Ensuring compliance with machine safety rules and regulations requires a deep understanding of effective engineering controls. For businesses striving to create a safe work environment, engineering controls provide a reliable solution by addressing risks at the source.

At Pacific Blue Engineering, we specialize in integrating custom automation and controls solutions to prioritize safety from the plant floor to the enterprise level. This article explores examples of engineering controls that effectively enhance machine safety and ensure compliance with industry standards.

Understanding Engineering Controls

Engineering controls refer to physical changes made to machinery or work environments to mitigate or eliminate hazards. These controls focus on designing out the risk, thereby minimizing the potential for human error.

Unlike administrative controls, which rely on worker behavior or personal protective equipment (PPE), engineering controls provide a more robust, long-term solution by modifying the equipment itself.

Here are just of few engineering controls examples, demonstrating their importance:

• Prevent Injuries: Engineering controls are designed to remove hazards or create safeguards that prevent workers from coming into contact with dangerous machine parts.
• Compliance with Regulations: Machine safety rules and regulations, such as OSHA and ANSI standards, often require specific engineering controls to be in place for compliance.
• Reduce Human Error: By automating safety features or installing physical guards, engineering controls reduce reliance on operator judgment and manual intervention, which can lead to errors.

Effective Engineering Controls for Machine Safety

Next, let’s take a look at specific engineering controls examples that help you keep workers safe and comply with machine safety rules and regulations.

Machine Guarding Systems

One of the most common engineering controls examples is the installation of machine guards. These physical barriers protect operators from moving parts, flying debris, or other mechanical hazards. Guards are often required by machine safety rules and regulations and can be designed to allow for easy maintenance without removing protection.

Types of systems include:

• Fixed Guards: Permanently attached and designed to enclose dangerous machine components.
• Interlocked Guards: Connected to the machine’s control system, preventing the machine from operating unless the guard is in place.
• Adjustable Guards: Used when flexibility is needed, allowing the guard to adapt to different tasks or machine configurations.

Emergency Stop Controls

Emergency stop controls, or E-stops, are another critical engineering control designed to immediately halt machine operation in the event of a malfunction or safety issue. These controls must be easily accessible and clearly marked to ensure they can be activated quickly in an emergency.

Presence-Sensing Devices

Technology has enabled the development of presence-sensing devices, such as light curtains or pressure-sensitive mats, which detect the presence of an operator near a machine and stop its operation.

These systems provide a hands-free, automatic method of protecting workers without hindering productivity. A good example is light curtains that emit infrared beams that, when interrupted, immediately halt the machine’s operation. Another is pressure-sensitive mats placed on the floor around dangerous machinery, which shut down the machinery when pressure is applied, indicating a worker has stepped into the danger zone.

Two-Hand Controls

Two-hand control systems are designed to require both of an operator’s hands to be used simultaneously to activate a machine. This ensures that the operator’s hands are clear of any hazardous areas while the machine is in motion.

Benefits of two-hand controls include:

• Prevents Accidental Start-Up: The machine will not engage unless both hands are in position, reducing the risk of unintentional activation.
• Enhances Safety: By requiring both hands, this system prevents operators from being in harm’s way when the machine is running.

Automated Safety Interlocks

Automated safety interlocks are systems that link machine operation to safety conditions. For example, a machine may be programmed to shut down if a protective door is opened or if a safety guard is removed. This ensures that dangerous parts of the machine are never exposed while the machine is operational.

Compliance with Machine Safety Rules and Regulations

Machine safety rules and regulations are designed to protect workers and ensure the safe operation of industrial equipment. Compliance requires not only an understanding of the regulations but also the implementation of effective engineering controls. Some of the most relevant regulations include:

• OSHA Standards: The Occupational Safety and Health Administration (OSHA) enforces safety regulations that require machine safeguarding and other engineering controls in the workplace.
• ANSI Standards: The American National Standards Institute (ANSI) sets guidelines for machine safety, including the proper design and use of engineering controls.
• ISO Standards: The International Organization for Standardization (ISO) provides global standards for machine safety, focusing on risk reduction through engineering controls.

Reduce Hazards at the Source

Engineering controls are a vital component of machine safety and compliance in any industrial setting. By eliminating or reducing hazards at the source, these controls create a safer work environment and help businesses meet regulatory requirements. From guarding systems to automated safety interlocks, engineering controls provide an effective way to protect workers and enhance the safety of industrial machinery.

By understanding and implementing these examples of engineering controls, businesses can ensure that they are not only protecting their workforce but also staying compliant with machine safety rules and regulations. Machine safety is a shared responsibility, but with the right engineering controls in place, the risks can be significantly reduced.

See how Pacific Blue Engineering can help you keep workers safe and comply with machine safety rules and regulations. Contact Pacific Blue Engineering today.