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IMPORTANTE - OSHA - Machine Safety Case History PDF
IMPORTANTE - OSHA - Machine Safety Case History PDF
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2
Occupational Safety and
Health Administration
Contents
Introduction 5 Safeguarding Roll-Forming and
OSHA Standards 5 Roll-Bending Machines 33
National Consensus Standards 6 Other Controls for Roll-Forming and
Roll-Bending Machines 34
Recognizing Amputation Hazards 7 Hazards of Shearing Machines 35
Hazardous Mechanical Components 7 Safeguarding Shearing Machines 36
Hazardous Mechanical Motions 7 Other Controls for Shearing Machines 36
Hazardous Activities 9 Hazards of Food Slicers 37
Hazard Analysis 9 Safeguarding and Other Controls for
Food Slicers 38
Controlling Amputation Hazards 9 Hazards of Meat Grinders 38
Safeguarding Machinery 9 Safeguarding and Other Controls for
Primary Safeguarding Methods 10 Meat Grinders 39
Guards 10 Hazards of Meat-Cutting Band Saws 39
Safeguarding Devices 13 Safeguarding and Other Controls for
Secondary Safeguarding Methods 16 Meat-Cutting Band Saws 40
Probe Detection and Safety Edge Devices 16 Hazards of Drill Presses 41
Awareness Devices 17 Safeguarding and Other Controls for
Safeguarding Methods 17 Drill Presses 42
Safe Work Procedures 18 Hazards of Milling Machines 43
Complementary Equipment 18 Safeguarding and Other Controls for
Administrative Issues 19 Milling Machines 44
Inspection and Maintenance 19 Hazards of Grinding Machines 45
Lockout/Tagout 20 Safeguarding and Other Controls for
Grinding Machines 46
Specific Machine Hazards and Hazards of Slitters 46
Safeguarding Methods 20
Safeguarding and Other Controls for
Hazards of Mechanical Power Presses 20
Slitters 47
Safeguarding Mechanical Power Presses 22
Other Controls for Mechanical Power Press OSHA Assistance 49
Servicing and Maintenance 23
Training 24 References 51
Additional Requirements 24
Power Press Brakes 25 Appendix A.
Hazards of Power Press Brakes 25 Amputation Hazards Not Covered
Safeguarding Power Press Brakes 25 in this Guide 53
Other Controls for Power Press Brakes 26
Hazards of Conveyors 26 Appendix B.
Safeguarding Conveyors 28 Amputation Hazards Associated
Other Controls for Conveyors 29 with Other Equipment and Activities 54
Hazards of Printing Presses 30
Safeguarding Printing Presses 31 Appendix C.
Other Controls for Printing Presses 32 OSHA Regional Offices 55
Hazards of Roll-Forming and
Roll-Bending Machines 33
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Occupational Safety and
Health Administration
Introduction machinery in general industry, construction, mar-
itime and agricultural operations; however, many
Amputations are among the most severe and dis- of the described safeguarding techniques may be
abling workplace injuries that often result in perma- used to prevent other amputation injuries. Ad-
nent disability. They are widespread and involve ditionally, while this manual concentrates attention
various activities and equipment. (The U.S. Bureau on concepts and techniques for safeguarding
of Labor Statistics 2005 annual survey data indicat- mechanical motion, machines obviously present a
ed that there were 8,450 non-fatal amputation cases variety of other types of energy hazards that cannot
involving days away from work for all private be ignored. For example, pressure system failure
industry. Approximately forty-four percent (44%) of could cause fires and explosions. Machine electri-
all workplace amputations occurred in the manu- cal sources also pose electrical hazards that are
facturing sector and the rest occurred across the addressed by other OSHA standards, such as the
construction, agriculture, wholesale and retail trade, electrical standards contained in Subpart S. Full
and service industries.) These injuries result from discussion of these matters is beyond the scope of
the use and care of machines such as saws, press- this publication. For compliance assistance purpos-
es, conveyors, and bending, rolling or shaping es, references and the appendices are provided on
machines as well as from powered and non-pow- applicable OSHA standards, additional information
ered hand tools, forklifts, doors, trash compactors sources, and ways you may obtain OSHA assistance.
and during materials handling activities.
Anyone responsible for the operation, servicing, OSHA Standards
and maintenance (also known as use and care) of Although this guide recommends ways to safeguard
machines (which, for purposes of this publication and lockout/tagout energy sources associated with
includes equipment) employers, employees, machinery hazards, there are legal requirements in
safety professionals, and industrial hygienists OSHA standards that you need to know about and
should read this publication. Primary safeguarding, comply with. The following OSHA standards are a
as used in this publication, includes control meth- few of the regulations that protect employees from
ods that protect (e.g., prevent employee contact amputation hazards.
with hazardous machine areas) employees from
machine hazards through effective machine guard- Machinery and Machine Guarding:
ing techniques. In addition, a hazardous energy 29 CFR Part 1910, Subpart O
control (lockout/tagout) program needs to comple-
ment machine safeguarding methods in order to 1910.211 Definitions
protect employees during potentially hazardous 1910.212 General requirements for all
servicing and maintenance work activities. machines
This guide can help you, the small business 1910.213 Woodworking machinery require-
employer, identify and manage common amputa- ments
tion hazards associated with the operation and care 1910.215 Abrasive wheel machinery
of machines. The first two sections of the document, 1910.216 Mills and calenders in the rubber
Recognizing Amputation Hazards and Controlling and plastics industries
Amputation Hazards, look at sources of amputa- 1910.217 Mechanical power presses
tions and how to safeguard machinery and control 1910.218 Forging machines
employee exposure to hazardous energy (lockout/ 1910.219 Mechanical power-transmission
tagout) during machine servicing and maintenance apparatus
activities. The section on Specific Machinery Control of Hazardous Energy (Lockout/Tagout):
Hazards and Safeguarding Methods identifies the 29 CFR 1910.147
hazards and various control methods for machinery
Hand and Power Tools:
associated with workplace amputations, such as:
29 CFR Part 1926, Subpart I
mechanical power presses, press brakes, convey-
ors, printing presses, roll-forming and roll-bending 1926.300 General requirements
machines, shears, food slicers, meat grinders, meat- 1926.303 Abrasive wheels and tools
cutting band saws, drill presses, milling machines, 1926.307 Mechanical power-transmission
grinding machines, and slitting machines. apparatus
The information in this booklet does not specif-
ically address amputation hazards on all types of Conveyors:
29 CFR 1926.555
Punch
Stock
Die
Nip Point
Nip Point
Blade
Stock
Nip
Nip Point Point
Nip
Point
8
Occupational Safety and
Health Administration
Hazardous Activities Controlling Amputation
Employees operating and caring for machinery
perform various activities that present potential
Hazards
amputation hazards. Safeguarding is essential for protecting employees
from needless and preventable injury. A good rule
Machine set-up/threading/preparation,* to remember is:
Machine inspection,*
Any machine part, function, or process that may
Normal production operations,
cause injury must be safeguarded.
Clearing jams,*
Machine adjustments,* In this booklet, the term primary safeguarding
Cleaning of machine,* methods refers to machine guarding techniques
Lubricating of machine parts,* and that are intended to prevent or greatly reduce the
Scheduled and unscheduled maintenance.* chance that an employee will have an amputation
injury. Refer to the OSHA general industry (e.g.,
* These activities are servicing and/or mainte- Subpart O) and construction (e.g., Subparts I and
nance activities. N) standards for specific guarding requirements.
Many of these standards address preventive meth-
Hazard Analysis ods (such as using barrier guards or two-hand trip-
You can help prevent workplace amputations by ping devices) as primary control measures; while
looking at your workplace operations and identify- other OSHA standards allow guarding techniques
ing the hazards associated with the use and care of (such as a self-adjustable table saw guard) that
the machine. A hazard analysis is a technique that reduce the likelihood of injury. Other less protective
focuses on the relationship between the employee, safeguarding methods (such as safe work methods)
the task, the tools, and the environment. When that do not satisfactorily protect employees from
evaluating work activities for potential amputation the machine hazard areas are considered second-
hazards, you need to consider the entire machine ary control methods.
operation production process, the machine modes Machine safeguarding must be supplemented
of operation, individual activities associated with by an effective energy control (lockout/tagout)
the operation, servicing and maintenance of the program that ensures that employees are protected
machine, and the potential for injury to employees. from hazardous energy sources during machine
The results from the analysis may then be used servicing and maintenance work activities.
as a basis to design machine safeguarding and an Lockout/tagout plays an essential role in the pre-
overall energy control (lockout/tagout) program. vention and control of workplace amputations. In
This is likely to result in fewer employee amputa- terms of controlling amputation hazards, employ-
tions; safer, more effective work methods; reduced ees are protected from hazardous machine work
workers compensation costs; and increased em- activities either by: 1) effective machine safeguard-
ployee productivity and morale. ing, or 2) lockout/tagout where safeguards are ren-
dered ineffective or do not protect employees from
hazardous energy during servicing and mainte-
nance operations.
Additionally, there are some servicing activities,
such as lubricating, cleaning, releasing jams and
making machine adjustments that are minor in
nature and are performed during normal produc-
tion operations. It is not necessary to lockout/
tagout a machine if the activity is routine, repetitive
and integral to the production operation provided
that you use an alternative control method that
affords effective protection from the machines
hazardous energy sources.
Safeguarding Machinery
The employer is responsible for safeguarding
machines and should consider this need when pur-
chasing machinery. Almost all new machinery is
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Occupational Safety and
Health Administration
remove them. Generally, guards are designed not Figure 11 Self-Adjusting Guard on a Radial Saw
to obstruct the operators view or to prevent
employees from doing a job.
In some cases, guarding may be used as an
alternative to lockout/tagout because employees
can safely service or maintain machines with a
guard in place. For example, polycarbonate and
wire-mesh guards provide greater visibility and can Handle
Switch
Guard
Entering
Stock
Exiting
Stock
Transparent Insert
Bar
Fixed Barrier that allows for Can be constructed to suit Sometimes not practical
stock feeding but does not many applications. for changing production
permit operator to reach Permanently encloses runs involving different
the danger area. the point of operation or size stock or feeding
hazard area. methods.
Provides protection Machine adjustment and
against machine repeat. repair often require guard
Allows simple, in-plant removal.
construction, with mini- Other means of protecting
mal maintenance. maintenance personnel
often required
(lockout/tagout).
Adjustable Barrier that adjusts for Can be constructed to May require frequent
a variety of production suit many applications. maintenance or
operations. Can be adjusted to admit adjustment.
varying stock sizes. Operator may make
guard ineffective.
Self- Barrier that moves Off-the-shelf guards are Does not provide
Adjusting according to the size of the often commercially avail- maximum protection.
stock entering point of able. May require frequent
operation. Guard is in place maintenance and
when machine is at rest adjustment.
and pushes away when
stock enters the point of
operation.
Interlocking Shuts off or disengages Allows access for some May require periodic
Barrier power and prevents minor servicing work, in maintenance or adjust-
Guards machine start-up when accordance with the lock- ment.
guard is open. Should out/tagout exception, Movable sections cannot
allow for inching of without time-consuming be used for manual feed-
machine. removal of fixed guards. ing.
Some designs may be
easy to defeat.
Interlock control circuitry
may not be used for all
maintenance and servic-
ing work.
1 2
Occupational Safety and
Health Administration
Safeguarding Devices access to a hazard are not considered primary safe-
Safeguarding devices are controls or attachments guards. (See Table 2 and Figures 13 through 17 for
that, when properly designed, applied and used, the types of safeguarding devices.)
usually prevent inadvertent access by employees to
hazardous machine areas by: Figure 13 Pullback Device on a Power Press
Pullback
These types of engineering controls, which Straps
either prevent the start of or stop hazardous
motion, may be used in place of guards or as
supplemental control measures when guards alone Wristbands
do not adequately enclose the hazard. In order for
these safeguarding devices to accomplish this
requirement, they must be properly designed and
installed at a predetermined safe distance from the
machines danger area. Other safeguarding devices
(probe detection and safety edge devices) that
merely detect, instead of prevent, inadvertent
Pullback Cords connected to Allows the hands to enter Close supervision ensures
Devices operators wrists and the point of operation for proper use and adjust-
linked mechanically to feeding and removal. ment. Must be inspected
the machine automatically Provides protection even prior to each operator
withdraw the hands from in the event of mechani- change or machine set-up.
the point of operation cal repeat. Limits operators move-
during the machine cycle. ment and may obstruct
their work space.
Operator may easily make
device ineffective by not
adjusting the device
properly.
Restraint Wrists are connected by Simple, few moving Close supervision re-
Devices cords and secured to a parts; requires little quired to ensure proper
fixed anchor point which maintenance. use and adjustment.
limit operators hands from Operator cannot reach Must be inspected prior
reaching the point of oper- into the danger area. to each operator change
ation at any time. Little risk of mechanical or machine set-up.
failure; provides protec- Operator must use hand
tion even in the event of tools to enter the point of
mechanical repeat. operation.
Limits the movement of
the operator; may
obstruct work space
around operator.
Operator may easily make
device ineffective by dis-
connecting the device.
Presence- Interlock into the machines Adjusts to fit different Restricted to machines
Sensing control system to stop stock sizes. that stop operating cycle
Devices operation when the sens- Allows access to load before operator can reach
ing field (photoelectric, and unload the machine. into danger area (e.g.,
radio frequency, or electro- Allows access to the machines with partial
magnetic) is disturbed. guarded area for main- revolution clutches or
tenance and set-up hydraulic machines).
activities. Must be carefully main-
tained and adjusted.
Does not protect
operator in the event
of a mechanical failure.
Operator may make
device ineffective.
Presence- Interlock into machines Full visibility and access Restricted to machines
Sensing control system to stop to the work area. that stop operating cycle
Mats operation when a predeter- Install as a perimeter before operator can reach
mined weight is applied to guard or over an entire into danger area (e.g.,
the mat. A manual reset area. machines with part-
switch must be located out- Configure for many revolution clutches or
side the protected zone. applications. hydraulic machines).
Some chemicals can
degrade the mats.
Does not protect
operator during
mechanical failures.
1 4
Occupational Safety and
Health Administration
Table 2. Types of Safeguarding Devices (continued)
Two- Requires concurrent and Operators hands are at Requires a partial cycle
Hand continued use of both a predetermined safety machine with a brake
Control hands, preventing them distance. and anti-repeat feature.
from entering the danger Operators hands are free Operator may make
area. to pick up new parts after devices without anti-
completion of first part of tiedown ineffective.
cycle. Protects the operator
only.
Two- Requires concurrent use of Operators hands are at Operator may make
Hand Trip both hands, prevents them a predetermined safety devices without anti-
from being in danger area distance. tiedown ineffective.
when machine cycle starts. Can be adapted to Protects the operator
multiple operations. only.
No obstruction to hand Sometimes impractical
feeding. because distance require-
ments may reduce pro-
duction below acceptable
level.
May require adjustment
with tooling changes.
Requires anti-repeat
feature.
Gate
1 6
Occupational Safety and
Health Administration
ers because primary safeguarding methods are not Safe Distance Safeguarding
possible. However, probe detection devices do not Safeguarding by safe distance (by location) may
prevent inadvertent access to the point-of-operation involve an operator holding and supporting a work-
danger area; rather, they serve as a warning mech- piece with both hands at a predetermined mini-
anism and may prevent the initiation of or stop the mum safe distance or, if both hands cannot be used
machine cycle if an employees hand or finger(s) is to hold the work-piece at a distance so that the
too close to the hazard area. operator cannot reach the hazard with the free
A safety edge device (sometimes called a bump hand. For example, the feeding process itself can
switch) is another type of safeguard that detects the create a distance safeguard if the operators main-
presence of an employee when they are in contact tain a safe distance between their hands and the
with the devices sensing edge. A safety edge point of operation. Additionally, where material
device protects employees by initiating a stop com- position gauges are used, they need to be of suffi-
mand when the sensing surface detects the pres- cient height and size to prevent slipping of the
ence of a person; however, they do not usually, material past the gauges.
when used by themselves, prevent inadvertent Another example of a safe distance safeguard-
access to machine danger areas. Therefore, addi- ing method is the use of gravity feed methods that
tional guarding or safeguarding devices must be reduce or eliminate employee exposure to machine
provided to prevent employee exposure to a hazards as the part slides down a chute into the
machine hazard. point of operation. Automatic and semiautomatic
feeding and ejection methods can also protect the
Awareness Devices employee by minimizing or eliminating employee
Awareness devices warn employees of an impend- exposure with potentially hazardous machinery
ing, approaching or present hazard. The first type components. An employee places the part in a
is an awareness barrier which allows access to magazine which is then fed into the point of opera-
machine danger areas, but it is designed to contact tion. Automatic and semiautomatic ejection methods
the employee, creating an awareness that he or she include pneumatic (jet of air), magnetic, mechanical
is close to the danger point. Awareness signals, (such as an arm), or vacuum. Figures 18 and 19
through the use of recognizable audible or visual illustrate different types of automatic feeding and
signals, are other devices that alert employees to ejecting methods.
an approaching or present hazard. Lastly, aware-
ness signs are used to notify employees of the Figure 18 Power Press with a Plunger Feed
nature of the hazard and to provide instructions
and training information. OSHA standard 1910.145
provides design, application, and use specifications
for accident prevention (danger, caution, safety Point of
Operation
instruction) signs and (danger, caution, warning) Guard
tags.
Nest
Safeguarding Methods
Safeguarding methods protect employees from
hazards by the physical arrangement of distance,
holding, openings or the positioning of the
machine components to ensure that the operator
cannot reach the hazard. Some safeguarding work
Plunger Plunger
methods include safe distance safeguarding, safe Handle
holding safeguarding and safe opening safeguard-
ing. Requirements for these secondary control
measures may be found in ANSI B11.19-2003.
Proper training and supervision are essential to
ensure that these secondary safeguarding methods
are being used properly. Safeguarding work meth-
ods may require the use of awareness devices,
including the use of accident prevention signs where
there is a need for warning or safety instruction.
1 8
Occupational Safety and
Health Administration
ing or safeguarding devices and they need to be Administrative Issues
designed to allow employees hands to remain out- As an employer, you need to consider housekeep-
side of the machine danger area. Using hand tools ing practices, employee apparel, and employee
requires close supervision to ensure that the opera- training. Implement good housekeeping practices
tor does not bypass their use to increase produc- to promote safe working conditions around ma-
tion. It is recommended that these tools be stored chinery by doing the following:
near the operation to promote their use.
To prevent injury and repetitive trauma disor- Remove slip, trip, and fall hazards from the
ders, hand-feeding tools should be shatterproof areas surrounding machines;
and ergonomically designed for the specific task Use drip pans when oiling equipment;
being performed. (Figure 21 shows typical hand- Remove waste stock as it is generated;
feeding tools.) Make the work area large enough for machine
operation and maintenance; and
Figure 21 Typical Hand-Feeding Tools Place machines away from high traffic areas to
reduce employee distraction.
2 0
Occupational Safety and
Health Administration
is removed either automatically or manually, a new
makes a single stroke. To stop the press, the
work-piece is fed into the die, and the process is
reverse takes place. Thus, the part-revolution
repeated. (See Figure 23.)
clutch can be disengaged at any time during the
cycle to stop the cycle before it completes the
Figure 23 Part Revolution Mechanical Power Press with
downstroke.
a Two-Hand Control
2 2
Occupational Safety and
Health Administration
Figure 24 Hand-Feeding Tools Used in Conjunction with
No Hands-in-Die Policy Pullbacks on a Power Press
Case History #5
An operator was bending metal parts using a 36-
Point of Operation
ton part-revolution power press brake that was
foot-activated and equipped with a light curtain.
About 3-4 inches of the light curtain had been
blanked out during a previous part run. While
adjusting a part at the point of operation, the
Press Bed
employee accidentally activated the foot pedal
and amputated three fingertips.
Applicable Standards
29 CFR 1910.147, Control of hazardous energy
In other instances, such as with special-purpose
(lockout/tagout).
power press brakes, machines are equipped with
29 CFR 1910.212, General requirements for all
advanced control systems that are adaptable to all
machines.
forms of safeguarding concepts and devices, such
29 CFR 1910.219, Mechanical power-transmis-
as two-hand controls and multiple operator/helper
sion apparatus.
actuating controls. For example, two-hand down,
foot through (actuation) methods are used to safe-
guard employees while they operate press brakes.
With this safeguarding system, an operator uses a Sources of Additional Information
two-hand control to lower the press brake ram, for
OSHA Publication 3067, Concepts and
example, to within 1/4 inch or less of the lower die
Techniques of Machine Safeguarding
(which is considered a safe opening). The operator
(http://www.osha.gov/Publications/Mach_
then has the ability to maneuver and align the
Safeguard/toc.html)
work-piece within this 1/4 inch safe opening area
OSHA Machine Guarding eTool (http://www.
and he or she is protected from the amputation
osha.gov/SLTC/etools/machineguarding/index.
hazard. Then the foot control is used by the opera-
html)
tor to safely actuate the machine to produce the
OSHA Lockout/Tagout Interactive Training
desired product.
Program (http://www.osha.gov/dts/osta/
Because of constraints imposed by certain man-
lototraining/index.htm)
ufacturing or fabricating processes, safeguarding
OSHA Directive CPL 02-01-025 [CPL 2-1.25],
by maintaining a safe distance from the point of
Guidelines for Point of Operation Guarding of
operation may be acceptable. However, this is per-
Power Press Brakes
mitted only when safeguarding by barrier guard
ANSI B11.3-2002, Safety Requirements for
or safeguarding devices is not feasible (impossi-
Power Press Brakes
ble) that is, where the use of primary safeguard-
ing method (such as a restraint device) is not fea-
sible. Additional information about a safe distance
Hazards of Conveyors
safeguarding program can be found in OSHA
Conveyors are used in many industries to transport
Instruction 02-01-025 [CPL 2-1.25] Guidelines for
materials horizontally, vertically, at an angle, or
Point of Operation Guarding of Power Press
around curves. Many conveyors have different and
Brakes.
unique features and uses, so that hazards vary due
2 6
Occupational Safety and
Health Administration
to the material conveyed, the location of the con- Figure 27 Belt Conveyor
veyor, and the proximity of the conveyer to the
employees. Types include unpowered and pow-
ered, live roller, slat, chain, screw, and pneumatic. Belt
Conveyors eliminate or reduce manual material
handling tasks, but they present amputation haz-
ards associated with mechanical motion. (See
Figures 27 through 30 for examples of common
conveyors.)
Conveyor-related injuries typically involve a
employees hands or fingers becoming caught in
nip points or shear points on conveyors and may Fixed Guard Over
Power-Transmission
occur in these situations: Apparatus
Case History #6
While removing a cleaning rag from the ingoing
nip point between the conveyor belt and its tail Figure 29 Chain Driven Live Roller Conveyor
pulley (the unpowered end of the conveyor), an
employees arm became caught in the pulley, Fixed Guard
which amputated his arm below the elbow.
In-Running
Case History #7 Nip Point
While servicing a chain-and-sprocket drive
Chain
assembly on a roof tile conveyor system, an
employee turned off the conveyor, removed the
guard, and began work on the drive assembly
without locking out the system. When someone Sprocket
started the conveyor, the employees fingers
Roller Fixed Guard
became caught in the chain-and-sprocket drive
In-Running
and were amputated. Nip Point
Fixed Guard
Screw Conveyors
Hazards: Screw conveyors are troughs with a
revolving longitudinal shaft on which a spiral or
twisted plate is designed. In-going nip points, of
Fixed Guard Over turning helical flights for the entire length of the
Power-Transmission
Apparatus screw conveyor, exist between the revolving
shaft and trough. Since the trough is not usually
required to be covered for proper operation of
Safeguarding Conveyors the conveyor and because many screw convey-
As conveyor hazards vary depending on the appli- ors are located at or near the floor level, the haz-
cation, employers need to look at each conveyor to ard of stepping into the danger area is ever pres-
evaluate and determine what primary safeguarding ent. Once caught, the victim is pulled further into
methods and energy control (lockout/tagout) the path of the conveying medium.
practices are required. Where necessary for the
Controls: A screw conveyor housing must com-
protection of employees, conveyors need to have
pletely enclose the moving elements (screw
mechanical guards that protect the employee from
mechanism, power transmission apparatus) of
nip points, shear points, and other moving parts,
the conveyor, except for the loading and dis-
including power-transmission apparatus. Guards
charge points. Permanently affixed grids or poly-
may include barriers, enclosures, grating, fences, or
carbonate can be installed for visibility purposes
other obstructions that prevent inadvertent physical
to allow the operator to inspect the operation.
contact with operating machine components, such
Alternatively, the trough side walls should be
as point of operation areas, belts, gears, sprockets,
high enough to prevent employees from reach-
chains, and other moving parts. A brief description
ing over and falling into the trough. Open
of the hazards and recognized safeguarding meth-
troughs can be used if covers are not feasible;
ods is presented for common types of conveyors.
but employees need to be protected by second-
ary safeguarding methods, such as a railing or
Typical Conveyor Hazards and fence.
Safeguarding Methods Feed loading and discharge points can usually
be guarded by providing enclosures, screening,
Belt Conveyors
grating, or some other interruption across the
Hazards: Belt-conveyor drive mechanisms and openings which will allow the passage of the
conveying mediums are hazardous as are the fol- material without allowing the entry of a part of
lowing belt-conveyor areas: 1) conveyor take-up the employees body into the moving part(s).
and discharge ends; 2) where the belt or chain
enters or exits the in-going nip point; 3) where Chain Conveyors
the belt wraps around pulleys; 4) snub rollers
Hazards: Nip points occur when a chain contacts
where the belt changes direction, such as take-
a sprocket, such as when a chain runs around a
ups; 5) where multiple conveyors are adjoined;
sprocket or when the chain is supported by a
or 6) on transfers or deflectors used with belt
sprocket or when a shoe above the chain pre-
conveyors.
cludes the chain from lifting off the sprocket. Nip
Controls: The hazards associated with nip and points also occur at drives, terminals, take-ups
shear points must be safeguarded. Side guards (automatic take-ups may also have shear points),
(spill guards), if properly designed can prevent and idlers. Employee clothing, jewelry, and long
employee contact with power-transmission com- hair may also get entangled and caught in the
ponent, in-going nip points and the conveying moving chain conveyor.
2 8
Occupational Safety and
Health Administration
this method when employees need to be at or
Controls: Sometimes, moving chains cannot be near unguarded moving parts.
enclosed without impairing the functioning of the Use prominent awareness devices, such as
conveyor. However, in some cases, barrier warning signs or lights, to alert employees to
guards may be installed around the moving parts the conveyor operation.
for hazard enclosure purposes or, in other in- Allow only trained individuals to operate con-
stances, nip and shear points may be eliminated veyors and only trained, authorized staff to per-
by placing a guard at the nip point or shear form servicing and maintenance work.
point. Other secondary safeguarding options Visually inspect the entire conveyor and imme-
include safeguarding by distance (location) and diate work area prior to start-up to determine
the use of awareness devices. that the actuation will not cause an employee
hazard.
Roller Conveyors Inspect and test conveyor safety mechanisms,
such as its alarms, emergency stops, and safe-
Hazards: Roller conveyors are used to move
guarding methods.
material on a series of parallel rollers that are
Do not use any conveyor which is unsafe until it
either powered or gravity-fed. Powered roller
is made safe.
conveyors have the hazard of snagging and
Forbid employees from riding on conveyors.
pulling objects, including hands, hair, and cloth-
Prohibit employees working with or near con-
ing into the area between the rollers and the sta-
veyors from wearing loose clothing or jewelry,
tionary components of the conveyor. In-going
and require them to secure long hair with a net
nip points generally exist between the drive
or cap.
chain and sprockets; between belt and carrier
Install emergency stop devices on conveyors
rollers; and at terminals, drives, take-ups, idlers,
where employees work when they cannot other-
and snub rollers.
wise control the movement of the conveyor.
Controls: Roller conveyors need to, where feasi- This recognized safety feature provides employ-
ble, have permanent barrier guards that can be ees with the means to shut off the equipment in
adjusted as necessary to protect the employee the event of a hazardous situation or emergency
from nip and shear points. For example, the incident.
unused section of rollers closest to the employ-
ees needs to be guarded when transporting For emergency stop devices, you will need these
small items on a roller conveyor that do not engineering controls:
require the use of the entire roller width. Also,
conveyor hazards may be reduced by eliminating Equip conveyors with interlocking devices that
or minimizing projections from the roller and shut them down during an electrical or mechani-
through the use of pop-up rollers. Other second- cal overload such as product jam or other stop-
ary safeguarding options include safeguarding page. Emergency devices need to be installed so
by distance (location) and the use of awareness that they cannot be overridden from other loca-
devices. tions.
When conveyors are arranged in a series, all
should automatically stop whenever one stops.
Other Controls for Conveyors Equip conveyors with emergency stop controls
The following are some secondary safeguarding that require manual resetting before resuming
methods, work practices, and complementary conveyor operation.
equipment that may be used to supplement pri- Install clearly marked, unobstructed emergency
mary safeguarding or alone or in combination stop buttons or pull cords within easy reach of
when primary safeguarding methods are not feasi- employees.
ble: Provide continuously accessible conveyor belts
with emergency stop cables that extend the
Safeguarding by safe distance (by location) entire length of the conveyor belt to allow access to
locating moving parts away from employees to the cable from any point along the belt.
prevent accidental contact with the hazard Ensure that conveyor controls or power sources
pointis one option for safeguarding convey- can accept a lockout/tagout device to allow safe
ors. It is particularly difficult, however, to use maintenance practices.
3 0
Occupational Safety and
Health Administration
Figure 31 Roll-to-Roll Offset Printing Press
Case History #8
An employee was adding ink at the top of a
printing press when he spotted a small piece of
wood in the area of the moving rollers. He
caught his hand in the moving rollers as he
attempted to remove the wood and had to have
his forearm surgically amputated.
Case History #9
An offset printing press operator lost his right
hand while attempting to remove dried ink on a
moving roller using a rag. The guard covering
the lower ink train rollers had been flipped up,
exposing the rollers. The rag got caught in a
nearby roller, pulling the employees hand into
the in-going nip point. The employee immediate-
Figure 32 Sheet-Fed Offset Printing Press
ly hit the press stop button, but the roller rotated
one-half turn before stopping. His hand was
crushed and had to be amputated at the hospital.
Source: OSHA IMIS Accident Investigation Database.
3 2
Occupational Safety and
Health Administration
Hazards of Roll-Forming and The most common type of amputation hazard
Roll-Bending Machines associated with roll-forming and roll-bending
Roll-forming and roll-bending machines primarily machines are point of operation hazards created by
perform metal bending, rolling, or shaping func- in-running nip points. Amputations occur when the
tions. Roll-forming is the process of bending a hands of the operator feeding material through the
continuous strip of metal to gradually form a pre- rolls get caught and are then pulled into the point
determined shape using a self-contained machine. of operation. Causes of amputations related to roll-
Roll-forming machines contain a series of rolls that forming and roll-bending machines can occur from
may or may not have braking systems. Roll-form- the following:
ing machines may also perform other processes
on the metal, including piercing holes, slots, or Having an unguarded or inadequately guarded
notches; stamping; flanging; and stretch-bending. point of operation;
Roll-bending machines usually have three rolls Locating the operator control station too close to
arranged like a pyramid and they perform essential- the process;
ly the same process as roll-forming, except that the Activating the machine inadvertently; and
machine produces a bend across the width of flat Performing cleaning, clearing, changing, or
or pre-formed metal to achieve a curved or angular inspecting tasks while the machine is operating
configuration. or is not properly locked or tagged out.
Roll-forming and roll-bending machines fre-
quently are set up and operated by one person. Case History #10
(Figure 33 illustrates a roll-forming machine pro- While feeding a metal sheet into a roller, an
ducing a finished product. Figure 34 illustrates the employee caught his right hand in the roller and
in-feed section of a roll-forming machine.) amputated one finger.
Operator
Control Safeguarding Roll-Forming and Roll-
Station
Bending Machines
Roll-forming and roll-bending machines are avail-
Figure 34 In-Feed Area of a Roll-Forming Machine able in a wide variety of sizes and designs, and
safeguarding methods must be tailored for each
Power Transmission Apparatus machine. Several factors affect the ways to safe-
Entering guard the equipment, including whether a machine
Stock
has a brake system, its size, operating speed, thick-
ness of product, length of production runs, required
production accuracy, sheet feeding methods, and
part removal methods. Depending on the size and
type of machine, a number of different primary
safeguarding methods may be required to ade-
quately protect the operator as well as other em-
ployees nearby. For example, you can do the
following:
3 4
Occupational Safety and
Health Administration
Hazards of Shearing Machines
Mechanical power shears contain a ram for their Shears can be categorized as stand-alone manu-
shearing action. The ram moves a non-rotary al shears, stand-alone automatic shears, and
blade at a constant rate past the edge of a fixed process-line shears.
blade. Shears may be mechanically, hydraulically,
Stand-alone manual shears. An operator controls
hydra-mechanically, pneumatically, or manually
them from a control station. The operator feeds
powered and are used to perform numerous func-
the shear either by hand or by activating the
tions such as squaring, cropping, and cutting to
automatic loading mechanism and activates the
length.
equipment using hand or foot controls or a trip-
In the basic shear operation, stock is fed into the
ping device on the back side of the shear. An
point of operation between two blades. A hold-
example is an alligator shear.
down may then be activated that applies pressure
to the stock to prevent movement. One complete Stand-alone automatic shears. These feed and
cycle consists of a downward stroke of the top stroke automatically and continuously. The oper-
blade until it passes the lower fixed blade followed ator uses hand-activated or foot-activated con-
by an upward stroke to the starting position. (See trols to initiate the operation, which requires lim-
Figures 35 and 36 for examples of alligator and ited additional operator interaction. An example
power squaring shears.) is a guillotine shear.
Process-line shears. These are integrated into an
Figure 35 Hydraulic Alligator Shear
automated production process and are controlled
Point of automatically as part of the process. Examples
Operation Guard include crop shears and cut-to-length shears.
3 6
Occupational Safety and
Health Administration
training under the direct supervision of experi- pushing/guarding device or plunger may be used
enced operators until they can work safely on to apply pressure to the food against the slicer
their own. blade, or pressure may be applied by gravity and/or
Instruct employees to perform routine mainte- by an attachment connected to the food holder.
nance on the clutch and braking systems. (See Figure 37.)
Instruct employees to inspect all guarding to
ensure that it is in place properly before the Figure 37 Meat Slicer
machine is operated.
Instruct supervisors to ensure that operators Meat Holder
Thickness
Adjustment
Applicable Standards
29 CFR 1910.212, General requirements for all
Amputations resulting from work with food
machines
slicers can occur as follows:
29 CFR 1910.219, Mechanical power-transmis-
sion apparatus
When the operator adjusts or services the slicer
29 CFR 1910.147, Control of hazardous energy
while it is still operating or while it is switched
(lockout/tagout)
off but still plugged in, or energized. In the latter
case, amputations occur when the operator acci-
dentally switches the slicer on.
Sources of Additional Information
When the operator fails to use the sliding attach-
OSHA Instruction CPL 03-00-002, National ment on the food-holding device, especially
Emphasis Program on Amputations. when slicing small pieces of meat.
OSHA Publication 3067, Concepts and When the operator hand-feeds food into a
Techniques of Machine Safeguarding chute-fed slicer without using the proper push-
(http://www.osha.gov/Publications/Mach_ ing/guarding device or plunger.
Safeguard/toc.html)
OSHA Machine Guarding eTool (http://www.
osha.gov/SLTC/etools/machineguarding/index. Case History #14
html) Two employees, an operator and an assistant,
OSHA Lockout/Tagout Interactive Training were using a meat slicer to slice turkey. The
Program (http://www.osha.gov/dts/osta/ assistant was holding a box of turkey in a tilted
lototraining/index.htm) position while the operator fed the turkey into
ANSI B11.4-2003, Safety Requirements for the slicer. The operator removed the guard
Shears. from the meat slicer because the turkey kept
jamming. The slicers knives caught the opera-
tors glove and pulled his hand into the knives,
Hazards of Food Slicers amputating his finger just above the nail.
Food slicers are electrically powered machines typi-
cally equipped with a rotary blade, an on/off switch,
thickness adjustment, and a food holder or chute. A
3 8
Occupational Safety and
Health Administration
Control of hazardous energy (lockout/tagout), 29
she reassembled it. Also, she did not use the CFR 1910.147, standard. You can avoid slicer
plunger provided for feeding the meat into the lockout/tagout if the equipment is cord-and-plug
grinder. The machine pulled her hand into the connected equipment simply by having exclu-
3-inch diameter auger and amputated it above sive control over the attachment plug after you
the wrist. shut the slicer off and unplug it from the energy
source.
Source: OSHA IMIS Accident Investigation Database.
Applicable Standards
29 CFR 1910.147, Control of hazardous energy
Safeguarding and Other Controls for
(lockout/tagout).
Meat Grinders
29 CFR 1910.212, General requirements for all
Meat grinders must be retrofitted with a primary
machines.
safeguard, such as a properly designed tapered
29 CFR 1910.219, Mechanical power-transmis-
throat or fixed guard, in cases where the machine
sion apparatus.
design is such that an employees hand may come
in contact with the point-of-operation (that is the
auger cutter area). You should buy meat grinders
Sources of Additional Information
already equipped with this primary safeguard.
The following are some other secondary safe- OSHA Instruction CPL 03-00-002, National
guarding methods, work practices, and comple- Emphasis Program on Amputations.
mentary equipment that may be used to supple- OSHA Publication 3067, Concepts and
ment primary safeguarding or alone or in combina- Techniques of Machine Safeguarding
tion when primary safeguarding methods are not (http://www.osha.gov/Publications/Mach_
feasible: Safeguard/toc.html)
OSHA Machine Guarding eTool (http://www.
Develop and implement safe work (operating) osha.gov/SLTC/etools/machineguarding/index.
procedures for meat grinders to ensure that the html)
guards are adequate and in place, and that the OSHA Lockout/Tagout Interactive Training
grinder feeding methods are performed safely. Program (http://www.osha.gov/dts/osta/
Conduct periodic inspections of grinder opera- lototraining/index.htm)
tions to ensure compliance.
Use warning signs to alert employees of the
hazard and safety instructions. Hazards of Meat-Cutting Band Saws
Ensure that all operators receive appropriate Band saws can cut wood, plastic, metal, or meat.
on-the-job training under direct supervision of These saws use a thin, flexible, continuous steel
experienced operators until they can work safely strip with cutting teeth on one edge that runs
on their own. around two large motorized pulleys or wheels. The
Provide operators with properly sized plungers blade runs on two pulleys (driver and idler) and
to eliminate the need for their hands to enter the passes through a hole in the work table where the
feed throat during operation. operator feeds the stock. Blades are available with
Instruct operators to use the proper plunger various teeth sizes, and the saws usually have
device to feed meat into grinders. No other adjustable blade speeds.
device should be used to feed the grinder. Unlike band saws used in other industries,
Instruct employees to operate grinders only with meat-cutting band saws are usually constructed of
feeding trays and throats installed. stainless steel for sanitary purposes and for easy
Instruct operators to use the meat grinder only cleaning. The table, which may slide or roll, has a
for its intended purpose. pushing guard installed to protect the operator
Instruct operators to turn off and unplug grinders while feeding the saw. Meat-cutting band saws
when not in use or when left unattended for any may also be equipped with a fence and pushing
period of time. guard to feed the meat through the band saw. (See
Perform servicing and maintenance under an Figure 39.)
energy control program in accordance with the
Fixed
Power
Transmission Safeguarding and Other Controls for
Apparatus
Guard Meat-Cutting Band Saws
Primary safeguarding methods that you can use
Blade include the following:
Sliding
Table Install a self-adjusting guard over the entire
blade, except at the working portion, or point
of operation of the blade. The guard must be
adjustable to cover the unused portion of the
Pushing
Guard blade above the meat during cutting operations.
Enclose the pulley mechanism and motor com-
pletely.
Operator
Control The following are some secondary safeguard-
ing methods, work practices, and complementary
equipment that may be used to supplement pri-
mary safeguarding or alone or in combination
when primary safeguarding methods are not fea-
Amputations occur most frequently when opera- sible:
tors hands contact the running saw blade while
feeding meat into the saw. The risk of amputation Develop and implement safe work (operating)
is greatest when operators place their hands too procedures for meat-cutting band saws to
close to the saw blade, in a direct line with the saw ensure that the guards are adequate and in
blade, or beneath the adjustable guard during feed- place and that operators safely perform feeding
ing operations. Here are some common causes of methods.
amputations involving meat-cutting band saws: Ensure that all operators receive adequate on-
the-job training under the direct supervision of
The operators hand slips off the meat or other- experienced operators until they can work safely
wise accidentally runs through the blade. on their own.
The operator attempts to remove meat from the Use warning signs to alert employees of the
band saw table while the blade is still moving. hazard and safety instructions.
The operators gloves, jewelry, or loose-fitting Install a brake on one or both wheels to prevent
clothing became entangled in the saw blade. the saw blade from coasting after the machine is
shut off.
Provide a pushing guard or fence to feed meat
Case History #18 into the saw blade.
While operating a band saw to cut pork loin, an Instruct operators to use the pushing guard or
employee amputated his right index finger when fence to feed the saw, especially when cutting
his hand slipped and contacted the moving blade. small pieces of meat.
Instruct operators to adjust the point of opera-
Case History #19 tion guard properly to fit the thickness of the
An operator amputated the tip of his right ring meat.
finger while using a band saw to cut 1/4 -inch Instruct operators to use only sharp meat-cut-
slabs of meat from a 4-inch thick piece of beef. ting blades and to tighten blades to the appro-
As the piece of meat got smaller, his hands priate tension with the machines tension control
device.
4 0
Occupational Safety and
Health Administration
Instruct operators not to wear gloves, jewelry, or material on the drill press bed, securing the work
loose-fitting clothing while operating a band to the bed so that it will not rotate during drilling,
saw and to secure long hair in a net or cap. turning the drill press on, and pulling the drill press
Prohibit operators from removing meat from the lever down so that the drill bit will be lowered into
band saw while the saw blade is still moving. the stock. (See Figure 40.)
Instruct operators to turn off and unplug band
saws when not in use or when left unattended Figure 40 Drill Press with a Transparent Drill Shield
for any period of time.
Conduct periodic inspections of the saw opera-
tion to ensure compliance.
Perform servicing and maintenance under an Drill Bit
energy control program in accordance with the
Control of hazardous energy (lockout/tagout), 29
Clamps to
CFR 1910.147, standard. You can avoid slicer Hold Work in
lockout/tagout if the equipment is cord-and-plug Place
connected equipment simply by having exclu-
sive control over the attachment plug after you
shut the band saw off and unplug it from the
energy source.
Applicable Standards
Amputations typically occur when the operators
29 CFR 1910.147, Control of hazardous energy
gloves, loose-fitting clothing, or jewelry become
(lockout/tagout).
entangled in the rotating drill bit. Here are some
29 CFR 1910.212, General requirements for all
other causes of drill press-related amputations:
machines.
29 CFR 1910.219, Mechanical power-transmis-
Inadequately guarding points of operation or
sion apparatus.
power-transmission (such as belt and pulleys)
devices;
Removing a part from a drill press while wear-
Sources of Additional Information
ing gloves;
OSHA Publication 3067, Concepts and Making adjustments to the drill press, such as
Techniques of Machine Safeguarding setting the depth, securing the material to the
(http://www.osha.gov/Publications/Mach_ drill press bed, and repositioning the wood or
Safeguard/toc.html) metal, while the drill bit is still rotating;
OSHA Machine Guarding eTool (http://www. Changing the drill bit with the operating control
osha.gov/SLTC/etools/machineguarding/index. unprotected so that a falling object or otherwise
html) bumping the switch can accidentally start up the
OSHA Lockout/Tagout Interactive Training press spindle and tool assembly;
Program (http://www.osha.gov/dts/osta/ Performing servicing and maintenance activities,
lototraining/index.htm) such as changing pulleys and belts, without de-
OSHA Publication 3157, A Guide for Protecting energizing and locking/taging out the drill press.
Workers from Woodworking Hazards (http://
www.osha.gov/Publication/osha3157.pdf)
Case History #20
A mechanic amputated the first joints of his left
Hazards of Drill Presses index and middle fingers while changing the belt
Electric drill presses use a rotating bit to drill or cut position on a multi-pulley drill press. While the
holes in wood or metal. The holes may be cut to a mechanic was pulling the belt on, it suddenly
desired preset depth or completely through the went around the outside pulley, pulling the
stock. A basic drill press operation consists of mechanics fingers through the nip point.
selecting an appropriate drill bit, tightening the bit
in the chuck, setting the drill depth, placing the
4 2
Occupational Safety and
Health Administration
Figure 41 Bed Mill
Applicable Standards
29 CFR 1910.147, Control of hazardous energy
(lockout/tagout).
29 CFR 1910.212, General requirements for all
Control
machines. System
29 CFR 1910.213, Woodworking machinery
requirements.
29 CFR 1910.219, Mechanical power-transmis-
sion apparatus.
Milling
Cutter
Milling
Sources of Additional Information Bed
4 4
Occupational Safety and
Health Administration
Amputation injuries can occur when the opera-
Sources of Additional Information tors hands enter the point of operation during the
following activities:
OSHA Publication 3067, Concepts and
Techniques of Machine Safeguarding
Bypassing the grinding machine safety switch
(http://www.osha.gov/Publications/Mach_
feature in order to clean the machine while it is
Safeguard/toc.html)
running;
OSHA Machine Guarding eTool (http://www.
Wearing gloves while grinding, where it is possi-
osha.gov/SLTC/etools/machineguarding/index.
ble to have the glove get caught between the
html)
revolving disc and the table;
OSHA Lockout/Tagout Interactive Training
Fixing a jammed grinder machine by turning
Program (http://www.osha.gov/dts/osta/
the machine off, removing the blade guard and
lototraining/index.htm)
reaching into the danger area before the blades
National Safety Council, Accident Prevention
stop turning;
Manual for Industrial Operations: Engineering
Operating a grinding machine with non-func-
and Technology. 10th Ed. Itasca, IL
tional interlocks and without the guard in place;
ANSI B11.8-2001, Safety Requirements for
Using an incorrectly adjusted or missing work
Manual Milling, Drilling and Boring Machines
rest or a poorly maintained or unbalanced abra-
with or without Automatic Control
sive wheel;
Adjusting the work rest, balancing the wheel,
cleaning the area around the abrasive wheel and
Hazards of Grinding Machines
loading and unloading parts or measuring parts
Grinding machines primarily alter the size, shape,
while the abrasive wheel is still rotating;
and surface finish of metal by placing a work-piece
Attempting to stop a rotating abrasive wheel by
against a rotating abrasive surface or wheel. Grind-
hand.
ing machines may also be used for grinding glass,
ceramics, plastics, and rubber.
Examples of grinding machines include abrasive
Case History #24
belt machines, abrasive cutoff machines, cylindrical
After grinding a piece of steel on an off-hand
grinders, centerless grinders, gear grinders, internal
grinder, an employee turned off the machine and
grinders, lapping machines, off-hand grinders, sur-
tried to stop the wheel with a piece of scrap
face grinders, swing frame grinders, and thread
steel. His hand slipped and hit the rotating abra-
grinders. (See Figure 42.)
sive wheel, amputating the tip of his left middle
finger.
Figure 42 Horizontal Surface Grinder
Install safety guards that cover the spindle end, Applicable Standards
nut, and flange projections or otherwise ensure
ANSI B7.1-1970, Safety Code for the Use, Care
adequate operator protection;
and Protection of Abrasive Wheels [incorporat-
Install adjustable and rigid work rests on off-
ed by reference in 1910.94(b)(5)(i)(a),
hand grinding machines; and
1910.215(b)(12) and 1910.218(j)(5)].
Install guards over power belts and drives.
29 CFR 1910.147, Control of hazardous energy
(lockout/tagout).
The following are some secondary safeguarding
29 CFR 1910.215, Abrasive wheel machinery.
methods, work practices, and complementary
29 CFR 1910.219, Mechanical power-transmis-
equipment that may be used to supplement primary
sion apparatus.
safeguarding or alone or in combination when
29 CFR 1926.303, Abrasive wheels and tools.
primary safeguarding methods are not feasible:
4 6
Occupational Safety and
Health Administration
Figure 43 Paper Slitter Safeguarding and Other Controls for
Slitters
The following primary safeguards may be used to
protect employees from the hazardous portions of
the slitter and auxiliary equipment:
4 8
Occupational Safety and
Health Administration
OSHA Assistance Consultation Services
Consultation assistance is available on request to
employers who want help in establishing and main-
OSHA can provide extensive help through a variety of taining a safe and healthful workplace. Largely funded
programs, including technical assistance about effec- by OSHA, the service is provided at no cost to the
tive safety and health programs, state plans, work- employer. Primarily developed for smaller employers
place consultations, voluntary protection programs, with more hazardous operations, the consultation
strategic partnerships, training and education, and service is delivered by state governments employing
more. An overall commitment to workplace safety and professional safety and health consultants. Compre-
health can add value to your business, to your work- hensive assistance includes an appraisal of all mech-
place, and to your life. anical systems, work practices, and occupational safe-
ty and health hazards of the workplace and all aspects
Safety and Health Program Management Guidelines
of the employers present job safety and health pro-
Effective management of employee safety and health gram. In addition, the service offers assistance to
protection is a decisive factor in reducing the extent employers in developing and implementing an effec-
and severity of work-related injuries and illnesses and tive safety and health program. No penalties are pro-
their related costs. In fact, an effective safety and posed or citations issued for hazards identified by the
health program forms the basis of good employee consultant. OSHA provides consultation assistance to
protection and can save time and money (about $4 the employer with the assurance that his or her name
for every dollar spent) and increase productivity and and firm and any information about the workplace will
reduce employee injuries, illnesses, and related work- not be routinely reported to OSHA enforcement staff.
ers compensation costs.
Under the consultation program, certain exemplary
To assist employers and employees in developing employers may request participation in OSHAs Safety
effective safety and health programs, OSHA pub- and Health Achievement Recognition Program
lished recommended Safety and Health Program (SHARP). Eligibility for participation in SHARP in-
Management Guidelines (54 Federal Register (16): cludes receiving a comprehensive consultation visit,
3904-3916, January 26, 1989). These voluntary guide- demonstrating exemplary achievements in workplace
lines can be applied to all places of employment cov- safety and health by abating all identified hazards, and
ered by OSHA. developing an excellent safety and health program.
The guidelines identify four general elements criti- Employers accepted into SHARP may receive an
cal to the development of a successful safety and exemption from programmed inspections (not com-
health management system: plaint or accident investigation inspections) for a peri-
Management leadership and employee involvement, od of 1 year. For more information concerning consul-
Worksite analysis, tation assistance, see OSHAs website at
Hazard prevention and control, and www.osha.gov.
Safety and health training.
The guidelines recommend specific actions, under Voluntary Protection Programs (VPP)
each of these general elements, to achieve an effec- Voluntary Protection Programs and on-site consulta-
tive safety and health program. The Federal Register tion services, when coupled with an effective en-
notice is available online at www.osha.gov. forcement program, expand employee protection to
help meet the goals of the OSH Act. The VPPs moti-
State Programs vate others to achieve excellent safety and health
The Occupational Safety and Health Act of 1970 (OSH results in the same outstanding way as they estab-
Act) encourages states to develop and operate their lish a cooperative relationship between employers,
own job safety and health plans. OSHA approves and employees, and OSHA.
monitors these plans. Twenty-four states, Puerto Rico For additional information on VPP and how to
and the Virgin Islands currently operate approved apply, contact the OSHA regional offices listed at the
state plans: 22 cover both private and public (state end of this publication.
and local government) employment; Connecticut,
New Jersey, New York and the Virgin Islands cover Strategic Partnership Program
the public sector only. States and territories with their OSHAs Strategic Partnership Program, the newest
own OSHA-approved occupational safety and health member of OSHAs cooperative programs, helps
plans must adopt standards identical to, or at least as encourage, assist, and recognize the efforts of part-
effective as, the Federal OSHA standards. ners to eliminate serious workplace hazards and
achieve a high level of employee safety and health.
Whereas OSHAs Consultation Program and VPP entail
5 0
Occupational Safety and
Health Administration
References American National Standards Institute/
Conveyor Equipment Manufacturers
Association
American National Standards Institute
ANSI/CEMA 350-2003, Screw Conveyors for Bulk
ANSI B5.52M-1980 (R1994), Presses, General Material
Purpose, Single Point, Gap Type, Mechanical
ANSI/CEMA 401-2003, Unit Handling
Power (Metric)
ConveyorsRoller ConveyorsNon-powered
ANSI B5.371970 (R1994), External Cylindrical
ANSI/CEMA 402-2003, Unit Handling
Grinding MachinesCenterless
ConveyorsBelt Conveyors
ANSI B5.42198 (R1994), External Cylindrical
ANSI/CEMA 403-2003, Unit Handling
Grinding MachinesUniversal
ConveyorsBelt Driven Live Roller Conveyors
ANSI B7.12000, Use, Care, and Protection of
ANSI/CEMA 404-2003, Unit Handling
Abrasive Wheels
ConveyorsChain Driven Live Roller Conveyors
ANSI B11.1-2001, Safety Requirements for
ANSI/CEMA 405-2003, Unit Handling
Mechanical Power Presses
ConveyorsSlat Conveyors
ANSI B11.3-2002, Safety Requirements for the
ANSI/CEMA 406-2003, Unit Handling
Construction, Care, and Use of Power Press
ConveyorsLine-shaft Driven Live Roller
Brakes
Conveyors
ANSI B11.4-2003, Safety Requirements for
Construction, Care, and Use of Shears
American National Standards Institute/
ANSI B11.8-2001, Safety Requirements for American Society of Mechanical
Manual Milling, Drilling and Boring Machines Engineers
with or without Automatic Control
ANSI B11.91975 (R2005), Safety Requirements ANSI/ASME B20.1-2003, Safety Standard for
for the Construction, Care, and Use of Grinding Conveyors and Related Equipment
Machines
ANSI B11.12-1996, Safety Requirements for National Institute for Occupational
Construction, Care, and Use of Roll-Forming and Safety and Health
Roll-Bending Machines
NIOSH Current Intelligence Bulletin (CIB) 49,
ANSI B11.141996, Coil Slitting Machines
Injuries and Amputations Resulting from Work
Safety Requirements for Construction, Care and
with Mechanical Power Presses (May 22, 1987)
Use
ANSI B11.19-2003, Performance Criteria for
Safeguarding
National Safety Council
ANSI B20.1-57, Safety Code for Conveyors, National Safety Council, Accident Prevention
Cableways, and Related Equipment [incorporat- Manual for Industrial Operations: Engineering
ed by reference in 1926.555(a)(8)] and Technology. 9th ed. Itasca, IL
ANSI B65.1-2005, Safety StandardPrinting National Safety Council, Accident Prevention
Press Systems Manual for Business and Industry: Engineering
ANSI B65.2-2005, Binding and Finishing and Technology 11th ed. Itasca, IL
Systems
ANSI O1.1-2004, Safety Requirements for
Woodworking Machinery
5 2
Occupational Safety and
Health Administration
Appendix A. Amputation Hazards Associated with
Plastics Machinery
Amputation Hazards Not Plastics processing machines are complex pieces
Covered in this Guide of equipment that require safeguarding and a haz-
ardous energy control program. Serious injuries,
The following amputation hazards and related including fatalities, amputations, avulsions, burns
activities are not specifically covered in detail in this and cuts can occur, especially during servicing and
document. They are either covered in other OSHA maintenance work. You can find specific guidance
publications or specific OSHA standards. While at OSHAs Machine Guarding eTool section for
you may find the general hazard recognition and Plastics Machinery (http://www.osha.gov/SLTC/
machine guarding concepts presented in the etools/machineguarding/plastics/h_injectmold.html).
Recognizing Amputations Hazards and Controlling
Amputation Hazards sections of this document Amputation Hazards in Agriculture and
helpful, please refer to the applicable topic-specific Maritime Operations
resources and standards listed in the reference sec- Requirements for machine guarding in agriculture
tion of this publication for a complete discussion of operations are contained in the Standards for
these hazards. Agriculture, 29 CFR Part 1928 Subpart DSafety for
Agricultural Equipment, and requirements for
Amputation Hazards Associated machine guarding in maritime operations can be
with Saws found in the Shipyard Employment Standards, 29
Saws are the top source of amputations in whole- CFR Part 1915 Subpart HTools and Related
sale and retail trade and in the construction indus- Equipment, the Marine Terminals Standard, 29 CFR
try. Stationary saws, such as band, radial arm and Part 1917 Subpart GMachine Guarding, and the
table saws, account for a substantial number of Longshoring Standard, 29 CFR Part 1918 Subpart
IGeneral Working Conditions.
amputations in the workplace. Sawing machinery
used for woodworking applications is not specifical-
Additional Health and Safety Hazards
ly addressed in this guide.
Other health and safety hazards associated with
You can find specific guidance on these saws in
using stationary machines, but not addressed in
OSHA Publication 3157, A Guide for Protecting
this guide, include noise, vibration, ergonomic
Workers from Woodworking Hazards; 29 CFR
stresses, exposure to hazardous chemicals (e.g.,
1910.213, Woodworking machinery requirements;
metalworking fluids) and dust, electric hazards, and
29 CFR 1910.243, Guarding of portable powered
flying objects.
tools; and 29 CFR 1926.304, Woodworking tools.
Please visit the OSHA website at www.osha.gov
For additional information on how to safeguard
for more information on how to recognize and con-
saws and implement hazardous energy control
trol these hazards.
practices, you can find guidance at OSHAs
Machine Guarding eTool section for Saws (http://
www.osha.gov/SLTC/etools/machineguarding/saws.
html) Also, the national consensus standard, ANSI
O1.1-2004, Safety Requirements for Woodworking
Machinery, may provide you with valuable infor-
mation on how to prevent amputations.
5 4
Occupational Safety and
Health Administration
Appendix C. Region VII
(IA,* KS, MO, NE)
OSHA Regional Offices City Center Square
1100 Main Street, Suite 800
Region I Kansas City, MO 64105
(CT,* ME, MA, NH, RI, VT*) (816) 426-5861
JFK Federal Building, Room E340
Boston, MA 02203 Region VIII
(617) 565-9860 (CO, MT, ND, SD, UT,* WY*)
1999 Broadway, Suite 1690
Region II PO Box 46550
(NJ,* NY,* PR,* VI*) Denver, CO 80202-5716
201 Varick Street, Room 670 (720) 264-6550
New York, NY 10014
(212) 337-2378 Region IX
(American Samoa, AZ,* CA,* HI,* NV,*
Region III Northern Mariana Islands)
(DE, DC, MD,* PA, VA,* WV) 71 Stevenson Street, Room 420
The Curtis Center San Francisco, CA 94105
170 S. Independence Mall West (415) 975-4310
Suite 740 West
Philadelphia, PA 19106-3309 Region X
(215) 861-4900 (AK,* ID, OR,* WA*)
1111 Third Avenue, Suite 715
Region IV Seattle, WA 98101-3212
(AL, FL, GA, KY,* MS, NC,* SC,* TN*) (206) 553-5930
61 Forsyth Street, SW
Atlanta, GA 30303 * These states and territories operate their own
(404) 562-2300 OSHA-approved job safety and health programs
and cover state and local government employees
Region V as well as private sector employees. The
(IL, IN,* MI,* MN,* OH, WI) Connecticut, New Jersey, New York and Virgin
230 South Dearborn Street Islands plans cover public employees only. States
Room 3244 with approved programs must have standards that
Chicago, IL 60604 are identical to, or at least as effective as, the
(312) 353-2220 Federal standards.
Note: To get contact information for OSHA Area
Region VI Offices, OSHA-approved State Plans and OSHA
(AR, LA, NM,* OK, TX) Consultation Projects, please visit us online at
525 Griffin Street, Room 602 www.osha.gov or call us at 1-800-321-OSHA.
Dallas, TX 75202
(214) 767-4731 or 4736 x224