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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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BASICS OF MACHINE GUARDING
Where Mechanical Hazards Occur
The Point of Operation: Where work is performed
on the material, such as:
Cutting
Shaping
Boring
Forming of stock LATHE
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BASICS OF MACHINE GUARDING
Where Mechanical Hazards Occur
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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BASICS OF MACHINE GUARDING
Where Mechanical Hazards Occur
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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BASICS OF MACHINE GUARDING
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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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions and Actions
Recognition of these hazards is the first steptoward protecting workers from the danger
they present.
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
Motions
Rotating
Reciprocating
Transversing NIP POINT
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Actions
Act ions
Cutting
Punching
Shearing
Bending
SHEARITE
CUTTING BLADES
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
Rotating Motions
- Collars - Couplings - Cams
- Clutches - Flywheels - Shaft ends
- Spindles - Meshing gears - Horizontal shafts
- Vertical shafts
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
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
BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
Reciprocating Motions
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
Reciprocating Motions
MOTIONRECIPROCATING
CAUGHT IN-BETWEEN
OR STRUCK-BY
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
Transversing Motions
TRAVEL
IN-RUNNING NIP POINTS
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Motions
Rotating Motions
NIP POINTS
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Actions
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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BASICS OF MACHINE GUARDING
Hazardous Mechanical Actions
Cutting Actions
BandsawsCircular saws
Boring machines
Drilling machines
Turning machines (lathes)Milling machines
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BASICS OF MACHINE GUARDING
Hazardous Mechanical Actions
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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BASICS OF MACHINE GUARDING
Hazardous Mechanical Actions
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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BASICS OF MACHINE GUARDING
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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BASICS OF MACHINE GUARDING
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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BASICS OF MACHINE GUARDING
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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BASICS OF MACHINE GUARDING
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
BASICS OF MACHINE GUARDING
Protective Clothing and Equipment Considerations:
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BASICS OF MACHINE GUARDING
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.
METHODS OF MACHINE GUARDING
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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
Safeguards Are Grouped Under 5 Classifications:
Guards
DevicesLocations/Distance
Feeding and ejection methods
Miscellaneous aids
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METHODS OF MACHINE GUARDING
GUARDS
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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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
METHODS OF MACHINE GUARDING
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
METHODS OF MACHINE GUARDING
Interlocked Guards:
IMPORTANT
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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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
METHODS OF MACHINE GUARDING
Self-Adjusting Guards:
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METHODS OF MACHINE GUARDING
DEVICES
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METHODS OF MACHINE GUARDING
Devices:
Devices fall into four general types:
Presence-Sensing devices
Pullback devices
Restraint devices
Safety trip controls
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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
Presence-Sensing:
Photoelectric
Radiofrequency
Electromechanical
PRESS PRESS
ACME
PRESSES
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METHODS OF MACHINE GUARDING
Presence-Sensing:
Before beginning the process of
procurement, design, or installation, theequipment manufacturer should be
consulted for advice.
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METHODS OF MACHINE GUARDING
Presence-Sensing:
Photoelectric
Radiofrequency
Electromechanical 20 TON
PRESS PRESS
ACMEPRESSES
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NYLON PULLBACK STRAPS ATTACHED
TO WRISTBANDS
METHODS OF MACHINE GUARDING
Pullback Devices:
Attached to Wrists
Positioning Critical
Adjustment Critical
Maintenance Critical
Training Critical
Must Stop Machine
Immediately!
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METHODS OF MACHINE GUARDING
Restraint Devices:
Uses Cables or Straps
Affixes to Hands
May Need Feeding Tools
Adjustment Critical
Positioning Critical
Maintenance Critical
Training Critical
Must Restrain Body Part
From Hazard!
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METHODS OF MACHINE GUARDING
Safety Trip Controls:
Body Trip Bars
Hand/Arm Trip Bars
Tripwire Cables Positioning Critical
Adjustment Critical
Maintenance Critical
Training Critical
Manual Reset Needed
Must Stop Machine
Immediately!
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20 TON
PRESS PRESS
ACMEPRESSES
METHODS OF MACHINE GUARDING
Two-Hand Control:
Needs Constant Pressure
Needs Concurrent Pressure
Positioning Critical
Adjustment Critical
Maintenance Critical
Training Important
Must Stop Machine
Immediately!
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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
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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METHODS OF MACHINE GUARDING
Mechanical Power Transmission Apparatus Guards:
The only openings usually needed are for:
LubricationAdjustment
Repair
Inspection
300 RPM
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METHODS OF MACHINE GUARDING
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
LOCKOUT TAGOUT OVERVIEW
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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.
LOCKOUT TAGOUT OVERVIEW
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LOCKEDOUT
This Lock/Tag may
only be removed by
NAME: _______________
DEPT : _______________
EXPECTED COMPLETION
DATE: ________________
TIME: _________________
DO NOT OPERATE
DANGER
LOCKOUT TAGOUT OVERVIEW
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LOCKOUT TAGOUT OVERVIEW
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