OSH for ENGINEERS

ENGG 1030

Joanne S. Dionela, ChE

9. Machine/
Equipment Safety
Machine Safety 3

WHAT is a 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 4

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
and Risks
Machine Hazards 6

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 7

A. Location: C. Actions
1. Point of Operation 1. Cutting
2. Power Transmission Apparatus/Device 2. Punching
3. Other moving parts 3. Shearing

B. Motions 4. Bending

1. Rotating (including in-running nip

points)
2. Reciprocating
3. Traversing

RULE OF THUMB: 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.
Common Machine Hazards: Location 8

A. Location:
1. Point of Operation
2. Power Transmission
Apparatus/Device
3. Other moving parts
Common Machine Hazards: Motions 9

B. Motions
1. Rotating (including in-running
nip points)
Common Machine Hazards: Motions 10

2. Reciprocating 3. Traversing
Common Machine Hazards: Actions 11

C. Actions
1. Cutting
2. Punching
3. Shearing
4. Bending
Common Machine Hazards: Actions 12

1. Cutting
2. Punching
Common Machine Hazards: Actions 13

3. Shearing 4. Bending
Machine-related Risks 14

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
Control
Machine Safety Model 16

1. Hazards Identification
2. Risk Assessment
3. Controls
➢ Develop controls
➢ Implement Controls
➢ Evaluate Controls (Review, re-assess
risks, continuously improved)
Machine Hazards Controls 17

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 18

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
Machine Guarding 19

A “guard” prevents entry into the danger area.

Four types of machine guards:

1. Fixed
2. Interlocked
3. Adjustable
4. Self-adjusting
Machine Guarding 20

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.
Machine Guarding 21

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.
Machine Guarding 22

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 23

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
Machine Devices 24

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. Radio frequency presence-sensing
device
3. Electro-mechanical sensing device
4. Safety Mat
Machine Devices 25

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.
Machine Devices 26

PULLBACK/RESTRAINTS
Uses a series of cables attached to the operator’s hands, wrists, and/or arms and to a
moving or fixed point
Machine Devices 27

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

Gate Open Gate Closed

Machine Devices 28

SAFETY TRIP CONTROLS

These devices provide a quick means for deactivating the machine in an emergency
situation.
Other Methods 29

• 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
Administrative Controls 30

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.
Administrative Controls 31

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 32

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.
Questions?