M achines S afety

Dr. Muham m ad Us m an Farooq

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Objectives
• To protect workers from the hazards of machinery and to prevent
accidents, incidents and ill health resulting from the use of
machinery at work by providing guidelines

a) Ensuring that all machinery for use at work is designed

and manufactured to eliminate or minimize the hazards
associated with its use.
b) Ensuring that employers are provided with a mechanism
for obtaining from their suppliers necessary and sufficient
safety information about machinery to enable them to
implement effective protective measures for workers.
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1. Introduction
Safe machine operations require
• Identify machinery and equipment hazards in the workplace

• Eliminate or reduce the risk of those hazards causing harm.

• Managing the risks associated with use of machinery and

equipment in the workplace.

• How to prevent?
• Safe use, safe design
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These incidents can cause

 Damage to the body, e.g. cuts, crushing of limb, etc

 Injuries by energies released from the machine, e.g. electrical shock, burn, etc
 Fatalities
2. Incident History 5

Incidents occurred due to

3. Lack of maintenance

1- Lack of protection (e.g. equipment safeguards)


3. Machine Hazards
When identifying the hazards related with machines, we shall consider:
 Type of machines (lever, pully, screw, axel..)
 Layout of machines (static or moveable)
 Driven method (Electricity, air, etc.)
 Operating parameters, e.g. Speed, pressure,
temperature, size of cut, mobility, etc.
 Materials to be processed or handled and method
of feed (hard or soft)
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 Operator position and controls
 Access for setting adjustments and
maintenance.
 Environmental factors, e.g. Dust, fumes,
noise, temperature, humidity etc
 Operating requirements including what
the operator needs to do.
3. Machine Hazards 7

Typical hazards related with operation of machines include:

• Machines have moving parts. e.g.

The action of moving parts may • High pressure fluid ejection

have sufficient force in motion to • Electrical shock

cause injury to people. • Noise and vibration

• e.g. crushing, shearing, cutting, • Contact with extremes of

temperature
stabbing or puncture
• Ergonomics
3. Machine Hazards MECHANICAL HAZARDS
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HAZARD RISK

Rotating shafts, pulleys, sprockets

Entanglement
and gear

Hard surfaces moving together Crushing

Scissor or shear action Severing

Sharp Edge- moving or stationary Cutting or puncturing

Slips, trips and falls (e.G.,

Cable or hose connection
Oil leaks)
3. Machine Hazards MECHANICAL HAZARDS
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Unguarded Rotating Parts of Machine

Belt &
pully

Chain &
sprocket

Rack &
pinion

Rotating
cylinders
 3. Machine Hazards NON-MECHANICAL HAZARDS
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• Associated with machinery and equipment can include harmful emissions, chemicals and
chemical by-products, electricity and noise.
• Cause serious injury if not adequately controlled.
• In some cases, people exposed to these hazards may not show signs of injury or illness for years.
Non- Mechanical HAZARD
When reviewing machinery and
Dust Mist (vapours/fumes)
equipment for possible non-mechanical Explosive or flammable
Noise
hazards, consider how machines and atmosphere
Heat (radiated or
equipment can affect the area Ignition source
conducted)
(environment) around them. High intensity light Chemicals

Heavy metals Pressurized fluids/gases

4. Machine Safety 11

Identify the existing controls Identify the need for additional control

• Any safeguards in place? • What is the risk level with the

• Any written procedures to consideration of existing controls?

control or mitigate the risk? • High risk must be reduced to at least

• What are the PPE used? medium risk before startup of work

• Whether the risk level can be further

reduced to As Low As Reasonably
Practical ?
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4. Machine Safety
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4. Machine Safety
Control Measures
4. Machine Safety 14

Types of machine guarding

1 . Fi xe d g u a rd

2 . I n t e rl o cke d g u a rd

3 . A d j u s t abl e g u a rd

4 . S e l f - a d j u s t i n g g u a rd
4. Machine Safety
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Ma ch ine G u a rd

1- Fixed Guard of Machine

Inspection panel
• Advantages
• Maximum protection

Fixed Guard
• Variety of applications
• In-house fabrication
• Low cost & maintenance
• Disadvantages
• Poor visibility
• Must remove for repairs
requiring LOTO
4. Machine Safety
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Ma ch ine G u a rd

2- Interlocked Guard of Machine

• Switch that when opened stops power

• Advantage
• Maximum protection

Interlocked guard on • Portion of guard easily removed for

revolving drum
access

• Disadvantage
• Can be overridden by employee
• High cost
• Maintenance required
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4. Machine Safety Ma ch ine G u a rd

3- Adjustable Guard of Machine

• Advantage
Bandsaw blade
adjustable guard • Flexibility
• In-house fabrication

• Disadvantage
• Not maximum protection
• Rely on worker to properly
position.
• May prohibit easy access
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4. Machine Safety Ma ch ine G u a rd

4- Self-adjusting Guard

• Advantage
• Employee not involved in
positioning
• Readily available
Circular table saw self-adjusting
guard • Disadvantage

• Not maximum protection

• May need frequent fine
tuning
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4. Machine Safety
Devices 1-Pullback Device
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4. Machine Safety
Devices 2- Restraint Device
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4. Machine Safety
Devices 3- Safety Tripwire Cable

Tripwire
Cable
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4. Machine Safety
Devices 4- Two-hand Control
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4. Machine Safety
Devices 5- Gates

Gate Open Gate Closed

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4. Machine Safety
Devices 6- Sensor
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4. Machine Safety
7- Safeguard by Distance
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4. Machine Safety
8- Automatic Feed and Robot

Robot
Automatic Feed
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4. Machine Safety Holding/Hand Tools
A hand tool is any tool that is powered by hand rather than a motor. Categories of hand tools
include

Spanner Screwdrivers
Hacksaws Pliers
Cutting and Slicing Tools

(Knives, Box Cutters,

Scissors, Razor Blades..
Hammers
Chisels
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4. Machine Safety Holding/Hand Tools
Spark Resistant Tools
– Around flammable substances, sparks produced by iron and steel hand tools can
be a dangerous ignition source. Where this hazard exists, spark-resistant tools
made from brass, plastic, aluminum, or wood will provide for safety.

Power Tools Different types, determined

by their power source:

 Purchase quality tools • Electric

• Pneumatic
 Keep tools organized • Liquid fuel

 Keep tools clean • Hydraulic

 Use the right tool for the job.

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4. Machine Safety Emergency Switch:

Emergency switch is provided when

emergency stopping of machine is necessary,

the switch shall:

 Be easily accessible to the

operator
 Be designed for unexpected
activation

When necessary, buddy system shall be considered.

Emergency
Switch
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4. Machine Safety
Lockout/Tagout (LOTO) - LOTO is used to control the unexpected release of energy from
electricity, steam or gas
 Lockout/Tagout gets its name from the equipment used
 Lockout/Tagout must be used whenever you are performing service or maintenance on any
machine where you or someone else could be injured by the unexpected startup or release of
stored energy
 LOTO DOES NOT APPLY to single source plug and cord equipment when the equipment is
unplugged and under the exclusive control of the person performing the work

• Risk to individuals working on powered equipment or machinery can be

minimized by adhering to the six step process of LOTO.
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4. Machine Safety Types of LOTOs

LOTO Device

Caution Tag

Energy Isolating Device

Individual LOTO Lock

Supervisor Lock

Supervisor Tag
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4. Machine Safety Types of Lockout/Tagout Devices

Circuit
breaker
cover Physical Lockout for Circuit Breaker

Wall switch
cover

Gate valve locks

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4. Machine Safety Types of Lockout/Tagout Devices

Fuse cover

Plug lock Ball valve locks Hasp Group lockbox

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4. Machine Safety Types of Hazardous Energy
Mechanical
 Pneumatic
• Relating to springs, rotating parts, etc.
• May be in cylinders, lines and pipes
Magnetic
• Can be found in capacitors and superconducting  Thermal
magnetic energy storage • Can be hot or cold
Gravity
 Chemical
• Can be found in machinery or equipment parts that
might descend, slide or fall if left unblocked • Produced as a result of a chemical reaction
Electrical  Steam
• Relating to or operated by electricity – AC or DC • Water vapor kept under pressure so as to
supply energy for heating or mechanical
Hydraulic work
• Involving, moved or operated by a fluid under
pressure, either internal or external
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4. Machine Safety
What must workers do before maintenance
activities?
1. Prepare for shutdown
2. Shut down the machine
3. Disconnect or isolate the machine from
the energy source(s)
4. Apply the lockout or tagout device(s) to
the energy-isolating device(s);
5. Release, restrain, or render safe all
potential hazardous stored or residual
energy. Regularly inspect to avoid re-
accumulation of energy if necessary.
6. Verify the isolation and de-energization
of the machine.
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4. Machine Safety Lockout/Tagout (LOTO) Procedure

What must be included in the What must workers do before removing

LOTO Procedure?
 A statement on how to use the procedures;
 Steps to shut down, isolate, block, and secure
machines;
 Steps designating the safe placement, removal,
and transfer of LOTO devices and identifying
who has responsibility for the LOTO devices;
and
LOTO device and reenergize the machine?
Step 1: Inspect machines or their
components to assure that they are
operationally intact and that nonessential
items are removed from the area
Step 2: Check to assure that everyone is
positioned safely and away from machines.

 Requirements to determine and verify the

effectiveness of lockout devices, tagout
devices, and other energy-control measures.
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4. Machine Safety Lockout/Tagout (LOTO) Procedure
What are the limitations for tagout
devices?
 A tagout device is a prominent warning
of the hazards

 Tags do not provide the physical restraint

of a lock

 Tags may evoke a false sense of security

 Therefore, lockout devices is considered

more secure and more effective than
tagout devices in protecting employees
from hazardous energy.
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4. Machine Safety
Training PPE
Before using any machine, you should: Before using any machine, you should
ensure that:
 Be trained by qualified person/agent
 Proper PPE is used to conduct the work
 Clarify any doubt on machine usage
 The PPE is in good condition
 Have the correct certificate, if required by
law  Proper training has been given on how to
use PPE
 Inspect the machine for good condition
(or inspected by qualified persons)

 Do not operate machine unless

authorized
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Ergonomic Risk Factors

Risk of injury increases with: Ergonomic

 Prolonged exposure to any of these
ergonomic risk factors 1. Awkward Posture
 Presence of multiple risk factors 2. Force
within a single job task 3. Repetition
4. Static Loading
5. Vibration
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4. Machine Safety Ergonomics
Some basic tips to improve ergonomics:
Use correct
Use
material
equipment to
handling
aid material position
handling

Maintain
Do the work

comfortable with proper

position when tools
working
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4. Machine Safety

Use Tools with Better Grip Select the Correct posture for the Job

• Work near elbow • Avoid overhead

height to avoid reaching and
excessive bending kneeling when
possible
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4. Machine Safety
Ergonomics

Adopt the Correct Posture

Select the Correct Tool

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4. Machine Safety
Safe Practices

The following practices shall be observed at all times:

 Always use the safety devices correctively;

 Do not wear loose clothing/ties when operating machines with rotating parts;

 Tie up or cover up long hair;

 Use devices to remove trapped materials from machine;

 Switch off the machine before retrieving dropped material(s) from inside the
machine.
Thank You