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9. Machine/Equipment Safety

MACHINE - A tool containing one or more parts that uses energy to perform an intended action.
Usually powered by mechanical, chemical, thermal, or electrical means, and are
often motorized.
Historically, a power tool also required moving parts to classify as a machine. However, the
advent of electronics has led to the development of power tools without moving parts that are
considered machines.
A simple machine is a device that simply transforms the direction or magnitude of a force, but a
large number of more complex machines exist. Examples include vehicles, electronic
systems, molecular machines, computers, television, and radio.

KEY PARTS OF MACHINES

1. The point of operation: that point where work is performed on the material, such as
cutting, shaping, boring, or forming of stock.
2. 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.
3. 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
mechanisms and auxiliary parts of the machine

MACHINE HAZARDS & RISKS

When identifying hazards related with machines, we need to consider the following:
1. Type of machines
2. Layout of machines, operator position and control
3. Energy sources
4. Operating parameters (speed, pressure, temperature, size of cut, mobility, etc.)
5. Materials to be processed or handled and method of feed
6. Worker access for setting adjustments and maintenance
7. Environmental factors (dust, fumes, noise, temperature, humidity)
8. Operating requirements including what the operator needs to do.

Common Machine Hazards

A. Location:
1. Point of Operation
2. Power Transmission Apparatus/Device
3. Other moving parts

B. Motions
1. Rotating (including in-running nip points)
2. Reciprocating
3. Traversing
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C. Actions
1. Cutting
2. Punching
3. Shearing
4. Bending

A good rule to remember is: Any machine part, function, or process which many cause injury
or damage is a hazard and 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 controlled.

A. Location:
1. Point of Operation
2. Power Transmission Apparatus/Device
3. Other moving parts

B. Motions
1. Rotating (including in-running nip points)
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2. Reciprocating

3. Traversing

C. Actions

1. Cutting
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2. Punching

3. Shearing

4. Bending
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Machine-related Risks
1. Mechanical: Crushing, cutting or severing, stabling or puncture, abrasion
2. High pressure fluid ejection or release of containment/energy
3. Flying particles/projectiles
4. Electrical shock
5. Noise, vibration, impact
6. Contact with extreme temperature and pressure
7. Ergonomics

MACHINE/EQUIPMENT HAZARDS CONTROLS

Machine Safety Model

1. Hazards Identification
2. Risk Assessment
3. Controls
 Develop controls
 Implement Controls
 Evaluate Controls (Review, re-assess risks, continuously improved)

Machine Hazards Controls

1. Elimination
2. Substitution
3. Engineering Controls:
• Machine Guarding
• Devices
• Other Methods
4. Administrative Controls:
• Safe work practices (Standards, Procedures, Machine Safety Program, Training,
Inspections/Audits)
5. Personal Protective Equipment

Machine Guarding Principles

An effective guard must:
1. Prevent contact between hazardous moving parts and body or clothing
2. Secure guard: not easily removed
3. Protect from objects falling into machinery
4. Create no new hazards: sharp/rough edges
5. Create no interference with job/comfort/speed
6. Allow safe lubrication: without removing guards if possible
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MACHINE GUARDING
 A “guard” prevents entry into the danger area.

Four types of machine guards:

1. Fixed
2. Interlocked
3. Adjustable
4. Self-adjusting

FIXED
As its name implies, a fixed guard is a permanent part of the machine. It is not dependent upon
moving parts to function. It may be constructed of sheet metal, screen, wire cloth, bars, plastic,
or any other material that is substantial enough to withstand whatever impact it may receive and
to endure prolonged use. This guard is usually preferable to all other types because of its
relative simplicity.

INTERLOCKED
When this type of guard is opened or removed, the tripping mechanism and/or power
automatically shuts off or disengages, the moving parts of the machine are stopped, and the
machine cannot cycle or be started until the guard is back in place. An interlocked guard may use
electrical, mechanical, hydraulic, or pneumatic power or any combination of these. Interlocks
should not prevent "inching" by remote control if required. Replacing the guard should not
automatically restart the machine. To be effective, all removable guards should be interlocked to
prevent occupational hazards

ADJUSTABLE
Adjustable guards are useful because they allow flexibility in accommodating various sizes of
stock

SELF-ADJUSTING
The openings of these barriers are determined by the movement of the stock. As the operator
moves the stock into the danger area, the guard is pushed away, providing an opening which is
only large enough to admit the stock. After the stock is removed, the guard returns to the rest
position. This guard protects the operator by placing a barrier between the danger area and the
operator. The guards may be constructed of plastic, metal, or other substantial material. Self-
adjusting guards offer different degrees of protection..

MACHINE DEVICES
 A “device” controls entry into the danger area.

Six types of Machine Devices:

1. Presence sensing device
2. Two hand control
3. Pullbacks/restraints
4. Moveable barriers (gates)
5. Safety trip controls

PRESENCE-SENSING DEVICE (PSD)

These devices either stop the machine, or will not start the cycle, if a hand or any part of the
body is inadvertently placed in the danger area. There are 4 types of presence sensing
devices.
1. Light Curtain (photoelectric-optical) presence sensing device.
2. Radiofrequency presence-sensing device
3. Electro-mechanical sensing device
4. Safety Mat
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TWO-HAND CONTROL
These devices prevent the operator from reaching into the point of operation when the machine
cycles by requiring the hands to be on palm buttons or levers.

PULLBACK/RESTRAINTS
Uses a series of cables attached to the operator’s hands, wrists, and/or arms and to a moving or
fixed point

MOVABLE BARRIERS
A gate is a moveable barrier which protects the operator at the point of operation before the
machine cycle can be started.

SAFETY TRIP CONTROLS

These devices provide a quick means for deactivating the machine in an emergency situation.

Other Methods
• When guards or devices cannot be used, “Other Methods” can be selected. These other
methods (safe distance, safe holding, safe opening, safe position of controls) are
methods of safeguarding that can be applied to machines with unique safeguarding
problems.
• Other methods do not provide the protection of guards or devices. These methods
require placement or adjustment for each operation. They depend upon specific
procedures, work rules, extensive training and supervision to prevent the tendency to
circumvent the method used

SAFE WORK PRACTICES

 Always use the safety devices correctively.
 Do not wear loose clothing/ties when operating machines with rotating parts.
 Tie up or cover up long hair.
 Use devices to remove trapped materials from machine.
 Switch off the machine before retrieving dropped material(s) from inside the machine.

TRAINING
 Operators/affected employees should receive training on:
 Hazards associated with particular machines
 How the safeguards provide protection and the hazards for which they are intended
 How and why to use the safeguards
 How and when safeguards can be removed and by whom
 What to do if a safeguard is damaged, missing, or unable to provide adequate
protection

PERSONAL PROTECTIVE EQUIPMENT (PPE)

Before using any machine, you should ensure that:
1. Proper PPE is used to conduct the work.
2. The PPE is in good condition.
3. Proper training has been given on how to use PPE.