Today’s machines and machine controls can do amazing things: automate processes, monitor environmental conditions and machine health, power sophisticated infrastructure, and protect your assets.

However, they can be dangerous if the right safety protocols are not in place. According to the latest data from the Centers for Disease Control (CDC), in 2022, there were more than 5,800 fatalities in workplaces, and machine-related death accounted for more than 12%.

The Occupational Health and Safety Administration (OSHA) has regulations that cover machine safety. Here are the top five that organizations need to know about.

1. Machine Guarding (29 CFR 1910.212)

Machine guarding is a critical safety requirements in industrial settings. This regulation requires that all machines have adequate guards to protect operators from hazards created by points of operation, ingoing nip points, rotating parts, flying chips, and sparks. The guards must be directly attached to the machine when possible and must be able to withstand the rigors of normal operation.

Guards should prevent workers’ hands, arms, or other body parts from making contact with dangerous moving parts. They must be durable, secure, and difficult to remove or tamper with. Importantly, these guards should not interfere with machine operation or create additional hazards.

Regular inspection and maintenance of guards ensure their continued effectiveness in preventing accidents.

2. Lockout/Tagout (LOTO) Procedures (29 CFR 1910.147)

The Control of Hazardous Energy regulation, commonly known as Lockout/Tagout, is designed to prevent the unexpected startup or release of stored energy during machine maintenance and servicing. This regulation requires specific procedures for shutting down equipment, isolating it from its energy source, and preventing accidental startup.

Key components of a compliant LOTO program include:

• Written energy control procedures for each piece of equipment
• Training for authorized and affected employees
• Regular inspections of energy control procedures
• Standardized locks and tags that identify the worker performing the maintenance
• Specific procedures for shift changes and group lockouts

3. Electrical Work Practices (29 CFR 1910.333)

While often associated with LOTO procedures, this regulation specifically addresses electrical safety requirements. It mandates proper grounding of equipment, protection from electric shock, and safe work practices around electrical components.

The regulation requires:

• Regular inspection and maintenance of electrical systems
• Proper insulation and grounding
• Clear marking of electrical hazards
• Safe work practices for both qualified and unqualified workers
• Appropriate personal protective equipment (PPE) for electrical work

4. Emergency Stops and Safety Markings (29 CFR 1910.144)

Emergency stop devices serve as a critical safety feature in machine operations. E-stop requirements are embedded in several OSHA regulations and apply across industries.

Regulations require readily accessible emergency stop buttons or devices that can quickly shut down equipment in dangerous situations. These devices must be clearly marked, easily visible, and maintained in proper working order.

OSHA machine safety compliance includes:

• Strategic placement of emergency stops “within easy reach of operators”
• Clear marking with bright colors (typically red) and proper labeling
• Regular testing to ensure proper function
• Training for all operators on emergency stop locations and procedures
• Documentation of testing and maintenance

5. Training Requirements (29 CFR 1910.147(c)(7))

OSHA requires training for all employees who work with or around dangerous machinery. This training must be documented and updated as needed, particularly when new equipment is introduced or procedures change.

OSHA machine safety training programs must cover:

• Recognition of applicable hazards
• Purpose and use of energy control procedures
• Steps for shutting down, isolating, blocking, and securing machines
• Purpose and use of safety devices and guards
• Limitations of safety devices
• Proper use of personal protective equipment
• Emergency procedures and reporting

Other Machine Safety Regulations

While these five OSHA machine safety regulations are some of the most important, there are other standards that address a wide variety of common machine safety concerns, including:

• Mechanical Power Presses (29 CFR 1910.217): Requires safeguards, inspections, and training to prevent injuries from mechanical power presses in manufacturing environments.
• PPE Standards (29 CFR 1910.132): Mandates hazard assessments and the use of appropriate personal protective equipment (PPE) to protect workers from machine-related risks.
• Walking-Working Surfaces (29 CFR 1910 Subpart D): Ensures that floors, walkways, and work areas around machinery are safe, clean, and free of slip, trip, and fall hazards.
• General Electrical Requirements (29 CFR 1910.303): Focuses on the safe design, installation, and maintenance of electrical systems to prevent shock, fire, and other electrical hazards.
• Powered Industrial Trucks (29 CFR 1910.178): Establishes safety standards for the operation and maintenance of forklifts and other industrial trucks to prevent accidents.

When you are designing, installing, and maintaining your machines and machine controls, it’s critical to work with experienced engineering and control system integrators. Pacific Blue Engineering provides custom automation solutions, legacy control modernization, and functional safety services for the most demanding projects.

Contact Pacific Blue Engineering today to how our Certified TUV Functional Safety Engineers and Machine Safety Consultants can guide your team through the standards and regulations.