Occupational Safety and Health Administration (OSHA) has designed machine guarding requirements to protect workers from injuries caused by moving machine parts.These standards are based on regulation 29 CFR 1910 Subpart O.
According to these OSHA regulations, machines are equipped with guards to prevent contact with dangerous parts such as belts, pulleys, gears, and cutting edges. Guards should also prevent injuries from flying debris or sparks and contain moving parts that might pose a risk during operation.
Machine guards must be firmly secured and not create new hazards themselves. There are three main types of guards:
- Fixed
- Adjustable
- Self-adjusting
As an employer, you are responsible for maintaining guards in proper condition and ensuring that workers are trained to use machines safely. OSHA also places high priority on regular inspection and prompt correction of any issues.
What is Machine Guarding?
Machine guarding refers to the use of physical barriers or devices to protect workers from the dangerous moving parts of machinery. The point is to prevent accidents such as cuts, crushes, and amputations by keeping workers away from hazardous areas during operation.
For example, think of an industrial sewing machine. Such a machine has a shield that partially covers or guards its fast-spinning and sharp blade to reduce the likelihood of its human operators getting injured or even maimed during operations.
This is just one example. Various equipment require a wide range of ergonomic and engineering designs to ensure worker and workplace safety.
Examples of Machine Hazards Requiring Guarding
The type of machine guarding will depend on a number of things. This includes the type of equipment and the layout of the factory or work floor, as well as the knowledge and training of the workers.
Here is a list of machine parts and working conditions that require machine guarding:
- Rotating parts. This applies to machine parts that include gears, pulleys, and shafts.
- Point of operation. This refers to where work is being performed on the material.
- Flying chips or sparks. There are operations, such as in welding, that involve flying sparks that may carry risks of burning to the worker.
- Pinch points. This refers to locations between moving parts. If workers body parts such as fingers get stuck in such points, it can lead to severe injuries.
- Cutting edges. This refers to blades, knives, and saws. These parts, especially when they are fast moving, threaten workers with severe cuts or even amputation injuries.
- In-running nip points. This refers to the points between rollers or belts. They’re similar to pinch points, and workers can get severely injured if their clothes or body parts get stuck in those points.
Types of Machine Guards and Their Functions
Machine guards come in various types, each serving to protect workers from specific machine hazards while allowing safe operation. Here’s a list of the various types of guards.
- Fixed Guards: These are permanent barriers that cover hazardous areas, such as rotating parts or cutting edges. They are simple and effective, providing reliable protection.
- Interlocking Guards: These guards automatically shut off the machine if the guard is removed or opened. They ensure the machine cannot operate while exposed to danger.
- Adjustable Guards: These are flexible guards that can be manually repositioned to accommodate different sizes of materials or parts being processed.
- Self-Adjusting Guards: These guards automatically move to expose only the necessary part of the machine when in use and return to a safe position afterward, minimizing exposure.
OSHA Standards for Machine Guarding
OSHA’s machine guarding standards, outlined in 29 CFR 1910 Subpart O, require employers to protect workers from dangerous machine parts, such as moving components, points of operation, and flying debris.
Machine guards must prevent contact with hazards, be securely attached, and not create additional risks. Employers must ensure regular inspection, maintenance of guards, and proper employee training.
Here is a list of the most common OSHA standards for machine guarding:
- General Requirement. Machines must have guards to protect operators from hazards like rotating parts, flying chips, and sparks.
- Point of Operation. Machine points where work is performed must be guarded.
- Anchoring of Fixed Machinery. Machines must be securely anchored to prevent movement during operation.
- Protection from Flying Debris. Machines must be designed to prevent ejected parts or materials from harming workers.
- Emergency Stops. Machines should be equipped with emergency stop devices when applicable.
Cal OSHA vs. OSHA: Machine Guarding Requirements
Cal/OSHA and federal OSHA both have machine guarding requirements, but there are key differences due to California’s stricter regulations.
- Specific Standards. Cal/OSHA often has more detailed or stricter standards compared to federal OSHA. For example, California mandates more comprehensive protection in certain industries.
- State Enforcement. Cal/OSHA enforces its own regulations, which may include more frequent inspections and stricter penalties than federal OSHA.
- Environmental Considerations. Cal/OSHA often integrates safety requirements with environmental laws, especially in industries like agriculture and construction, which can affect machine guarding compliance.
The table provides more details on the differences:
| Aspect |
OSHA |
Cal OSHA |
| General Guarding Requirement | Requires guards to protect workers from hazards like rotating parts and flying debris. | Similar requirement, but emphasizes specific types of machines, including presses and cutters. |
| Point of Operation Guarding | General guidelines for guarding points of operation. | More detailed standards for machine types, including specific guarding dimensions and equipment use. |
| Guard Openings | No specific table for guard openings; requires prevention of contact with hazardous parts. | Provides maximum permissible guard openings based on dimensions (Table G-3, Figure G-8). |
| Interlocking Guards | General requirement for interlocking systems where applicable. | Detailed regulations for interlocking guards on power presses, focusing on safety and functionality. |
| Emergency Stops | Encouraged for all machines, with general guidelines for placement and accessibility. | Cal/OSHA may require more stringent use of emergency stop mechanisms on specific machine categories. |
| Regulation Scope | Federal standards apply across the U.S., with general coverage for industries. | Stricter requirements in specific industries, such as agriculture and construction, within California. |
| Inspection and Enforcement | Enforced by federal OSHA, with penalties for non-compliance. | Enforced by Cal/OSHA, with potentially more frequent inspections and higher penalties in California. |
Common Machine Guarding Violations
Employers should guard their worker’s reputation against machine guarding violations. Doing so reduces the risk of injuries and the liabilities that come with them.
Here is a list of the most common machine guarding violations to avoid:
- Missing or inadequate guards on moving parts like belts, gears, or blades
- Failure to guard points of operation where material is worked on
- Improperly maintained or insecure guards
- Neglecting regular inspections
- Leaving worn or damaged guards in use
- Lack of proper employee training
Employers should take special care to regularly inspect machinery to ensure that all guarding requirements are in place. More importantly, they should make sure that workers are trained and educated in using machines properly to avoid injuries.
Best Practices for Compliance
Machine guarding best practices include providing comprehensive employee training on equipment operation, wearing personal protective gear, and using lockout/tagout procedures.
The installation of physical barriers like wire systems, guardrails, and safety bollards to prevent accidents is also a major necessity. Mesh netting can catch falling materials, and staff should avoid loading zones unless authorized.
Regular maintenance checks and safety audits can help ensure ongoing compliance and hazard identification. Proper training and protective systems significantly reduce risks, making work environments safer for everyone involved.
Conclusion
Machine guarding requirements help protect your employees against injuries. When it comes to using machinery, efficiency and cost-cutting are not the main priority. Safety requirements should also be considered. As a matter of fact, when looking at the various benefits of machine guarding requirements from Osha and Cal OSHA, it would be safe to say that following machine guarding requirements may be more efficient and cost-saving in the long run.
Not only would you be able to avoid hefty fines and fees, you will also be able to keep your workers safe and productive from avoiding injuries. Lastly, with guarding requirements in place, workers can feel more safe.
