Machine Guarding

OSHA 10-hour Outreach Training

General Industry

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Introduction
Possible machinery-related injuries include:
• Crushed fingers or hands
• Amputations
• Burns
• Blindness
A good rule to remember is:
Any machine part, function, or process which may cause
injury must be safeguarded.

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Introduction
Lesson objectives:
1. Identify the main causes of machinery accidents.
2. Recognize basic machinery parts that expose workers
to hazards.
3. Recognize workplace situations involving machinery
that requires guarding.
4. Identify the requirements for safeguards.
5. Identify types of machine guards including types of
devices used to safeguard machines.

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Machinery Accidents
Examples of how machine accidents can occur:
• Reaching-in to “clear” equipment
• Not using Lockout/Tagout
• Unauthorized persons doing maintenance or
using the machines
• Missing or loose machine guards

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Machinery Accidents
Amputations:
• Unguarded/inadequately safeguarded
machinery
• Materials handling activities
• Activities involving
Source: OSHA

stationary machines

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
Three fundamental machine areas:
• Point of operation
• Power transmission device
• Operating controls – mechanical or electric
power control

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards

Point of operation:
• Where work is performed on material
• Examples
• Cutting
• Shaping
• Boring
• Forming

Source: OSHA DTE

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
Power transmission device:
• Parts that transmit energy to the part of the
machine performing work
• Examples
• Flywheels
• Pulleys – Cams
• Belts – Spindles
• Connecting rods – Chains
• Couplings – Cranks
– Gears

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
Hazardous motions and actions:
• Motions
• How the machine part moves
• Examples: rotating, in-running nip points,
reciprocating, and transversing
• Actions
• Operation that the machine part performs
• Examples: cutting, punching, shearing, bending

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
• Rotating parts with hazardous projections

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
• Common nip points on rotating parts

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
• Nip points between rotating elements and parts with longitudinal
motions

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
• Nip points between rotating machine
components

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
• Reciprocating motions:
• Back-and-forth
• Up-and-down

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
• Transverse motion – movement
in straight, continuous line

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
• Cutting action – may involve rotating, reciprocating, or
transverse motion

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
• Punching action – power applied to a slide (ram) for purpose of
blanking, drawing, or stamping metal or other materials

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
• Shearing action – applying power to a slide or knife in order to
trim or shear metal or other materials.

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Basic Machinery Parts and Hazards
• Bending action – applying power to draw or stamp metal or other
materials

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Machinery That Requires Guarding
Machines that require point of operation guarding:
• Guillotine cutters
• Shears
• Alligator shears
• Power presses
• Milling machines
• Power saws
• Jointers
• Portable power tools
• Forming rolls and calenders

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Machinery That Requires Guarding
• Exposure of fan blades:
• Guard when periphery of blades is less
than 7’ above the floor or working level
• Guards with openings no larger than ½”

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Machinery That Requires Guarding
• Abrasive wheel machinery:
• Adjustable tongue guard to
within ¼” of wheel
• Work rest with maximum
opening of 1/8”
• Cover spindle end, nut, flange projections

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Machinery That Requires Guarding
Revolving barrels, containers, and drums:
• Guard by an enclosure which is interlocked with drive
mechanism
• Guards with openings no larger than ½”

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Machinery That Requires Guarding

Power-transmission apparatus:
Unguarded belt
• Shafting, flywheels, pulleys, and pulley
belts, chain drives, etc.
• Less than 7 feet from the
floor or working platform
must be guarded

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Machinery That Requires Guarding
Machinery associated with amputations – examples:
1. Mechanical power 7. Food slicers
presses 8. Meat grinders
2. Power press breaks
9. Meat-cutting
3. Powered and non- band saws
powered conveyors
10. Drill presses
4. Printing presses
11. Milling machines
5. Roll-forming and roll-
bending machines 12. Grinding machines
6. Shearing machines 13. Slitters

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Requirements for Safeguards
Safeguards must meet these minimum
general requirements:
• Prevent contact
• Be secured
• Protect from falling objects
• Create no new hazards
• Create no interference
• Allow safe lubrication

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Safeguarding machinery:
• Primary methods
• Guards
• Devices
• Ensure employee protection
• Properly designed, constructed, and installed
• Used and maintained in good operating condition

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
• Secondary methods
• Probe detection and safety edge devices
• Awareness devices
• Safeguarding methods
• Safe distance
• Safe holding
• Safe opening
• Safe work practices
• Safe work procedures
• Complementary equipment

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Guards:
• Preferable to other control methods
• Provide physical barrier that prevents contact
with dangerous machine parts
• Four general types
• Fixed
• Interlocked
• Adjustable
• Self-adjusting

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Fixed guard:
• Provides a barrier
• Permanent part of the machine, preferable to all other types
of guards.

Source of photos: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Interlocked guards:
• Shuts off or disengages power, stops moving parts, and
prevents starting of machine when guard is open
• May use electrical, mechanical, hydraulic, or pneumatic power,
or combination

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Adjustable guards:
• Shuts off or disengages power
• Stops moving parts
• Prevents starting of machine when guard is open

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Self-adjusting guards:
• Openings of barriers determined by movement of the
stock
• Places barrier between danger area and operator

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Devices:
• Controls or attachments that prevent inadvertent
access by employees to hazardous machine areas
• Examples
• Presence sensing
• Photoelectric – Safety trip controls
• Radiofrequency – Two-hand control
• Electromechanical
• Pullback – Two-hand trip
• Restraint – Gate

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Presence-sensing devices:
• Photoelectric
• Radiofrequency
• Electromechanical

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Pullback devices:
• Utilize a series of cables attached to
operator
• Automatically withdraws hands from
point of operation when slide/ram
begins to descend

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards

Source: OSHA Source: OSHA

• Hands in die, feeding • Die closed

• Point of operation exposed • Hands withdrawn from point of
operation by pullback device
• Pullback device attached and
properly adjusted

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Restraint devices:
• Utilize cables/straps attached to
operator’s hands and a fixed point
• No extending/retracting action
involved
• Hand-feeding tools may be necessary

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Safety trip controls:
• Deactivates the machine in an
emergency situation
• Examples
• Pressure-sensitive bar
• Safety tripod
• Safety tripwire
• Positioning is critical; must
stop machine before body
reaches danger area

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards
Two-hand controls:
• Deactivates the machine in an
emergency situation
• Pressure-sensitive
• Positioning is critical; must
stop machine before body
reaches danger area

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of
Gate devices:
Machine Safe Guards
• Moveable barrier that protects operator at point
of operation before machine cycle can be started
• Must be interlocked so machine cannot begin
cycle unless gate guard is in place
• Must be closed before machine can function
• Types
• “A” Gate
• “B” Gate

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of
Gate devices:
Machine Safe Guards Gate Open

• Moveable barrier that protects

operator at point of operation
before machine cycle can be
started
• Must be interlocked so machine
cannot begin cycle unless gate Gate Closed
guard is in place
• Must be closed before machine
can function

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Types of Machine Safe Guards

Type “A” Gate Operation Type “B” Gate Operation

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Additional Safeguarding
Location/distance:
• The dangerous moving part of a machine must
be so positioned that those areas are not
accessible or do not present a hazard
• Feeding process safeguarded
by maintaining safe distance
to protect worker
• Operator’s controls located
safe distance from machine

Source: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Additional Safeguarding Transparent
Enclosure
Guard
Feeding and ejection methods: Stock Feed
Roll
• Automatic/
semi-automatic feed
• Automatic/
semi-automatic ejection Completed Work
• Robots

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Additional Safeguarding
Miscellaneous aids:
• Awareness barriers
• Protective shields
• Hand-feeding tools

Source of graphics: OSHA

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Identify the Hazard

Unguarded lower blade and

arbor end of radial saw.
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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Identify the Hazard

Guard removed from chain rail exposing pins on

the spiked chain and sprocket mechanism.

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Summary
• Safeguards are essential for protecting workers
from needless and preventable machinery-
related injuries
• The point of operation, as well as all parts of
the machine that move while the machine is
working, must be safeguarded
• A good rule to remember is:
Any machine part, function, or process which
may cause injury must be safeguarded

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Knowledge Check
1. All machines consist of three fundamental areas, including __.
a. Flywheels, connecting rods, and transverse moving parts
b. Point of operation, power transmission device, and operating controls
c. Reciprocating parts, rotating parts, and on/off switch
d. Feed mechanisms, auxiliary machine parts, and nip points

Answer: b. point of operation, power transmission device,

and operating controls

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Knowledge Check
2. Rotating, in-running nip points, reciprocating, and transversing
are types of hazardous ___.
a. motions
b. actions
c. guards
d. devices

Answer: a. motions

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Knowledge Check
3. Cutting, punching, shearing, and bending are types of hazardous
___.
a. motions
b. actions
c. guards
d. devices

Answer: b. actions

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Knowledge
4. Which of theCheck
following explains how a guard protects workers?
a. Stops the machine when a worker enters the danger area
b. Restrains the worker from entering the danger area
c. Creates distance to keep the worker from entering the danger area
d. Provides a barrier to prevent access to the danger area

Answer: d. Provides a barrier to prevent

access to the danger area
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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup
 Knowledge Check
5. Which of the following is an example of a safeguarding device?
a. Protective shield
b. Hand-feeding tool
c. Safety trip control
d. Awareness barrier

Answer: c. Safety trip control

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PPT 10-hr. General Industry – Machine Guarding v.03.01.17 Created by OTIEC Outreach Resources Workgroup