Just a presentation that I did at the OSHA Waubonsee Safety Days.

1. Machine Guarding
Draft 1 16 2016
1
johnanewquist@gmail.com
815 354-6853

2. Introduction to Machine Guarding
• The intent of machine
guarding is to
minimize the risk of
accidents from
machine operator
contact.
2

3. Introduction to Machine Guarding
• Safeguards are
essential for protecting
workers from needless
and preventable
injuries such as
crushed hands and
arms, severed fingers,
and blindness.
3

4. Activity
• Employees make
contact with a machine
- usually the moving
part - for many
reasons, including:
• List 5
4

5. Introduction to Machine Guarding
• Amputations are some of the
most serious and debilitating
workplace injuries.
• They are widespread and
involve a variety of activities
and equipment.
• Amputations occur most often
when workers operate
unguarded or inadequately
guarded machines.
5

6. Introduction to Machine Guarding
• Besides normal operations, the
following activities involving
stationary machines also expose
workers to potential amputation
hazards:
• setting-up, threading, preparing,
adjusting, cleaning, lubricating
and maintaining machines as
well as clearing jams.
6

7. Machinery & Machine Guarding
[1910.211 – .219]
7
MACHINE GUARDS – GENERAL
GRINDERS – WORK RESTS
POWER TRANSMISSION APPARATUS – PULLEYS
GRINDERS – TONGUE GUARDS
MACHINE GUARDS – POINT OF OPERATION
SUBPARTO
287
382
470
626
1563
219(d)(1)
215(a)(4)
215(b)(9)
212(a)(3)(ii)
212(a)(1)
OSHA Top 5 2015

8. Current Events
• These are some of the
recent machine
guarding stories.
8

9. February 2016
• A Utah supermarket worker
died on the job Wednesday
after accidentally getting caught
in the bakery’s industrial mixer,
police said.
• “In the process of working with
that machine, she somehow got
caught up and pulled into the
machine,” Sandy Police Sgt.
Dean Carriger said.
9

10. Oct 2015
10

11. August 2015
• The first day on the job for a
new employee ended tragically
when a 21-year-old man
suffered severe burns and the
loss of four fingers at a
manufacturing plant in Elyria,
Ohio, in March
• The accident happened when
the man, who had been working
for a few hours when the
incident occurred, was trying to
clear a jam in a plastic molding
machine.
11
Blow Molding machine

12. August 2015
• Osceola WI
• $207,600
• Egregious spot welder
guarding.
• Two Amputations in 2015
• 1300+ lbs. ram pressure
• Senses metal on metal contact
• Soft touch 50 pounds of
pressure
12

13. July 2015
• San Luis Obispo, CA
• The machine's blades "came
around and broke his arm and
came around again and broke
his arm a little further up the
next turnaround," said San Luis
Obispo Fire Battalion Chief
Neal Berryman
• Berryman said the man's head
or neck would have been hit
next.
13

14. July 2015
• MIDDLEFIELD, Ohio – Shady
Knob violated the law when
they allowed a 14-year-old boy
to operate machinery, which
resulted in him losing his hand.
• “Workers under age 18 are
prohibited from operating
power-driven woodworking
machinery, such as the wood
planer used here,” said Howard
Eberts, OSHA’s area director in
Cleveland. 14
Unsafe!
Safe

15. April 2015
• Elk Grove Village, IL
• The worker became
caught in a power lathe, a
machine that spins quickly
to shape or cut products
including metal and wood
15

16. April 2015
• Ohio
• $1.4 million penalties
• Willful Lockout and guarding
• On April 7, a 17-year-old temp
employee suffered the
amputation of his left leg from
the knee down when he was
cleaning the liver-giblet chiller
machine.
• The teen has been unable to
return to work due to his
injuries, and he was fired after
the incident.
16

17. March 2015
• Island Lake IL
• The machinist was
using sandpaper to
remove surface rust
from a part of a
computer-run
machine.
• His hand was caught
and pulled into
rotating parts,
breaking his bones.
• The worker
underwent several
surgeries and
rehabilitation
17

18. March 2015
• Chicago
• Allen says that on March
25, a fourteen-year-old
boy was operating a planer
at the business, when his
shirt became caught in the
machinery which caused
severe damage to one of
the teen's hands
18

19. February 2015
• Ashley Furniture Industries Inc.
employees have suffered more
than 1,000 work-related
injuries, including more than
100 amputations from
woodworking machinery, over
a three-and-a-half year period.
• $1,760,000 fine
19

20. December 2015
• Tragedy struck a Sparks, NV,
machine shop when a 33-year-
old machinist died after his
clothing became entangled in a
vertical lathe and pulled him
into the equipment.
• Rescuers responded to a call
about 6 a.m. Dec. 10 at Ebara
International Corporation, but
were unable to save Jason
Cheely.
20
Typical lathe

21. October 2014
• The employee was killed after
he became entangled in a
conveyor belt at the company's
lumber mill in Fulton.
• The worker, employed at the
company for less than two
weeks, was cleaning up sawdust
and bark around an unguarded
conveyor when the
entanglement occurred

22. June 2014
• Belvidere, IL
• Jake Frisella, a 21-year-old
machine operator, was fatally
crushed reaching into an auto
bumper machine to align parts
on June 10, 2014.
• A Stateline family has filed a
lawsuit against a manufacturer
they say installed a machine
that led to the death of their 21-
year-old son.
22
Typical Auto bumper
assembly machine

23. July 2014
• Cordova NY
• A 45-year-old lost part of
three fingers when his left
hand caught in a table saw
at a Cordova company that
fabricates reusable
shipping containers.
• Doctors reattached the
fingers, but had to
amputate the tip of his left
middle finger.
• The employee has been
unable to return to work.
This is a guarded
table saw.
This table saw is in
violation because it
does not have a
guard, anti-kickback,
and a spreader.

24. Activity
• Do you know of any accidents
in your facility where an
employee has been injured or
killed because a machine
safeguard was not in use at the
time?
• Or any accident which could
have been prevented if better
safeguarding had been
available?
• Briefly describe what happened,
what was done to prevent its
recurrence and what happened
to the employee.
• __________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________
__________________24

25. Safety Codes
• Safety Code for Mechanical
Power Transmission Apparatus
published in the 1940’s by
American Standards
Association
• Very similar to OSHA
1910.219 std.
• Required forethought guarding
vs. afterthought guarding for
machine manufacturers
25

26. IL 2000-2007
• 3984 Amputations
• 50% of top 10 were temp agencies
• 11.5% of the companies had two
amputations
• 343 whole hand, 68 forearm, 20 upper arm
• 24 Whole foot, 32 whole leg, 24 lower leg
26

27. Basics of Machine Safeguarding
• There seems to be as
many hazards created by
moving machine parts as
there are types of
machines.
• Safeguards are essential
for protecting workers
from needless and
preventable injuries
27
Four slide machine

28. Basics of Machine Safeguarding
• All machines consist
of three fundamental
areas
• the point of operation,
• the power
transmission device
• the operating controls
This plastic injection
molding machine has
an interlocked guard
protecting the point of
operation.

29. Basics of Machine Safeguarding
• The point of operation
is where work is
performed on the
material, such as
cutting, shaping,
boring, or forming of
stock.
A forming press would need
guards or light curtains to
prevent entry during
operations.

30. Nip Point
• Nip point - location
where machine pieces
come together such as
belts and a pulley, two
in-running rollers, etc.
• Also called the Bite
30

31. Basics of Machine Safeguarding
• The power transmission
apparatus is all
components of the
mechanical system which
transmit energy to the part
of the machine performing
the work.
• These components include
flywheels, pulleys, belts,
connecting rods,
couplings, cams, spindles,
chains, cranks, and gears.
Many deaths have occurred
when caught in the
unguarded rotating shafts of
equipment.

32. Basics of Machine Safeguarding
• Motions
Rotating: in-running nip points,
spindles, shaft ends, couplings
Reciprocating: back-and-forth,
up-and-down
Transverse: movement in a
straight, continuous line
• Operations
Cutting: bandsaws, drills,
milling machines, lathes
Punching: punch presses,
notchers
Shearing: mechanical,
pneumatic, or hydraulic shears
Bending: press brakes, tube
benders, plate rolls

33. ANSI B Series
• The user shall ensure
that set-up and
maintenance personnel
and operators are
trained to perform the
functions for which
they are responsible.
33

34. ANSI B Series
The user shall designate, provide,
and ensure the use of at least one of
the following methods of
safeguarding that affords protection
for the operator, consistent with the
requirements of the task:
• guard(s)
• safeguarding device(s)
• awareness barrier(s) or
awareness device(s)
• safe work procedure(s).
34

35. Machine Hazards?
35

36. Machine Hazards?
36

37. Machine Hazards?
37

38. Machine Hazards?
38

39. Machine Hazards?
39

40. Machine Hazards?
40

41. Principles of Machine Guarding
• Safe Distance - 7’ rule of belts,
etc.
• Guards - employees can’t get in
hazardous area through the use
of barriers.
• Table 0-10 for guard opening
design (next page)
• Devices - Presence sensing
mats, pullbacks, light curtains,
restraints
41

42. Table O-10
• Distance of opening from the
point of operation hazard (in
inches)
• 1/2 to 1 1/2
• 1 1/2 to 2 1/2
• 2 1/2 to 3 ½
• 3 1/2 to 5 ½
• 5 1/2 to 6 ½
• 6 1/2 to 7 ½
• 7 1/2 to 12 ½
• 12 1/2 to 15 ½
• 15 1/2 to 17 ½
• 17 1/2 to 31 ½
• Maximum width of opening
(in inches)
• ¼
• 3/8
• ½
• 5/8
• ¾
• 7/8
• 1 ¼
• 1 ½
• 1 7/8
• 2 1/8
42

43. Types of Machine Safeguards
• Barriers and guards
• Mechanical or electronic
devices that restrict
contact, such as presence-
sensing, restraining, or
tripping devices, two-hand
controls, or gates.
• Feeding and ejection
methods that eliminate
part handling in the hazard
zone.
43

44. Light Curtains
• Some amputations are linked to
machine failure, such as failure
of a single-stroke linkage
resulting in a "double cycle,"
electronic failure of two-hand
controls, brake failure resulting
in the slide falling, and jammed
relays in light curtains.
44

45. • Unguarded nip points,
rotating parts
• No P.O.O. Guarding
• Tongue grinder ¼”
• Work Rest 1/8”
• Unguarded pulleys
• Unguarded Vertical
Belts
• Chain and sprocket not
guarded
• Lower blade guard
radial arm saw
• No punch press
inspection records
• Unguarded horizontal
belts
45
Most Cited

46. Amputations Most Wanted
46

47. Circular Saws
• Lower blade guard
required
• Clean saw and blade
to prevent guard from
sticking
• Aurora 1998 - 100+
stitches from saw
47

48. Circular saw
• Employee #1 was cutting 2x4
sections with the saw in his
right hand, and he was using his
left hand to position the wood.
• Employee #1 made a cut across
the wood and his right foot
stepped on the power cord,
causing the saw to shift its
direction and cut his left hand.
• Employee #1 will regain full
function of his left fingers, but
he will suffer some nerve
damage in his thumb.
48

49. Vertical Bandsaw
• Adjustable guard to
height of product
• Many injuries by
guiding product into
POO
• Handling cold slippery
products will increase
chances of slipping
into POO
• Consider tools or “no
Touch”
49

50. Horizontal Bandsaw
• Unused portion of
blade need to be
guarded
• No oversized blades
used
50

51. Any Issues?
51

52. Radial Arm Saw
• Lower blade
awareness device
• Retracts to original
position
• Does not extend past
plane of table
• Anti-kick back device
52

53. Radial Arm saw
• June 30, 2008,
• Employee was using a radial
arm saw to cut a piece of 2-in.
by 6-in. lumber for a Truss
brace.
• Using the radial arm saw
mounted on a bench, he placed
the piece of lumber beneath the
16-in. blade holding it with his
left hand.
• The running saw vibrated
forward and struck the lumber,
amputating the small finger in
the process. 53

54. Table Saws
• Top guard
• Magnetic restart
• Spreader
• Push sticks
• Anti-kick device
54

55. Table saw
On December 29, 2011, Employee
#1, a 29-year-old male was
operating a Sears brand hand-fed
table saw in the rear of facility.
Employee #1 was ripping about two-
inches off one end of pine boards,
and the board momentarily paused
close to the end of the cut and then
went forward.
55

56. Chop Saw
• Lower blade
awareness device
• Speed marked on saw
• Clean saw blades to
prevent varnish/sap
buildup
56

57. Conveyors
• Emergency stops
placed
• ANSI B20.1
• In-running nip points
guarded by fixed
guards
• This elevator section
unguarded
57

58. MIOSHA
conveyors
• Rule 1411.
• (1) An employer shall provide
training to an employee
working on or by a conveyor
regarding the hazards and
safeguards of such work.
• (2) An employer shall establish
an inspection program to
maintain conveyor components
in a condition which does not
constitute a hazard to the
employee.
58

59. Take-up Coils/Reels
• Often slow moving
• Several amputations
due getting caught in
nip point
• Interlock guards or
barriers used
• Unguarded fabrictake-
up roll nip point
59

60. Packaging Machines
• Multiple pinch points
• Employee reach in to
clear jams
• Fixed guards or light
curtains
• Lockout is needed
• 1999 - Aurora
amputation
60

61. Belt Sanders
• Hazard is nip point
• Use fixed guard
61

62. Inspecting Secondary
Operations Equipment
Drill Presses:
1. On drill presses, drive belts are properly
guarded & compartment closed.
2. Point of Operation guarding, in place and
used. If applicable.
3. Check equipment for damage, including
wiring.

63. Drill Press
• Hair or clothing get
caught in rotating shaft
• Automatic ones can
guard against pinch
point via 1/4 opening
or presence sensing
devices
63

64. Lathe Safety

65. 65

66. 66

67. 67

68. December 2015
• Tragedy struck a Sparks, NV, machine
shop when a 33-year-old machinist died
after his clothing became entangled in a
vertical lathe and pulled him into the
equipment.
• Rescuers responded to a call about 6 a.m.
Dec. 10 at Ebara International
Corporation, but were unable to save Jason
Cheely.
68
Typical lathe

69. Lathes
• Eye protection glasses
with side-shields.
• Use complete enclosure
guard
• Interlock No loose
sleeves, long hair, or
jewelry
• Work is securely clamped
in the chuck.
• Start the lathe at low
speed and increase the
speed gradually.
• Removing the chuck key
immediately after use.
69

70. Lathes 2010 - 2012
• While working in
the Laboratory’s
machine shop,
Michele’s hair got
caught in one of the
shop’s wood lathes,
On November 9, 2010, Employee
#1 was working on a lathe
machine.
He caught his clothing in the
machine.
A witness to the incident said, that
somehow, Employee #1 worked
his way out of the lathe; however,
due to the force of him pulling
away from the machine, he fell to
the concrete, hit his head, and was
killed. 70

71. Lathes
• February 24, 2012, Employee
#1, a 45-year-old lathe operator,
was moving product from an
external inspection area to lathe
operation area.
• He reached across the
protruding stack which was
being run when the lathe caught
his jacket, pulling him into the
rotation cycle.
• He died of his injuries 10 days
after the accident.
71

72. Issues?
72

73. Auctioned or Used Machines
• Often missing guards
• Employer must guard
even if not designed
with them
• Consult ANSI
standard applicable
73

74. Summary
• If a four year could get
hurt with a machine, an
adult will eventually
get hurt too.
74