NUMBER: EHS007
TITLE: Machine Guarding ProgramDATE OF ADOPTION: 3/30/2006 / DATE OF REVISION:
APPROVED BY: / AT:
1.0 Purpose 2
2.0 Scope and Applicability 2
3.0 Reference 3
4.0 Policy Statement 3
5.0 Definitions 3
6.0 General Provisions 4
6.1 Required Employee Training 4
6.2 Recognizing Where Hazards Occur 4
6.3 Machine Guard Types 5
6.4 Machine Guarding Requirements 7
6.5 Machinery Maintenance and Repair 7
7.0 Specific Responsibilities 8
7.1 District Engineer/Bureau Administrator 8
7.2 Supervisors 8
7.3 Employee 8
7.4 Health and Safety Unit 8
8.0 Audit and Review 8
8.1 Subject and Frequency of Audit and Review
9.0 Personnel Actions 9
9.1 Discipline
Appendix A: Machine Guarding Needs Checklist 10
Appendix B: General Machine Guarding Requirements 13
1.0 Purpose
The purpose of this Machine Guarding Program is to establish requirements for the safety of Clarkson University employees while working on or near machines with moving parts that could represent an immediate hazard if not properly guarded. This program is also intended to comply with OSHA standards for machine guarding.
2.0 Scope and Applicability
A wide variety of operating motions and actions of mechanical equipment are known to present physical hazards to employees. These may include but are not limited to the movement of rotating parts, reciprocating arms, moving belts, meshing gears, cutting teeth, and operational areas intended to impact or shear.
This document provides guidelines for recognizing and safeguarding machine hazards. It includes provisions for training, specific and inferred machine guarding requirements, for safety during machinery maintenance and repair.
This safety policy and procedure also details the responsibility of employees, Supervisors, Department Heads and Mangers.
Equipment to which this program applies includes but is not limited to:
· Woodworking Machines (Circular, Radial, Portable Saws)
· Planers, Jointers and Sanders
· Drill Presses
· Power Lawnmowers
· Metal Working Machines
· Power Shears
· Abrasive Wheel Machines (Grinders)
· Equipment with Pulleys and Sprockets
· Chain Hoists
· Powered Belts
· Flywheels
· Hand and Portable Power Tools
Employees must receive sufficient operator training, as determined by the Department Supervisor and/or Manager, before working on any powered, mechanical equipment or machine.
3.0 References
This document utilizes references from the following sources:
· The Occupational Safety and Health Standards for General Industry (29 CFR 1910.212 through 1910.244).
4.0 Policy Statement
It is the policy of Clarkson University to provide a place of employment free from recognized hazards that cause or are likely to cause death or serious physical harm to employees. Therefore, any machine, part, function, or process that represents a hazard from exposure shall be guarded by sufficient physical barrier(s) or other means intended to prevent inadvertent access to the hazardous area. Additional methods of protection to be considered are; engineering controls, administrative rules, safe work practices, Personal Protective Equipment (PPE), and proper training in Machine Guarding requirements and standards which are intended to minimize hazards to ensure the safety of employees from the physical/mechanical hazard of operating machinery.
5.0 Definitions
Abrasive Wheel: A bench grinder wheel consisting of various particles bonded together and used for grinding objects to a particular shape or size.
Electrical Guard: Electronic means of protection provided to protect employees from electrical components or accidental equipment start-up.
Guard: An enclosure designed to protect employees from rotating or moving mechanical parts.
Kickback Device: Any device that protects the operator from equipment throwing the work back towards the operator.
Portable: Hand-held and operated.
Shield: An enclosure or barrier designed to protect employees from operating areas as well as from being struck by projectiles from a machine or process.
Two-Hand Trip Device: Mechanical or electrical actuating means of a machine or process, which requires the use of two hands and cannot be “tied-down” so as to be operated with one hand. The location of this device is also determined by the speed of the operating cycle, assuring that the operator cannot “beat” the cycle once the Two-Hand Trip Device has been acutated.
6.0 General Provisions
It is the responsibility of each Department Head, Manager, Supervisor, and employee to ensure implementation of Clarkson’s Machine Guarding Program. It is also the responsibility of each employee to report immediately any unsafe acts or conditions relative to machine operations or equipment use.
The Safety Office shall develop, administer and audit this program in compliance with OSHA 1910.212 – 244.
6.1 Required Employee Training
Employees who are required to operate power equipment and machines shall be trained in the safety features and safe guards of the equipment by a competent individual or Supervisor. Employee training should include the following instructions and hands-on information:
· Proper start up and shut down procedures, including emergency shut down.
· Full description and location of specific hazards associated with the machine
· Proper guarding and how it provides protection from the hazard for which it is intended
· Precautions to be taken during machine maintenance or repair when the guards are required to be removed.
· What to do and who to contact if a guard is found to be damaged, missing, or defective.
Employees shall be trained upon initial assignment or when any changes are made to the equipment or its machine guards. Training shall be documented and retained by the Supervisor.
6.2 Hazard Recognition – Mechanical Equipment
The moving parts on mechanical equipment are required to be guarded. The three focus areas for machine guarding are:
· The Point of Operation
· Power Transmission Apparatus
· Exposed Moving Parts
The Point of Operation is that area of the machine where work pieces or materials are placed for procedures such as cutting, shaping, boring, or forming.
Power Transmission Apparatus are the components of a mechanical system, which transfers energy into a mechanical motion which performs work. These components may include flywheels, pulleys, belts, connecting rods, couplings, cams, spindles, chains, cranks, and gears.
Exposed Moving Parts includes any part of the machine that moves during operation. These can be reciprocating, rotating, and transverse parts, as well as feed mechanisms and auxiliary equipment.
Hazard Recognition is key to developing a Machine Guarding system which will prevent hands, feet, heads, clothing and tools from access to areas where they can be grabbed, struck, pulled into or crushed. Recognizing and reporting hazards is everyone’s responsibility.
6.3 Machine Guard Types
The barriers used to prevent access to dangerous places can take any number of several forms. The four general types of guards are:
· Fixed
· Interlocked
· Adjustable
· Self-adjusting
A fixed guard is a permanent part of the machine. It is not dependent upon moving parts to perform its intended function. Figure 1 presents an example of a fixed guard.
Interlocked guards are those which, when opened or removed, automatically shut off or disengage the power to the machine. Figure 1
Adjustable guards allow flexibility in accommodating various sizes of stock as illustrated in Figures 2, 3, and 4.
Figure 2 Figure 3 Figure 4
Self-adjusting guards also allow a sufficient opening to admit stock of various sizes, however, after the stock is removed, the guard returns to its rest position. Self-adjusting guards provide more continuous protection by maintaining a barrier between the danger area and the worker during non-operational periods. Figure 5 presents an example of a self-adjusting guard.
6.4 Machine Guarding Requirements
Any machine guard must protect employees from mechanical hazards while allowing the intended work to be done. To do so, these machine guards must:
· Prevent contact
· Be structurally sound and secure
· Not create new hazards
· Not interfere with job performance
· Allow for safe “routine maintenance” of the machine
Examples of guarding methods include barrier type guards, two hand-tripping devices, and electronic safety devices. Depending on the seriousness of exposures, several methods of guarding may be required at the same time as counter measures or back-ups. For example; Two hand tripping devices frequently accompany adjustable barrier guards
Appendix A presents a checklist to help determine machine guarding needs.
Appendix B presents general machine guarding requirements.
6.5 Machinery Maintenance and Repair
Machine guard design should permit routine lubrication and adjustments without removal of the guards. If machine guards must be removed, the maintenance and repair crew must never fail to replace them. Ideally, maintenance work should not be performed until the machine is disconnected and locked out. For some equipment, like mechanical power presses, safety blocks should be used as an additional safeguard even though the machine may be locked out electronically. (Refer to the Lockout Program for details on Lockout Procedures.)
All machines will be maintained in good condition. This includes replacing dull blades, cutting heads, and damaged or unserviceable parts. Equipment blade changes or adjustments will be performed only when the power source has been disconnected and/or locked out. Equipment on which guards cannot be installed shall be removed from service. This likely includes older equipment which never had factory-installed guarding.
All guard adjustments will be made by an employee who is trained and knowledgeable about the particular piece of equipment.
7.0 Specific Responsibilities
7.1 Department Heads and Managers
Department Heads and their Managers are responsible for ensuring that adequate funds are available and budgeted for the purchase, installation and maintenance of machine guards for their areas. They will also be responsible for identifying the employees affected by this program. Managers will coordinate the required training for employees and assure compliance with this program.
7.2 Supervisors
Supervisors will ensure that affected employees are trained in the safe operation of all machines used in the performance of their duties.
Supervisors will ensure that an adequate supply of Personal Protective Equipment (PPE) is maintained in inventory and that employees are provided with PPE as necessary for their job.
7.3 Employee
Employees shall immediately inform their supervisor if any guarding system or shield is damaged or has become inoperable. No employee shall operate a machine that does not have all its guards properly installed. Employees shall not remove or otherwise modify any machine guard, except to perform allowed maintenance or service repair, at which time the use of Lock-outs shall be employed, as necessary, to assure zero energy is available to the machine.
7.4 Safety Office
The Safety Office will provide assistance to Department Heads, and Managers and Supervisors as necessary on matters concerning this program. Additionally, the Safety Office will provide consultative assistance and conduct audits to ensure effective implementation of this program.
8.0 Audit and Review
Department Heads and Managers shall routinely review the compliance of this program in their area, particularly with regard to machinery changes, changes in employee work assignments, or trends which increase the potential for occupational injury/illness.
The Safety Office will conduct an annual Audit and Review of the program to assure that it remains effective and compliant with all applicable regulations and standards. Audit procedures will include a random inspection of equipment to verify that required guarding methods and procedures are in place and effective.
A copy of this program shall be provided to employees, employee representative and regulatory inspectors upon reasonable request.
9.0 Personnel Actions
As a condition of employment, all employees of Clarkson University are required to participate actively in safety programs and to follow established health and safety-related policies, procedures, instructions, and/or rules. Total cooperation from management and employees is necessary to meet this work standard. Disciplinary action, in some instances up to and including dismissal, may be taken in cases where it is determined that disregard for safety and health has occurred.
Appendix A: Machine Guarding Needs Checklist
Requirements for All Safeguards
Yes / NoDo the safeguards prevent workers’ hands, arms, and other body parts from making contact with dangerous moving parts?
Are the safeguards firmly secured and not easily removed?
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 improvements be made to the existing safeguards?
Mechanical Hazards
The point of operation:
Is there a point-of-operation safeguard provided for the machine?Does it keep the operator’s hands, fingers, and body out of the danger area?
Is there evidence that the safeguards have been tampered with or removed?
Could you suggest a more practical, effective safeguard?
Could changes be made on the machine to eliminate the point-of-operation hazard entirely?
Power transmission apparatus:
Are there any unguarded gears, sprockets, pulleys, or fly-wheels on the apparatus?Are there any exposed belts or chain drives?
Are there any exposed set screws, key ways, or collars?
Are starting and stopping controls within easy reach of the operator?
If there is more than one operator, are separate controls provided?
Other moving parts:
Are safeguards provided for all hazardous moving parts of the machine, including auxiliary parts?Appendix A: (Continued)
Non-mechanical Hazards
Yes / NoHave appropriate measures been taken to safeguard workers against noise hazards?
Have special guards, enclosures, or Personal Protective Equipment (PPE) been provided, where necessary, to protect workers from exposure to harmful substances used in machine operation?
Electrical Hazards
Is the machine installed in accordance with National Fire ProtectionAssociation and National Electrical Code requirements?
Are there loose conduit fittings?
Is the machine properly guarded?
Is the power supply correctly fused and protected?
Training
Do operators and maintenance workers have the necessary training in using the safeguards?Have operators and maintenance workers been trained in locating safeguards, how they provide protection, and what hazards they protect against?
Have operators and maintenance workers been trained in the circumstances in which guards can be removed?
Have workers been trained in the procedures to follow if they notice damaged, missing, or inadequate guards?
Protective Equipment and Proper Clothing