1. Machine Guarding Element Summary Training
8.0 Process Safety
Machine Guarding

2. 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.

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

4. 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

5. Power Transmission Apparatus Example
BEFORE
AFTER

6. 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

7. Point of Operation Example
BEFORE
AFTER

8. Point of Operation Example
BEFORE
AFTER

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

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

11. 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.

12. 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

13. Hazardous Motions Example
BEFORE
AFTER

14. 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

15. BEFORE
AFTER

16. 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

17. 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

18. 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.

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

20. Eaton Minimum Requirements Barrier Guards (Fixed)
BEFORE
AFTER

21. 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

22. INTERLOCKED Barrier Guard
FIXED
Barrier Guard

23. 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

24. 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

25. 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

26. Pressure Sensitive Mat

27. 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.

28. 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

29. 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

30. 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.

31. 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

32. 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

33. 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)

34. QUESTIONS?
Contact your EH&S Manager with any questions