UNIT 2 – OCCUPATIONAL SAFETY

MODULE 8: MACHINE SAFETY

From electrical safety, we now go on to machine safety. This module aims to introduce you to the
principles of machine safety as a tool to eliminate industrial injuries and accidents. As an OSH officer,
you must be able to understand the basics of machine guarding to prevent accidents, injuries and deaths
happening in your assigned work area.

Machines make things easy and comfortable for us. They enable us to do a lot of things that we won’t be
able to do otherwise. They are very much a part of our lives but we must be aware that they may also be
sources of injuries and even deaths in the workplace if not used properly.

Any part, function or process involving machines may cause injuries. To eliminate the hazards posed by
machines, you must have sufficient understanding of machine safety particularly of the four major
areas: adjustment and repair, servicing and maintenance, moving parts (machine guarding), and point-
of-operation in every machine.

Machine guards are classified into those that prevent access and those that prevent hazardous motion.
However, machine guards alone cannot prevent injuries – there is a need to educate and train workers
on machine safety. Lock-Out/Tag-Out (LOTO) is an effective system for controlling accidents in servicing
and maintenance of machines.

Objectives

Working on this module should help you to

 recognize the principles of machine guarding

 identify areas where machine guards are needed
 enumerate the types of machine guards
 differentiate a lock-out from tag-out

A machine is a tool used to make work easier. It is basically an assemblage of parts that transmit forces,
motion and energy in a predetermined manner. Simple machines are mechanical devices that change
the direction or magnitude of a force. They are the "building blocks" of which the more complicated
machines or compound machines are made.

The Industrial Revolution

It was only during the industrial revolution that modern machines were used extensively. Prior to this,
all operations were manually done. The start of the 18 th century marked the start of the industrial
revolution. Modern machines were conceptualized and created. These enabled factories to produce
goods faster, but at the same time lead to poor working conditions and a lot of accidents, giving rise to a
growing concern for machine safety. Machine safety covers 4 basic areas: adjustment and repair,
servicing and maintenance, moving parts and point of operation.
Hazardous mechanical motions and actions

Now, let us try to understand an important aspect of machine safety – the basic types of hazardous
mechanical motions and actions.

These include the movement of rotating members, reciprocating arms, moving belts, meshing gears,
cutting teeth, and any other part that impacts or shears. These different types of hazardous mechanical
motions and actions are present in varying combinations in nearly all machines and recognizing them is
the first step toward protecting workers from the dangers they present.

Motions
- Rotating
- Reciprocating
- Transversing
Rotating shaft and pulley
with projecting key and
set screw

Rotating coupling with

projecting bolt
Rotating pulley with
spokes and projecting
Rotating burr

Rotating motion can be dangerous - even smooth, slowly rotating shafts can catch clothing,
and through mere skin contact force an arm or hand into a dangerous position. Injuries due
to contact with rotating parts can be severe.
Collars, couplings, cams, clutches, flywheels, shaft ends, spindles, meshing gears, and
horizontal or vertical shafting are some examples of common rotating mechanisms which
may be hazardous. The danger increases when projections such as set screws, bolts, nicks,
abrasions, and projecting keys or set screws are exposed on rotating parts.

Nip Points

In-running nip point (or points where parts of

the hand, body or clothes can get caught in-
between) hazards, are caused by the rotating
parts of machinery. There are three main
types of in-running nips.

- Parts rotating in opposite directions

- Nip points between rotating and

tangentially moving parts. Some
examples are: the point of contact
between a power transmission belt
and its pulley, a chain and a sprocket,
and a rack and pinion.

- Nip points between rotating and fixed

parts which create a shearing,
crushing, or abrading action. Examples
are: spoked hand wheels or flywheels,
screw conveyors, or the periphery of
an abrasive wheel and an incorrectly
adjusted work rest.
Reciprocating

Reciprocating motions may be hazardous because during the back-and-forth or up-and-

down motion, a worker may be struck by or caught between a moving and a stationary part.

Transversing

Transverse motion (movement in a straight, continuous line) creates a hazard because a

worker may be struck or caught in a pinch or shear point by the moving part.
Mechanical Actions

Cutting

The danger of cutting action exists at the point of operation where finger, arm and body
injuries can occur and where flying chips or scrap material can strike the head,
particularly in the area of the eyes or face. Such hazards are present at the point of
operation in cutting wood, metal, or other materials.

Examples of mechanisms involving cutting hazards include band saws, circular saws,
boring or drilling machines, turning machines (lathes), or milling machines.

Punching

Punching action results when power is applied to a slide (ram) for the purpose of
blanking, drawing, or stamping metal or other materials. The danger of this type of
action occurs at the point of operation where stock is inserted, held, and withdrawn by
hand.

Typical machines used for punching operations are power presses

Shearing

Shearing action involves applying power to a slide or knife in order to trim or shear
metal or other materials. A hazard occurs at the point of operation where stock is
actually inserted, held, and withdrawn.

Examples of machines used for shearing operations are mechanically, hydraulically, or

pneumatically powered shears.

Bending

Bending action results when power is applied to a slide in order to draw or stamp metal
or other materials. A hazard occurs at the point of operation where stock is inserted,
held, and withdrawn.

Equipment that uses bending action includes power presses, press brakes, and tubing
benders.
Areas where machine guarding are necessary

Dangerous moving parts in three basic areas require safeguarding:

The point of operation: that point where work is performed on the material, such as cutting,
shaping, boring, or forming of stock.

Power transmission apparatus: all components of the mechanical system which 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.

Other moving parts: all parts of the machine which move while the machine is working. These
can include reciprocating, rotating, and transverse moving parts, as well as feed mechanism and
auxiliary parts of the machine.

In general, any machine part, function, or process which may cause injury must be guarded.

Importance of machine safety

Why it is necessary to have safety program for machine operations? Because, we know that machines
can cause:
- severe accidents
- loss of trained and skilled employee/s
- loss of production
- damage to equipment
- incurring training cost for new employee/s
- overtime cost
- possible litigation
- accident investigation

Machines can also cause:

- lost time expense
- cost of machine down time
 - cost of machine damage and repairs
- lost time due to time spent on accident investigation and other statutory requirements
- loss of production

Types of machine guards

PREVENTING ACCESS

Fixed enclosing guards

If the hazard is on a part of the machinery which does not require access, it should be
permanently guarded with fixed enclosing guards.

PREVENTING DANGEROUS MOTIONS

When frequent access is required, physical guarding at the hazard is sometimes too restrictive
for part loading or adjustment. In this situation, a device is required to prevent dangerous
motion while allowing unrestricted access by sensing the presence of the operator and sending
a stop signal.

Movable guards with interlocking switches

If access is required in a hazardous area of a machine, an operator can be protected by
an inter-lock with the power source which ensures that whenever the guard door is not
closed, the power is switched off.
Two hand controls
There are other ways of preventing access while the machine is in a dangerous
condition. The use of two hand controls (also referred to as bi-manual controls) is
common in certain types of machinery. Two start buttons have to be operated at the
same time to run the machine. This ensures that both hands of the operator are in a
safe position and therefore cannot be in the hazard area.

Pullback Devices
These are mechanical devices attached to the operator's hands and connected to the
moving portion of the die. If properly adjusted, it withdraws the operator's hands if
they are inadvertently within the point of operation as the dies close.

Photoelectric light curtain

These devices emit a “curtain” of harmless infrared light beams in front of the hazard
area. When any of the beams are blocked, the light curtain control circuit sends a stop
signal to the guarded machine.
Light curtains are extremely versatile and can guard areas many meters wide.
By using mirrors, light beams can be diverted all around the corners to enclose a
machine.

There are many applications ranging from totally enclosing perimeter guards for
industrial robots, to point of access guards for certain types of presses.

Safety mats
These devices are used to guard a floor area around a machine. Interconnected mats are
laid around the hazard area and any pressure will cause the mat controller unit to send
a stop signal to the guarded machine.

Pressure-sensitive mats are often used within an enclosed area containing several
machines (e.g., flexible manufacturing or robotics cells). When access into the cell is
required (example: for setting or robot “teaching”), dangerous motion can be prevented
if the operator stays within the safe area.

Pressure-sensitive edges

These devices are flexible edging strips which can be fixed to the edge of a moving part
such as a machine table or powered door where there is a risk of crushing or shearing
hazard. If the moving part strikes the operator (or vice versa), the flexible sensitive edge
is depressed and will send a stop signal to the power source.

Emergency stops

Wherever there is a danger of an operator getting into trouble on a machine there must
be a facility for fast access to an emergency stop device.

The usual way of providing this is in the form of a mushroom headed push-button which
the operator strikes in the event of an emergency. The emergency stops must be
strategically placed, in sufficient quantity around the machine to ensure that there is
always one in reach at the occurrence of hazard.

Grab wire switches

For machinery such as conveyors etc., it is often more convenient and effective to use a
grab wire device along the hazard area. These devices use a steel wire rope connected
to latching pull switches so that pulling on the rope will operate the switch and cut off
the machine power.

Telescopic trip switches

 Other variations include telescopic antenna switches where deflection of the antenna
causes the switch to cut off the machine power. These devices are more commonly used
as trip devices on machinery such as pillar drills. The switch is mounted on the drill and
the antenna is extended down next to the drill bit. In the event that the operator
becomes entangled with the drill, he will be pulled onto the antenna thus operating the
switch.

Robotics application

This depends on the nature of the machine and the hazard.

Requirements of effective safeguards (Rule 1200)

Must prevent contact

Safeguards should prevent human contact with any potentially harmful machine part. The
prevention extends to machine operators and any other person who might come in contact with
the hazard.

Must be secured and durable

Safeguards should be attached so that they are secured Workers should not be able to render
them ineffective by tampering with or disabling them. This is critical because removing
safeguards to speed-up production is a common practice. Safeguards must also be durable
enough to withstand the rigors of the workplace because worn-out safeguards can’t protect
workers properly.

Must provide protection against falling objects

Objects falling into moving machine mechanisms increase the risk of accidents, property
damage, and injury. Objects that fall on a moving part can be thrown out, creating dangerous
projectile. Therefore, safeguards must do more than just prevent human contact. They must
also shield the moving parts of machines from falling objects.

Must not create new hazards

 Safeguards should overcome the hazards in question without creating new ones. A safeguard
with a sharp edge, unfinished surface or protruding bolts introduces new hazards while
protecting against the old.

Must not create interference

Safeguards can interfere with the progress of work if they are not properly designed. Such
safeguards are likely to be disregarded or disabled by workers due to the pressure of production
deadlines.
Must allow safe maintenance

Safeguards should be designed to allow the more frequently performed maintenance tasks (e.g.,
lubrication) to be accomplished without removal of guards. For example, locating the oil
reservoir outside the guard with a line running to the lubrication point will allow for daily
maintenance without removing the guard.

The Hierarchy of Measures

Each measure must be considered according to the hierarchy below. This may result in a combination
of measures being used.

1. Fixed Enclosing Guards - If access to dangerous parts is not required, the solution is to protect
them by some type of fixed enclosing guard.

2. Movable (interlocked) guards or protection devices (e.g., light curtains, presence sensing
mats, etc.) - If access is required, things get a little more difficult. It will be necessary to ensure
that access can only be permitted while the machine is safe. Protective measures such as
interlocked guard doors and/ or trip systems will be required. The choice of protective device or
system should be based on the operating characteristics of the machine.

3. Protection appliances (e.g., jigs, holders, push sticks, etc) - These are used often in
conjunction with guards to feed a work piece while keeping the operator’s body away from the
danger zone.

4. Information, instruction, training and supervision - It is important that operators have the
necessary training in safe working methods for a machine. However, this does not mean that
measures (a), (b) or (c) can be omitted. It is not enough to merely tell an operator that he/she
must not go near dangerous parts (as an alternative to guarding them). Operators must be
trained on the hazards of their work and how to use and maintain the safety devices as well as
give safety reminders to make them aware all the time.

5. Personal Protective Equipment - In addition to the above measures, it may also be necessary
for the operator to use equipment like special gloves, goggles, etc. The machinery designer
should specify what sort of equipment is required. The use of personal protective equipment is
not the primary safeguarding method but should complement the measures shown above.

The protective device must be appropriate for the type of work being undertaken.
Lock-out/Tag-out System

Another aspect of machine safety is during maintenance work and servicing. The lock-out/tag-out
system is effective for preventing accidents during maintenance works.

It is a method that is especially designed to protect against the unexpected startup of a machine that is
supposed to be turned off. This is important because statistics indicate that six percent of all workplace
fatalities are caused by the unexpected activation of machines while they are being serviced, cleaned, or
otherwise maintained. The Lock-out/Tag-out System is designed to protect against the unexpected
startup of machine that is supposed to be "OFF" or an unexpected release of energy (hazardous energy).

The “Fatal Five” Main Causes of Maintenance Injuries:

 Failure to stop equipment
 Failure to disconnect from power source
 Failure to dissipate (bleed, neutralize) residual energy
 Accidental restarting of equipment
 Failure to clear work areas before restarting

Hazardous Energy Sources Found in the Workplace

- Electrical - sudden turning on of power source or stored energy in capacitors

- Mechanical
- Thermal - such as steam or due to chemical reaction
- Potential - stored energy that may be due to gravity, hydraulics, pneumatics,
vacuum or springs

Types of Lock-out Devices

- Plug Locks
- Ball Valve Lock-out
- Gate Valve Lock-out
- Group Lock-out Hasp
 - Electrical
- Hydraulic, pneumatic, and other pressurized systems

Lockout Procedure
- Alert the operator(s) that power is being disconnected.
- Preparation for Shutdown
- Equipment Shutdown
- Equipment Isolation
- Application of Lock-out Devices
- Control of Stored Energy
- Equipment Isolation-Verification

Removal of Lock-out
- Ensure equipment is safe to operate
- Safeguard all employees
- Remove lock-out/tag-out devices. Except in emergencies, each device must be
removed by the person who placed it .
- Last person to take off lock
- Follow checklist

To observe proper LOTO procedures, most firms maintain some forms of documentation.

SUMMARY

Remember that any machine part, function, or process which many 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.