Machinery Safety
description
Transcript of Machinery Safety
![Page 1: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/1.jpg)
Machinery Safety
Machine Guarding for Warehouse and Maintenance Workers
What is wrong with this picture?
This material was produced and revised (using information from OSHA’s website, publications and CDC website) under grant
[SH20856SH0] from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor
does mention of trade names, commercialproducts, or organizations imply endorsement by the U.S. Government
![Page 2: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/2.jpg)
2
The Problem• Workers who operate and maintain
machinery each year suffer approximately– 18,000 amputations, lacerations, crushing
injuries, and abrasions– 800 deaths
OSHA 7100
![Page 3: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/3.jpg)
3
The Problem: Machinery Associated with Amputations
1. Mechanical power presses2. Power press brakes3. Powered and non-powered conveyors4. Printing presses5. Roll-forming and roll-bending machines6. Shearing machines7. Food slicers8. Meat grinders9. Meat-cutting band saws10.Drill presses11.Milling machines12.Grinding machines
![Page 4: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/4.jpg)
4
Causes of Machine Incidents
• Reaching in to “clear” equipment• Not using Lockout/Tagout• Unauthorized person doing
maintenance or using the machines• Missing or loose machine guards• Lack of training
![Page 5: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/5.jpg)
5
Prevention
• Any machine part, function, or process which may cause injury must be safeguarded.
• Where the operation of a machine can injure the operator or other workers, the hazard must be controlled or eliminated
![Page 6: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/6.jpg)
6
OSHA CitationsFiscal Year 2010
• Machines, general requirements (1910.212)– 10th most frequently cited standard– 5th ranked standard in assessed penalties
• Lockout/Tagout (1910.147)– 5th most frequently cited standard– 4th ranked standard in assessed penalties
![Page 7: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/7.jpg)
Machine Guarding
OSHA’s 1910 Subpart O
![Page 8: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/8.jpg)
8
Objectives
• Explain the general requirements for guarding the hazards of machines
• Describe precautions to be taken around machinery
• Identify important terms associated with guarding machinery
![Page 9: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/9.jpg)
9
Machine Guarding
Group Worksheet
![Page 10: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/10.jpg)
10
3 Basic Areas To Be Safeguarded
• Point of Operation• Power Transmission Apparatus• Other Moving Parts
![Page 11: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/11.jpg)
11
Hazard Identification
• Motions– Rotating (including in-
running nip points)– Transverse– Reciprocating
• Actions– Cutting– Punching– Shearing– Bending
![Page 12: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/12.jpg)
12
Rotating Motion
• Hazard – Machinery grips and moves clothing, hair and body parts into danger area
• Danger increases when projections are present – Screws, bolts,
nicks, abrasions, etc.
![Page 13: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/13.jpg)
13
Rotating Parts with Projections
Rotating pulley with spokes and projecting burr on face of pulley Rotating coupling with
projecting bolt heads
Rotating shaft and pulleys with projecting key and set screw
BURR
OSHA 3067
![Page 14: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/14.jpg)
14
In-Running Nip Points
Nip Point
Nip Point
Nip Point
Nip PointNip Point
Nip Point
OSHA 3067
![Page 15: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/15.jpg)
15
In-Running Nip Points
Nip Point
Nip Point
Nip Point
Nip Points
OSHA 3067
![Page 16: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/16.jpg)
16
Transverse Motion• Movement in a straight, continuous line
around rotating component • Hazard may strike or catch employee a
pinch or shear point
OSHA 3067
![Page 17: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/17.jpg)
17
Reciprocating Motion• Back and forth / up and down• Hazard - Caught between moving part
and stationary object
OSHA 3067
![Page 18: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/18.jpg)
18
Bending Actions
• Power applied to slide to draw or stamp metal or other materials in a bending motion
• Example: Press Brake, Tube Benders
OSHA 3067
![Page 19: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/19.jpg)
19
Bending ActionsPress Brake
![Page 20: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/20.jpg)
20
Punching Actions
• Power applied to slide ram for purpose of blanking, drawing or stamping
• Example: Power press
![Page 21: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/21.jpg)
21
Shearing Actions• Apply power to slide or knife to trim or
cut
OSHA 3067
![Page 22: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/22.jpg)
22
Shearing ActionsSheet Metal Shear
OSHA 7100
![Page 23: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/23.jpg)
23
Cutting Actions
• Rotating, reciprocating or transverse motion
• Examples: Band saw, circular saws, lathes, drills
OSHA 3067
![Page 24: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/24.jpg)
24
Classification of Safeguards
• Guards• Devices• Location/distance• Automatic/semiautomatic feed or
ejection• Miscellaneous
![Page 25: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/25.jpg)
25
Types of Guards• Fixed
– Provide secure barrier• Interlocked
– Cuts off power when guard opened or removed• Adjustable
– Barrier manually moved to accommodate stock or operation
• Self-adjusting– Barrier automatically moves to accommodate
operation
![Page 26: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/26.jpg)
26
Fixed Guards
• Advantages– Maximum
protection– Variety of
applications– In-house
fabrication– Low cost &
maintenance
• Disadvantages– Poor visibility– Must remove for repairs
requiring LOTO
OSHA 3067
![Page 27: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/27.jpg)
27
Interlocked Guards
• Switch that when opened stops power• Advantage
– Maximum protection– Portion of guard easily removed for access
• Disadvantage– Can be overridden by employee– High cost– Maintenance required
![Page 28: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/28.jpg)
28
Adjustable Guards
• Advantage– Flexibility– In-house fabrication
• Disadvantage– Not maximum
protection– Rely on worker to
properly position– May prohibit easy
access
Bandsaw blade adjustable guard
OSHA 3067
![Page 29: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/29.jpg)
29
Self-adjusting Guards
• Advantage– Employee not
involved in positioning– Readily available
• Disadvantage– Not maximum
protection– May need frequent
fine tuningOSHA 3067
![Page 30: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/30.jpg)
30
Self-adjusting GuardTable Circular Saw
OSHA 10 Hour GI Presentation
![Page 31: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/31.jpg)
31
Devices
• Presence sensing– Photoelectrical– Radiofrequency– Electromechanical
• Safety Controls– Safety trip control– Two-hand control/trip
• Gates
![Page 32: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/32.jpg)
32
Presence-Sensing Device
www.osha.gov/SLTC/etools/machineguarding/presses/psd.html
![Page 33: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/33.jpg)
33
Two-Hand Control
.
• Requires constant, concurrent pressure to activate the machine
• The operator’s hands are required to be at a safe location (on control buttons) and at a safe distance from the danger area while the machine completes its closing cycle
OSHA 10 hour
![Page 34: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/34.jpg)
34
Safety Tripwire Cables
• Device located around the perimeter of or near the danger area
• Operator must be able to reach the cable to stop the machine
OSHA 10 hour
![Page 35: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/35.jpg)
35
Gate• Movable barrier device which protects the operator at the
point of operation before the machine cycle can be started
• If the gate does not fully close, machine will not function
Gate Open Gate ClosedOSHA 10 hour
![Page 36: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/36.jpg)
36
GateVertical Downstroke Baler
www.cdc.gov/niosh/hc14.html
![Page 37: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/37.jpg)
37
Safeguard by location/distance
• Position dangerous parts of machine in inaccessible areas during normal operation– Moving parts more
than 7 feet above floor– Controlled access
room– Control station at safe
distance from machine
OSHA 10 hour
![Page 38: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/38.jpg)
38
Feeding and Ejection Methods
• Automatic / semiautomatic feed• Automatic / semiautomatic ejection• Robots
![Page 39: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/39.jpg)
39
Automatic Feed(shown on power press)
Transparent EnclosureGuard
Stock FeedRoll
Danger
Area
Completed Work
OSHA 3170
![Page 40: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/40.jpg)
40
Robots
• Machines that load and unload stock, assemble parts, transfer objects, or perform other tasks
• Best used in high-production processes requiring repeated routines where they prevent other hazards to employees
Press
FixedBarrier
Robot
StockConveyor
OSHA 3170
![Page 41: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/41.jpg)
41
Miscellaneous
• Awareness Barriers• Protective Shields• Hand tools
![Page 42: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/42.jpg)
42
Awareness Devices• Alert employees to hazard
– Signs– Awareness signals
(audible or visual)
– Awareness barriers (allows access to machine danger areas, but is designed to contact employee, creating an awareness that employee is close to danger point)
![Page 43: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/43.jpg)
43
Protective ShieldsThese do not give complete protection from machine hazards, but do provide some protection from flying particles, splashing cutting oils, or coolants.
![Page 44: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/44.jpg)
44
Holding Tools
• Used to place and remove stock in the danger area
• Not to be used instead of other machine safeguards, but as a supplement
OSHA 3067
![Page 45: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/45.jpg)
45
Requirements for Safeguards
• Prevent contact• Secure, tamper-resistant, and durable• Protect from falling objects• Create no new hazards• Create no interference• Allow safe lubrication and maintenance
![Page 46: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/46.jpg)
46
Requirements of Safeguards
• Fixed guards should used whenever possible
• Machines designed for fixed location shall be secured to prevent movement
• Conform to ANSI and OSHA requirements
![Page 47: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/47.jpg)
47
Machine Safety Responsibilities
• Management– ensure all machinery is properly guarded
• Supervisors– train employees on specific guard rules in their
areas– ensure machine guards remain in place and are
functional– immediately correct machine guard deficiencies
![Page 48: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/48.jpg)
48
Machine Safety Responsibilities
• Employees– do not remove guards unless machine is
locked and tagged– report machine guard problems to
supervisors immediately– do not operate equipment unless guards are
in place
![Page 49: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/49.jpg)
49
Employee Training • Hazards associated with particular machines• How the safeguards provide protection and the
hazards for which they are intended• How and why to use the safeguards • How and when safeguards can be removed and by
whom • What to do if a safeguard is damaged, missing, or
unable to provide adequate protection
![Page 50: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/50.jpg)
50
Some Examples of Machine Guarding
![Page 51: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/51.jpg)
51
Abrasive Wheel MachineryImproper Work Rest and Tongue
![Page 52: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/52.jpg)
52
Abrasive Wheel MachineryWork rests on offhand grinding machines must be kept adjusted closely to the wheel with a maximum opening of 1/8-inch to prevent the work from being jammed between the wheel and the rest, which may result in wheel breakage.
OSHA 3067
![Page 53: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/53.jpg)
53
Abrasive Wheel MachineryThe distance between the wheel periphery and the adjustable tongue must never exceed 1/4-inch.
OSHA 10 hour
![Page 54: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/54.jpg)
54
Abrasive Wheel Machinery• When installing new abrasive wheel
– Inspect for condition and compatibility– Conduct ring test
Click on picture for video
OSHA 7100
![Page 55: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/55.jpg)
55
Abrasive Wheel Machinery
Checklist
![Page 56: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/56.jpg)
56
Power-Transmission Apparatus
Power-transmission apparatus (shafting, flywheels, pulleys, belts, chain drives, etc.) less than 7 feet from the floor or working platform must be guarded.
Unguarded beltand pulley
OSHA 10 hour
![Page 57: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/57.jpg)
57
Portable Circular Saws
Stock
Guard
Blade
Guard Retracted
OSHA 3067
![Page 58: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/58.jpg)
58
Table Saw
• On/off switch should be located at knee height -- so you can turn off machine while your hands are on the material
• Blade must be guarded• Automatic brake a
good safety feature
Guard
www.osha.gov/SLTC/etools/machineguarding/saws/tablesaws.html
![Page 59: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/59.jpg)
59
Table Saw -- Kickback
• Back of the blade, as it rises out of table, is the critical “kickback zone”
• Material tends to be lifted off of the table• If wood moves sideways at this point, it
will be caught by the rotational motion and will be flung back toward the operator!
![Page 60: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/60.jpg)
60
Preventing Kickbacks
• Use a splitter or wedge inserted into the saw kerf to separate material
• Make sure rip fence is perfectly parallel to the blade
![Page 61: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/61.jpg)
61
Table Saw - Splitters• Metal fins, secured behind and in line with the
blade -- must move freely & not stick open• Anti-kickback pawls also attached
Splitter & anti-kickback pawls
www.orosha.org/pdf/pubs/2980.pdf
![Page 62: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/62.jpg)
62
Table Saw - Push Sticks
Push stick
www.osha.gov/SLTC/etools/machineguarding/saws/tablesaws.html
![Page 63: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/63.jpg)
63
Radial Arm Saw
Anti-Kickback Device
Lower Blade Guard
![Page 64: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/64.jpg)
64
Machinery: General Safety Principles
• Securely fasten equipment to eliminate movement or “walking”
• No loose clothing, long hair, jewelry, or gloves around rotating machine parts
• Respect machine guards• Keep electrical cords and plugs intact• Inspect machinery before each use
![Page 65: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/65.jpg)
65
Machinery: General Safety Principles
• Do not leave machines running and unattended
• Never attend to brush debris from the table surface while the machine is running
• An active brake mechanism adds greatly to safety
• Easily reached “off” switch increases safety
![Page 66: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/66.jpg)
66
Machine Guarding
Checklist
![Page 67: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/67.jpg)
Case Studies
![Page 68: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/68.jpg)
Quiz
![Page 69: Machinery Safety](https://reader036.fdocuments.in/reader036/viewer/2022062309/56815b74550346895dc96e3b/html5/thumbnails/69.jpg)
Resources• OSHA Machine Guarding Website
http://www.osha.gov/SLTC/machineguarding/index.html
• OSHA Machine Guarding eToolhttp://www.osha.gov/SLTC/etools/machineguarding/index.html
• OSHA Amputation Fact Sheethttp://www.osha.gov/OshDoc/data_General_Facts/amputation-factsheet.pdf
• Safeguarding Equipment and Protecting Employees from Amputationshttp://www.osha.gov/Publications/osha3170.pdf
69