MACHINE SAFEGUARDING:

POTENTIAL FOR A
REDUCTION IN
AMPUTATIONS

A Confidential Consulting Service by The University of Alabama

The University of Alabama College of Continuing Studies 205/348-7136
Box 870388 Martha Parham West Tuscaloosa, Alabama 35487-0388
1-800-452-5928 FAX (205)348-9286
These guidelines are intended to provide information for the development of safe work practices of
safeguarding machines. This information is not considered a substitute for any provision of the
OSHA standards pertaining to machine guarding requirements.

TABLE OF CONTENTS

INTRODUCTION...............................................................................................................
GUIDELINES FOR MACHINE SAFEGUARDING.............................................................
COMMON ELEMENTS FOR SAFEGUARDING ALL MACHINES....................................
Job Hazard Analysis...............................................................................................
Cooperation and Assistance...................................................................................
Training.................................................................................................................10
Standards That Are Common................................................................................11
SPECIFIC REQUIREMENTS FOR WOODWORKING MACHINES...............................12
Overview...............................................................................................................12
Standards..............................................................................................................12
SPECIFIC REQUIREMENTS FOR METAL WORKING MACHINES..............................15
Overview...............................................................................................................15
Standards..............................................................................................................15
METHODS OF MACHINE SAFEGUARDING.................................................................16
RESOURCES..................................................................................................................22

INTRODUCTION
Amputations have a tremendous cost for both the employer and the employee.
For the employee, it means a permanent physical disability that could profoundly affect
that individuals livelihood. Many times there are psychological implications.
The employer may lose a valuable, well-trained employee, pay thousands of dollars in
medical bills, legal fees and/or stiff regulatory penalties.
As part of its strategic plan activity, OSHA has targeted industries that have
woodworking, metal working machines, or any machinery or equipment which could
cause an amputation, for inspection. The agency is determined to reduce the rate of
injuries and amputations associated with the use of un-safeguarded equipment.
In an attempt to assist the employer in understanding the regulations and safe work
practices of safe guarding machines, this pamphlet is a guide toward recognizing and
correcting associated hazards, conducting a job hazard analysis and a reference toward
understanding the applicable standards.
Of course, insuring safe guarding of wood working and metal working machinery will
help in the reduction of amputations in the workplace.

GUIDELINES FOR MACHINE SAFEGUARDING

The Occupational Safety and Health Administration (OSHA) requires that machine
guarding be provided and maintained in a manner sufficient to protect machine
operators and other persons present in machine areas from hazards associated with the
operation of machines. Such hazards include those created by points of operation, inrunning nip points, rotating parts, flying chips and sparks. The following information is
provided to assist machine operators and machine shop supervisors and managers in
carrying out their responsibilities for assuring machine safety through hazard
identification and evaluation, safeguarding, and safe operation.
Types and Points of Hazardous Machine Operations
Motions
Rotating: in-running nip points, spindles, shaft ends, couplings
Reciprocating: back-and-forth, up-and-down
Transverse: movement in a straight, continuous line
Operations
Cutting: bandsaws, drills, milling machines, lathes
Punching: punch presses, notchers
Shearing: mechanical, pneumatic, or hydraulic shears
Bending: press brakes, tube benders, plate rolls
Safeguarding Requirements
Machine safeguards should be installed and maintained to ensure that they:
PREVENT CONTACT
Safeguards must minimize the possibility of the operator or another worker
placing their hands into hazardous moving parts.
REMAIN SECURE
Workers should not be able to easily remove or tamper with the
safeguard.
PROTECT FROM FALLING OBJECTS
Safeguards should ensure that no objects can fall into moving parts.
CREATE NO NEW HAZARDS
A safeguard defeats its purpose if it creates a hazard of its own.
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CREATE NO INTERFERENCE
A safeguard should not create an unacceptable impediment for the worker.
ALLOW SAFE MAINTENANCE AND LUBRICATION
It should be possible to lubricate the machine without removing the
safeguard.
Types of Machine Safeguards
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Barriers and guards that prevent contact with machinery.

Mechanical or electrical devices that restrict contact, such as presencesensing, restraining, or tripping devices, two-hand controls, or gates.
Feeding and ejection methods that eliminate part handling in the hazard
zone.
Aids such as awareness signs that do not provide physical protection, but
warn of a danger area.

COMMON ELEMENTS FOR SAFEGUARDING ALL MACHINES

Job Hazard Analysis
A job hazard analysis can be performed for all jobs in the workplace, whether the job
task is special (non-routine) or routine. Even one-step jobs such as those in which
only a button is pressed can and perhaps should be analyzed by evaluating
surrounding work conditions.
To determine which jobs should be analyzed first, review your job injury and illness
reports. Obviously, a job hazard analysis should be conducted first for jobs with the
highest rates of disabling injuries and illnesses. Also, jobs where close calls or near
misses have occurred should be given priority. Analyses of new jobs and jobs where
changes have been made in processes and procedures should follow. Eventually, a job
hazard analysis should be conducted and made available to employees for all jobs in
the workplace.
Involving the Employee
Once you have selected a job for analysis, discuss the procedure with the employee
performing the job and explain its purpose. Point out that you are studying the job itself,
not checking on the employees job performance. Involve the employee in all phases of
the analysis from reviewing the job steps and procedures to discussing potential
hazards and recommended solutions. You also should talk to other workers who have
performed the same job.
Conducting the Job Hazard Analysis
Before actually beginning the job hazard analysis, take a look at the general conditions
under which the job is performed and develop a checklist. Below are some sample
questions you might ask.
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Are there materials on the floor that could trip a worker?

Is lighting adequate?
Are there any live electrical hazards at the jobsite?
Are there any chemical, physical, biological, or radiation hazards
associated with the job or likely to develop?
Are tools including hand tools, machines, and equipment in need of
repair?
Is there excessive noise in the work area, hindering worker
communication or causing hearing loss?
Are job procedures known and are they followed or modified?
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Naturally this list is by no means complete because each worksite has its own
requirements and environmental conditions. You should add your own questions to the
list. You also might take photographs of the workplace, if appropriate, for use in making
a more detailed analysis of the work environment.
Breaking Down the Job
Nearly every job can be broken down into job tasks or steps. In the first part of the job
hazard analysis, list each step of the job in order of occurrence as you watch the
employee performing the job.
Be sure to record enough information to describe each job action, but do not make the
breakdown too detailed. Later, go over the job steps with the employee.
Identifying Hazards
After you have recorded the job steps, next examine each step to determine the
hazards that exist or that might occur. Ask yourself these kinds of questions.
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Is the worker wearing personal protective clothing and equipment,

including safety harnesses that are appropriate for the job?
Are work positions, machinery, pits or holes, and hazardous operations
adequately guarded?
Are lockout procedures used for machinery deactivation during
maintenance procedures?
Is the worker wearing clothing or jewelry that could get caught in the
machinery or otherwise cause a hazard?
Are there fixed objects that may cause injury, such as sharp machine
edges?
Is the flow of work improperly organized (e.g., Is the worker required to
make movements that are too rapid)?
Can the worker get caught in or between machine parts?
Can the worker be injured by reaching over moving machinery parts or
materials?
Is the worker at any time in an off-balance position?
Is the worker positioned to the machine in a way that is potentially
dangerous?
Is the worker required to make movements that could lead to or cause
hand or foot injuries, or strain from lifting the hazards of repetitive motions?
Can the worker be struck by an object or lean against or strike a machine
part or object?
Can the worker be injured from lifting or pulling objects, or from carrying
heavy objects?
5

Do environmental hazards dust, chemicals, radiation, welding rays, heat, or

excessive noise result from the performance of the job?

Repeat the job observation as often as necessary until all hazards have been identified.
Recommending Safe Procedures and Protection
After you have listed each hazard or potential hazard and have reviewed them with the
employee performing the job, determine whether the job could be performed in another
way to eliminate the hazards, such as combining steps or changing the sequence, or
whether safety equipment and precautions are needed to control the hazards. An
alternative or additional procedure is to videotape the worker performing his or her job
and analyze the job procedures.
If safer and better job steps can be used, list each new step, such as describing a new
method for disposing of material. List exactly what the worker needs to know to perform
the job using the new method. Do not make general statements about the procedure,
such as Be Careful. Be as specific as you can in your recommendations.
You may wish to set up a training program using the job hazard analysis to retrain your
employees in the new procedures, especially if the are working with highly toxic
substances or in hazardous situations. (Some OSHA standards require that formal
training programs be established for employees.)
If no new procedures can be developed, determine whether any physical changes
such as redesigning equipment, changing tools, adding machine guards, personal
protective equipment, or ventilation will eliminate or reduce the danger.
If hazards are still present, try to reduce the necessity for performing the job or the
frequency of performing it.
Go over the recommendations with all employees performing the job. Their ideas about
the hazards and proposed recommendations may be valuable. Be sure that they
understand what they are required to do and the reasons for the changes in the job
procedures.

Job Hazard Analysis Form

JOB TITLE:

Grinding Iron Castings

DATE OF ANALYSIS:

January 1, 2000

JOB LOCATION:

Finishing Area, Plant #2

STEP
1.
2.
3.

Reach into metal box to right of

machine, grasp casting, and carry to
wheel.
Push casting against wheel to grind
off burr.
Place finished casting in box to left
of machine.

HAZARD
1.

Strike hand on edge of metal box or

casting; cut hand on burr. Drop
casting on toe.
Strike hand against wheel. Flying
sparks or chips. Wheel breakage.
Not enough of wheel guarded. No
dust removal system. Sleeves could
get caught in machinery.
Strike hand against metal box or
castings.

2.

3.

Job Hazard Analysis

RECOMMEND
PROTECTIVE
1.
2.

3.

Provide gloves
Provide larger
Install local ex
safety goggles
wear short or
Provide for rem
stock.

Revising the Job Hazard Analysis

A job hazard analysis can do much toward reducing accidents and injuries in the
workplace, but it is only effective if it is reviewed and updated periodically. Even if no
changes have been made in a job, hazards that were missed in an earlier analysis
could be detected.
If an illness or injury occurs on a specific job, the job hazard analysis should be
reviewed immediately to determine whether changes are needed in the job procedure.
In addition, if a close call or near miss has resulted from an employees failure to
follow job procedures, this should be discussed with all employees performing the job.
Any time a job hazard analysis is revised, training in the new job methods, procedures,
or protective measures should be provided to all employees affected by the changes. A
job hazard analysis also can be used to train effectively new employees on the steps
and job hazards.

Cooperation and Assistance

Safety in the workplace demands cooperation and alertness on everyones part.
Supervisors, operators, and other workers who notice hazards in need of safeguarding,
or existing systems that need repair or improvement, should notify the proper authority
immediately.
Supervisors have these additional, specific responsibilities with regard to safety in the
workplace; encouraging safe work habits and correcting unsafe ones; explaining to the
worker all the potential hazards associated with the machines and processes in the
work area; and being responsive to employer requests for action or information
regarding machine hazards. The first-line supervisor plays a pivotal role in
communicating the safety needs of the worker to management and the employers
safety rules and policies to the worker.
Sometimes the solution to a machine safeguarding problem may require expertise that
is not available in a given establishment. The readers of this manual are encouraged to
find out where help is available and, when necessary, to request it.
The machines manufacturer is often a good place to start when looking for assistance
with a safeguarding problem. Manufacturers can often supply the necessary literature or
advice. Insurance carriers, too, will often make their safety specialists available to the
establishments whose assets they insure. Union safety specialists can also lend
significant assistance.
Some government agencies offer consultation services, providing for onsite evaluation
of workplaces and the recommendation of possible hazard controls. OSHA funds one
such program, which is offered free of charge to employers in every state. Delivered by
state governments or private contractors, the consultation program is completely
separate from the OSHA inspection effort; no citations are issued and no penalties are
proposed. The trained professional consultants can help employers recognize hazards
in the workplace and can suggest general approaches for solving safety and health
problems. In addition, the consultant can identify sources of other available help, if
necessary.
Anyone with questions about Federal standards, about the requirements for machine
safeguarding, or about available consultation services should contact OSHA.

Training
Employees must be trained on all machinery or equipment they are required to use.
Usually, shop personnel are trained by their supervisor or a designated trainer, only
trained personnel or those undergoing supervised on-the-job training should be allowed
to operate shop machinery or equipment. All operators should be trained in the proper
operation, safety procedures, hazard recognition, and emergency shutdown procedures
for each machine or piece of equipment they use.
The operator training programs should be tailored to an employees work area.
Employees learn more and draw a greater benefit from training that duplicates their
daily work rather than a canned program. As a minimum, the training program should
include:
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The nature of hazards for each piece of equipment.

Safety procedures for special set-ups for each tool.
How to use safeguards.
What to do in case guards are missing.
How to perform work in a safe manner.

Additionally, the training should be devised so employees can demonstrate their

knowledge and skills required to perform their tasks. The supervisor must determine
that the employee knows and understands the features of the equipment, all applicable
safety rules, and is skilled in operating the equipment.
Employers should certify that employees have been trained by preparing a certification
record which includes the identity of the person trained, the signature of the employer or
the person who conducted the training, and the date the training was completed. The
certification should be prepared at the completion of the training and maintained on file
for the duration of the employees employment. The certification record should be made
available upon request.

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Standards That Are Common

29 CFR 1910.212 is applicable to machines found in general industry.
1910.212(a)(1) Requires employees to be protected from the point-of-operation.
In-going nip points and rotating parts.
The Following are some machines which usually require point-of-operation guarding:
Guillotine Cutters
Shears
Alligator Shears
Hydraulic Presses
Riveters
Milling Machines
Power Saws
Jointers
Portable Power Tools
Forming Rolls and Calenders
This standard also covers revolving barrels, drums and containers, guarding of fan
blades and the anchoring of fixed machinery.
29 CFR 1910.219 Is applicable to mechanical power transmission apparatus.
The Following Is a List of Some Items Covered under this Standard:
V-belts
Cranks
Fly Wheels
Connecting Rods, Tails Rods
Extension Rod Pistons
Shafting, Projected Shaft Ends
Key Ways, Projected Keys or Set Screws
Belt, Rope and Chain Drives
Gear, Sprocket and Chains
Collars and Couplings
Pulleys

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SPECIFIC REQUIREMENTS FOR WOODWORKING MACHINES

Overview
Many injuries that occur in woodworking occupations result from employees failing to
follow prescribed safe operational practices. These failures arise from worker attitudes,
inadequate training, and supervisory failure to enforce safe job procedures. The use of
machine guards, environmental controls, good training, and maintenance programs,
coupled with supervisory enforcement of protective equipment use and safe job
practices can eliminate most mishap-producing factors.
Among the most frequently occurring woodworking accidents are two involving saws:
(1) blade cuts or abrasions, (2) kickbacks.

Standards
29 CFR 1910.213 is the specific standard that covers the principle hazards of
woodworking equipment.
The following is a breakdown by category of some types of equipment covered under
this standard.
Circular, Crosscut, and Rip Saws
Guarding beneath the table level should be provided to enclose the saw blade
from unintentional contact and prevent contact with moving parts of the drive
mechanism. Saws must be equipped with a hood that covers the blade and
automatically adjusts itself to the thickness of the material upon which it rides.
The hood covers the part of the saw blade exposed above the material and is
adaptable to cover tilted blades. When ripping, table saws must be provided with
a spreader to prevent the woods internal stresses from clamping down on the
saw blade and an anti-kickback device to prevent the stock from possible
kickback.
Radial Saws
Radial saws must be equipped with a hood that encloses the saw blade and the
arbor ends. The lower section of the hood must be hinged so it rises and falls
and adjusts itself automatically to the thickness of the material as the saw passes
through it. An anti-kickback device or hold-down wheels must also be installed on
saws used for ripping. The device must be adaptable to any thickness of stock.

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Band Saws
Both upper and lower wheels must be completely enclosed on both sides. The
enclosures should be capable of being removed easily to permit saw blade
maintenance. The working part of a saw blade, between the guide rolls and the
upper wheel enclosure, must be guarded to prevent accidental contact with the
saw blade. The guard must be self-adjusting and attached to the gauge so that,
in any position of the gauge, the guard completely covers the portion of the saw
blade between the guide rolls and the upper wheel enclosure.
Jointers
Each hand-fed planer and jointer with a horizontal or vertical head should be
equipped with a cylindrical cutting head, the knife projection of which must not
exceed 0.125 inch (0.31 centimeters) beyond the cylindrical body of the head.
Also, jointers with front-table-mounted fences must be equipped with an
adjustable device to prevent thin stock from slipping laterally under the portion of
the fence at the rear of the table. An automatic guard must be provided that
covers the section of the cutter head near the operator (on working side of the
fence) and contacts the wood to prevent any opening from remaining between
the guard and wood during the operation. The guard should also cover the
section of the cutter head on the non-working side of the fence, especially when
the fence is moved toward the automatic guard. The guard over the section of
the cutting head on the rear side of the fence should consist of a sliding metal
shield that automatically adjusts to the exposed length of the cutter head.
Power Feed Planers
Guards must be provided for feed rolls, cutting heads, and hold-down rolls at the
discharge end. Feed rolls should be guarded by a metal strip in front of the rolls
under which the material may pass. This prevents an operators fingers from
being drawn into the rolls while feeding the machine. Where the top roll is
corrugated, the strip should extend over the top of the roll. Cutting heads and
discharge rolls must be guarded by a solid metal enclosure of substantial
construction. The hood of an exhaust system may form part or all of the
enclosure. When other than corrugated top feed rolls are used, an anti-kickback
device should be installed.
Shapers
Shapers must be equipped with a braking device that brings the cutting head to a
stop within 10 seconds after power is shut off. Cutting heads must be enclosed
by a guard. The guard must not be less than the greatest diameter of the cutter.
13

Whenever possible, hold-downs and jigs should be used to limit exposure of

hands to cutters. It is good practice when a blade is removed from a spindle for
sharpening, or for some other purpose, that all other blades be removed at the
same time.
Lathes
Rotating, cutter-head type lathes must be provided with a hinged metal shield or
hood that completely covers the knifes and material when the machine is in
operation. Exhaust system hoods may be included as part of the guard if they
comply with standard guard designs. Automatic lathes should be equipped with a
brake that brings the rotating material to a quick, but not instantaneous, stop after
power is shut off.
Sanding Machines
Feed rolls of self-feed sanding machines should be protected with a semicylindrical guard to prevent hands from coming in contact with the in-running rolls
at any point. The guard and its mounting should be designed to remain in
adjustment for any thickness of stock. Drum/disk sanding machines should have
an exhaust hood, or other guard, so arranged as to enclose the revolving
drum/disk, except for the working portion of the drum/disk above the table. Belt
sanding machines should be provided with guards at each nip point. These
guards must effectively prevent hands or fingers from coming in contact with the
nip points. The unused run of the sanding belt must be guarded against
accidental contact.
Boring and Mortising Machines
The top of the driving mechanism must be enclosed.
Tenoning Machines
Feed chains and sprockets of double end tenoning machines must be completely
enclosed, except for that portion of chain used for conveying the stock. Sprockets
and chains must be guarded at the sides by plates projecting beyond the
periphery of sprockets and the ends of lugs at the rear ends of frame over which
feed conveyors run. Each tenoning machine that has cutting heads and saws
must be covered by metal guards when used. These guards should cover at
least the unused part of the periphery of the cutting head. Where an exhaust
system is used, the guard may form part or all of the exhaust hood.
14

SPECIFIC REQUIREMENTS FOR METAL WORKING MACHINES

Overview
Metal working machine safeguarding must protect the operator from mechanical
hazards and prevent any part of the operators body from making contact with
dangerous moving parts, yet not create new hazards or create interference from
performing.
OSHA requirements for safeguarding metal working machines are intended to minimize
potential for injury while rotating, revolving, reciprocating, slitting, shearing, punching, or
bending actions are occurring and to prevent entry of the hands or fingers or any part of
the body into the point-of-operation by reaching over, through, under or around a guard
through the use of guarding, safe distance location, hand tools or other devices.

Standards
29 CFR 1910.215

Abrasive wheel grinders, control wheel breakage, prevent contact

with abrasive surfaces, control angular exposure of the grinding
wheel and insure secure mounting of the wheel.

29 CFR 1910.216

Mills and calendars, provide for and arrangement of safety stopping

devices for rolls, control the stopping limits and provide for an alarm
system for assistance in an emergency.

29 CFR 1910.217

Mechanical power presses, limit exposure to the point-of-operation

by enclosing the dies with barrier guards, or through the use of
presence sensing devices, two-hand controls, pull-backs, restraints
or gates while initiating the stroke, as long as the devices maintain
proper adjustment.
Hand-feeding tools can be used in conjunction with some of the
mentioned devices but are not recognized as a point-of-operation
device themselves.
Training and die-setting procedures are required before operation.

29 CFR 1910.218

Forging machines, require certification of records, recording

inspections of guards and protective devices, training for proper
inspection and maintenance and for proper anchoring of the
hammer as well as the machine itself and the use of hand-tools.

15

METHODS OF MACHINE SAFEGUARDING

There are many ways to safeguard machinery. The type of operation, the size or shape
of stock, the method of handling, the physical layout of the work area, the type of
material, and production requirements or limitations will help to determine the
appropriate safeguarding method for the individual machine.
As a general rule, power transmission apparatus is best protected by fixed guards that
enclose the danger area. For hazards at the point-of-operation, where moving parts
actually perform work on stock, several kinds of safeguarding are possible. One must
always choose the most effective and practical means available.
We can group safeguards under five general classifications.
Guards
Guards are barriers which prevent access to danger areas. There are four general types
of guards:
Fixed:
As its name implies, a fixed guard is a permanent part of the machine. It
is not dependent upon moving parts to perform its intended function. It
may be constructed of sheet metal, screen, wire cloth, bars, plastic, or
any other material that is substantial enough to withstand whatever
impact it may receive and to endure prolonged use. This guard is usually
preferable to all other types because of its relative simplicity and
performance.
Interlocked:
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.
An interlocked guard may use electrical, mechanical, hydraulic,
or pneumatic power or any combination of these. Interlocks should not
prevent inching by remote control if required. Replacing the guard
should not automatically restart the machine.
Adjustable:
Adjustable guards are useful because they allow
flexibility in accommodating various sizes of stock.

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Self-Adjusting:
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 which is only large
enough to admit the stock. After the stock is removed, the guard returns
to the rest position. This guard protects the operator by placing a barrier
between the danger area and the operator. The guards may be
constructed of plastic, metal, other substantial material. Self-adjusting
guards offer different degrees of protection.

Devices
A safety device may perform one of several functions. It may: stop the machine if a
hand or any part of the body is inadvertently placed in the danger area; restrain or
withdraw the operators hands from the danger area during operation; require the
operator to use both hands on machine controls, thus keeping both hands and body out
of danger; or provide a barrier which is synchronized with the operating cycle of the
machine in order to prevent entry to the danger area during the hazardous part of the
cycle.
Presence-Sensing
The photoelectric (optical) presence-sensing device uses a
system of light sources and controls which can interrupt the machines
operating cycle. If the light field is broken, the machine will not cycle. This
device must be used only on machines which can be stopped before the
worker can reach the danger area.
The radiofrequency (capacitance) presence-sensing device
uses a radio beam that is part of the machine control circuit. When the
capacitance field is broken, the machine will stop or will not activate. Like the
photoelectric device, this device shall only be used on machines which can be
stopped before the worker can reach the danger area.
The electromechanical sensing device has a probe or contact bar which
descends to a predetermined distance when the operator initiates the machine
cycle. If there is an obstruction preventing it from descending its full
predetermined distance, the control circuit does not actuate the machine cycle.
Pullback1
Pullback devices utilize a series of cables attached to the operators hands,
wrists, and/or arms. This type of device is primarily used on machines with
stroking action. When the slide/ram is up, the operator is allowed access to the
point-of-operation. When the slide/ram begins to descend, a mechanical
linkage automatically assures withdrawal of the hands from the point-ofoperation.

Pullback or Restraint devices are used on power presses only.

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Restraint2
The restraint (holdout) device utilizes cables or straps that are
attached to the operators hands and a fixed point. The cables or straps must
be adjusted to let the operators hands travel within a predetermined safe area.
There is no extending or retracting action involved. Consequently, hand-feeding
tools are often necessary if the operation involves placing material into the
danger area.

Safety Trip Controls

Safety trip controls provide a quick means for deactivating the
machine in an emergency situation. A pressure-sensitive body bar, when
depressed, will deactivate the machine. If the operator or anyone trips, loses
balance, or is drawn into the machine, applying pressure to the bar will stop the
operation. The positioning of the bar, therefore, is critical.

Two-Hand Control
The two-hand control requires constant, concurrent pressure
by the operator to activate the machine. This kind of control requires a partrevolution clutch, brake, and a brake monitor if used on a power press. With
this type of device the operators hands are required to be a safe location (on
control buttons) and at a safe distance from the danger area while the machine
completes its closing cycle.

Two-Hand Trip
The two-hand trip requires concurrent application of both of the
operators control buttons to activate the machine cycle, after which the hands
are free. This device is usually used with machines equipped with fullrevolution clutches. The trips must be placed far enough from the point-ofoperation to make it possible for the operator to move his or her hands from the
trip buttons or handles into the point-of-operation before the first half of the
cycle is completed. Thus the operators hands are kept far enough away to
prevent them from being accidentally placed in the danger area prior to the
slide/ram or blade reaching the full down position.
Gate
A gate is a movable barrier which protects the operator at the
point-of-operation before the machine cycle can be started. Gates are, in many
instances, designed to be operated with each machine cycle.

Pullback or Restraint devices are used on power presses only.

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Safeguarding by Location/Distance
The examples mentioned below are a few of the numerous applications of the principle
of safeguarding by location/distance. A thorough hazard analysis of each machine and
particular situation is absolutely essential before attempting this safeguarding technique.
To safeguard a machine by location, the machine or its dangerous moving parts must
be so positioned that hazardous areas are not accessible or do not present a hazard to
a worker during the normal operation of the machine. This may be accomplished by
locating a machine so that a plant design feature, such as a wall, protects the worker
and other personnel. Additionally, enclosure walls or fences can restrict access to
machines. Another possible solution is to have dangerous parts located high enough to
be out of the normal reach of any worker.
The feeding process can be safeguarded by location if a safe distance can be
maintained to protect the workers hands. The dimensions of the stock being worked on
may provide adequate safety. For instance, if the stock is several feet long and only one
end of the stock is being worked on, the operator may be able to hold the opposite end
while the work is being performed. An example would be a single-end punching
machine. However, depending upon the machine, protection might still be required for
other personnel.

Guarding by Distance

The positioning of the operators control station provides another potential approach to
safeguarding by location. Operator controls may be located at a safe distance from the
machine if there is no reason for the operator to tend it.
Feeding and Ejection Methods to Improve Operator Safety
Many feeding and ejection methods do not require the operator to place his or her
hands in the danger area. In some cases, no operator involvement is necessary after
the machine is set up. In other situations, operators can manually feed the stock with
the assistance of a feeding mechanism. Properly designed ejection methods do not
require any operator involvement after the machine starts to function.
Some feeding and ejection methods may even create hazards themselves. For
instance, a robot may eliminate the need for an operator to be near the machine but
may create a new hazard itself by the movement of its arm.
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Using these feeding and ejection methods does not eliminate the need for guards and
devices. Guards and devices must be used wherever they are necessary and possible
in order to provide protection from exposure to hazards.
Types of Feeding and Ejection Methods:
Automatic Feeds reduce the exposure of the operator during the work process, and
sometimes do not require any effort by the operator after the machine is set up and
running.
With semi-automatic feeding, as in the case of a power press, the operator uses a
mechanism to place the piece being processed under the ram at each stroke. The
operator does not need to reach into the danger area, and the danger area is
completely enclosed.
Automatic ejection may employ either an air-pressure or a mechanical apparatus to
remove the completed part from a press. It may be interlocked with the operating
controls to prevent operation until part ejection is accomplished. This method requires
additional safeguards for full protection of the operator.
Using a semi-automatic ejection mechanism on a power press. When the plunger is
withdrawn from the die area, the ejector leg, which is mechanically coupled to the
plunger, kicks the completed work out.
Robots are machines that load and unload stock, assemble parts, transfer objects, or
perform other tasks. Essentially, they perform work otherwise done by an operator. They
are best used in high production processes requiring repeated routines. However, they
may create high hazard themselves, and if they do, appropriate guards must be used.
Miscellaneous Aids
While these aids do not give complete protection from machine hazards, they may
provide the operator with an extra margin of safety. Sound judgement is needed in their
application.
The awareness barrier does not provide physical protection, but serves only to remind a
person that he or she is approaching the danger area. Generally, awareness barriers
are not considered adequate where continual exposure to the hazard exists.
Shields, another aid, may be used to provide protection from protection from flying
particles, splashing cutting oils, or coolants.

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Holding tools can place or remove stock. A typical use would be for reaching into the
danger area of a press or press brake.
A push stick or block may be used when feeding stock into a saw blade. When it
becomes necessary for hands to be in close proximity to the blade, the push stick or
block may provide a few inches of safety and prevent injury.

NOTES:

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RESOURCES
CONSULTATION PROGRAM
www.alabamasafestate.ua.edu
Safe State Program, The University of Alabama
425 Martha Parham West
P.O. Box 870388
Tuscaloosa, AL 35487-0388
1-800-452-5928
(205) 348-7136
OSHA
www.osha.gov
Birmingham Area Office
Todd Mall
2047 Canyon road
Birmingham, AL 35216-1981
(205) 731-1534
(205) 731-0504 FAX
Mobile Area Office
3737 Government Boulevard, Suite 100
Mobile, AL 36693-4309
(334) 441-6131
(334) 441-6396 FAX
NATIONAL SAFETY COUNCIL
www.bhm.tis.net/~nacnsc
Birmingham (205) 325-7233
(205) 325-1467
Decatur

(256) 308-1133
(256) 308-1161

Mobile(334) 660-1794
E-Mail nacnsc@HiWAAY.com

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