceration. The edges of guards, for instance, should be
rolled or bolted in such a way that they eliminate sharp edges.
• Create no interference: Any safeguard which impedes a worker from performing the job quickly and comfortably
might soon be overridden or disregarded. Proper safeguarding can actually enhance efficiency since it can relieve
the worker’s apprehensions about injury.
• Allow safe lubrication: If possible, one should be able to lubricate the machine without removing the safeguards.
Locating oil reservoirs outside the guard, with a line leading to the lubrication point, will reduce the need for the
operator or maintenance worker to enter the hazardous area.

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Training
Even the most elaborate safeguarding system cannot offer effective protection unless the worker knows how to use it and
why. Specific training is a crucial part of any effort to provide safeguarding against machine-related hazards. Thorough
operator training should:
1. Identify and describe the hazards associated with particular machines.
2. Discuss the safeguards and how they provide protection.
3. Discuss how to use the safeguards and why.
4. Discuss how and under what circumstances safeguards can be removed.
5. Discuss under what circumstances a safeguard can be removed, and by whom.
6. Describe what to do if a safeguard is damaged, missing, or unable to provide adequate protection.

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