Machine Guarding…
✓The operations for adjustment, cleaning, greasing
1. Fixed Guards
• These are permanently attached to the machine
or tool, don’t have any
moving parts, and can’t be moved while the
machine is in use.
• They’re most often used to enclose the point of
operation, or other hazards
that the operator doesn’t need to interact with, like
fan blades or flywheels.
• Fixed guards are permanent features of the
machine and must be
disassembled and removed to perform any kind of
adjustment or
maintenance.
2. Adjustable Guards
• These are like fixed guards which are permanent,
but they can be
adjusted to allow the machine to handle different
sizes of material.
• They must be manually adjusted and locked into
place, so all employees
who will operate adjustable guards must be trained
on their use.
• If improperly adjusted or locked, adjustable
guards can fail to prevent
contact with moving parts, causing serious or even
fatal injury.
3. Self-Adjusting Guards
• These guards serve the same purpose as
adjustable guards, but
automatically adapt to the size of the material.
• When the machine is at rest, these guards sit all
the way down.
• When the machine is in use, the operator feeds
material into the machine,
which opens the guard just enough to let the
material in.
• These guards are commonly found on table saws
and woodworking tools.
4. Interlocking Guards
• These are also known as barrier guards,
automatically shut off or disengage the
power source when the guard is open or removed.
• These are particularly useful in situations where
operators need to be able to
open the guard or access the guarded parts of the
machine, such as when
clearing jams.
• These guards allow safe access to interior parts of
the machine without requiring
a total disassembly.
• However, they can be easy to open on accident
and require careful adjustment
and maintenance.
Principles of Machine Guarding
1. Point of Operation
• The point of operation refers to the location
where the machine processes materials. If
the point of operation exposes an employee to a
health or safety risk, a machine guard
is required.
• According to the Occupational Safety and Health
Standards (OSHA), guards must affix
to the machine directly whenever possible.
2. Power Off
• Every piece of machinery requires a power source
to operate, whether it’s electric,
atomic, hydraulic, or pneumatic. As long as there is
an electrical current or flow of
power, the machine is still in use.
• Machine guards must stop the current entirely to
achieve the power-off stage
3. Power Locking Mechanism
• After powering off a device, workers should also
lock it in the “off” position.
• Achieving this locked state requires a special
padlock.
• Every person working on the machine should be
able to access and control this locking
mechanism easily.
4. Safety Guarding
• It’s crucial to prevent workers from making
contact with any moving parts. Installing safety
guarding will help reduce this risk.
• Placing a barrier on the point of operation may
reduce the chance of moving parts coming into
contact with a person’s limbs or clothing.
• Safety guarding protects three areas, including
the prime mover, transmission part form, and
the operating components.
handling to be minimized by combining and
5. Fencing and Enclosures
• A fixed enclosure or locking fence prevents access
to the machine’s moving parts.
This type of guarding should only allow authorized
personnel access to these areas of
the device.
• Fencing and enclosures are directly mounted on
or around the machine. These
fixtures must be installed at least 42 inches away
from the dangerous parts.
6. Position and Location Safety
• According to the Factories Act, “safe by position”
means making it impossible for
workers to touch any exposed or hazardous parts.
• Involves separating workers and machines by a
set distance, usually 6-8 feet.
7. Construction Safety
• Factories should consider safety well before
placing a machine into use.
During the building process, all parts of the device
should be constructed to
reduce the risk of bodily harm.
• Built-in safety design standards should house any
dangerous components
while allowing the machine to operate freely.
Requirements for Guards
1. Prevent contact
• The guard must prevent hands, arms, and any
other part of a operator's body from
making contact with dangerous moving parts.
2. Secure
• Operators should not be able to easily remove or
tamper with the guard. Guards and
safety devices should be made of durable material
that will withstand the conditions of
normal use. They must be firmly secured to the
machine.
3. Protect from falling objects
• The guard should ensure that no objects can fall
into moving parts.
Requirements for Guards…
4. Create no new hazards
• A guard cannot create a hazard such as a shear
point, a jagged edge, or an
unfinished surface that could cause a laceration.
5. Create no interference
• Any guard that prevents the operator from
performing the job quickly and comfortably
might soon be overridden or disregarded.
6. Allow safe lubrication
• If possible, operators should be able to lubricate
the machine without removing the
guards
Safe Guarding Devices
• Safeguarding devices are controls or attachments
that usually prevent
inadvertent access by employees to hazardous
machine areas, when properly
designed and installed.
• Examples include: presence sensing, pullback,
restraint, safety controls, and
gates.
• These devices may perform one of several
functions:
• It may stop the machine if a hand or any part of
the body is inadvertently placed
in the danger area.
• It may restrain or withdraw the operator's hands
from the danger area during
operation.
• It may require the operator to use both hands on
machine controls, thus
keeping both hands and body out of danger.
• It may provide a barrier which is synchronized
with the operating cycle of
the machine in order to prevent entry to the danger
area during the
hazardous part of the cycle.
Safe Handling and Operation of Materials and
Machinery
✓Only those materials and machines which meet
the essential requirements on safety
& health be put into service.
✓All parts of a machine which cause danger of a
person being trapped or cut must be
equipped with guards or protective devices.
and repairing must be performed
with the machine turned off and the power source
disconnected.
✓Loose clothing, loose hair or jewellery etc., must
be avoided while operating a
machine.
✓Every machine must be equipped with
emergency stoppage mechanisms that make
it possible to stop the machine safely under
emergency.
✓Every person who uses a machine has to receive
proper training and
information on the risk that the work involves.
✓The danger zones of the machines must be
marked with warnings and
signs.
✓Proper illumination should be provided.
✓Operators should read and adhere to
manufacturers operating manual and
instructions.
✓Proper housekeeping/maintenance.
✓All equipment and machinery should have proper
Identification number on
the tag.
✓Adequate space shall be given around the
equipment and machinery for
conducting inspection and for the repair &
maintenance work.
✓All machinery must be marked with items such as
the name and address of
the manufacturer, the CE mark, the type and serial
number.
✓There should be proper Controls and Control
Systems to reduce the risks
and it must be safe and reliable
✓Controls must be clearly visible, easily identifiable
and properly marked. It must be
positioned so that they may be operated safely and
their operation does not cause
additional risk.
✓START a machine by “ Voluntary actuation of a
control, STOP a machine by means
✓of control (fitted to the machine) which will bring
it safely to a complete halt.
✓In an emergency, interruption of the power
supply must not allow the machine to start
inadvertently, or allow parts of the machine or
work piece to be ejected.
✓Failure of a control circuit must not lead to a
dangerous situation and automatic and
manual protective devices must remain fully
effective.
✓Warnings should be issued in the language of the
country in which the
machinery is to be used. (This warnings should also
be in the language of
the operator.)
✓All machinery must be accompanied by
instructions.
✓Operators should be fully informed of the hazards
presented by machinery,
the risk control measures employed and correct
working procedures.
Material Handling
• Material handling is the job done by every worker
in an industry from
unloading raw materials, dispatching the finished
product and materials
handled between operations in every department
or plant of the company.
• Mechanical handling of materials reduces
manufacturing cost and increases
the productivity. At the same time mechanical
handling has , a new set of
hazards and injuries.
• Materials are handled in three methods
i. Manual handling
ii. With the help of hand tool
iii. Mechanized material handling
Manual Handling of Materials
• Manual handling means using physical strength to
move materials .
• This method increases the possibilities of injuries
and adds to the costof product.
• To reduce the number of material handling
injuries and increase the efficiency, material
eliminating operations or mechanization.
• Factors to be considered before attempting to lift
a load
i. Material to be handled, terrain or the surface.
ii. The distance to be moved.
iii. The direction of the load to be taken.
iv. Volume and weight, shape and size.
v. Frequency.
vi. Mode of handling
Proper Method of Manual Handling
❖Consider the size, weight and shape of the object
to be carried. Do not lift more
than the object that can be handled comfortably.
❖Set feet solidly. One foot can be slightly ahead of
the other for increased
effectiveness. Feet should be enough apart to give
good balance and stability(
approximately the width of the shoulder).
❖Get close to the load as possible. Bend legs about
90 degrees at the knees.
Crouch do not squat. It takes about twice as much
effort to get up from squat.
❖Keep the back as straight as possible. Bend at the
hips, not the middle of
the back.
❖Grip the object firmly. Maintain the grip while
lifting or carrying. Before
changing or adjusting the grip set the object down
again.
❖Straighten the legs to lift the object, and at the
same time bring the back to
a vertical position. Look upward when beginning to
lift.
❖Never carry a load you cannot see over or
around. Make sure the path of
travel is clear. Carry the object close to the body.
❖Never turn at the waist, to change the direction
or to put an object down.
Turn the whole body and crouch down to lower the
object. To keep hands
from being pinched against down first, so that the
fingers can be removed from under the sides.
Lifting and Carrying
❑When two or more men must carry a single
object, they should adjust the
load so that it rides in level and so that each person
carries an equal part of
the load. Trial lifts can be made before proceeding.
❑When two men carry long sections of pipe or any
lengthy material, they
should not carry on the same shoulder and walk in
unison. Shoulder pads
will prevent cutting of shoulders and help to reduce
fatigue.
❑When a gang of men carries a heavy object like a
rail, the foreman or the
leader should direct the work and special tools such
as tongs should be
used.
❑Normally the gang leader has different signals,
like blowing whistle or
hand clapping for different operations of which the
men are familiar.
❑New employees and men who move slowly need
special attention.
Safe lifting technique
• Plan: Check the path is clear. Know where you will
put the load down.
• Position body: Feet close to object and shoulder
width apart.
• Semi squat: Bend at the hips and knees not at the
back. You are aiming to
maintain your spine's three natural curves when
lifting. Get a good grip
with palms, not just fingers. Pull the load close to
your body.
• Brace: Brace core muscles (see below) and bring
head up into neutral so
you are looking ahead.
• Lift: Use a smooth action to straighten your legs;
sudden weight shift and
movement can cause injury. Keep the load close to
your body. Always
keep eyes and feet pointing in the same direction.
(Warning- do not twist.)
• Lower: Take as much care with lowering as with
lifting. Get as close as
possible to where the load will be placed. Use the ✓Never operate grinding wheels at speeds in
reverse of the above excess of therecommended speed.
procedure - bend knees to lower the load and ✓Never adjust the workpiece or work mounting
maintain spinal curves. deviceswhen the machine is operating.
Ensure the load is secure before you release your ✓Do not exceed recommended depth of cut for the
grip. grinding wheel or machine.
Pushing & pulling guidelines
✓Remove workpiece from grinding wheel before
• As a general guide, push where possible and pull
turning machine off.
an object where it is not
✓Use proper wheel guards on all grinding
possible to push.
machines.
• Don't bend over at your waist- keep your back
✓On bench grinders, adjust tool rest 1/16 to 1/8
straight.
inch from the wheel.
• Keep elbows close to the body.
Safe Practices For Welding And Cutting Operations
• Keep feet and eyes pointing in the same direction.
The following guidelines will be followed while
• Brace abdominals to protect lower back.
doing gas welding and cutting
• Keep palms facing upwards for pulling.
operations:
Material Handling Equipment
1. Hoses shall not be wrapped around cylinders.
• Wide variety of material handling equipment is in
2. Regulators shall be checked for leaks using soap
the market; some
and water solution.
equipment are for general purpose use and others
3. Torches shall be cleaned regularly and adequate
are of special purpose
purging before use.
use.
4. Hoses shall be in good condition, and a flame
• The choice of a particular equipment depends
arrestor must be fitted in the
upon the specific
supply line from the cylinder/ generator to the
requirements or the conditions of an industry.
burner/blow pipe and as near as
• best equipment will be one which permits smooth
possible to the burner/ blow pipe.
and continuous
5. Ensure adequate ventilation while doing welding
production flow, involves less accidents, reduces
& cutting operations in
production cycle time,
confined areas
promotes better working conditions, incurs less
fatigue to the operators
The following guidelines shall be followed while
and brings down the total material handling costs.
doing Electric Arc welding & Cutting
The following factors may be considered while
Operation:
selecting a material
1. The frame or case of the welding machine shall
handling equipment:
be efficiently grounded as per the
1. Material to be moved:
standards. There shall be safe power supply
• The size of material, its shape, weight, delicacy,
interrupting device to the welding machine.
nature (solid, liquid, gas) and its chances
2. Before starting the operation, all connections to
of getting damaged during handling, etc., should be
the machine will be checked to ensure they are
considered.
properly made.
2. Plant buildings and layout:
3. Electrodes shall be removed from holders when
• Widths of aisles, inequality in floor levels, width
not in use to eliminate danger of
of the doors, height of the ceiling, strength
electrical contact with persons or conducting
of floor and walls, columns and pillars etc., to a
objects. Electrode holders when not in use
great extent influence the choice of a
shall be so placed that possibilities of electrical
material handling equipment
contact between them and persons or
3. Type of production machines:
conducting objects are eliminated.
• Different machines have different outputs per
4. Any current carrying parts passing through the
unit time. The material handling equipment
portion of the holder which
should be able to handle the maximum output.
the welder grips in his hand shall be fully insulated
4. Type of material flow pattern:
against the maximum
• A vertical flow pattern will require elevators,
voltage encountered to ground.
conveyors, pipes etc., whereas horizontal flow
5. When job is finished, welding machine shall be
pattern will need trucks, overhead bridge cranes,
disconnected from the
conveyors, etc.
power source and remove the electrode from its
5. Type of production:
holder. Store the
• The type of production affects to a large extent
electrode holder in a safe place.
the selection of the material handling
6. Cable and power source shall be free from
equipment. Conveyors are more suitable for mass
dirt/grease. If the cables and
production on fixed routes and powered
other accessories are damaged, it should be
trucks for batch production; because conveyors
replaced immediately.
though costly, can handle more volume of
7. Maintain electrical cable is in good condition and
production per unit time as compared to trucks,
make sure connections
whereas a truck is more flexible equipment.
are tight.
6. Cost of material handling equipment
8. Keep cables as short as possible.
7. Life of the equipment.
9. Welding cables shall be kept dry where
8. Amount of care and maintenance required for
practicable, and free from grease
the material handling equipment.
and oil to prevent premature breakdown of the
insulation.
Manual Handling of Materials
10.All earth connections shall be checked to
The principles that contribute to safe manual
determine that they are
handling of materials (For
mechanically strong and electrically adequate for
example, a car are given below.
the required current. The
1. Correct Positioning of Feet
earth clamps shall conform to the relevant
2. Knees Bent
standards.
3. Straight Back.
…
4. Arms close to the Body.
• All welding and cutting operations carried on in
5. Correct Grip
confined spaces shall be
6. Head in Correct Position
adequately ventilated to prevent the accumulation
7. Use of Body Weight
of toxic gases or
✓When a heavy load is handled by two or men the
possible oxygen deficiency.
job should be levelled in
• Where welding operations are carried on in
such a way that load is shared equally by all.
confined spaces and welders &
✓It is advisable to employ men of similar physique
helpers are provided with approved air-supplied
and built for the purpose
respirators or hose masks,
a workman shall be stationed on the outside of
Safe Practices For Grinding
such confined space to
✓Wear goggles for all grinding machine operations. service the power and ventilation lines to ensure
✓Check grinding wheels for cracks before the safety of those
mounting. working within the confined space