LESSON 7: MACHINE

SAFETY

(GROUP 6)
What is machine?
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 “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 18th 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 led to
poor working conditions and a lot of accidents giving rise to a growing
concern for machine safety.
Hazardous mechanical motions and actions
The 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
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.
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 moves 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.
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
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.

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 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.
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.
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
Lock-out 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
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Identifications:
1. It is a tool used to make work easier.
2. This motion may be hazardous because during the back-and-forth or up-and-
down motion, a worker may be struck or caught between a stationary part.
3. The danger of this type of action occurs at the point of operation where stock is
inserted,held and withdrawn by hand.
4. If the hazard is on part of the machinery which does not require access, it should
be guarded by this type of machine.
5. This part where work isnperformed on the material,such as cutting,boring or
forming a stock.

Enumeration:
Give the “Fatal five” Main causes of Maintenance Injuries.