osha 10 hour machine guarding presentation #4
DESCRIPTION
OSHA 10 hour machine guarding presentation #4TRANSCRIPT
A good rule to remember is:
Any machine part, function, or process which may cause injury must be safeguarded.
Where the operation of a machine or accidental contact with it can injure the operator or others in the vicinity, the hazards must either be eliminated or controlled.
If it moves, it merits your attention!
1. Describe the basic hazards involving machinery including point of operation and power transmission devices.
2. Introduce control measures through effective machine guarding
principles and methods.
Goals
1910.212(a)(1) Types of guarding• One or more methods of machine guarding shall be
provided to protect the operator and other employees in the machine area from hazards such as those created by: – Point of operation,
– Ingoing nip points,
– Rotating parts,
– Flying chips and sparks
The point where work is actually performed.
Cutting
Shaping
Boring
Forming
Point of Operation Hazards
The purpose of machine guarding is to protect against and prevent injury from....
Point of operation
Nip points
Part One: The Principles
The purpose of machine guarding is to protect against and prevent injury from....
Point of operation
Nip points
Rotating parts
Part One: The Principles
The purpose of machine guarding is to protect against and prevent injury from....
Part One: The Principles
Point of operation
Nip points
Rotating parts
Flying Chips
The purpose of machine guarding is to protect against and prevent injury from....
Part One: The Principles
Point of operation
Nip points
Rotating parts
Flying Chips
Sparks
Where Mechanical Hazards Occur
Three basic areas require safeguarding
Where Mechanical Hazards Occur
1. Point of Operation
The components which transmit energy to the part of the machine performing the work.
Where Mechanical Hazards Occur
2. Power Transmission Devices
Flywheels Pulleys
Rods Cams
Couplers Spindles
Chains Sprockets
Gears Shafts
Cranks Belts
Where Mechanical Hazards Occur
2. Power Transmission Devices
All hazardous parts which move while the machine is working.
Reciprocating
Rotating
Transverse
Feed mechanisms
Where Mechanical Hazards Occur
3. All Other Moving Parts
Hazardous Mechanical Motions and Actions
A wide variety of mechanical motions and actions may present hazards to the worker.
• Rotating or reciprocating members
• Moving belts
• Meshing gears
• Cutting teeth
• Any part that impacts or shears
What are some hazards of rotating parts?
Rotating Motion
1. Parts rotating in opposite direction
In-running nip point hazards
Rotating Motion
2. Rotating and tangentially moving parts
In-running nip point hazards
Rotating Motion
3. Rotating and fixed parts
In-running nip point hazards
Rotating Motion
Reciprocating Motion
Transverse Motion
Standard Interpretations 12/20/1994 - Machine-guarding
requirements• By not specifying the types of machine guards that
must be used, this standard is referred to as a "performance" standard (i.e., the employer is free to adopt a machine guard that "performs" in such a manner as to meet the standard's objective--to protect employees from the identified hazards).
• If OSHA had specified the types of machine guards that must be used, the standard would be a "specification" standard.
Must prevent any contact to the machine hazard and installed to prevent contact from around, over, through, or under the guard!
“…so designed and constructed as to prevent the operator from having any part of his/her body in the danger zone during the operating cycle”
{29 CFR 1910.212(a)(3)(ii)}
Effective Safeguarding
• Must be in conformity with any appropriate standards
• Must not present a hazard in itself nor create interference
Effective Safeguarding
• Must not allow objects to fall into moving parts
• Allow safe maintenance and lubrication
• Must be affixed and secured to the machine where possible
Effective Safeguarding
There are many ways to safeguard machines!
Determine the appropriate safeguarding method.
Consider
• the type of operation and material
• the size or shape of stock
• the method of handling
• the physical layout of the work area
• production requirements/limitations
Part Two: Safeguarding
As a general rule, power transmission apparatus is best protected by fixed guards that enclose the danger areas.
Enclosed shaft end
Part Two: Safeguarding
Enclosed chain & sprocket
For hazards at the point of operation, several types of safeguarding may be considered.
Because safeguarding the point of operation can provide challenges, one must always choose the most effective and practical means available.
Let’s take a look at some strategies
Part Two: Safeguarding
1. Guards
Fixed
Interlocked
Adjustable
Self-adjusting
Part Two: Safeguarding
2. Devices
Presence Sensing
Pullback
Restraint
Safety Controls
Gates
Part Two: Safeguarding
Rockford Systems, Inc.
3. Location/Distance
4. Feeding/Ejection Methods
Automatic/Semi-Auto feed Automatic/Semi-Auto ejectionRobotics
Part Two: Safeguarding
Guard was hanging at the work bench!
Effective?
Effective?
Guards are barriers which prevent access to danger areas.
First Safeguarding Strategy: Guards
Fixed Guards
– A permanent part of the machine
– Not dependent upon moving parts to perform its intended function
– Constructed of sheet metal, screen, wire cloth, bars, plastic, or substantial material
– Usually preferable to all other types because of its simplicity and
permanence
First Safeguarding Strategy: Guards
Interlocked Guards
When this type of guard is opened/removed
– the tripping mechanism and/or power automatically
shuts off or disengages
– the machine cannot cycle or be started until the guard is back in place
First Safeguarding Strategy: Guards
Interlocked Guards
– They may use electrical, mechanical, hydraulic, or pneumatic power or
any combination of these
– Replacing the guard should not automatically restart the machine
First Safeguarding Strategy: Guards
Interlocked Guards
Interlocked guarding can be defeated!
This was taped down.
Adjustable Guards
– These guards allow flexibility in accommodating various sizes of
stock
First Safeguarding Strategy: Guards
Self-Adjusting Guards
The openings of these guards 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
First Safeguarding Strategy: Guards
Self-Adjusting Guards
A safety device may perform one of several functions.
Rockford Systems, Inc.
Second Safeguarding Strategy: Devices
Presence-Sensing Devices
Photoelectric (optical)
– Uses a system of light sources and controls which can interrupt the machine's operating cycle
Second Safeguarding Strategy: Devices
• It may stop the machine if a hand or any part of the body is
inadvertently placed in the danger area
Equipment Resale, Inc
Second Safeguarding Strategy: Devices
Presence-Sensing Devices
Radiofrequency (capacitance)
– Uses a radio beam that is part of the machine control circuit
– When the capacitance field is broken, the machine will stop or will not activate
Second Safeguarding Strategy: Devices
Presence-Sensing Devices
Electromechanical
– Has a probe or contact bar which descends to a predetermined distance when the operator initiates the machine cycle
– If there is an obstruction preventing it from descending its full predetermined distance, the control circuit does not actuate the machine cycle
Second Safeguarding Strategy: Devices
• Restrain or withdraw the operator's hands from the danger area
during operation
Rockford Systems, Inc.
Second Safeguarding Strategy: Devices
Pullback
– Pullback devices utilize a series of cables attached to the operator's hands, wrists, and/or arms
– This type of device is primarily used on machines with stroking action
– When the slide/ram is up between cycles, the operator is allowed access to the point of operation
Second Safeguarding Strategy: Devices
Restraint
– The restraint (holdout) device utilizes cables or straps that are attached
to the operator's hands at a fixed point
– The cables or straps must be adjusted to let the operator's hands travel within a
predetermined safe area - there is no extending or retracting action involved
Second Safeguarding Strategy: Devices
• Require the operator to use both hands on machine controls
Rockford Systems, Inc.
Second Safeguarding Strategy: Devices
Two Hand Controls
– Requires constant, concurrent pressure by the operator to activate the machine
– With this type of device, the operator’s hands
are required to be at a safe location (on the
control buttons) and at a safe distance from the danger area
Second Safeguarding Strategy: Devices
Two Hand Trips
– This device requires concurrent application of both the operator’s
control buttons to activate the
machine cycle, after which the hands are free.
Second Safeguarding Strategy: Devices
Safety Trip Controls
– Provide a quick means for deactivating the machine in an emergency situation
– A pressure-sensitive bar, when depressed, will
deactivate the machine
Second Safeguarding Strategy: Devices
Safety Trip Controls
– Safety tripwire cables may also be located around the perimeter or near the danger area
Second Safeguarding Strategy: Devices
• 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
Rockford Systems, Inc.
Second Safeguarding Strategy: Devices
Gates
– A gate is a movable barrier which protects
the operator at the point of operation
before the machine cycle can be
started
– Usually designed to operate with each
machine cycle
Second Safeguarding Strategy: Devices
Guarding by Location/Distance
– The machine or its dangerous moving parts are positioned so that hazardous areas are not accessible or do not present a hazard during normal operation
– walls or other barricades (fences)
– height (above worker)
– size of stock (single end feeding, punching)
Another Safeguarding Strategy
Is this adequate distance?
Is this adequate location?
Feeding and Ejection
– Automatic and Semiautomatic Feeding
Another Safeguarding Strategy
Feeding and Ejection
– Automatic Ejection
Another Safeguarding Strategy
Feeding and Ejection
– Semiautomatic Ejection
Another Safeguarding Strategy
Robotics
– Machines that load and unload stock, assemble parts, transfer objects,
and perform other tasks
– They perform work otherwise done by the operator
– Best used in high production processes requiring repeated routines
Another Safeguarding Strategy
Robotics
Does not give complete protection from machine hazards, but may provide the operator with an extra margin of safety.
Examples:
•Awareness barriers
•Shields
•Holding tools
•Push sticks or blocks
Miscellaneous Aids
1910.212(a)(3)(iii) Hand Tools• Special hand tools for placing
and removing material shall
be such as to permit easy
handling of material without
the operator placing a hand in
the danger zone* *Such tools shall not be in lieu of other guarding
required by this section, but can only be used to
supplement protection provided.
1910.212(a)(3)(iv) Examples of machines
• Types of machines which normally require point
of operation guarding:
– Mills
– Drills
– Grinders
– Power presses
– Shears
– Saws
1910.212(a)(4) Barrels, containers, and drums
• Revolving drums, barrels,
and containers shall be
guarded by an enclosure
which is interlocked with
the drive mechanism, so
that the barrel, drum, or
container cannot revolve
unless the guard
enclosure is in place
1910.212(a)(5) Exposure of blades• When the periphery of the blades of a fan is
less than seven (7) feet above the floor or
working level, the blades shall be guarded
• The guard shall have openings no larger than
one-half (1/2) inch.
1910.212(b) Anchoring fixed machinery
• Machines designed for a fixed location shall be
securely anchored to prevent walking or moving
This pedestal grinder is designed for anchoring,
and is not anchored, creating a potential
hazard
CPL 2-1.35 National Emphasis Program on Amputations
• Identify and reduce workplace hazards likely to cause amputations
• top five machines that cause amputations are: – Saws, – Shears, – Slicers, – Slitters, and – Presses.
Saws• Used primarily in woodworking and
manufacturing shops• Two types
– Table – Radial arm
• Other types include:
Hand heldBand saw Miter saw
Shears
• Self-contained machines using a mechanically
driven ram
• Ram moves a nonrotary blade at a constant
rate past the edge of fixed blade
Slicers• Commonly used to slice meat
and food
• Use rotary blade
• Guillotine cutters used in other
industries
• Most injuries occur in
restaurants and grocery
stores
Power Presses
• NEP covers all types of
power presses
• Presses consist of
stationary bed, and slide
• Used in a variety of
industries
Program Procedures
• NEP includes three
activities:
– Outreach
– Targeting/selection
– Inspection
• If present, a thorough
inspection will be
conducted focusing on:
– Nip points
– Pinch points
– Shear points
– Cutting actions
– Point(s) of operation
1910.213(a)(12) Guarding blades under tables
• For all circular saws where conditions are such that there is a possibility of contact with the portion of the saw either beneath or behind the table, that portion of the saw shall be: – Covered with an exhaust hood, or, if no exhaust
system is required,
– With a guard that shall be arranged as to prevent accidental contact with the saw
1910.213(b) Machine controls and equipment
• A mechanical or electrical power
control shall be provided on
each machine to make it
possible for the operator to cut
off the power from each
machine without leaving his
position at the point of operation
1910.213(b)(3) Non-restart devices
• On applications where injury to the operator
might result if motors were to restart after
power failures, provision shall be made to
prevent machines from automatically restarting
upon restoration of power
1910.213(b)(4) Location of controls
• Power controls and operating
controls should be located
within easy reach of the
operator while he is at his
regular work location, making
it unnecessary for him to
reach over the cutter to make
adjustments
1910.213(c) Ripsaws• Each circular hand-fed ripsaw shall be guarded
by a hood which shall completely enclose that
portion of the saw above the table and that
portion of the saw above the material being cut
• Each hand-fed circular ripsaw shall be
furnished with a spreader to prevent material
from squeezing the saw or being thrown back
on the operator
1910.213(c)(2) Spreaders
Spreader
1910.213(c)(3) Non-kickback fingers• Each hand-fed circular
ripsaw shall be
provided with non-
kickback fingers or
dogs so located as to
oppose the thrust or
tendency of the saw to
pick up the material or
to throw it back toward
the operator
1910.213(g)(1) Swing cutoff saws
• Each swing cutoff saw shall be provided with a
hood that will completely enclose the upper half
of the saw, the arbor end, and the point of
operation at all positions of the saw
• Each swing cutoff saw shall be provided with an
effective device to return the saw automatically
to the back of the table when released at any
point of its travel
1910.213(g)(2) Swing cutoff saws
1910.213(h) Radial saws• The upper hood completely encloses the upper portion
of the blade down to a point that will include the end of the saw arbor
• Radial saws used for ripping provided with nonkickback fingers or dogs located on both sides of the saw so as to oppose the thrust or tendency of the saw to pick up the material or to throw it back toward the operator
1910.213(i) Bandsaws
• All portions of the saw blade shall be enclosed
or guarded, except for the working portion of the
blade between the bottom of the guide rolls and
the table
1910.213(i) Bandsaws• Bandsaw wheels shall be
fully encased
• The outside periphery of
the enclosure shall be
solid
• The front and back of the
band wheels shall be
either enclosed by solid
material or by wire mesh
or perforated metal
Treadle
• Each operating treadle shall be covered by an
inverted U-shaped metal guard, fastened to the
floor, and of adequate size to prevent
accidental tripping
1910.215(a)(2) Guard design• The safety guard shall cover
the spindle end, nut, and flange
projections
• The safety guard shall be
mounted so as to maintain
proper alignment with the wheel
1910.215(a)(2) Guard design• The strength of the fastenings shall exceed the
strength of the guard, except:
– Where the work provides suitable protection, the
guard may expose the spindle end, nut and flange
– Where the work entirely covers the side of the
wheel the side cover(s) of the guard may be omitted
1910.215(a)(4) Work Rests• On off hand grinding, work rests are required, to support
the work• Rigid construction, and adjustable with wheel wear• Must be kept closely adjusted, max gap = 1/8" to prevent
work from jamming & breaking wheel
• Securely clamped after each adjustment• Adjustments made only when wheel is stopped
Work rest is closelyadjusted
1910.215(b)(9) Exposure adjustment
• Safety guards of the type where the operator stands in front of the opening, shall be so constructed so that the peripheral protecting member can be adjusted to the constantly decreasing size of the wheel
• The distance between the periphery and the adjustable tongue guard shall never exceed one-fourth inch
1910.215 (d) Mounting• Inspection:
– Immediately before mounting, all wheels shall be closely
inspected and sounded by the user (ring test) to make sure they
have not been damaged in transit, storage, or otherwise
– The spindle speed of the machine shall be checked before
mounting of the wheel to be certain that it does not exceed the
maximum operating speed marked on the wheel
• Sound the wheel by tapping around the wheel periphery with a wood handled screwdriver*
• Good wheel portions will “ring” like a bell
• Cracks will sound “dead”
1910.215 (d) Mounting -Ring Test
*A non-metallic implement, wood mallets may be needed for larger wheels
• The spindle speed of the machine shall be checked before mounting of the wheel to be certain that it does not exceed the maximum operating speed marked on the wheel.
1910.215 (d) Mounting
Compare this number to the spindle speed on the grindermotor
Definitions• "Full revolution clutch" means a type of clutch
that, when tripped, cannot be disengaged until
the crankshaft has completed a full revolution
and the press slide a full stroke.
• "Part revolution clutch" means a type of clutch
that can be disengaged at any point before the
crankshaft has completed a full revolution and
the press slide a full stroke.
1910.217(c)(2) Point of operation guards
• It shall prevent entry of hands or fingers into the
point of operation by reaching through, over,
under or around the guard;
• It shall conform to the maximum permissible
openings of Table O-10;
Table O-10 [In inches]___________________________________________________ | Distance of opening from point | Maximum width of of operation hazard | opening____________________________ |__________________ |
1/2 to 1 1/2 ................. | 1/41 1/2 to 2 1/2 ............... | 3/82 1/2 to 3 1/2 ............... | 1/23 1/2 to 5 1/2 ............... | 5/85 1/2 to 6 1/2 ............... | 3/46 1/2 to 7 1/2 ............... | 7/87 1/2 to 12 1/2 .............. | 1 1/412 1/2 to 15 1/2 ............. | 1 1/215 1/2 to 17 1/2 ..........… | 1 7/817 1/2 to 31 1/2 ............. | 2 1/8
____________________________ |__________________
• Preventing and/or
stopping normal
stroking of the press
if the operator's
hands are
inadvertently placed
in the point of
operation;
Presence sensing device
1910.217(c)(2) Point of operation guards
• Requiring application of both of the operator's hands to machine operating controls and locating such controls at such a safety distance from the point of operation that the slide completes the downward travel or stops before the operator can reach into the point of operation with his hands; or
1910.217(c)(2) Point of operation guards
Presence sensing devices
• The device may not be used on
machines using full revolution clutches!
1910.217(c)(3)(iv)(d) Pull-out device
• Each pull-out device in use shall be visually inspected and checked for proper adjustment at the start of each operator shift, following a new die set-up, and when operators are changed.
• Necessary maintenance or repair or both shall be performed and completed before the press is operated.
• Records of inspections and maintenance shall be kept in accordance with paragraph (e) of this section.
Pullbackdevice
Adjustablewrist
straps
1910.219(b)(1) Flywheels• Flywheels 7 feet or less above
the ground shall be guarded• Sheet, perforated, or expanded
metal or woven wire, or with• Guard rails between 15 to 20
inches from flywheel rim• Toe board if within 12 inches of
floor or extends into a pit• All projections shall be covered
1910.219.(c) Shafting
• Each continuous line of shafting shall be
secured in position against excessive end
movement
• Inclined and vertical shafts* shall be securely
held in position against endwise thrust
*Particularly inclined idler shafts
• All exposed parts of horizontal shafting 7 ft. or less above
the floor shall be guarded (except: runways used for
oiling or running adjustments) by a stationary casing, or
by a trough
• Troughs must enclose sides and top, or sides and
bottom of shafting as location requires
1910.219.(c) Shafting
Projecting end shafts shall
present a smooth edge
and project not more than
1/2 the diameter of the
shaft
Unused key ways shall be
filled up or covered
1910.219.(c) Shafting
1910.219(d) Pulleys• Pulleys, any parts of which are seven feet or less from
the floor or working platform, shall be guarded in
accordance with the standards specified in paragraphs
(m) & (o)
• Pulleys serving as balance wheels (e.g., punch presses)
on which the point of contact between belt and pulley is
more than six feet six inches from the floor or platform
may be guarded with a disc covering the spokes
Distance between pulleys = 2 inches
Belt width = three inches
Guides must be placedin this area
Example
seven ft. minimumFloor
Unguarded portion
Guard
1910.219 (f) Gears sprockets and chains
• Gears, sprockets and
chains shall be guarded by
one of the following
methods:
• By a complete enclosure; or
• By a standard guard as in
paragraph (o), at least
seven feet high, extending
six inches above the mesh
point of the gears; or