Machine Safety Hazards and Safeguarding
Machine Safety Hazards and Safeguarding
2 ©2006 TEEX
Key parts of machines
3 ©2006 TEEX
Key parts of machines
4 ©2006 TEEX
5 ©2006 TEEX
Hazards to be Guarded
6 ©2006 TEEX
Rotating Parts
7 ©2006 TEEX
In-Running Nip Points
8 ©2006 TEEX
Reciprocating Parts
9 ©2006 TEEX
Transverse motion
10 ©2006 TEEX
Cutting action
11 ©2006 TEEX
Punching action
12 ©2006 TEEX
Shearing action
13 ©2006 TEEX
Bending action
14 ©2006 TEEX
Guarding Principles
15 ©2006 TEEX
Part Two:
Safeguarding
There are many ways to safeguard
machines!
4. Feeding/Ejection Methods
Automatic/Semi-Auto feed
Automatic/Semi-Auto
ejection Robotics
Effective
Safeguarding
• Must be in conformity with any
appropriate standards.
• Must not present a hazard in itself
nor create interference.
• Allows safe maintenance
and lubrication.
Effective
Safeguarding
• Must not allow product or objects to fall into
moving parts or onto people.
• Get Buy-in from Operators, PM Tech, Lube and
Maintenance Techs.
First Safeguarding Strategy: Guards
Enclosed
shaft end
Enclosed chain
& sprocket
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.
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
Second Safeguarding Strategy:
Devices
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
Identify the
Action
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
Is this adequate guarding by
location?
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
Robotics
Miscellaneous Aids
concentrations.
greater rates.
damaged or broken.
*Storage and Handling
• Keep cylinders away from physical damage, heat, and tampering.
• Securely chain equipment to prevent falling.
• Store away from flammable and combustible materials.
• Store extra gas and oxygen cylinders separately.
• Store in an upright position.
• Close cylinder valves before moving.
• Protective caps or regulators should be kept in place.
• Roll cylinders on bottom edges to move—Do not drag.
• Allow very little movement when transporting.
*General Gas Welding
Safety Tips
• Inspect equipment for leaks at all connections using approved leak-test solution.
• Inspect hoses for leaks and worn places.
• Replace bad hoses.
• Protect hoses and cylinders from sparks, flames, and hot metal.
• Use a flint lighter to ignite the flame.
• Stand to the side (away from the regulators) when opening cylinder valves.
• Open cylinder valves very slowly to keep sudden high pressures from exploding the
regulators.
• Onlyopen the acetylene cylinder valve ¼-¾ turn; leave wrench in place so the cylinder
can be quickly closed in an emergency.
• Open and light acetylene first, then open and adjust oxygen to a neutral flame.
• Follow the manufacturer's recommendations for shutting off the torch. If the guidelines
are not readily available, the commonly accepted practice is to close the oxygen valve
first.
• When finished, close cylinder valves, bleed the lines to take pressure off regulators,
neatly coil hoses, and replace equipment.
*Personal Protective
Equipment
• Infrared radiation is a cause of retinal burning and cataracts. Protect your
eyes with safety glasses.
• Protect your body from welding spatter and optical radiation hazards with
protective clothing. Such as:
• Woolen or heavy cotton clothing
• Flame-proof apron
• Welding gloves
• Properly fitted clothing that is not frayed or worn
• Shirts should have long sleeves
• Pants should be straight legged and covering shoes when arc welding
• Fire-resistant welder’s cap or shoulder covers are needed for overhead work
• Check protective clothing equipment before each use to make sure it is in
good condition.
• Keep clothes free of grease and oil.
*Proper Ventilation
*Be sure there is adequate ventilation available when welding in confined
areas or where there are barriers to air movement. Natural drafts, fans,
and positioning of the head can help keep fumes away from the welder’s
face.
*VENTILATION IS SUFFICIENT IF**:
• The room or welding area contains at least 10,000 cubic feet for each
welder.
• The ceiling height is not less than 16 feet.
• Cross ventilation is not blocked by partitions, equipment, or other
structural barriers.
• Welding is not done in a confined space.
***If these space requirements are not met then the area needs to be
equipped with mechanical ventilating equipment that exhausts at least
2000 cfm of air for each welder, except where local exhaust hoods or
*Safety in Arc Welding
What is Arc Welding?
95
Fumes and Gases
• Fumes and gases can be
hazardous to your health
• Keep your head out of the
fumes
• Use enough ventilation,
exhaust at the arc, or both,
to keep fumes and gases
from your breathing zone
and the general area
• See product labeling and
MSDS for ventilation and
respirator requirements
96
Electric Shock
• Electric shock can kill
• Do not touch live electrical
parts
– Primary Voltage –230, 460
volt input power
– Secondary Voltage – 6 to
100 volts for welding
• Insulate yourself from
work and ground
• Follow all warnings on Do not make repairs
yourself, alert your
welding equipment instructor immediately!
97
Arc Rays
98
Fire and Explosion Hazards
• Welding sparks can cause
fires and explosions
• Sparks and spatter from the
welding arc can spray up to
35 feet from your work
• Flammable materials should
be removed from the welding
area or shielded from sparks
and spatter
• Have a fire extinguisher ready
• Inspect area for fires 30
minutes after welding
99
Noise
100
Protective Clothing
101
Manual Handling
• Heavy materials which are not safe to handle manually must be handled by
mechanical means and this includes lifting, transporting, stacking, loading and
workplace. There is no doubt that machines can do many tasks more quickly and
5. Incompetent operator.
1. Poorly maintained tools, equipment and machines are prone to accidents due to failure of electrical,
mechanical, and hydraulic systems that can cause serious injury to personnel and property damage.
2. Risk of load failure due to inadequate and incorrect selection of handling tools and machinery.
3. There is a risk of collision with property or personnel due to congested operating space.
4. An untrained and unauthorized machine operator can cause serious accidents and injure other personnel.
5. Risk of material failure during handling due to overloading of machines, tools and equipment.
6. Equipment can fall due to improper loading and transportation, poor rigging and lifting, and over
7. The use of machines without guards presents a high risk of serious injury.
Dos
3. The identification number and the safe working load must be marked on all tools and hoists.
4. Check the functioning of emergency switch, limit switches and over load alarm before actually
5. Estimate the weight, distance, and hazards before lifting the load.
10. Special care should be taken when using the forklift and other portable hydraulic equipment.
11. When lifting the load with slings, make sure that all sharp corners are padded with soft material.
15. Use an appropriate guide rope while lifting and shifting the material.
4. Don’t use the equipment for any other purpose than intended.
6. Don’t load the machines and equipment above its safe working load.
8. Don’t use equipment, tools, hoist and tackles with a missing label or tag.
[Link]’t use chemical contaminated web slings, wire sling or belt without re-inspection.
[Link]’t use a hoist, slings, chains and other lifting tools and tackles that have lost more than
10% of its breaking strength.
Manual Handling Risk Assessme
nt
• A manual handling risk assessment is used to identify hazards that may cause musculoskeletal injuries to workers
when they perform manual handling.
• Similar to a regular risk assessment, a manual handling risk assessment is carried out to identify and evaluate risk
factors.
• Specifically activities of lifting, putting down, carrying, moving, and handling objects during work operations.
• Once a manual handling risk assessment is completed, health and safety workers work to develop processes and
preventive measures.
• Assessing manual handling risks is crucial to protect workers from musculoskeletal disorders (MSDs), increase job
satisfaction, and improve quality of work.
How do you carry out a manual
handling risk assessment?
• Determine the task – Ask the workers how the task is done.
Establish the scope of the manual handling activity and its
important stages. This helps pinpoint the exact moment an injury
may happen.
• Retrieve essential information – This includes technical
information such as load factors of TILE. Load factors to consider
are the weight, size, and shape. Another essential information is
knowing what postures will the worker be in, size of the space,
number of manual handling tasks, and the employee’s technical
knowledge.
• Determine the risk factors – Find out the hazards and risk
factors. Every factor needs evidence on why it’s a potential risk for
the manual handling activity.
• Identify potential improvements – Consult with the
personnel using the objective results of the manual
handling risk assessment. These improvements should
reduce or prevent injury due to manual handling
activity. HSA suggests developing a safe system of work
plan and to use equipment when possible.
• Review the changes – A staff member should do
regular inspections to check the effectiveness of the
implemented improvements. Risk assessments are a
continuous process that should be updated regularly
and revised when necessary.
4 Key Areas of Manual Handling
• When performing manual handling risk assessments,
the assessor mainly focuses on the 4 key areas of
manual handling which is often referred to as the
acronym TILE (Task, Individual, Load, and Environment)
• In some safety circles, “other factors” have been
identified as another key area for evaluating manual
handling risks, turning the assessment method into
TILEO (Task, Individual, Load, Environment, and Other
factors).
• Task: Manual handling tasks that are too strenuous, involves long distances, and
experience, unfamiliar with the job, physical capabilities, and prior history of injuries.
• Load: This risk can be caused by objects that are too heavy, too large, difficult to
grasp or reach, obscures the worker’s view, and unbalanced, unstable or if its contents
can move.
• Other factors: monotonous tasks at a high pace and prolonged work without resting,
among others.
Use Proper Lifting Techniques
• Avoid lifting heavy items above chest height.
• Use the “big toe” test to test the weight of the object. If you can push the
item with your toe, it is safe to move it alone. If not, ask for help.
• When picking up a heavy item from the ground, stand close to the load
with your feet shoulder-width apart.
• Squat down, bending at your knees, keeping your back as straight as
possible.
• Make sure you have a firm grasp on the object before lifting. Use handles,
if available.
• If you are lifting with a partner, coordinate lifting time.
• Once the object is lifted off of the ground, carry it as close to your body as
possible to prevent the object from losing its center of gravity and falling
to the ground.
Solutions for Pulling
• Keep your feet hip-width apart.
• When bending forward to pull, drop your hips and bend
your knees. Concentrate on keeping your core muscles
tight to decrease pressure on your back.
• Always face the object you are pulling. Take
small, backward steps once you start to move.
Push Before Pulling
• It is safer to push rather than pull.
• Keep your back straight and bend your knees.
• Do not twist at your hips to push, but rather keep your
core tight and use your legs and body weight to move
the object.
• Face the load squarely rather than at the top or bottom
of the object.
How to Maintain hooks
1. Before use, hooks must be inspected by an experienced rigger.
2. Remove a hook from service if any of the following are in evidence:
a. Cracks, nicks or gouges
b. Twist exceeding 10 degrees from plane of unbent hook
c. Damage or malfunction to the latch
d. Throat opening exceeding 15 percent
e. Wear exceeding 10 percent of original dimension
f. Damage from heat
g. Unauthorized repairs
[Link], nicks and gouges should be removed by a qualified person. Grind lengthwise,
following the contour of the hook.
[Link] removing the damaged area results in a loss of more than 10 percent of the original
dimension, the hook must be replaced.
[Link] repair, alter or reshape a hook by welding, heating, burning or bending, unless
approved by the hook manufacturer.
[Link] lifting, ensure the hook, not the latch, supports the load. The sling or lifting device
must always be seated properly in the bowl of the hook.
[Link] side load, back load or point load a hook. All reduce hook strength and create an
unsafe condition. Point loading can reduce hook capacity as much as 60 percent.
CLAMP Maintenance
• Routine maintenance keeps your clamps in top condition so they can live their best
– and longest – lives.
• Keeping your clamps clean will extend their life span and ensure your workspace (and final
product) stays free of marks or residue.
• The easiest way to prevent glue from adhering to your clamps is to use a protective layer –
like painter’s tape, packing tape, or parchment paper – between your project and your
clamp
After clamp use
• Once a clamp’s job is finished, remove it from the workpiece immediately.
• After every use, wipe each part of the clamp with a dry cloth.
• Clearing any dust or debris will ensure there’s no buildup, and keeping clamps clean will
help to avoid slippage when working on your next project.
• Any dirt, dust, or debris has the potential to damage your clamp’s working ability and can
even leave marks or stains on the surface of your workpiece.
• You can also regularly buff your bar with paste wax, keeping all the moving parts of your
clamp in top condition and preventing rust development.
Clamp storage
Always store clamps away from heat in a secure, safe, dry place.
When possible, separate clamp heads to prevent them from sticking together.