Technological University of the

Philippines
Graduate School Program

Machinery Safeguards
Barriers and Enclosure Guards
Controls and Operating Safely

By : Jessie R. Ortiz

Barrier Guards
Barrier Guards are appropriate safeguards
for full revolution and part revolution
mechanical power presses. They are
designed to keep the operator's hands
and arms from entering the "danger
zone" as prescribed by the particular
machine. Barrier guards are usually the
first
point-of-operation
safeguard
considered for machines.

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

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

Adjustable Guards
Advantage
Flexibility
In-house fabrication

Disadvantage
Bandsaw blade
adjustable guard

Not maximum
protection
Rely on worker to
properly position
May prohibit easy
access

OSHA 3067

Self-adjusting Guards
Advantage
Employee not
involved in
positioning
Readily available

Disadvantage
Not maximum
protection
May need frequent
fine tuning
OSHA 3067

Self-adjusting Guard
Table Circular Saw

Second Choice Devices (control access)

Devices control access to the point of operation and may
replace or supplement guards. To qualify as a device, it may
perform one of several functions.

Stop the machine if a hand or any part of the body is inadvertently placed in
the danger area

Restrain or withdraw the operator's hands from the danger area during
operation.

Require the operator to use both hands on machine controls, thus keeping
both hands and body out of danger.

Provide a barrier which is synchronized with the operating cycle of the

machine in order to prevent entry to the danger area during the hazardous
part of the cycle.

Allow safe lubrication and maintenance and not create hazards or interfere
with normal machine operation.

Be secure, tamper-resistant and durable.

Machine Guarding Devices

A device controls entry into the danger area.
Six types of Machine Devices:
1.Presence sensing device
2.Two hand control
3.Pullbacks/restraints
4.Moveable barriers (gates)
5.Safety trip controls

Presence Sensing Devices

These devices either stop the machine, or will not start the
cycle, if a hand or any part of the body is inadvertently placed in
the danger area. There are 4 types of presence sensing devices.
The light curtain (photoelectric-optical) presence
sensing device uses a system of light sources and
controls that can interrupt the machine's operating
cycle. If the light field is broken, the machine stops
and will not cycle. This device must be used only on
machines which can be stopped before the worker
can reach the danger area. The light curtain must
be positioned at a minimum safe distance from the
machines point of operation. If the light curtain is
too close to the point of operation, the workers
hand could reach a danger zone before the
machine has time to stop.

Presence sensing devices

Radiofrequency presence-sensing device
Uses a radio beam that is part of the machine
control circuit. When the capacitance field is broken,
the machine will stop or will not activate. Like the
light curtain, this device shall only be used on
machines which can be stopped before the worker
can reach the danger area and must be adjusted to
the minimum safe distance.
This requires the machine to have a friction clutch or
other reliable means for stopping. Because the
radiofrequency device is very sensitive, the antenna
design requires a great deal of experience and for
other technical reasons it is no longer being used in
the machine guarding area.

Presence sensing devices

Electro-mechanical sensing device
Has a probe or contact bar which descends to
a predetermined distance when the operator
initiates the machine cycle. If there is an
obstruction preventing it from descending its
full predetermined distance, the control circuit
does not actuate the machine cycle.
An electro-mechanical sensing device is shown
on a riveter. The sensing probe in contact with
the operator's finger is also shown. The
machine will not operate until the probe comes
in contact with the material. The finger
prevents this by not allowing the probe to come
all the way down and contact the material. The
electro-mechanical sensing device is
sometimes called a Touch O-Matic.

Presence sensing devices

Safety Mat
The safety mat is a pressure sensitive
safeguarding product that is designed to detect
the presence of people on its sensing surface.
Picture shows guarding application using
pressure sensitive floor mats. It can be used to
detect the presence of someone or something
within the protected area and can be used to
safeguard a floor area around a machine or
robot.
A matrix of interconnected mats (safety mat
system) can be laid around the hazardous area
and any pressure (e.g. an operators footstep)
will cause the controller unit to send a stop
signal to the machine. They can also be used
as a point of entry alert method. Other
safeguarding devices such as pressure
sensitive safety edges and bumpers also fall
into this family of devices.
Source: Omron Industrial Automation

Guarding Devices Pullback/Restraints

Uses a series of cables attached to the operators hands,
wrists, and/or arms and to a moving or fixed point.
The pullback is primarily used on machines
with stroking action. When the slide/ram is up,
the operator is allowed access to the point of
operation. When the slide/ram begins to
descend, a mechanical linkage automatically
assures withdrawal of the hands from the point
of operation.

The restraint (holdout) device uses cables or

straps that are attached to the operator's hands
and a fixed point. The cables or straps must be
adjusted to let the operator's hands travel within
a predetermined safe area. There is no
extending or retracting action involved.
Consequently, hand-feeding tools are often
necessary if the operation involves placing
material into the danger area.

Guarding Devices Safety Trip Controls

These devices provide a quick means for deactivating the
machine in an emergency situation.

A pressure-sensitive body bar, when depressed, will deactivate the machine.

If the operator or anyone trips, loses balance, or is drawn toward the machine,
applying pressure to the bar will stop the operation. The positioning of the bar,
therefore, is critical. It must stop the machine before a part of the employee's
body reaches the danger area.

When pressed by hand, the safety trip-rod deactivates the machine. Because
it has to be actuated by the operator during an emergency situation, its proper
position is also critical.

Safety tripwire cables are located around the

perimeter of or near the danger area. The
operator must be able to reach the cable with
either hand to stop the machine. All of these
tripwires, rods or other safety devices must be
manually reset to restart the machine.

Guarding Devices gates & moveable barriers

A gate is a moveable barrier which protects the operator at the
point of operation before the machine cycle can be started.
Gates are, in many instances, designed to be
operated with each machine cycle. If the gate is
not permitted to descend to the fully closed
position, the press will not function. Another
potential application of this type of guard is
where the gate is a component of a perimeter
safeguarding system. Here the gate may
provide protection not only to the operator but
to pedestrian traffic as well. There are two types
of gate functions:
A type A gate remains closed during the entire cycle of the machine. Use for
full or part revolution clutches.
A type B gate opens after the die closing portion of the machine cycle has
been completed. Use for part revolution clutch only.

Guarding Devices Two hand controls/trips

These devices prevent the operator from reaching into the
point of operation when the machine cycles by requiring the
hands to be on palm buttons or levers.
The two-hand control requires constant, concurrent pressure by the operator to
activate the machine. This kind of control requires a part-revolution clutch, brake, and
brake monitor if used on a power press as shown. With this type of device, the
operator's hands are required to be at a safe location (on control buttons) and at a
minimum safe distance from the danger area while the machine completes its closing
cycle.
The two-hand trip requires concurrent application of both of the operator's control
buttons to activate the machine cycle, after which the hands are free. This device is
usually used with machines equipped with full-revolution clutches. The trips
must be placed far enough from the point of
operation to make it impossible for the operator
to move his or her hands from the trip buttons
or handles into the point of operation before the
first half of the cycle is completed. Thus the
operator's hands are kept far enough away to
prevent them from being accidentally placed in
the danger area prior to the slide/ram or blade
reaching the full "down position.

Enclosures
Protective enclosures keep material contained
within the machine area, and prevent people
or items from accidentally entering the
operating machines space.

Third Choice -Other Methods

Controls and Operating Safely
When guards or devices cannot be used, Other Methods
can be selected. These other methods (safe distance,
safe holding, safe opening, safe position of controls) are
methods of safeguarding that can be applied to machines
with unique safeguarding problems.
Other methods do not provide the protection of guards or
devices. These methods require placement or adjustment
for each operation. They depend upon specific
procedures, work rules, extensive training and supervision
to prevent the tendency to circumvent the method used.

Other Methods
Safe Holding
This method is one that is designed and constructed so when
the operator is required to hold or support the work piece, the
operator is prevented from inadvertently reaching into the
hazard area.

Other Methods
Safe Opening
This method is one that provides small opening to the hazardous area. It
meets one of the following conditions:
1.The opening, when no work piece is in place is small enough to prevent any part of

operators body from entering the area (1/4 inch or less opening); or
2.When part is in place, opening is only 1/4 inch to prevent any part of the operators

body from entering the hazardous area. The machine cannot cycle unless the work
piece is in place. Openings for two-dimensional work pieces meet the following
conditions:

Maximum area of any guard opening should be 7 square inches (example:

opening 2-1/2 inches by 2-1/2 inches has an area of 6-1/4 inches);

Longest dimension of a rectangular opening should be 3.5 inches;

The maximum shorter dimension of the rectangular opening should be 2

inches;

The minimum distance from the guard to any point of operation is 4 inches.

Other Methods
Safe Position of Controls
Operating controls are properly positioned by one of these methods:
1.Controls that require continuous actuation to complete the hazardous portion
of the cycle positioned so that no part of the operators body can reach the
hazardous area during the hazardous portion of the cycle or until cessation of
hazardous motion; or
2.Controls for single-cycle machines located far enough from the hazardous
area that no part of the operators body can enter before the machine completes
the hazardous portion of its cycle or until
cessation of motion. Remote controls cannot be easily
moved or are securely fixed in position.

Other Methods
Safe Distance
Eliminates the need for operators hands or other parts of the body to be in
or near the hazardous area during the hazardous portion of the cycle by one
of the following:
1.Work practice;
2.Size and location of work piece; or
3.Operator location where the operator is not required to place any part of body
within the established safe distance during hazardous portion of cycle, nor is the
operator required to enter the safe distance for the purpose of loading, unloading,
adjusting, measuring, cleaning.

Link to Table 200-2 safe distanc

e for fixed barricades

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

24

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

25

Managing the Safeguarding Program

There is more to machine safeguarding than just guarding

machines. The employer must:
Ensure that employees are trained to do the job,
Ensure that employees wears personal protective

equipment to protect against other hazards,

Establish safe operating procedures,
Supervise to ensure compliance with company rules.

Managing the Safeguarding Program

Even the most elaborate safeguarding system cannot offer effective protection
unless the worker knows how to use it and why. Specific and detailed training is
therefore a crucial part of any effort to provide safeguarding against machinerelated hazards. Thorough operator training should involve instruction or hands-on
training in the following key areas:
1.Parts and functions of the machine
2.Basic operator controls
3.Operator Responsibilities
4.Safeguarding
A description and identification of the hazards associated with particular
How to use the safeguards and why
How and under what circumstances safeguards can be removed, and by whom

(in most cases, repairs or maintenance personnel only).

What to do (e.g., contact the supervisor) if a safeguard is damaged, missing, or
unable to provide adequate protection.

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

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

Training
Operators/affected employees should receive
training on:
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

Checklist

Printable Checklist in MS Word format

MACHINE SAFEGUARDING CHECKLIST

Yes

N
o

Do the safeguards
provided
meet the
minimum
rule requirements?
Answers
to the following
questions
should
help determine
the safeguarding needs of the workplace, by drawing
attention
to hazardous
conditions
practices
Do the safeguards
prevent
workersor
hands,
armsrequiring
and othercorrection
body parts from making contact with
dangerous moving parts?
Are the safeguards firmly secured and not easily removable?
Do the safeguards ensure that no objects will fall into the moving parts?
Do the safeguards permit safe, comfortable and relatively easy operation of the machine?
Can the machine be oiled without removing the safeguard?
Is there a system for shutting down the machinery before safeguards are removed?
Can the existing safeguards be improved?
Mechanical Hazards
Is there a point of operation safeguard provided for the machine?
Does it keep the operators hands, fingers, body out of the danger area?
Is there evidence that the safeguards have been tampered with or removed?
If there is more than one operator, are separate controls provided?
Could you suggest a more practical, effective safeguard?
Could changes be made on the machine to eliminate the point of operation hazard entirely?
Are there any unguarded gears, sprockets, pulleys or flywheels on the apparatus?
Are there any exposed belts or chain drives?
Are there any exposed set screws, keyways, collars, etc.?
Are starting and stopping controls within easy reach of the operator?
Are safeguards provided for all hazardous moving parts of the machine including auxiliary parts?

Yes

N
o

Further Information
L & I DOSH Machine Safeguarding ideas bank
Oregon OSHA Machine Safeguarding at the Point of Operation
OSHA Machine Guarding eTool
OSHA Concepts & Techniques of Machine Guarding
OSHA Safeguarding Equipment for Small Business
OSHA Guide for Protecting Workers from Woodworking Hazards
WorkSafe BC Safeguarding in Metal Products Manufacturing
WorkSafe BC Safeguarding in Food Products Manufacturing
WorkSafe BC Guarding for Woodworking

Thank You!