welcome machine guarding corporate safety training 29 cfr 1910.211-222

WELCOME

MACHINE GUARDING

CORPORATE SAFETY TRAINING

29 CFR 1910.211-222

Accident Prevention.

Introduce Machine Guarding and Establish Its Role in Today’s Industry.

Introduce Basic Concepts and Techniques of Machine Safeguarding.

Provide Machine Safeguarding Skills for Maintenance Workers and Floor Supervisors.

COURSE OBJECTIVES(Continued)

29CFR - Safety and Health Standards

1910 - Industrial Safety

212 - General Requirements for All Machines213 - Woodworking Machinery214 - Cooperage Machinery215 - Abrasive Wheel Machinery216 - Mills and Calenders in the Rubber Industry217 - Mechanical Power Presses218 - Forging Machines219 - Mechanical Power Transmission Apparatus

APPLICABLE REGULATIONS

INDUSTRY CONSENSUS STANDARDS

ANSI - B11.2 Hydraulic presses B11.3 Power Press Brakes B11.10 Metal Sawing Machines B11.11 Gear Cutting Machines B11.12 Roll-Forming and Bending Machines B11.14 Coil Slitting Machines B11.15 Pipe, Tube, and Shape Bending B11.16 Metal Powder Compacting Presses B11.17 Horizontal Hydraulic Extrusion B11.18 Coiled Steel Processing

ANSI - B11.19 Machine Tools, Safeguarding B11.20 Manufacturing Systems/Cells

INDUSTRY CONSENSUS STANDARDS

PROGRAM REQUIREMENTS

Install Machine Safeguards

Review Job Specific Hazards

Implement Corrective Actions

Conduct Hazard Assessments

Conduct Accident Investigations

Provide Training to All Required Employees

Control Workplace Hazards Using PPE As a Last Resort

ALL EMPLOYERS MUST:

MACHINE GUARDING IS IMPORTANT

Improve Quality. Improve Absenteeism. Maintain a Healthier Work Force. Reduce Injury and Illness Rates. Acceptance of High-Turnover Jobs. Workers Feel Good About Their Work. Reduce Workers’ Compensation Costs. Elevate SAFETY to a Higher Level of Awareness.

A GOOD PROGRAM WILL HELP:

PROGRAM IMPLEMENTATION

DEDICATION PERSONAL INTEREST MANAGEMENT COMMITMENT

IMPLEMENTATION OF A MACHINE GUARDING PROGRAM REQUIRES:

NOTE:

UNDERSTANDING AND SUPPORT FROM THE WORK FORCEIS ESSENTIAL, WITHOUT IT THE PROGRAM WILL FAIL!

MANAGEMENT’S ROLE

Considerations:

1. Support the Machine Guarding Effort.

2. Ensure Your Support Is Visible.

3. Get Involved.

4. Attend the Same Training As Your Workers.

5. Insist on Periodic Follow-up & Program Review.

6. Implement Ways to Measure Effectiveness.

THE SUPERVISOR’S ROLE

Considerations:

1. Treat All “Near-Misses” As an Accident.2. Get Involved in the Guarding of Machines.3. Complete the Paperwork (Work Orders, Policy Changes, Etc.) To Make Guarding Improvements.4. Get Your Workers Involved. 5. Never Ridicule Any Injury or Near Miss. 6. Be Professional - You Could Save a Life Today. 7. Attend the Same Training As Your Workers. 8. Follow-up on the Actions You Took.

THE EMPLOYEE’S ROLE

Considerations:

1. Report All Accidents and Near-Misses Immediately.

2. Contribute to Make Corrective Actions.

3. Always Provide Complete and Accurate Information.

4. Report All Machine Guarding Problems or Deficiencies

5. Follow-up With Any Additional Information.

Hold Regular Guarding Accident Review Meetings. Document Meetings. Encourage Employee Involvement. Bring Employee Guarding Complaints, Suggestions,

or Concerns to the Attention of Management. Provide Feedback Without Fear of Reprisal. Analyze Statistical Data Concerning Accidents, and

Make Recommendations for Corrective Action. Follow-up Is Critical.

SAFETY COMMITTEE Safety Committees Should:

REMEMBER

Any machine part, function, or process which may cause injury must be safeguarded. When 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.

BASICS OF MACHINE GUARDING

Where Mechanical Hazards Occur

The Point of Operation:

Power Transmission Apparatus:

Other Moving Parts:



The Point of Operation: Where work is performed on the material, such as:

Cutting Shaping Boring Forming of stock

LATHE



Power Transmission Apparatus: All components of the mechanical system which transmit energy to the part of the machine performing the work.

300 RPM



Other Moving Parts: Any part of the machine which moves while the machine is working.

Rotating parts Feed mechanisms Reciprocating parts Transverse moving parts Auxiliary parts of the machine


Hazardous Mechanical Motions and Actions

A wide variety of mechanical motions and actions may present hazards to the worker:

Rotating members Reciprocating arms Moving belts Meshing gears Cutting teeth Any parts that impact or shear


Hazardous Mechanical Motions and Actions

Recognition of these hazards is the first step toward protecting workers from the danger they present.


Hazardous Mechanical Motions

Motions

Rotating Reciprocating Transversing NIP POINT


Hazardous Mechanical Actions

Actions

Cutting Punching Shearing Bending

SHEARITESHEARITECUTTING BLADESCUTTING BLADES



Rotating Motions

- Collars - Couplings - Cams

- Clutches - Flywheels - Shaft ends

- Spindles - Meshing gears - Horizontal shafts

- Vertical shafts



Rotating Motions

Rotating motions can grip clothing, and through mere skin contact force a limb into a dangerous position. The danger increases when projections such as set screws, bolts, nicks, abrasions, and projecting keys or set screws are exposed on rotating parts.

MOTIONRECIPROCATING

NIP POINT NIP POINT



Reciprocating Motions



Reciprocating Motions

MOTIONRECIPROCATING

CAUGHT “IN-BETWEEN”OR “STRUCK-BY”



Transversing Motions

TRAVEL

IN-RUNNING NIP POINTS



Rotating Motions

NIP POINTS



Cutting Actions

- Rotating motions- Reciprocating motions- Transversing motions

The danger of cutting action exists at the point of operation where finger, arm and bodily injuries can occur and where flying chips or scrap material can strike the head, particularly in the area of the eyes or face.



Cutting Actions

Bandsaws Circular saws Boring machines Drilling machines Turning machines (lathes) Milling machines



Punching Actions

Power presses Iron workers

20 TON

PRESS PRESS

ACMEPRESSES

The principle hazard occurs at the point of operation where stock is inserted, held or withdrawn.



Shearing/Bending Actions

Mechanical shears Hydraulic shears Pneumatic shears

DANGERCUTTING EDGE

PRESS PRESS

SHEARITEPOWER SHEARS

SHEAR TERROR

The principle hazard occurs at the point of operation where stock is inserted, held or withdrawn.


Requirements for Safeguards

Be securely attached Create no new hazards Withstand operational conditions Allow for safe routine maintenance Allow for safe operator adjustments Withstand environmental conditions Provide protection from falling objects Prevent contact with hazardous conditions Create no interference in the conduct of work


Nonmechanical Hazard Considerations:

Power sources are potential sources of danger How will guarding affect equipment operation? Ensure proper grounding of systems Replace frayed, exposed , or old wiring Consider effects of - High pressure systems - Extreme temp. conditions - Pulsation, vibration, or leaks - Noise or unwanted sounds - Cutting fluids and coolants

HOT SURFACE


Operator Training Considerations:

Provide instruction and or hands-on training Discuss the purpose of safeguards Cover associated hazards thoroughly Involve guard designers in the training Describe how to properly use safeguards Describe how safeguards provide protection Describe circumstances for safeguard removal Explain what to do if safeguards are damaged Explain what to do if safeguards are missing


Operator Training Considerations:

Defeating, altering, or removing safeguards can cause injury to co-workers and can leave the person performing such actions liable under the OSHA Act of 1970.

ENGINEERING CONTROLS FIRST CHOICE

Work Station Design Tool Selection and Design Process Modification Mechanical Assist

ADMINISTRATIVE CONTROLS SECOND CHOICE

Training Programs Job Rotation/Enlargement Pacing Policy and Procedures

PERSONNEL PROTECTIVE EQUIPMENT LAST CHOICE

Gloves Wraps Shields Eye Protection Non-Slip Shoes Aprons


Protective Clothing and Equipment Considerations:


Protective Clothing and Equipment Considerations:

Appropriate for the particular hazard(s) Maintained in good condition Properly stored when not in use Kept clean, fully functional, and sanitary

METHODS OF MACHINE GUARDING

Guarding Method Dependant on:

Type of material Type of operation Method of handling Size or shape of stock Physical layout of the work area Production requirements or limitations

Manufacturers Recommendation:

Before beginning the process of guard procurement, design, or installation, the equipment manufacturer should be consulted for advice.



Generally:

Power transmission apparatus is best protected by fixed guards that enclose the danger areas

Point of operation hazard guarding will vary


Safeguards Are Grouped Under 5 Classifications:

Guards Devices Locations/Distance Feeding and ejection methods Miscellaneous aids


GUARDS


Guards:

Guards are barriers which prevent access to danger areas, there are four general types:

Fixed guards Interlocked guards Adjustable guards Self-Adjusting guards


Fixed Guards:

Fixed guards are a permanent part of the machine and not dependent upon moving parts to perform its intended function.


Fixed Guards:

ADVANTAGES

Can be constructed to suit many different applications In-plant construction is often possible Can provide maximum protection Usually requires minimum maintenance Can be suitable to high production operations Can be suitable to high repetition operations


Fixed Guards:

LIMITATIONS

May interfere with visibility Can be limited to specific operations Machine adjustments and repair often require guard

removal, thereby necessitating other means of protection for maintenance personnel


Interlocked Guards:

Interlocked guards are designed to automatically shut off or disengage the machine if the guard is opened or removed

AUTOMATICAUDIBLE ALARM

AUTOMATICVISUAL ALARM

Interlocked guards may use:

Electrical power Mechanical power Hydraulic power Pneumatic power


Interlocked Guards:

OR ANY COMBINATION OF POWER SOURCES

Interlocks should not prevent “inching” by remote control if required

Replacing guards should not automatically restart the machine


Interlocked Guards:

IMPORTANT


Interlocked Guards:

ADVANTAGES

Can provide maximum protection Allows access to machine for removing jams without time

consuming removal of fixed guards

LIMITATIONS

Requires careful adjustment and maintenance May be easy to disengage jams


Adjustable Guards:

Typically adjusted by the operator Accommodate various sizes of stock May require additional operator training Adjustable guards are typically used on:

Bandsaws Tablesaws Power presses Routers Similar equipment


Adjustable Guards:

ADVANTAGES

Can be constructed to suit many specific applications Can be adjusted to admit varying sizes of stock

LIMITATIONS

Hands may enter danger area Protection may not be complete at all times May require frequent maintenance and or adjustment The guard can be defeated by the operator May interfere with visibility


Self-Adjusting Guards:

Adjusts automatically to the work Accommodate various sizes of stock May require additional operator training Self-Adjusting guards are typically used on:

Radial arm saws Tablesaws Circular saws Routers Jointers Similar equipment

ADVANTAGES

Off-the-shelf guards are often commercially available

LIMITATIONS

Protection may not be complete at all times May require frequent maintenance and or adjustment May interfere with visibility


Self-Adjusting Guards:


DEVICES


Devices:

Devices fall into four general types:

Presence-Sensing devices Pullback devices Restraint devices Safety trip controls


Devices:

Devices may perform one of several function:

Stop a machine if a body part is in danger Restrain or withdraw a hand if it is in danger Require activation by the use of both hands Provide a barrier synchronized to the operation


Presence-Sensing:

Photoelectric Radiofrequency Electromechanical

PRESS PRESS

ACMEPRESSES


Presence-Sensing:

Before beginning the process of procurement, design, or installation, the equipment manufacturer should be consulted for advice.


Presence-Sensing:

Photoelectric Radiofrequency Electromechanical

20 TON

PRESS PRESS

ACMEPRESSES

NYLON PULLBACK STRAPS ATTACHED TO WRISTBANDS


Pullback Devices: Attached to Wrists Positioning Critical Adjustment Critical Maintenance Critical Training Critical Must Stop Machine Immediately!


Restraint Devices:

Uses Cables or Straps Affixes to Hands May Need Feeding Tools Adjustment Critical Positioning Critical Maintenance Critical Training Critical Must Restrain Body Part From Hazard!


Safety Trip Controls: Body Trip Bars Hand/Arm Trip Bars Tripwire Cables Positioning Critical Adjustment Critical Maintenance Critical Training Critical Manual Reset Needed Must Stop Machine Immediately!

20 TON

PRESS PRESS

ACMEPRESSES


Two-Hand Control:

Needs Constant Pressure Needs Concurrent Pressure Positioning Critical Adjustment Critical Maintenance Critical Training Important Must Stop Machine Immediately!


Location/Distance Safeguarding: Position Dangerous Areas of Machines So That They Are

Not Assessable During Normal Operations. Examples Include:

Position Hazard Areas Against a Wall Locate Hazards Out of Reach of Operators Add Enclosures or Fences to Restrict Access Design Stock Feeding Openings Away From Hazards Position the Operators Control Station Away From Hazards


Feeding and Ejection Methods: Automatic Feeds - Fed From Rolls, Indexed by Machine

Semiautomatic Feeds - Fed by Chutes, Movable Dies, Dial Feed, Plungers, or Sliding Bolsters

Automatic Ejection - Air or Mechanical Ejection

Semiautomatic Ejection - Air or Mechanical Ejection Initiated by The Operator

Robotics - Perform Work Usually Performed by Operator


Feeding and Ejection Methods: Manufacturers Should Be Consulted to Determine:

Feeding and Ejection Add-on Options Latest Technology Available Best Available Technology Operator Training Requirements Maintenance Staff Training Requirements Cost Estimates for Upgrades Feasibility Assessment Information


Miscellaneous Aids: Examples of Possible Applications:

Awareness Barriers - (Not adequate for continuous hazards) Color coding of hazard areas Signage Shields (i.e. splash, eye protective, thermal etc.) Holding and Positioning Tools


Guard Construction:

Many Machines Come With Safeguards Many Older Machines Now Have Safeguards Available Manufacturers Are Increasingly More Concerned With Liability Companies Not Specialized in Guarding Issues


Builder Designed and Installed Guards:

Usually Conform to Design and Function of Machine Better

Can Be Designed to Strengthen the Machine in Some Way or to Serve Some Additional Functional Purposes


User Designed and Installed Guards:

Often the Only Practical Solution for Older Equipment Can Be Designed and Built to Fit Unique & Changing Situations Can Be Installed on Individual Dies and Feeding Mechanisms Can Help Promote Safety Consciousness in the Workplace Sometimes Do Not Conform As Well As “Builder Designed” Depending on Talent and Resources May Be Poorly Designed


Point-of-Operations Guards :

Complicated by the Number and Complexity of Machines in Use Must Fully Safeguard the Employee Must Allow Production to Continue Hazard Analysis Is Usually Required If Poorly Designed, Built, or Installed Guards May Create a

Hazard Rather Than Eliminating One.

Defined as: “The area on a machine where work is actually performed upon the material being processed.”


Mechanical Power Transmission Apparatus Guards:

The only openings usually needed are for:

Lubrication Adjustment Repair Inspection

300 RPM


Guard Material:

Under Many Circumstances, Metal Is the Best Material for Guards. Guard Framework Is Usually Made From Structural Shapes, Pipe, Bar, or Rod Stock. Filler Material Generally Is Expanded or Perforated or Solid Sheet Metal or Wire Mesh. It May Be Feasible to Use Plastic or Safety Glass Where Visibility Is Required.

Guards Made of Wood Generally Are Not Recommended Because of Their Flammability and Lack of Durability and Strength. However, in Areas Where Corrosive Materials Are Present, Wooden Guards May Be the Better Choice.

29CFR - SAFETY AND HEALTH STANDARDS

1910 - GENERAL INDUSTRY

147 - LOCKOUT TAGOUT STANDARD

LOCKOUT TAGOUT OVERVIEW

29CFR - 1910 - 147

TITLE - CONTROL OF HAZARDOUS ENERGY

SEPTEMBER 1, 1989 - FINAL RULE ISSUED JANUARY 2, 1990 - FINAL RULE TOOK EFFECT


Authorized Employee

The Person Who Locks or Tags Out Machines To Perform Servicing or Maintenance.

Affected Employee

An Employee Whose Job Requires Him or Her To Operate or Use a Machine or Piece of Equipment On Which Servicing or Maintenance Is Being Performed.


LOCKEDOUT

This Lock/Tag mayonly be removed by

NAME: _______________DEPT : _______________EXPECTED COMPLETIONDATE: ________________TIME: _________________

DO NOT OPERATE

DANGER



1. Covered If an Employee Must Remove or Bypass Guards or Devices

2. Covered Where Employees Are Required to Put A Body Part in a Machine Process Area

3. Covered Where Employees Are Required to Put A Body Part in a Machine Having a Danger Zone

Normal Operations

REMEMBER, YOU CONTROL YOUR FACILITY OR AREA!

REVIEW THEIR PROCEDURES WITH THEM BEFORE STARTING THE JOB!

DETERMINE THEIR SAFETY PERFORMANCE RECORD!

DETERMINE WHO IS IN CHARGE OF THEIR PEOPLE!

DETERMINE HOW THEY WILL AFFECT YOUR EMPLOYEES!

TIPS FOR USING CONTRACTORS

welcome machine guarding corporate safety training 29 cfr 1910.211-222

Documents

machine slide

machine guarding program

machine guarding problems

machine guarding effort

guarding of machines

machine tools

shear slide

rpm slide