Machine Guarding Element Summary Training 8.0 Process Safety Machine Guarding

Why is this Important? This man lost his finger when a machine in a factory cut it off. There was no machine guard in place as required by law.

Machine Guards Machine guards protect workers from machine hazards: Power transmission apparatus Point of operation Hazardous moving parts

Power Transmission Apparatus Definition Power transmission apparatus is any moving part of a machine that transfers power: Shafts and couplings Belt and pulley mechanisms Chain and sprocket assemblies Gears Flywheels

Power Transmission Apparatus Example BEFORE AFTER

Point of Operation Definition Point of operation is any area of the machine where work is performed on a material: Cutting Forming Shaping Drilling Bending Polishing Heating

Point of Operation Example BEFORE AFTER

Point of Operation Example BEFORE AFTER

Hazardous Motions Definition Hazardous motions include parts of the machine which move while the machine is working: Rotating parts Nip points Reciprocating motions

Hazardous Motions Rotating Parts Rotating parts are dangerous Can grip hair and clothing Can force the hand or arm into a dangerous position

Hazardous Motions Nip Points Caused by rotating parts on machines Can pull body parts into machines Photograph shows a reciprocating component of a chip handling system. Employees in the walkway are protected from the moving parts by a shield.

Hazardous Motions Reciprocating Motions Reciprocating motions include back-and-forth or up-and-down motions Worker may be struck by moving part Worker may be caught between a moving part and a stationary part

Hazardous Motions Example BEFORE AFTER

Eaton Minimum Requirements All Machines Persons must not be able to be able to reach over, under, around, or through a guard to access a moving part Materials used to construct guards shall be strong enough to protect persons from identified hazards Guards must be free of sharp edges and other hazards that may injure persons who handle the guard Guards must be designed and constructed to be easy to use

BEFORE AFTER

Eaton Minimum Requirements All Machines CONTINUED Where visibility of the operation is required, safeguarding must permit viewing of the hazard area without requiring a guard or safety device to be bypassed or removed To facilitate maximum visibility, the color of wire mesh should be darker than the area being guarded Use of BLACK mesh enhances visibility

Eaton Minimum Requirements All Machines CONTINUED Workers may not be exposed to moving equipment or other hazards while performing tasks such as lubrication, adjustment or diagnostic procedures Provisions must be made to keep guards in place and protective devices functional while performing routine tasks Special openings Feed tubes for lubrication Tool extensions

Eaton Minimum Requirements All Machines CONTINUED Machine hazards associated with power transmission apparatus, point of operation and other hazardous machine motions should be safeguarded by one or more of the following techniques: Barrier guards (fixed, adjustable or interlocked) Presence sensing devices Safety mats Two-handed control devices Pull back and restraint devices The above list is not all-inclusive. Additional safeguarding techniques such as safety edge devices, movable barrier devices, or safe holding practices may be utilized in accordance with local regulatory requirements or established industry practices such as ANSI B11.19.

Eaton Minimum Requirements Barrier Guards (Fixed) Guarding Action Barrier between worker and hazard Special Requirements Guards must not be easily removable Guard removal must require use of tool Advantages Can be used in many applications Provides maximum protection Disadvantages May interfere with visibility Limits access to machine adjustment

Eaton Minimum Requirements Barrier Guards (Fixed) BEFORE AFTER

Eaton Minimum Requirements Barrier Guards (Interlocked) Guarding Action Stops machine when guard is open Special Requirements Interlock must be designed for guarding applications Motion must cease before interlock releases guard Machine must be manually reset before re-start Advantages Used when fixed guards not practical Allows easier access to machine Disadvantages Requires periodic adjustment Can be bypassed

INTERLOCKED Barrier Guard FIXED Barrier Guard

Eaton Minimum Requirements Two-Hand Control Devices Guarding Action Keeps hands out of danger zone Special Requirements Must meet control reliability standards Must be located away from danger zone Multiple operators must have controls Advantages Allows easy placement of materials Easy to view point of operation Disadvantages Only protects operator – not passersby Can be bypassed

Eaton Minimum Requirements Pull Back and Restraint Devices Guarding Action Pulls operator’s hands out of danger zone Special Requirements Only use if other guarding methods not feasible Must be approved by group EHS manager Additional protection required for multiple operators Advantages Allows easy placement of materials Easy to view point of operation Disadvantages Limits movement of operator Requires periodic adjustment Only protects operator – not passersby Requires close supervision

Eaton Minimum Requirements Presence Sensing Devices and Safety Mats Guarding Action Stops machine when body motion detected Special Requirements Must meet control reliability standards Sensing field must be sized to detect motion Machine must be manually reset before re-start Advantages Allows easy placement of materials Easy to view point of operation Disadvantages Machine must be able to stop quickly Expensive

Pressure Sensitive Mat

Eaton Minimum Requirements Operator Inspections Operators must complete visual inspections of applicable guards and safeguarding devices The inspections must be completed at the beginning of each shift or prior to operation if the machine is used less than daily Inspections should verify that: Fixed guards are securely fastened to the machine Adjustable guards are adjusted to prevent access to danger zone Guards are free of damage such as sharp edges and loose parts Presence sensing devices are in the “active” mode Inspections must be documented on the applicable 5S/6S checklist, TPM checklist or equivalent document Functional testing of safeguarding devices such as interlocks, light curtains, area scanners, and safety mats must be completed in accordance with manufacturer’s recommendations. In the absence of specific requirements, functional testing shall occur on a quarterly basis.

Eaton Minimum Requirements Functional Testing Functional testing of electronic safeguarding devices such as interlocks, light curtains, area scanners and safety mats must be completed in accordance with manufacturer’s recommendations In the absence of specific requirements, functional testing shall occur on a quarterly basis

Eaton Minimum Requirements Deficiencies When a daily inspection or functional testing indicates a safeguarding deficiency, the equipment shall be removed from service until the deficiency is corrected Missing Guard

Eaton Minimum Requirements Energy Control / Lockout Energy control must be used when performing servicing or maintenance on a piece of equipment whenever a safeguarding device is removed or bypassed; or any part of the body is placed into an area where injury could result if the equipment were to start unexpectedly.

Eaton Minimum Requirements Training Requirements Operators, maintenance personnel, supervisors and other individuals who may be exposed to the hazards of machine operations must receive machine safeguarding awareness training. The training content should include, but is not limited to: Types and function of safeguarding; Proper operation of the safeguarding; Daily visual inspections of safeguarding; and Functional testing of the safeguarding

Eaton Minimum Requirements Training Requirements CONTINUED Refresher training must be provided to introduce new or revised safeguarding techniques resulting from process and equipment changes, as well as correction of deficiencies discovered during audits Absent of any changes to the site’s machine safeguarding process, refresher training must be provided every three years

Eaton Minimum Requirements Records Retention The following documentation must be maintained in accordance with the retention periods listed below or as required by applicable regulatory requirements: Inspections of pull back or restraint devices (3 months) Daily visual inspections (3 months) Functional testing protocol and test records (1 year) Training records (2 years from date of training)

QUESTIONS? Contact your EH&S Manager with any questions