Machine Guarding

Limits of machine – Use limits
• Use limits
– Personnel operating the machine
 how competent/what age?
 any impairments –
visual/hearing/physical?
 male/female?
– Other personnel in the vicinity
 other operators
 non-operator employees
 non-employees
TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 8

Limits of machine – Space limits
• Space limits
– Physical limits of the machine to
be assessed
– Range of movement
– Space requirements for
operation and maintenance

Limits of machine – Time limits
• Time limits
– ‘Life limit’ – general wear and tear
– Maintenance intervals
– Housekeeping

Hazard identification
Mechanical

Risk reduction
DESIGN
INITIAL OUT PROTECTIVE SAFETY INFORMATION TRAINING
DESIGN HAZARDS MEASURES CONTROLS
ORGANISATION
RISK
SAFE SYSTEMS
REDUCTION RISK OF WORK
HIGH REDUCTION
RISK
REDUCTION RISK
RISK
REDUCTION
REDUCTION
RISK
LOW

Design out the hazards
• Mechanical risk
reduction involves
removing or reducing
to a minimum trap, nip
or pinch points.

Machinery Safety
Presented by Paul Laidler

Machinery Division
• Assistance in meeting the requirements of machinery safety legislation

– Machinery, Low Voltage and Electro Magnetic Compatibility (EMC)
Directives
– Work Equipment Directive – PUWER and LOLER
• Comprehensive risk assessments
• Guidance on technical file construction and declaration of
conformity/incorporation
• Pre-purchasing CE Audits
• Safety Related Control System validation

Formal Training
• 3 University Certificate Courses in Professional Development:

– European Machine Safety Requirements
– Electrical Machinery Safety
– Functional Safety
• Accredited by the University of Teesside

Machinery Safety Engineering Services
• Engineering design
– Site survey and function design specification
– Factory acceptance test
– Installation and commissioning
• Machine guarding
– Design, manufacture and installation of machine guarding and Safety
Related Control Systems
– Solutions include perimeter guarding, light curtains, scanners, interlocking
etc.

Hierarchy Of Control
Control Measures
• Design the hazard out.

• Remove the need for man machine interface.
• Design in safeguards.
• Reduce the possibility of occurrence.
• Reduce the degree of harm.
• Warn and inform (but only if you can achieve adequate safety).

Risk reduction
INITIAL DESIGN PROTECTIVE SAFETY INFORMATION TRAINING

DESIGN OUT MEASURES CONTROLS
HAZARDS ORGANISATION
RISK
SAFE SYSTEMS
HIGH REDUCTION
RISK
REDUCTION RISK
RISK
REDUCTION
REDUCTION
RISK
LOW

Protective measures (Guarding)
To prevent access

Risk assessment
1. Determine the limits of the machine
2. Hazard identification
3. Risk estimation

Determine the limits of the machine
• Use limits
• Space limits
• Time limits

To reduce risks from debris and ejected parts

To reduce risks of damage from outside (e.g. FLT’s)
Barriers

Risk reduction
DESIGN
INITIAL PROTECTIVE SAFETY INFORMATION TRAINING
OUT
DESIGN MEASURES CONTROLS
RISK
SAFE SYSTEMS
HIGH REDUCTION
RISK
REDUCTION RISK
RISK
REDUCTION
REDUCTION
RISK
LOW

Risk reduction
DESIGN
INITIAL PROTECTIVE SAFETY INFORMATION TRAINING
OUT
DESIGN MEASURES CONTROL
S
RISK
SAFE SYSTEMS
HIGH REDUCTION
RISK
REDUCTION RISK
RISK
REDUCTION
REDUCTION
RISK
LOW

Machinery Directive EHSR’s
• 1.4.1 General requirements
• Guards and protective devices must:

− be of robust construction,
− be securely held in place,
− not give rise to any additional hazard,
− not be easy to by-pass or render non-operational,
− be located at an adequate distance from the danger zone,
− cause minimum obstruction to the view of the production process,

• 1.4.1 General requirements cont
• In addition, guards must, where possible, protect against the ejection or

falling of materials or objects and against emissions generated by the
machinery.

Training, Organisation and SOP
Organisation includes:
– a coherent Health and Safety structure,
– a management structure with clearly defined responsibilities,
– an involved workforce,
– safe systems of work.

Legislation
• Machinery Directive
2006/42/EC

• 1.4.2.1 Fixed guards
• Fixed guards must be fixed by systems that can be opened or removed only
with tools.
• Their fixing systems must remain attached to the guards or to the machinery
when the guards are removed.
• Where possible, guards must be incapable of remaining in place without
their fixings.

• 1.4.2.2 Interlocking movable guards
• Interlocking movable guards must be designed in such a way that the

absence or failure of one of their components prevents starting or stops the
hazardous machinery functions.

Safety circuits guards

Safety circuits guards

Risk reduction
INITIAL DESIGN PROTECTIVE SAFETY INFORMATION TRAINING

DESIGN OUT MEASURES CONTROLS
RISK
SAFE SYSTEMS
HIGH REDUCTION
RISK
REDUCTION RISK
RISK
REDUCTION
REDUCTION
RISK
LOW

Information
• Information may take the form of:

– manuals for operation, maintenance
and safety;
– drawings and parts lists;

Information
Notices, can be of several forms

such as warning, mandatory and
prohibition
Service information

Risk reduction
INITIAL DESIGN PROTECTIV SAFETY INFORMATION TRAINING

DESIGN OUT E CONTROL ORGANISATION
HAZARDS MEASURES S
RISK SAFE SYSTEMS
HIGH REDUCTION
RISK
REDUCTION RISK
RISK
REDUCTION
REDUCTION
RISK
LOW

HSE Horse

• 1.3.7 Risks related to moving parts

• The moving parts of machinery must be designed and constructed in such a
way as to prevent risks of contact which could lead to accidents or must be
fitted with guards or protective devices.
• 1.3.8 Choice of protection against risks arising from moving parts

• Guards or protective devices designed to protect against risks arising from
moving parts must be selected on the basis of the type of risk.

To prevent access

• 1.6.4 Operator intervention

• Machinery must be so designed, constructed and equipped that the need for
operator intervention is limited. If operator intervention cannot be avoided, it
must be possible to carry it out easily and safely.

Legislation
• Machinery Directive
2006/42/EC

Definition of a Safety Component
• Which serves to fulfil a safety function,
• which is independently placed on the market,
• the failure and/or malfunction of which endangers

the safety of persons.

Definition of a Safety Component
Safety devices that fall under the scope of the Directive Annex V
Indicative list:
• Extraction systems.
• Guards and protection devices.
• Control devices for calling lifting appliances and anti fall devices for hoists.
• Protective devices designed to detect the presence of a person.
• Safety belts and seat harnesses.
• Hydraulic non return valves where they are used to prevent falls.

PUWER 98 Regulations
• Regulation 11 Dangerous parts of machinery

(1) Every employer shall ensure that measures are taken
(a) to prevent access to any dangerous part of machinery or to any rotating part
or
(b) to stop the movement of any dangerous part of machinery or rotating part
before any part of a person enters a danger zone.

Dangerous parts of machinery
Q Is there access to dangerous parts of machinery?
Q Are all guards securely held in place?
Q Can the guarding be bypassed or disabled?
Q Are interlocks fitted, positive acting, correctly positioned and

functional?

R11 – Dangerous parts of machinery

Use of Standards

BS EN 349
• This standard enables users to avoid hazards from crushing

zones. It specifies minimum gaps relative to parts the
human body.

BS EN 349

BS EN 953
• Guards are used for numerous reasons including.

• Containment of ejected parts
• Containment of hazardous substances
• Noise reduction
• Radiation containment
• Explosion (blast panels designed to dissipate force)
• Viewing of process

Distance Guarding - Fixed

The Role of EN Standards
Machinery manufactured in conformity with specified published European

Harmonised standards will be presumed to comply with the Essential Health
and Safety Requirements covered by those standards

The Role of EN Standards Globally
Many of the Standards now utilised in Europe are now globally recognised
standards
ISO
IEC

BS EN 953
Risk assessment
• In order to select and design types of guards appropriate to particular
machinery, it is important to assess the risk arising from the various hazards
present at that machinery and the foreseeable categories of persons at risk !
• see EN ISO 12100

Enclosing Fixed Guard

BS EN ISO 13857

BS EN 953
• Guards must be suitable for purpose.
• Guards shall be designed so far as is practicable to take into account

foreseeable use and reasonably foreseeable misuse.
• Guards shall be designed so as not to cause hazardous crushing or trapping

points, with parts of the machine or of other guards.

Combination of Guards & Protective Devices

Distance Tunnel Guard

BS EN 953 Selection of guards
• Guards should be selected from the following in the order of priority given:
a) Local guards enclosing individual danger zones if the number of danger
zones to protect is low. This can provide an acceptable residual risk and
permits access to non-hazardous machine parts for maintenance, setting,
etc.
b) A guard enclosing all the danger zones if the number or size of the danger
zones is high. In this case setting and maintenance points should, as far as
possible be located outside the guarded area.

Suitability of guards

Types of EN Standard
• “A” type apply to all machines
• “B” type are designed to promote safety and split into “B1” and “ B2”
• “C” type apply to a specific type of machine

IEC 60204 - 1
BS EN 12100- 2010 Electrical
Safety of machinery, Equipment
general principles for
design and risk
assessment.
BS EN ISO 13857
Upper and Lower limb TYPE C
access.
STANDARDS
for Machines
BS
PRISO
EN13850
418
BS EN 414
Emergency Stop
Emergency Stop
Safety of machinery
Rules for drafting and
Presentation of safety
SPECIFIC PROTECTIVE
standards
DEVICE STANDARDS
2 Hand Controls
Light Curtains
Safety Switches etc

BS EN ISO 13857

Type A Standards
• Applies to all machinery and are essential reading for machinery builders
and modifiers
• BS EN ISO 12100:2010 Safety of Machinery – General principles for design

– Risk assessment and risk reduction (ISO 12100:2010)

'B1' Standards
• Apply to all machinery and are designed to promote the essential factors
mentioned in the foreword.
'B2' Standards
• These are "apply when used" Standards, i.e. if a particular safety device is
chosen for a machine, then it must, be manufactured to the relevant
standard. E. g. Interlock switch, E stop switch.

Type C Standards
• BS EN 415 Series Safety of Packaging Machines
• BS EN 10218 Industrial Robots Recommendations for Safety. Parts 1 & 2.
• BS EN 12417 Safety of Machine tools Machining Centres.
• BS EN 692 Mechanical Presses

BS EN ISO 13857
• Scope
• This International Standard establishes values for safety distances in both
industrial and non-industrial environments to prevent machinery hazard
zones being reached. The safety distances are appropriate for protective
structures. It also gives information about distances to impede free access
by the lower limbs.

BS EN ISO 13857
• Use of Tables
• Reaching over protective structures:
• Table 1 shall be used where there is a Low Risk

• Table 2 shall be used where there is a High Risk.

BS EN ISO 13857

BS EN ISO 13857

BS EN 953
SCOPE
• This standard specifies general requirements for the design and construction
of guards provided to protect persons from mechanical hazards.

Legislation
• Provision and Use of Work

Equipment Regulations 1998

PUWER 98 Regulations
• Regulation 5 Maintenance
(1) Every employer shall ensure that work equipment is maintained in an
efficient state, in efficient working order and in good repair.
(2) Every employer shall ensure that where any machinery has a maintenance
log, the log is kept up to date.

Machine Guarding

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Limits of machine – Use limits

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 8

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 9

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 10

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 11

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 14

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 15

Presented by Paul Laidler

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 1

• Assistance in meeting the requirements of machinery safety legislation

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 2

• 3 University Certificate Courses in Professional Development:

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 3

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 4

• Design the hazard out.

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 12

INITIAL DESIGN PROTECTIVE SAFETY INFORMATION TRAINING

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 16

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 17

1. Determine the limits of the machine

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 5

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 6

To reduce risks from debris and ejected parts

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 18

To reduce risks of damage from outside (e.g. FLT’s)

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 19

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 13

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 20

• 1.4.1 General requirements

• Guards and protective devices must:

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 33

• 1.4.1 General requirements cont

• In addition, guards must, where possible, protect against the ejection or

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 34

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 29

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 30

• 1.4.2.1 Fixed guards

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 35

• 1.4.2.2 Interlocking movable guards

• Interlocking movable guards must be designed in such a way that the

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 36

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 23

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 24

INITIAL DESIGN PROTECTIVE SAFETY INFORMATION TRAINING

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 25

• Information may take the form of:

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 26

Notices, can be of several forms

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 27

INITIAL DESIGN PROTECTIV SAFETY INFORMATION TRAINING

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 28

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 31

• 1.3.7 Risks related to moving parts

• 1.3.8 Choice of protection against risks arising from moving parts

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 32

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 37

• 1.6.4 Operator intervention

TÜV SÜD Product Service 24/09/2013 Machine Guarding Webinar Slide 38