Employers have a responsibility to keep their workplaces safe and free from hazards, which is especially critical for employees working with and around machines. The Occupational Safety and Health Administration (OSHA) reports that every year, there are about 800 deaths of workers operating and maintaining machinery. Another 18,000 suffer injuries, including cuts, crushing injuries, and amputations.

Ensuring you have the proper machine guarding safety protocols in place helps keep your employees safe and mitigates your liability. Proper machine guarding can also improve productivity by reducing downtime caused by workplace accidents.

Here are some of the top questions about machine guarding safety.

What Are the Different Types of Machine Guards?

There are several types of machine guards, each tailored to specific applications. Common types include:

Fixed Guards

These are permanent barriers attached to machines. A simple, durable, and effective solution, but they often require removal to perform maintenance.

Interlocking Guards

Interlocking guards shut down the machine whenever the guard is opened or removed. They are often used on equipment that requires frequent operator access, such as robotic arms or presses.

Adjustable Guards

This type of machine guarding can be repositioned to accommodate various tasks or different sizes of materials being processed. They are ideal for machines that handle different workpieces but require regular adjustment.

Self-Adjusting Guards

These guards automatically move into place as the machine operates, providing protection without requiring manual adjustments. They are commonly found on saws and other cutting equipment.

Presence-Sensing Devices

Some advanced systems use sensors such as light curtains or pressure mats to detect when a worker enters a hazardous area. If detected, the machine stops immediately to prevent injury.

Two-Hand Controls

Two-hand controls are designed to require both of the operator’s hands to be used simultaneously to activate the machine, ensuring they stay clear of hazardous areas.

What Types of Machines Require Machine Guarding?

Any machine with exposed moving parts, sharp edges, or pinch points needs machine guarding safety equipment to protect workers from accidental contact.

Examples include:

• Cutting Machines: Saws, shears, and guillotines
• Rotating Equipment: Lathes, drills, and milling machines
• Presses and Punch Machines: Used in metal stamping or forming
• Conveyors: With moving belts or rollers that can trap limbs or clothing
• Robotic Systems: Used in automated manufacturing
• Mixers and Agitators: In food or chemical production
• Power Transmission Components: Gears, chains, and belts

What Are the OSHA Rules for Machine Guarding Safety?

OSHA enforces strict regulations for machine guarding to prevent workplace injuries. Key requirements include:

General Duty Clause

Under the OSH Act of 1970, employers must provide a workplace free from recognized hazards that could cause serious harm.

General Requirements for All Machines

29 CFR 1910.212 specifically requires all machines to be equipped with guards to prevent contact with moving parts and flying debris at the point of operation. They should prevent an operator from having any part of their body in the danger zone while operating.

This requirement also details specific types of machines and appropriate enclosures and machine guarding rules.

Inspections, Maintenance, and Lockout/Tagout

Regular inspections and employee training are essential to meet OSHA standards along with lockout/tagout for powered devices during maintenance.

How Do I Know if My Machine Guards Are Working Properly?

A few key steps can help you ensure your machine guards are working optimally:

1. Regular inspections: Conduct routine checks to ensure guards are securely attached and in good condition. Look for cracks, wear, or signs of tampering.
2. Test interlocking systems: For machines with interlocking guards, regularly test that the machine shuts down when the guard is removed or opened.
3. Verify proper alignment: Make sure adjustable and self-adjusting guards are correctly positioned to cover hazardous areas during operation.
4. Maintenance logs: Keep detailed records of inspections and maintenance to identify recurring issues and demonstrate compliance during audits.

Operators should also be trained to identify any machine guarding procedures that aren’t working properly and report them immediately.

What Are Some Common Mistakes Regarding Machine Guarding?

Even with the best intentions, we see errors in implementing machine guarding. Some common mistakes include:

1. Using inadequate guards: Guards that don’t fully cover hazards or are made from weak materials can fail to protect workers.
2. Removing or disabling guards: Operators sometimes remove guards for convenience, which exposes them to serious risks. This is a common issue, especially during maintenance or troubleshooting.
3. Failure to train employees: Workers may not understand how to use machine guards properly or why they are essential, leading to unsafe practices.
4. Improper maintenance: Failing to inspect and repair guards regularly.
5. Ignoring custom solutions: Machines with unique hazards may require custom-designed guards rather than relying on generic solutions.

Get Expert Help with Machine Guarding Safety

Pacific Blue Engineering provides functional safety services, custom automation solutions, and legacy control modernization to ensure you operate efficiently and safely. We can handle the most demanding and complex projects to meet your deadlines and specifications—and keep your workers safe.

Contact Pacific Blue Engineering today to ensure you comply with machine guarding safety regulations and protecting your employees.