RIMBERIO CO

MODULE 8: MACHINE SAFETY

UNIT 2 - OCCUPATIONAL SAFETY

OBJECTIVES

recognize the principles of machine guarding

identify areas where machine guards are needed

enumerate the types of machine guards

differentiate a lock-out from tag-out

WHAT IS A MACHINE?
a tool to make work easier
an assemblage of parts that transmit forces, motion,
and energy in a predetermined manner

WHAT IS A SIMPLE MACHINE?

"mechanical devices"
"building blocks" which the more complicated
machines or compound machines that are made.
THE INDUSTRIAL REVOLUTION
started in the 18th century
modern machines were
conceptualized, created, and used
extensively
all operations are manually done
produce goods faster,
but leads to poor working
conditions and a lot of accidents,
giving rise to a growing concern for
machine safety.
MACHINE SAFETY 4 BASIC AREAS:

adjustment and repair

servicing and maintenance

moving parts

point of operation.
 INCLUDES:

movement of rotating
members,
reciprocating arms,
moving belts,
meshing gears,
TYPES OF HAZARDOUS cutting teeth, and any
MECHANICAL MOTIONS other part that impacts
AND ACTIONS or shears.
 MOTIONS
01 Rotating
02
02 Reciprocating
03
Transversing
 ROTATING
Rotating motion can be dangerous:

even smooth, slowly rotating shafts danger increases when

can catch clothing, projections such as set screws,
through mere skin, contact force an bolts, nicks, abrasions, and
arm or hand into a dangerous projecting keys or set screws are
position. exposed on rotating parts.
Injuries due to contact with rotating
parts can be severe.
Rotating coupling with
projecting bolt

Rotating shaft and

pulley with projecting
key and set screw

Rotating pulley with

spokes and projecting
burr
 NIP POINTS
In-running nip points (or points
where parts of the hand, body, or
clothes can get caught in between)
hazards are caused by the rotating
parts of machinery.

three main types of in-running nips.

1.) Parts rotating in opposite directions

2.) Nip points between rotating and
tangentially moving parts

Some examples are:

the point of contact between a

power transmission belt and its
pulley,
a chain and a sprocket, and a rack
and pinion.
3.) Nip points between rotating and
fixed parts which create a shearing,
crushing, or abrading action.

Examples are:

spoked hand wheels

or flywheels,
screw conveyors, or the
periphery of an abrasive wheel and an
incorrectly adjusted work rest.
RECIPROCATING

can be dangerous:

in back-and-forth or
up-and-down motion,
struck by or caught between a
moving and a stationary part.
 TRANSVERSING
movement in a straight, continuous line

can be dangerous:

struck or caught in a pinch or

shear point by the moving part.
MECHANICAL
ACTIONS
01 CUTTING LIST OF
MECAHANICAL
02 PUNCHING
ACTIONS
03 SHEARING

04 BENDING
01 CUTTING
cutting hazards include:

band saws,
circular saws,
boring or drilling machines,
turning machines (lathes),
or milling machines.
02 PUNCHING
-results when power is applied to
a slide (ram) for the purpose of
blanking, drawing, or stamping
metal or other materials.
 03 SHEARING
-action involves applying power
to a slide or knife in order to trim
or shear metal or other materials.

Machines used for shearing:

mechanically,
hydraulically, and
pneumatically powered shears.
 04 BENDING
-action results when power is
applied to a slide in order to
draw or stamp metal or other
materials.

Equipment used for bending action includes:

power presses,
press brakes, and
tubing benders
 AREAS WHERE MACHINE
GUARDING ARE NECESSARY
''in general, any machine part, function, or process
which may cause injury must be guarded"
 DANGEROUS MOVING PARTS IN THREE
BASIC AREAS REQUIRE SAFEGUARDING:
THE POINT OF OPERATION:
-where work is performed on the material, such as cutting,
shaping, boring, or forming of stock.

POWER TRANSMISSION APPARATUS:

-mechanical system which transmit energy to the part

of the machine performing the work.

OTHER MOVING PARTS:

-which moves while the machine is working.
 we know that machines can cause:

- severe accidents
IMPORTANCE OF - loss of trained and skilled employee/s
MACHINE SAFETY - loss of production
- damage to equipment
- incurring training cost for new employee/s
- overtime cost
- possible litigation
- accident investigation
 Machines can also cause:

IMPORTANCE OF -lost time expense

MACHINE SAFETY - cost of machine down time
- cost of machine damage and repairs
- lost time due to time spent on accident
investigation and other statutory requirements
- loss of production
TYPES OF MACHINE GUARDS

PREVENTING ACCESS

FIXED ENCLOSING GUARDS

part of the machinery which does not

require access, it should be
permanently guarded with fixed
enclosing guards.
 TYPES OF MACHINE GUARDS

PREVENTING DANGEROUS MOTIONS

MOVABLE GUARDS WITH INTERLOCKING SWITCHES

-an operator can be protected by an

inter-lock with the power source which
ensures that whenever the guard door
is not closed, the power is switched off.
 TYPES OF MACHINE GUARDS

PREVENTING DANGEROUS MOTIONS

TWO HAND CONTROLS

-referred to as bi-manual controls)
-Two start buttons have to be operated
at the same time to run the machine.
This ensures that both hands of the
operator are in a safe position and
therefore cannot be in the hazard area.
 TYPES OF MACHINE GUARDS

PREVENTING DANGEROUS MOTIONS

PULLBACK DEVICES
-devices attached to the operator's
hands and connected to the moving
portion of the die
-If properly adjusted, it withdraws the
operator's hands if they are
inadvertently within the point of
operation as the dies close.
 TYPES OF MACHINE GUARDS

PREVENTING DANGEROUS MOTIONS

PHOTOELECTRIC LIGHT CURTAIN

-emit a “curtain” of harmless infrared
light beams in front of the hazard area.
-when beams are blocked, the light
curtain control circuit sends a stop
signal to the guarded machine.
 TYPES OF MACHINE GUARDS

PREVENTING DANGEROUS MOTIONS

LIGHT CURTAIN

-extremely versatile and can guard

areas many meters wide
-using mirrors, light beams can be
diverted all around the corners to
enclose a machine.
 TYPES OF MACHINE GUARDS

PREVENTING DANGEROUS MOTIONS

SAFETY MATS
-used to guard a floor area around a
machine.
-Pressure-sensitive mats are often
used within an enclosed area
containing several machines
 TYPES OF MACHINE GUARDS

PREVENTING DANGEROUS MOTIONS

PRESSURE-SENSITIVE EDGES
-flexible edging strips which can be
fixed to the edge of a moving part such
as a machine table or powered door
where there is a risk of crushing or
shearing hazard
 TYPES OF MACHINE GUARDS

PREVENTING DANGEROUS MOTIONS

EMERGENCY STOPS
-emergency stops must be strategically
placed, in sufficient quantity around the
machine to ensure that there is always
one in reach at the occurrence of
hazard.
 TYPES OF MACHINE GUARDS

PREVENTING DANGEROUS MOTIONS

GRAB WIRE SWITCHES

-convenient and effective
-these devices use a steel wire
rope connected to latching pull
switches so that pulling on the
rope will operate the switch and
cut off the machine power.
 TYPES OF MACHINE GUARDS

PREVENTING DANGEROUS MOTIONS

TELESCOPIC TRIP SWITCHES

-variations include telescopic
antenna switches
-more commonly used as trip devices
on machinery such as pillar drills.
-switch is mounted on the drill and
the antenna is extended down next
to the drill bit
 TYPES OF MACHINE GUARDS

PREVENTING DANGEROUS MOTIONS

ROBOTICS APPLICATION
-depends on the nature of
the machine and the
hazard.
 u ir em e n ts of
Req rds
t iv e sa fe g ua
effec
(R ul e 120 0 )
 01 -Must prevent contact

02 -Must be secured and durable

R ules 03 -Must provide protection against

falling objects

(12 0 0 ) 04 -Must not create new hazards

05 -Must not create interference

06 -Must allow safe maintenance

THE HIERARCHY OF MEASURES

1. Fixed Enclosing Guards

- If access to dangerous parts is not

required, the solution is to protect
them by some type of fixed
enclosing guard.
THE HIERARCHY OF MEASURES

2. Movable (interlocked) guards or protection devices

(e.g., light curtains, presence sensing mats, etc.)

-ensure that access can only be permitted while

the machine is safe.
-interlocked guard doors and/ or trip systems
will be required.
-protective device or system should be based on
the operating characteristics of the machine.
THE HIERARCHY OF MEASURES

3. Protection appliances
(e.g., jigs, holders, push sticks, etc)

-often used in conjunction with guards to

feed a work piece while keeping the
operator’s body away from the danger zone.
THE HIERARCHY OF MEASURES

4. Information, instruction, training and supervision

-Operators must be trained on the hazards

of their work and how to use and maintain
the safety devices as well as give safety
reminders to make them aware all the
time.
THE HIERARCHY OF MEASURES

5. Personal Protective Equipment

-The machinery designer should specify

what sort of equipment is required.
-The use of personal protective equipment is
not the primary safeguarding method but
should complement the measures
 The “Fatal Five” Main Causes of Maintenance Injuries:

Failure to stop equipment

Failure to disconnect from power source

Failure to dissipate (bleed, neutralize) residual energy

Accidental restarting of equipment

Failure to clear work areas before restarting

 Hazardous Energy Sources Found in the Workplace

Electrical - sudden turning on of power source or stored energy in

capacitors

Mechanical

Thermal - such as steam or due to chemical reaction

Potential - stored energy that may be due to gravity, hydraulics,

pneumatics, vacuum or springs
 Types of Lock-out Devices

Plug Locks

Ball Valve Lock-out

Gate Valve Lock-out

Group Lock-out Hasp

Electrical

Hydraulic, pneumatic, and other pressurized systems

 Lock-out Procedure

Alert the operator(s) that power is being disconnected.

Preparation for Shutdown

Equipment Shutdown

Equipment Isolation

Application of Lock-out Devices

Control of Stored Energy

Equipment Isolation-Verification
 Removal of Lock-out

Ensure equipment is safe to operate

Safeguard all employees

Remove lock-out/tag-out devices. Except in emergencies, each

device must be removed by the person who placed it.

Last person to take off lock

Follow checklist - To observe proper LOTO procedures, most firms

maintain some forms of documentation
 a n y m a ch in e p a rt ,
Remembe r t h a t
c es s w h ic h m a n y c au s e
function, o r p ro
sa fe g u a r d e d . W h en t h e
injury must b e
m a c h in e o r a cc i d e n t a l
operation o f a
c a n in ju re t h e o p er a t o r
contact w it h it
e v ic i n i ty , t h e h a za r d s
or others in t h
o n t r o ll e d o r el im in a t ed .
must be eit h er c