Vietnam Machine Safety

Machine Safeguarding
Nam Dinh, Vietnam

September 2020
Goals
• Introduce effective machine-guarding

principles, methods, and five primary
guarding strategies.
• Be able to determine machine-guarding

hazards and corrective measures to
eliminate those hazards.
I. Introduction
Injury data
60 57
50
40
32 33
30 DAYS
22 23 DAYS
20 DAYS
12 11
9
10 7
5 5 5
2
0
Sew ing Hot Universal Hot Melt Buffing Skiving Cutting mc Rolling mc Heat Punching Razor Scissors Others
mc Pressing Pressing mc mc mc Transfer mc blade
mc mc Label mc
I. Introduction
Days Missing
80
73
70 66
60
50
40
34
30 28
23 22 25
20 20
13 13
10 6 7
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec AVG
I. Introduction
Injury cases
Other, 43, 7%
GWE, 26, 4%
PPE, 62, 11%

Mc, 394, 68%
MMH, 58, 10%
Where,
Mc: Machine MMH: Manual Material Handling
GWE: General Working Environment PPE: Personal Protection Equipment
I. Introduction
Days Missing by Machines
1 Ass Line, 10, Grinding, 7, 2% 2 Eyelet, 56,

8
3% 18%
2 Skiving, 97,
33%
Cut, 19, 6% 2
Hotmelt, 52,
Hammar, 63, 17% 3
21% 4
3
Severity (body parts hurt)
Elbow
Foot Face 1% Wrist Leg Other Eye
1% 1% 1% 4%
3% 16%
Arm
5%
Head
2%
Hand
13%
Finger
53%
I. Introduction
Severity (days missing / case)
days missing / case
50 48.5
45
40
35
30
25
20
16
15 14 12.5
10 10 9.5
7 7
5
1.5
0
Skiving Hammar Hotmelt Lasting Ass Line Cutting Eyelet Grinding Stitching
Machine Name
I. Introduction
Causes of Machine Accidents
1. Reaching in to “clear” equipment
2. Missing or loose machine guards
3. Unauthorized persons doing
maintenance or using the machines
4. Not using Lockout/Tagout
I. Introduction
Brief to Lockout/Tagout
If you do not use Lockout/Tagout…
Assembly Line
Assembly Line
Skiving mc (sheet)
Skiving mc
Skiving mc
II. The Principles
The purpose of guard is to protect against and
prevent injury from...
1. Workers contact with moving parts . . . for
whatever reason:
– Work, curiosity, anger, illness, distraction, horseplay,
etc.
2. Work in progress contacting workers
– Kickback, splash, chips, etc.
3. Mechanical failure
4. Electrical failure
Where Hazards Occur
Dangerous moving parts in three basic areas
require safeguarding:
1. The point of operation:
– The point where work is performed…
• cutting, shaping, boring, forming
2. Power Transmission Apparatus:
3. Other moving parts:

Where Hazards Occur
1. Example for the point of operation:
Where Hazards Occur
1 Example for the point of operation:
Where Hazards Occur
2 Power transmission apparatus:
– All components of the mechanical system which
transmit energy to the part of the machine performing
the work. Includes…
• flywheels, connecting rods, spindles, gears, pulleys,
couplings, chains, belts, cams, cranks
Where Hazards Occur
3 Other moving parts:
– All parts of the machine that move while the machine
is working. Includes…
• reciprocating, rotating, feed mechanisms, transverse,
auxiliary parts
Where Hazards Occur
3 Example for other moving parts:
Where Hazards Occur
Quiz 1: identify the danger areas
Where Hazards Occur
The basic types of hazardous mechanical
motions and actions are:
Actions: Motions:
Cutting Rotating
Punching Reciprocating
Shearing transverse
Bending
Where Hazards Occur
Actions: Cutting
Where Hazards Occur
Actions: Punching
Where Hazards Occur
Actions: Shearing
Where Hazards Occur
Actions: Bending
Where Hazards Occur
Motions: Rotating
Where Hazards Occur
There are three main types of in-running nips...
1) Rotating in opposite direction
Rotating
cylinders
Where Hazards Occur
2) Rotating and moving tangentially
Belt and pulley
Chain and sprocket Rack and pinion

Where Hazards Occur
3) Rotating and fixed parts
Where Hazards Occur
Motions: Reciprocating
Where Hazards Occur
Motions: Reciprocating
Where Hazards Occur
Motions: Transverse
Where Hazards Occur
Motions: Transverse
Where Hazards Occur
Quiz 2: should it be safeguarded?
Nonmechanical Hazards
Original Buffer
Spring
Silencer
Training
Contents:
1. Hazards identification, Injury history if any
2. Safeguards, how to protect
3. How to use and why
4. Repair & maintenance
Training types:
5. Communication channels
1. New workers
2. New machines
3. New safeguards
4. Refreshment annual training
5. Injuries happened
Training
Personal Protective Equipment
Quiz 3: Link PPE to the hazards
Caps & Hair nets Splashing liquid/stocks

Face shield/goggles Heavy stock might fall down
Gloves Extremely hot oven
Ear plug Rotating parts
Safety shoes Impulse noises
Heat-proof full-body suit Moving rough-edge stocks
Where Hazards Occur
Gloves around rotating part:
Effective Safeguards
The safeguard must...
1. Prevent contact
2. Be secure
3. Protect from falling objects
4. Create no new hazards
5. Create no interference
6. Allow safe lubrication
Quiz & Summary
Quiz 4: Who wants to be millionaire:

III. Methods of Machine Guarding
• Guards • Location/distance
– fixed
• Feeding and ejection
– interlocked
methods
– adjustable
– automatic and/or semi-
– self-adjusting automatic feed and
ejection
• Devices
– robots
– presence sensing
– pullback • Miscellaneous aids
– restraint – awareness barriers
– safety controls (tripwire – protective shields
cable, two-hand control, etc.) – hand-feeding tools
– gates
– fixed • Feeding and ejection
– interlocked methods
– adjustable
ejection
• Devices
– robots
– pullback • Miscellaneous aids

– restraint – awareness barriers
– safety controls (tripwire – protective shields
cable, two-hand control, etc.)
– hand-feeding tools
– gates
1. Guards
Guards are barriers that prevent access to
danger areas.
1.1 Fixed Guards:
1. Guards
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
1. Guards
Examples of fixed guards...
1. Guards
1. Guards
1. Guards
1. Guards
Install finger
bar to prevent
injury
Machine Safety
1. Guards
Examples of fixed guards (video)...
Install a guard having openings
no larger than ½ inch
Install a guard having openings no larger than ½ inch
If periphery of fan blades more than 7 feet above the
ground or working level, not necessary for safeguarding
D should be less than 1/4’’ (0.635cm)
2
1
Quiz & Summary

1.2 Interlocked Guards
When this type of guard is opened or removed,
the tripping mechanism and/or power
automatically shuts off or disengages, and the
machine cannot cycle or be started until the
guard is back in place.
• Guard the dangerous part before the machine
can be operated.
• Keep the guard closed until the dangerous part
is at rest.
• Prevent operation of the machine if the
interlocking device fails.
• They may use electrical, mechanical, hydraulic,
or pneumatic power or any combination of
these.
• They should not prevent “inching” by remote
control if required.
• Replacing the guard should not automatically
restart the machine.
• All movable guards should be interlocked to
prevent occupational hazards.
1.3 Adjustable Guards
Provides a barrier which may be adjusted to
facilitate a variety of production operations
Adjustable
screw
1.4 Self-Adjusting Guards
The openings of these barriers are determined
by the movement of the stock.
As the operator moves the stock into the

danger area, the guard is pushed away,
providing an opening that is only large enough
to admit the stock.
After the stock is removed, the guard returns

to the rest position.
Placing Guards at a Safe Distance
The following 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.
Finger tips
4 fingers
palm
hand
• 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 1/2
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.
3 injuries
D

4 injuries
D should be less than

1/4’’ (0.635cm) + d
More Examples
The distance (Ds)

requirements:
Dc
Ds
Maintenance & LOTO also…
D

D D
D should be less than

1/4’’ (0.635cm)
Quiz & Summary

– fixed • Feeding and ejection
– interlocked methods
– adjustable – automatic and/or semi-
ejection
• Devices
– robots
– safety controls (tripwire cable,• Miscellaneous aids
two-hand control, etc.) – awareness barriers
– gates – protective shields
– restraint – hand-feeding tools
– pullback
A safety device may perform one of several
functions...
• Stop the machine if a hand or any part of the body is
inadvertently placed in danger area
• Restrain or withdraw the operator’s hands from the
danger area during operation
• Require the operator to use both hands on machine
controls
• Provide a barrier that is synchronized with the operating
cycle of the machine in order to prevent entry to the
danger area during the hazardous part of the the cycle
2.1 Presence-Sensing Devices
Photoelectric (optical)
• Uses a system of light sources and controls that can
interrupt the machine’s operating cycle
2.2 Safety Control Devices
2.2.1. Pressure-sensitive bar
• Provides a quick
means for deactivating
the machine in an
emergency. When
depressed, will
deactivate the
machine.
2.2.1. Pressure-sensitive bar
2.2.2. Safety triprod
2.2.2 Safety triprod
2.2.3. Safety tripwire cable
• May be located around the perimeter or near the danger
area
Safety Trip Controls
Emergency Power Off (EPO)
The Emergency Power Off

button doesn’t make sense…
2.2.4 Two-hand controls
• Requires constant, concurrent pressure by the operator
to activate the machine. 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.
2.2.5 Two-hand trips
D(s) is larger than 63 inches/second * T(s);

where:
D(s) = minimum safety distance (inches);
63 inches/second=hand speed constant; and
T(s) = stopping time of the press (seconds).
Distance between the two buttons

20cm-60cm
Button type
even with the cover, not projecting
Risk： Some injury happened
because hands are moving
2.2.5 Two-hand trips faster into the dangerous areas
before the dangerous areas
closed. So …
Improvement：adjust the
PLC electronic program of
the machine to make the
switch time-lapse. (Keeping
hands on the buttons for at
least 1 minute to start the m/c,
M/while the m/c is moving
down)
2.3 Gate
• A movable barrier that

protects the operator at the
point of operation before
the machine cycle can be
started.
• Usually designed to
operate with each machine
cycle.
2.3 Gate
2.3 Gate
2.3 Gate
2.4 Restraint Device
• Uses cables or straps

attached to the operator’s
hands and a fixed point
• Must be adjusted to let the
operator’s hands travel within
a predetermined safe area
• Hand-feeding tools are often
necessary if the operation
involves placing material into
the danger area
2.5 Pullback Device
• Utilizes a series of cables

attached to the operator’s
hands, wrists, and/or arms
• Primarily used on machines
with stroking action
• Allows access to the point of
operation when the
slide/ram is up
• Withdraws hands when the
slide/ram begins to descend
2.5 Pullback Device
• Hands in die, feeding • Die closed

• Point of operation exposed • Hands withdrawn from
• Pullback device attached point of operation by
and properly adjusted pullback device
– fixed
• Feeding and ejection
– interlocked
methods
– adjustable
– self-adjusting automatic feed and ejection
• Devices – robots
– presence sensing • Miscellaneous aids
– pullback – awareness barriers
– restraint – protective shields
– safety controls (tripwire – hand-feeding tools
cable, two-hand control, etc.)
– gates
3. Location & Distance
The machine or its dangerous moving parts are
positioned so that hazardous areas are not
accessible or do not present a hazard during
normal operation...
Examples:
• Walls
• Fences
• Height (above worker)
• Size of stock (single-end feeding, punching)
• Controls (positioned at a safe distance)
4. Feeding & Injection
Automatic and semiautomatic feed methods
Automatic feed methods
Robots
• Machines that load
and unload stock,
assemble parts,
transfer objects, and
perform other tasks.
• They perform work
otherwise done by
the operator
• Best used in high-
production
processes requiring
repeated routines.
5. 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
hand foot
switch switch
1．Simple designing
2．operating safely and easily
Quiz & Summary
EXAMPLES – Many ways
EXAMPLES – Many ways
Good ideas
Machine
hazards

Vietnam Machine Safety

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Machine Safeguarding

Nam Dinh, Vietnam

• Introduce effective machine-guarding

• Be able to determine machine-guarding

PPE, 62, 11%

1 Ass Line, 10, Grinding, 7, 2% 2 Eyelet, 56,

2. Power Transmission Apparatus:

3. Other moving parts:

Belt and pulley

Chain and sprocket Rack and pinion

Caps & Hair nets Splashing liquid/stocks

Quiz 4: Who wants to be millionaire:

– pullback • Miscellaneous aids

Quiz 5: Who wants to be millionaire:

As the operator moves the stock into the

After the stock is removed, the guard returns

D should be less than 1/4’’ (0.625cm)

D should be less than

The distance (Ds)

D should be less than 1/4’’ (0.635cm)

D should be less than

Quiz 6: Who wants to be millionaire:

The Emergency Power Off

D(s) is larger than 63 inches/second * T(s);

Distance between the two buttons

• A movable barrier that

• Uses cables or straps

• Utilizes a series of cables

• Hands in die, feeding • Die closed

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