Machine

Safety
Safeguarding any
machine part that
may cause injury.

Objectives:

1. To identify causes of machine related accidents

2. To provide ways of machine safeguarding
3. To articulate the importance of LOTO

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 Machine accidents is caused of any of the following actions:
1. an individual making unwanted contact with a moving
part of a machine
2. something flying from the machine
3. a machine malfunction, including mechanical and
electrical energy sources failure
4. workpiece movement during a forming or cutting process

Effects of Machine Related Accidents

Can Result to Severe Injuries

Loss of Trained and Skilled Employee

Loss in Productivity

Damaged Equipment

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 Where Mechanical
Hazards Occur

The point of operation:

That point where work is performed on the material, such as

cutting, shaping, boring, or forming.

Power transmission apparatus:

All components of the mechanical system that 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.

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 Hazardous Mechanical
Motions
• Rotating – turning around on an axis or
center
• Reciprocating – the back and forth
movements of a machine part
• Traversing – continuous straight line
motion of a machine element in either
direction

Hazards associated with Rotating Motions

Catching Body Parts

Rotating shaft and pulley with

projecting key and set screw

Rotating coupling with

projecting bolt Rotating pulley with spokes
and projecting burr

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 Pinch Points / Nip Points
Hazards
In-running nip points draw objects in and the
effect is crushing or shearing injury.

Rotating Parts in Opposite Direction

Between Rotating Part and

Pinch Points Tangentially Moving Part

Belt and Pulley

Chain and Rack and

Sprocket Pinion

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Pinch Points
Between a Rotating Part and
Fixed Parts

Cutting Hazards from

Rotating Parts

• caught by
• flying particles
• sparks

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Reciprocating Machine Movements

During the back-and- forth or up-and-down motion, a

worker can be struck by a moving part or caught between a
moving and a stationary part. These are normally referred to as
pinch points or caught-between hazards.

Punching Shearing Bending

Reciprocating Motion

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 Traversing Motion
This motion is hazardous due to continuous straight
line action and in-running nip points. Pinch and
shear points are also created between a fixed or
other moving object.

Purpose of Machine Safeguarding:

To minimize the risk of injury to machine

operators or other persons from
hazardous machine parts, materials being
processed, or scrap.

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Methods of Machine Safeguarding
GUARDS DEVICES
• Fixed • Presence sensing device
• Interlocked • Pullback device
• Adjustable • Restraint device
• Manually adjustable • Safety control devices
• Self-adjusting • Tripwire cable
• Two-hand Control
• Emergency Stop Button

Guards are barriers that prevent entry

of an individual’s hands or other body
parts into a hazard area.

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 Fixed Barrier Guard
This type of guard is attached to a fixed surface and
encloses the hazard. When in place, it prevents anyone
from going over, around, under or through it to the
hazard. The principal advantage of the fixed enclosing
guard is that it always prevents access to the hazard
area.

Movable guards w/ interlocking switches

This type prevents machine motion until the guard is moved

into place. The interlocking method may be mechanical,
electrical, pneumatic, or a combination of these. To be
effective, interlocking guards must:
1.Enclose the point of operation before the machine can be
operated.
2. Keep the point of operation enclosed before the
hazardous part of the machine motion ceases.
3. Prevent operation of the machine if the interlock fails.

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 Adjustable Guard
This type of guard can be positioned to accommodate a variety
of operations or work and when properly adjusted provides
adequate protection from the hazard at the point of operation.
Adjustment of the guard should only be performed during
setup.

Self-Adjusting Guard
Provides a barrier which moves according to
the size of the stock entering the danger area.

Requirements for Machine Guards

Safeguards must meet these minimum general requirements:

•Prevent employee contact with hazardous moving parts

•Secured and durable
•Prevent falling materials into moving parts
•Create no new hazards
•Must not interfere with worker productivity
•Should allow for proper and safe lubrication

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 Any mechanical or electrical devices designed to
protect a worker’s hands or other body parts from
coming into contact with a hazardous motion of a
machine.

Pullbacks and Restraint Devices

Holdout and restraint devices are cable and wristlet systems tha t
attached to an operator’s hands and to the machine’s moving
slide or ram, or to a fixed object away from the point of
operation. They are usually used on machines having
reciprocating motions.

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 Two-hand Controls
Two- hand controls are operator controls that require an
operator to hold both controls down during the hazardous
portion of the machine’s stroke.

Presence-sensing Devices

These are designed, constructed, and arranged to create a

sensing field, area, or plane that will detect in its field the
presence of an opaque object.

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Emergency Stop

o Emergency stop button

o Grabwire switch or
tripwire switch

Protective Shields
Provides some protection from flying
particles, splashing cutting oils or coolants

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 HOLDER, JIGS, PUSH STICKS

Control of All Energy Sources

Through
Lockout/Tagout System

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 Lock-out/Tag-out System
(LOTO)
The standard for the control of hazardous
energy sources which covers maintenance
of machines in which the unexpected start
up of machines or release of stored
energy could cause injury to employees.

Sources of Hazardous Energy

• Electrical – the uncontrolled current
and voltage in electrical circuits
• Mechanical – exposed crushing or
cutting parts of equipment or loose
parts
• Thermal – such as steam or due to
chemical reaction
• Potential - stored energy that may be
due to gravity, hydraulics, pneumatics,
vacuum or springs

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nLockout devices:
nA device that utilizes a positive means such as a lock
either key or combination type, to hold an energy isolating
device in the safe position and prevents the energizing of a
equipment
n Included are blank flanges

nTagout devices:

nA warning device, such as a tag and a means of attachment

n Can be securely fastened to an energy isolating device in
accordance with an established procedure to indicate that
the energy isolating device and the equipment being
controlled can not be operated until the tag is removed

Sequence of Lockout
• Notify the person in-charge/operator that maintenance
of the equipment will be conducted.
• Person in-charge/operator shall identify the type and
magnitude of energy that the machine utilizes.
• Deactivate the energy-isolating device(s) so that the
machine or equipment is isolated from the energy
source(s)
• Application of lock-out devices
• Stored or residual energy must be dissipated or
restrained
• Verification of equipment isolation

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 Removal of Lock-out

• Ensure that the equipment components are

operationally intact and it is safe to operate.
• Check the work area to ensure that all
employees are safe.
• Notify person in-charge of job completion.
• Remove lockout/tagout devices.

Summary:
1. Machine safety is preventing access to dangerous
motions or preventing dangerous motions to access.

2. Machine safeguarding is generally accomplished by the

use of machine guards and safety devices.

3. The lockout/tagout system is an effective safety program

when performing maintenance activity.

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