Industrial Machinery Safety
Transcript of Industrial Machinery Safety
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Machinery Safety
Machine Guarding for Warehouse and Maintenance Workers
What is wrong with this picture?
This material was produced and revised (using information from OSHA’s website, publications and CDC website) under grant
[SH20856SH0] from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor
does mention of trade names, commercialproducts, or organizations imply endorsement by the U.S. Government
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The Problem• Workers who operate and maintain
machinery each year suffer approximately– 18,000 amputations, lacerations, crushing
injuries, and abrasions– 800 deaths
OSHA 7100
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The Problem: Machinery Associated with Amputations
1. Mechanical power presses2. Power press brakes3. Powered and non-powered conveyors4. Printing presses5. Roll-forming and roll-bending machines6. Shearing machines7. Food slicers8. Meat grinders9. Meat-cutting band saws10.Drill presses11.Milling machines12.Grinding machines
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Causes of Machine Incidents
• Reaching in to “clear” equipment• Not using Lockout/Tagout• Unauthorized person doing
maintenance or using the machines• Missing or loose machine guards• Lack of training
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Prevention
• Any machine part, function, or process which may cause injury must be safeguarded.
• Where the operation of a machine can injure the operator or other workers, the hazard must be controlled or eliminated
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OSHA CitationsFiscal Year 2010
• Machines, general requirements (1910.212)– 10th most frequently cited standard– 5th ranked standard in assessed penalties
• Lockout/Tagout (1910.147)– 5th most frequently cited standard– 4th ranked standard in assessed penalties
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Machine Guarding
OSHA’s 1910 Subpart O
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Objectives
• Explain the general requirements for guarding the hazards of machines
• Describe precautions to be taken around machinery
• Identify important terms associated with guarding machinery
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Machine Guarding
Group Worksheet
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3 Basic Areas To Be Safeguarded
• Point of Operation• Power Transmission Apparatus• Other Moving Parts
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Hazard Identification
• Motions– Rotating (including in-
running nip points)– Transverse– Reciprocating
• Actions– Cutting– Punching– Shearing– Bending
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Rotating Motion
• Hazard – Machinery grips and moves clothing, hair and body parts into danger area
• Danger increases when projections are present – Screws, bolts,
nicks, abrasions, etc.
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Rotating Parts with Projections
Rotating pulley with spokes and projecting burr on face of pulley Rotating coupling with
projecting bolt heads
Rotating shaft and pulleys with projecting key and set screw
BURR
OSHA 3067
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In-Running Nip Points
Nip Point
Nip Point
Nip Point
Nip PointNip Point
Nip Point
OSHA 3067
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In-Running Nip Points
Nip Point
Nip Point
Nip Point
Nip Points
OSHA 3067
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Transverse Motion• Movement in a straight, continuous line
around rotating component • Hazard may strike or catch employee a
pinch or shear point
OSHA 3067
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Reciprocating Motion• Back and forth / up and down• Hazard - Caught between moving part
and stationary object
OSHA 3067
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Bending Actions
• Power applied to slide to draw or stamp metal or other materials in a bending motion
• Example: Press Brake, Tube Benders
OSHA 3067
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Bending ActionsPress Brake
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Punching Actions
• Power applied to slide ram for purpose of blanking, drawing or stamping
• Example: Power press
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Shearing Actions• Apply power to slide or knife to trim or
cut
OSHA 3067
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Shearing ActionsSheet Metal Shear
OSHA 7100
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Cutting Actions
• Rotating, reciprocating or transverse motion
• Examples: Band saw, circular saws, lathes, drills
OSHA 3067
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Classification of Safeguards
• Guards• Devices• Location/distance• Automatic/semiautomatic feed or
ejection• Miscellaneous
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Types of Guards• Fixed
– Provide secure barrier• Interlocked
– Cuts off power when guard opened or removed• Adjustable
– Barrier manually moved to accommodate stock or operation
• Self-adjusting– Barrier automatically moves to accommodate
operation
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Fixed Guards
• Advantages– Maximum
protection– Variety of
applications– In-house
fabrication– Low cost &
maintenance
• Disadvantages– Poor visibility– Must remove for repairs
requiring LOTO
OSHA 3067
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Interlocked Guards
• Switch that when opened stops power• Advantage
– Maximum protection– Portion of guard easily removed for access
• Disadvantage– Can be overridden by employee– High cost– Maintenance required
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Adjustable Guards
• Advantage– Flexibility– In-house fabrication
• Disadvantage– Not maximum
protection– Rely on worker to
properly position– May prohibit easy
access
Bandsaw blade adjustable guard
OSHA 3067
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Self-adjusting Guards
• Advantage– Employee not
involved in positioning– Readily available
• Disadvantage– Not maximum
protection– May need frequent
fine tuningOSHA 3067
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Self-adjusting GuardTable Circular Saw
OSHA 10 Hour GI Presentation
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Devices
• Presence sensing– Photoelectrical– Radiofrequency– Electromechanical
• Safety Controls– Safety trip control– Two-hand control/trip
• Gates
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Presence-Sensing Device
www.osha.gov/SLTC/etools/machineguarding/presses/psd.html
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Two-Hand Control
.
• Requires constant, concurrent pressure to activate the machine
• The operator’s hands are required to be at a safe location (on control buttons) and at a safe distance from the danger area while the machine completes its closing cycle
OSHA 10 hour
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Safety Tripwire Cables
• Device located around the perimeter of or near the danger area
• Operator must be able to reach the cable to stop the machine
OSHA 10 hour
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Gate• Movable barrier device which protects the operator at the
point of operation before the machine cycle can be started
• If the gate does not fully close, machine will not function
Gate Open Gate ClosedOSHA 10 hour
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GateVertical Downstroke Baler
www.cdc.gov/niosh/hc14.html
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Safeguard by location/distance
• Position dangerous parts of machine in inaccessible areas during normal operation– Moving parts more
than 7 feet above floor– Controlled access
room– Control station at safe
distance from machine
OSHA 10 hour
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Feeding and Ejection Methods
• Automatic / semiautomatic feed• Automatic / semiautomatic ejection• Robots
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Automatic Feed(shown on power press)
Transparent EnclosureGuard
Stock FeedRoll
Danger
Area
Completed Work
OSHA 3170
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Robots
• Machines that load and unload stock, assemble parts, transfer objects, or perform other tasks
• Best used in high-production processes requiring repeated routines where they prevent other hazards to employees
Press
FixedBarrier
Robot
StockConveyor
OSHA 3170
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Miscellaneous
• Awareness Barriers• Protective Shields• Hand tools
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Awareness Devices• Alert employees to hazard
– Signs– Awareness signals
(audible or visual)
– Awareness barriers (allows access to machine danger areas, but is designed to contact employee, creating an awareness that employee is close to danger point)
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Protective ShieldsThese do not give complete protection from machine hazards, but do provide some protection from flying particles, splashing cutting oils, or coolants.
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Holding Tools
• Used to place and remove stock in the danger area
• Not to be used instead of other machine safeguards, but as a supplement
OSHA 3067
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Requirements for Safeguards
• Prevent contact• Secure, tamper-resistant, and durable• Protect from falling objects• Create no new hazards• Create no interference• Allow safe lubrication and maintenance
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Requirements of Safeguards
• Fixed guards should used whenever possible
• Machines designed for fixed location shall be secured to prevent movement
• Conform to ANSI and OSHA requirements
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Machine Safety Responsibilities
• Management– ensure all machinery is properly guarded
• Supervisors– train employees on specific guard rules in their
areas– ensure machine guards remain in place and are
functional– immediately correct machine guard deficiencies
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Machine Safety Responsibilities
• Employees– do not remove guards unless machine is
locked and tagged– report machine guard problems to
supervisors immediately– do not operate equipment unless guards are
in place
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Employee Training • 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
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Some Examples of Machine Guarding
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Abrasive Wheel MachineryImproper Work Rest and Tongue
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Abrasive Wheel MachineryWork rests on offhand grinding machines must be kept adjusted closely to the wheel with a maximum opening of 1/8-inch to prevent the work from being jammed between the wheel and the rest, which may result in wheel breakage.
OSHA 3067
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Abrasive Wheel MachineryThe distance between the wheel periphery and the adjustable tongue must never exceed 1/4-inch.
OSHA 10 hour
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Abrasive Wheel Machinery• When installing new abrasive wheel
– Inspect for condition and compatibility– Conduct ring test
Click on picture for video
OSHA 7100
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Abrasive Wheel Machinery
Checklist
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Power-Transmission Apparatus
Power-transmission apparatus (shafting, flywheels, pulleys, belts, chain drives, etc.) less than 7 feet from the floor or working platform must be guarded.
Unguarded beltand pulley
OSHA 10 hour
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Portable Circular Saws
Stock
Guard
Blade
Guard Retracted
OSHA 3067
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Table Saw
• On/off switch should be located at knee height -- so you can turn off machine while your hands are on the material
• Blade must be guarded• Automatic brake a
good safety feature
Guard
www.osha.gov/SLTC/etools/machineguarding/saws/tablesaws.html
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Table Saw -- Kickback
• Back of the blade, as it rises out of table, is the critical “kickback zone”
• Material tends to be lifted off of the table• If wood moves sideways at this point, it
will be caught by the rotational motion and will be flung back toward the operator!
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Preventing Kickbacks
• Use a splitter or wedge inserted into the saw kerf to separate material
• Make sure rip fence is perfectly parallel to the blade
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Table Saw - Splitters• Metal fins, secured behind and in line with the
blade -- must move freely & not stick open• Anti-kickback pawls also attached
Splitter & anti-kickback pawls
www.orosha.org/pdf/pubs/2980.pdf
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Table Saw - Push Sticks
Push stick
www.osha.gov/SLTC/etools/machineguarding/saws/tablesaws.html
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Radial Arm Saw
Anti-Kickback Device
Lower Blade Guard
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Machinery: General Safety Principles
• Securely fasten equipment to eliminate movement or “walking”
• No loose clothing, long hair, jewelry, or gloves around rotating machine parts
• Respect machine guards• Keep electrical cords and plugs intact• Inspect machinery before each use
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Machinery: General Safety Principles
• Do not leave machines running and unattended
• Never attend to brush debris from the table surface while the machine is running
• An active brake mechanism adds greatly to safety
• Easily reached “off” switch increases safety
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Machine Guarding
Checklist
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Case Studies
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Quiz
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Resources• OSHA Machine Guarding Website
http://www.osha.gov/SLTC/machineguarding/index.html
• OSHA Machine Guarding eToolhttp://www.osha.gov/SLTC/etools/machineguarding/index.html
• OSHA Amputation Fact Sheethttp://www.osha.gov/OshDoc/data_General_Facts/amputation-factsheet.pdf
• Safeguarding Equipment and Protecting Employees from Amputationshttp://www.osha.gov/Publications/osha3170.pdf
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