Machine_Guarding_1.ppt

8/14/2019 Machine_Guarding_1.ppt

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WELCOME

MACHINE GUARDING

CORPORATE SAFETY TRAINING

29 CFR 1910.211-222


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Accident Prevention.

Introduce Machine Guarding and Establish Its

Role in Todays Industry.

Introduce Basic Concepts and Techniques of

Machine Safeguarding.

Provide Machine Safeguarding Skills forMaintenance Workers and Floor Supervisors.

COURSE OBJECTIVES(Continued)


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29CFR - Safety and Health Standards

1910 - Industrial Safety

212 - General Requirements for All Machines213 - Woodworking Machinery

214 - Cooperage Machinery

215 - Abrasive Wheel Machinery

216 - Mills and Calenders in the Rubber Industry

217 - Mechanical Power Presses218 - Forging Machines

219 - Mechanical Power Transmission Apparatus

APPLICABLE REGULATIONS


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INDUSTRY CONSENSUS STANDARDS

ANSI - B11.2 Hydraulic presses

B11.3 Power Press Brakes

B11.10 Metal Sawing MachinesB11.11 Gear Cutting Machines

B11.12 Roll-Forming and Bending Machines

B11.14 Coil Slitting Machines

B11.15 Pipe, Tube, and Shape BendingB11.16 Metal Powder Compacting Presses

B11.17 Horizontal Hydraulic Extrusion

B11.18 Coiled Steel Processing


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ANSI - B11.19 Machine Tools, Safeguarding

B11.20 Manufacturing Systems/Cells

INDUSTRY CONSENSUS STANDARDS


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PROGRAM REQUIREMENTS

Install Machine Safeguards

Review Job Specific Hazards

Implement Corrective Actions

Conduct Hazard Assessments

Conduct Accident Investigations

Provide Training to All Required Employees

Control Workplace Hazards Using PPE As a Last Resort

ALL EMPLOYERS MUST:


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MACHINE GUARDING IS

IMPORTANT

Improve Quality.

Improve Absenteeism. Maintain a Healthier Work Force.

Reduce Injury and Illness Rates.

Acceptance of High-Turnover Jobs.

Workers Feel Good About Their Work.

Reduce Workers Compensation Costs.

Elevate SAFETY to a Higher Level of Awareness.

A GOOD PROGRAM WILL HELP:


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PROGRAM IMPLEMENTATION

DEDICATION PERSONAL INTEREST

MANAGEMENT COMMITMENT

IMPLEMENTATION OF A MACHINE GUARDING

PROGRAM REQUIRES:

NOTE:

UNDERSTANDING AND SUPPORT FROM THE WORK FORCE

IS ESSENTIAL, WITHOUT IT THE PROGRAM WILL FAIL!


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MANAGEMENTS ROLE

Considerations:

1. Suppor t the Machine Guarding Effort.

2. Ensure Your Support Is Visible.

3. Get Involved.

4. Attend the Same TrainingAs Your Workers.

5. Insist on Periodic Follow-up & Program Review.

6. Implement Ways to Measure Effectiveness.


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THE SUPERVISORS ROLE

Considerations:

1. Treat All Near-Misses As an Accident.

2. Get Inv olv ed inthe Guarding of Machines.3. Complete the Paperwo rk(Work Orders, Policy

Changes, Etc.) To Make Guarding Improvements.

4. Get Your Workers Involved.

5. Never Ridicule Any Injury or Near Miss.6. Be Professional - You Could Save a Life Today.

7. Attend the Same TrainingAs Your Workers.

8. Fol low-upon the Actions You Took.


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THE EMPLOYEES ROLE

Considerations:

1. Report All Accidents and Near-Misses Immediately.

2. Contr ibuteto Make Corrective Actions.

3. Always Provide Complete and Accurate Information.

4. Report All Machine Guarding Problems or Deficiencies

5. Fol low-upWith Any Additional Information.


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Hold Regular Guarding Accident Review Meetings.

Document Meetings.

Encourage Employee Involvement.

Bring Employee Guarding Complaints, Suggestions,or Concerns to the Attention of Management.

Provide Feedback Without Fear of Reprisal.

Analyze Statistical Data Concerning Accidents, andMake Recommendations for Corrective Action.

Follow-up Is Critical.

SAFETY COMMITTEE

Safety Committees Should:


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REMEMBER

Any machine part, function, or process

which may cause injury must be

safeguarded. When the operation of amachine or accidental contact with it can

injure the operator or others in the vicinity,

the hazards must be either controlled or

eliminated.


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BASICS OF MACHINE GUARDING

Where Mechanical Hazards Occur

The Point of Operation:

Power Transmission Apparatus:

Other Moving Parts:


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The Point of Operation: Where work is performed

on the material, such as:

Cutting

Shaping

Boring

Forming of stock LATHE


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Power Transmission Apparatus: All components

of the mechanical system which transmit energyto the part of the machine performing the work.

300 RPM


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Other Moving Parts: Any part of the machine

which moves while the machine is working.

Rotating parts

Feed mechanisms

Reciprocating parts

Transverse moving parts Auxiliary parts of the machine


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Hazardous Mechanical Motions and Actions

A wide variety of mechanical motions and actions

may present hazards to the worker: Rotating members

Reciprocating arms

Moving belts

Meshing gears Cutting teeth

Any parts that impact or shear


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Hazardous Mechanical Motions and Actions

Recognition of these hazards is the first steptoward protecting workers from the danger

they present.


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Hazardous Mechanical Motions

Motions

Rotating

Reciprocating

Transversing NIP POINT


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Hazardous Mechanical Actions

Act ions

Cutting

Punching

Shearing

Bending

SHEARITE

CUTTING BLADES


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Rotating Motions

- Collars - Couplings - Cams

- Clutches - Flywheels - Shaft ends

- Spindles - Meshing gears - Horizontal shafts

- Vertical shafts


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Rotating Motions

Rotating motions can grip clothing, and through

mere skin contact force a limb into a dangerous

position. The danger increases when projections

such as set screws, bolts, nicks, abrasions, and

projecting keys or set screws are exposed onrotating parts.


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MOTIONRECIPROCATING

NIP POINT NIP POINT



Reciprocating Motions


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Reciprocating Motions

MOTIONRECIPROCATING

CAUGHT IN-BETWEEN

OR STRUCK-BY


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Transversing Motions

TRAVEL

IN-RUNNING NIP POINTS


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Rotating Motions

NIP POINTS


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Cutting Actions

- Rotating motions- Reciprocating motions

- Transversing motions

The danger of cutting action exists at the point of

operation where finger, arm and bodily injuries canoccur and where flying chips or scrap material can

strike the head, particularly in the area of the eyes or

face.


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Cutting Actions

BandsawsCircular saws

Boring machines

Drilling machines

Turning machines (lathes)Milling machines


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Punching Actions

Power pressesIron workers

20 TON

PRESS PRESS

ACMEPRESSES

The principle hazard occurs

at the point of operation

where stock is inserted, held

or withdrawn.


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Shearing/Bending Actions

Mechanical shearsHydraulic shears

Pneumatic shears

DANGERCUTTING EDGE

PRESS PRESS

SHEARITEPOWER SHEARS

SHEAR TERROR

The principle hazard occurs

at the point of operationwhere stock is inserted, held

or withdrawn.


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Requirements for Safeguards

Be securely attached

Create no new hazardsWithstand operational conditions

Allow for safe routine maintenance

Allow for safe operator adjustments

Withstand environmental conditionsProvide protection from falling objects

Prevent contact with hazardous conditions

Create no interference in the conduct of work


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Nonmechanical Hazard Considerations:

Power sources are potential sources of danger

How will guarding affect equipment operation?Ensure proper grounding of systems

Replace frayed, exposed , or old wiring

Consider effects of - High pressure systems

- Extreme temp. conditions

- Pulsation, vibration, or leaks

- Noise or unwanted sounds

- Cutting fluids and coolants

HOT SURFACE


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Operator Training Considerations:

Provide instruction and or hands-on training

Discuss the purpose of safeguardsCover associated hazards thoroughly

Involve guard designers in the training

Describe how to proper lyuse safeguards

Describe how safeguards provide protection

Describe circumstances for safeguard removal

Explain what to do if safeguards are damaged

Explain what to do if safeguards are missing


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Operator Training Considerations:

Defeating, altering, or removing safeguardscan cause injury to co-workers and can leave

the person performing such actions liable

under the OSHA Act of 1970.


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ENGINEERING CONTROLS FIRST CHOICEWork Station Design Tool Selection and Design

Process Modification Mechanical Assist

ADMINISTRATIVE CONTROLS SECOND CHOICETraining Programs Job Rotation/EnlargementPacing Policy and Procedures

PERSONNEL PROTECTIVE EQUIPMENT LAST CHOICEGloves WrapsShields Eye ProtectionNon-Slip Shoes Aprons


Protective Clothing and Equipment Considerations:


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Protective Clothing and Equipment Considerations:

Appropriate for the particular hazard(s)

Maintained in good conditionProperly stored when not in use

Kept clean, fully functional, and sanitary


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METHODS OF MACHINE GUARDING

Guarding Method Dependant on:

Type of material

Type of operationMethod of handling

Size or shape of stock

Physical layout of the work area

Production requirements or limitations


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Manufacturers Recommendation:

Before beginning the process of guard

procurement, design, or installation, the

equipment manufacturer should be

consulted for advice.



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Generally:

Power transmission apparatus is best protected

by fixed guards that enclose the danger areas

Point of operation hazard guarding will vary


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Safeguards Are Grouped Under 5 Classifications:

Guards

DevicesLocations/Distance

Feeding and ejection methods

Miscellaneous aids


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GUARDS


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Guards:

Guards are barriers which prevent access to

danger areas, there are four general types:

Fixed guards

Interlocked guards

Adjustable guards

Self-Adjusting guards


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Fixed Guards:

Fixed guards are a permanent part of the

machine and not dependent upon moving partsto perform its intended function.


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Fixed Guards:

ADVANTAGES

Can be constructed to suit many different applicationsIn-plant construction is often possible

Can provide maximum protection

Usually requires minimum maintenance

Can be suitable to high production operations

Can be suitable to high repetition operations


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Fixed Guards:

LIMITATIONS

May interfere with visibility Can be limited to specific operations

Machine adjustments and repair often require guard

removal, thereby necessitating other means of protection

for maintenance personnel


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Interlocked Guards:

Interlocked guards are designed to automatically

shut off or disengage the machine if the guard is

opened or removed

AUTOMATIC

AUDIBLE ALARM

AUTOMATIC

VISUAL ALARM


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Interlocked guards may use:

Electrical power

Mechanical power

Hydraulic power

Pneumatic power


Interlocked Guards:

OR ANY COMBINATION OF POWER SOURCES


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Interlocks should not prevent inching by

remote control if required

Replacing guards should not automatically

restart the machine


Interlocked Guards:

IMPORTANT


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Interlocked Guards:

ADVANTAGES

Can provide maximum protection Allows access to machine for removing jams without time

consuming removal of fixed guards

LIMITATIONS

Requires careful adjustment and maintenance May be easy to disengage jams


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Adjustable Guards:

Typically adjusted by the operator

Accommodate various sizes of stock

May require additional operator training

Adjustable guards are typically used on:

Bandsaws

Tablesaws

Power presses

Routers

Similar equipment


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Adjustable Guards:

ADVANTAGES

Can be constructed to suit many specific applicationsCan be adjusted to admit varying sizes of stock

LIMITATIONS

Hands may enter danger area

Protection may not be complete at all times

May require frequent maintenance and or adjustment

The guard can be defeated by the operator

May interfere with visibility


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Self-Adjusting Guards:

Adjusts automatically to the work

Accommodate various sizes of stock

May require additional operator training

Self-Adjusting guards are typically used on:

Radial arm saws

Tablesaws

Circular saws Routers

Jointers

Similar equipment


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ADVANTAGES

Off-the-shelf guards are often commercially available

LIMITATIONS

Protection may not be complete at all times

May require frequent maintenance and or adjustment

May interfere with visibility


Self-Adjusting Guards:


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DEVICES


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Devices:

Devices fall into four general types:

Presence-Sensing devices

Pullback devices

Restraint devices

Safety trip controls


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Devices:

Devices may perform one of several function:

Stop a machine if a body part is in danger Restrain or withdraw a hand if it is in danger

Require activation by the use of both hands

Provide a barrier synchronized to the operation


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Presence-Sensing:

Photoelectric

Radiofrequency

Electromechanical

PRESS PRESS

ACME

PRESSES


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Presence-Sensing:

Before beginning the process of

procurement, design, or installation, theequipment manufacturer should be

consulted for advice.


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Presence-Sensing:

Photoelectric

Radiofrequency

Electromechanical 20 TON

PRESS PRESS

ACMEPRESSES


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NYLON PULLBACK STRAPS ATTACHED

TO WRISTBANDS


Pullback Devices:

Attached to Wrists

Positioning Critical

Adjustment Critical

Maintenance Critical

Training Critical

Must Stop Machine

Immediately!


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Restraint Devices:

Uses Cables or Straps

Affixes to Hands

May Need Feeding Tools

Adjustment Critical



Training Critical

Must Restrain Body Part

From Hazard!


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Safety Trip Controls:

Body Trip Bars

Hand/Arm Trip Bars

Tripwire Cables Positioning Critical

Adjustment Critical


Training Critical

Manual Reset Needed

Must Stop Machine

Immediately!


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20 TON

PRESS PRESS

ACMEPRESSES


Two-Hand Control:

Needs Constant Pressure

Needs Concurrent Pressure


Adjustment Critical


Training Important

Must Stop Machine

Immediately!


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Location/Distance Safeguarding:

Position Dangerous Areas of Machines So That They Are

Not Assessable During Normal Operations. Examples

Include:

Position Hazard Areas Against a Wall

Locate Hazards Out of Reach of Operators

Add Enclosures or Fences to Restrict Access

Design Stock Feeding Openings Away From Hazards

Position the Operators Control Station Away From Hazards


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Feeding and Ejection Methods:

Automatic Feeds - Fed From Rolls, Indexed by Machine

Semiautomatic Feeds - Fed by Chutes, Movable Dies, DialFeed, Plungers, or Sliding Bolsters

Automatic Ejection - Air or Mechanical Ejection

Semiautomatic Ejection - Air or Mechanical Ejection Initiatedby The Operator

Robotics - Perform Work Usually Performed by Operator


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Feeding and Ejection Methods:

Manufacturers Should Be Consulted to Determine:

Feeding and Ejection Add-on Options

Latest Technology Available

Best Available Technology

Operator Training Requirements

Maintenance Staff Training Requirements

Cost Estimates for Upgrades

Feasibility Assessment Information


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Miscellaneous Aids:

Examples of Possible Applications:

Awareness Barriers - (Not adequate for continuous hazards)

Color coding of hazard areas

Signage

Shields (i.e. splash, eye protective, thermal etc.)

Holding and Positioning Tools


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Guard Construction:

Many Machines Come With Safeguards

Many Older Machines Now Have Safeguards Available

Manufacturers Are Increasingly More Concerned With Liability

Companies Not Specialized in Guarding Issues


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Builder Designed and Installed Guards:

Usually Conform to Design and Function of Machine Better

Can Be Designed to Strengthen the Machine in Some Way orto Serve Some Additional Functional Purposes


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User Designed and Installed Guards:

Often the Only Practical Solution for Older Equipment

Can Be Designed and Built to Fit Unique & Changing Situations

Can Be Installed on Individual Dies and Feeding Mechanisms

Can Help Promote Safety Consciousness in the Workplace

Sometimes Do Not Conform As Well As BuilderDesigned

Depending on Talent and Resources May Be Poorly Designed


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Point-of-Operations Guards :

Complicated by the Number and Complexity of Machines in Use

Must Fully Safeguard the Employee

Must Allow Production to Continue

Hazard Analysis Is Usually Required

If Poorly Designed, Built, or Installed Guards May Create aHazard Rather Than Eliminating One.

Defined as: The area on a machine where work is actually

performed upon the material being processed.


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Mechanical Power Transmission Apparatus Guards:

The only openings usually needed are for:

LubricationAdjustment

Repair

Inspection

300 RPM


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Guard Material:

Under Many Circumstances, Metal Is the Best Material for

Guards. Guard Framework Is Usually Made From Structural

Shapes, Pipe, Bar, or Rod Stock. Filler Material Generally IsExpanded or Perforated or Solid Sheet Metal or Wire Mesh.

It May Be Feasible to Use Plastic or Safety Glass Where

Visibility Is Required.

Guards Made of Wood Generally Are Not RecommendedBecause of Their Flammability and Lack of Durability and

Strength. However, in Areas Where Corrosive Materials Are

Present, Wooden Guards May Be the Better Choice.


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29CFR - SAFETY AND HEALTH STANDARDS

1910 - GENERAL INDUSTRY

147 - LOCKOUT TAGOUT STANDARD

LOCKOUT TAGOUT OVERVIEW

29CFR - 1910 - 147


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TITLE - CONTROL OF HAZARDOUS ENERGY

SEPTEMBER 1, 1989 - FINAL RULE ISSUED

JANUARY 2, 1990 - FINAL RULE TOOK EFFECT



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Authorized Employee

The Person Who Locks or Tags OutMachines To Perform Servicing

or Maintenance.

Affected Employee

An Employee Whose Job Requires Him or Her To Operate or Use a

Machine or Piece of Equipment On Which Servicing or Maintenance

Is Being Performed.



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LOCKEDOUT

This Lock/Tag may

only be removed by

NAME: _______________

DEPT : _______________

EXPECTED COMPLETION

DATE: ________________

TIME: _________________

DO NOT OPERATE

DANGER



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1. Covered If an Employee Must Remove or Bypass Guards

or Devices

2. Covered Where Employees Are Required to Put A Body

Part in a Machine Process Area

3. Covered Where Employees Are Required to Put A Body

Part in a Machine Having a Danger Zone

Normal Operations


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REMEMBER, YOUCONTROL YOUR FACILITY OR AREA!

REVIEWTHEIR PROCEDURES WITH THEM BEFORE

STARTING THE JOB!

DETERMINE THEIR SAFETY PERFORMANCE RECORD!

DETERMINE WHO IS IN CHARGE OF THEIR PEOPLE!

DETERMINE HOW THEY WILL AFFECT YOUR EMPLOYEES!

TIPS FOR USING CONTRACTORS

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