Safeguarding Equipment and Protecting Employees from Amputations

The following article is from the OSHA website and contains valuable information on how to implement a machine guarding program to protect your most valuable asset, your employees from machine related amputations at work.

This publication is in the public domain and may be reproduced, fully or partially, without permission. Source credit is requested, but not required. The full, 60 page handbook is available as a free download here.

Amputations are among the most severe and dis-abling workplace injuries that often result in permanent disability. They are widespread and involve various activities and equipment. (The U.S. Bureau of Labor Statistics 2005 annual survey data indicated that there were 8,450 non-fatal amputation cases – involving days away from work – for all private industry.

Anyone responsible for the operation, servicing, and maintenance (also known as use and care) of machines (which, for purposes of this publication includes equipment) — employers, employees, safety professionals, and industrial hygienists— should read this publication.

This guide can help you, the small business employer, identify and manage common amputation hazards associated with the operation and care of machines.

To prevent employee amputations, you and your employees must first be able to recognize the con-tributing factors, such as the hazardous energy associated with your machinery and the specific employee activities performed with the mechanical operation.

Understanding the mechanical components of machinery, the hazardous mechanical motion that occurs at or near these components and specific employee activities performed in conjunction with machinery operation will help employees avoid injury.

Consult these standards directly to ensure full compliance with the provisions as this publication is not a substitute for the standards. States with OSHA-approved plans have at least equivalent standards. Contact your state office for more information.

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Employers are responsible for providing a safe and healthful workplace for their employees. OSHA’s role is to assure the safety and health of America’s employees by setting and enforcing standards; providing training, outreach, and education; establishing partnerships; and encouraging continual improvement in workplace safety and health.

This publication is in the public domain and may be reproduced, fully or partially, without permission. Source credit is requested, but not required.

This information is available to sensory impaired individuals upon request. Voice phone: (202) 693- 1999; teletypewriter (TTY) number: (877) 889-5627.
Edwin G. Foulke, Jr.
Assistant Secretary of Labor for
Occupational Safety and Health

More machine guarding safety information at Lovegreen Machine Guarding

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Are there machines in your facility that violate OSHA safeguarding standards? We can help you find out with an on-site, machine safety survey. Our trained professionals will come to your site and perform a Machine Safeguarding Evaluation at 50% off the regular price.

From now until December 31st, 2009, Lovegreen Risk Management is offering you a chance to have your machines inspected for safety and regulatory compliance at 50% off our normal rates.

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Lovegreen Machine Guarding ---- 1.800.262.8284

Hazard Analysis & Machine Guarding

As an employer, you are concerned about maintaining productivity, efficiency, and employee morale. Companies that institute a comprehensive safety and machine guarding program are amazed at the positive effects on the company's business and employee attitudes! Our trained professionals will come to your site, perform a Hazard Analysis Safety Audit, and recommend proactive preventive measures.

So what is Hazard Analysis? The first thing to do is to identify potential machine hazards by determining how serious the hazard is. Will an employee be injured if this hazard is not reduced? Secondly, how likely is it that the hazard will result in an accident? Finally, how often is the machine used? A combination of all three variables results in an assessment of risk score. The higher the total score is, the higher the probability of an occurrence with the machine.

Once the hazard analysis has generated a risk score, it needs to be determined if the risk can be eliminated all together. Sometimes the fix is as simple as installing a panel over the hazard with tamper proof hardware. In most cases, if the safety risk must be managed if it cannot be eliminated. Guarding the hazard with physical barriers and electronic devices can reduce the level of risk and probability of an accident.

There are several areas of interest when performing a safety audit on a cutting or turning machine. The first step is to determine if the machine’s motor controls meet current standards. OSHA and ANSI standards require that machines have an emergency stop within the operator’s reach. It should be red, latch when pushed and have a yellow background. The standards also require that there must be a way to disconnect power coming to the machine. The switch must be able to be locked in the off position.

All machines must be equipped with a power outage device that does not allow the machine to restart automatically after a power outage. The operator must take an action, such as pushing the start button to restart the machine. Image the possibilities if a machine were to restart by itself when the power turns back on.

Another area to survey is the point of operation. This is the place where the machine does its work. For example, where a drill bit enters a piece of wood. This area must have a shield that protects the operator from chips, broken bits and coolant.

One area that needs special attention is the power-transmission components. This includes belts, pulleys, gears, couplings and rotating shafts. These items create pinch and entanglement hazards and require careful inspection. All areas power transmission items up to 7 feet from the floor must be guarded.

A final category is everything else that has not been covered yet. You need to make sure that the machine is securely anchored to the floor, a workbench or is on a mobile cart that has locking wheels. Make sure that all OEM parts, guards and labels are in place. Areas that cannot be guarded must have a sign that warns the operator.

Download a FREE Machine Safety Survey Tool to conduct your own surveys to uncover the most common problems on your woodworking and metal working machines. It is easy to use and to understand.

Lovegreen Machine Guarding

More Guarding - Fewer Accidents?

When it comes to machine guarding, does more guarding result in fewer accidents? I have often wondered that. It might depend upon how you define ‘accident’. Is a mishap where no injury occurs considered an accident? How about if it results in damage to the machinery or the work piece?

I recall when lap seat belts in cars were first encouraged there was criticism that though the seat belts would indeed keep people from flying through the windshields it didn’t necessarily make them safer. The drivers and passengers would still bend forward and their heads would collide with steering wheels and dashboards. The seat belts have been upgraded since with a locking over-the-shoulder harness. Softer dashboards, front and side air bags have also been added.

These safe guards have made a difference in fatalities. In Minnesota, 85% of the drivers wear their seat belts. Of the car accidents that result in a fatality, upwards of 55% involve people who weren’t wearing their safety belt. That 15% of the population who don’t wear their seat belt provide a disproportionately high amount of the car accident fatalities.

So if the fatalities resulting from an auto accident are down, is the number of accidents as a whole down because of seat belt use? Are the minor injuries also reduced? Some experts theorized with the advent of seat belts that more accidents would actually result. They theorized that people would feel safer while wearing a seat belt and then feel more invincible, causing them to drive more recklessly. This recklessness might appear as driving at faster speeds or trying to multitask by also talking on a cell phone or hunt for a radio station while driving.

I have seen this theory affirmed when taking hikes with a Boy Scout troop. Most of the hikes the troop takes are along well defined paths. When walking on these trails, a scout feels relatively safe and doesn’t really pay much attention to where he is stepping. On these hikes the scouts will often stumble over the odd tree root or rock that they failed to notice. Sometimes this led to a minor twisted ankle. These are accidents but not serious or life threatening.

On a couple of occasions the troop has hiked over very rugged terrain. The scouts have climbed over rock falls where sharp ridges of rock are protruding, and where it would be very easy to twist an ankle. If they should happen to fall, a serious accident could result. During these hikes I noticed the scouts paid close attention to what they were doing. They stepped carefully, kept their arms out for balance and were prepared to catch themselves by reaching out and grabbing on to something to prevent a fall.

As a leader and an adult in a position of responsibility there would be lots of butterflies in my stomach during these hikes. I would imagine all the possible accidents that could occur. Fortunately, during these more dangerous excursions, accidents did not occur.

So how does this translate into the world of machine guarding? It stands to reason that installing guards on shop machines might not reduce the number of accidents, but would make them less serious in nature. The accident might result in a cut or scratch rather than a lost digit.

Thanks to Andy Goettsch

Machine Guarding Basics

You might wonder why you would have to install guards on your woodworking or metal working machines. Aren't manufacturers required to install guards on the machines they sell? The short answer to that is no.

Many manufacturers continue to build and sell their tools without the necessary safeguards and electrical controls required by OSHA and various safety regulations. Current laws do not require the machine manufacturers to do so. OSHA requires that the employer make sure all of the machines that are used in the workplace comply with current standards.

Simply stated, it is up to you to make sure your machines are properly guarded so you do not get hurt or hurt anyone around you. Unfortunately, not every machine will perform the intended function without posing an injury hazard to the operator. Therefore, you must make a reasonable effort to protect the operator from its inherent hazards.

So where do most mechanical hazards occur? Moving parts pose hazards in three main places - The Point of Operation, Power Transmission and Other Moving Parts.

The Point of Operation is the place where machine's purpose takes place. For example, where a saw blade cuts wood or where a drill bit bores a hole. Common injuries include cuts ranging from minor to fatal, flying material chips, ejected parts and puncture wounds. These areas need to be guarded with chip shield or rigid barriers.

The Power Transmission is the point where power is transferred from the machine's motor to its point of operation. Belts, pulley and lead screws are a major source of crushed hands, entangled hair and clothing. These accidents occur quickly and often cause serious injury or fatalities. Exposed belts and pulleys should be covered with a panel that cannot be easily removed to protect the operator.

Other Moving Parts include any other machine part that moves in a rotating, reciprocating or feeding motion.

You might ask, “How do I know if a machine requires a safety guard? A good rule to remember is, "Any machine part, function, or process which may cause injury must be safeguarded. When the operation of a machine or accidental contact with it can injure the operator or others in the vicinity, the hazard must either be controlled or eliminated." (From the OSHA Machine-Guarding Standard)

After assessing the machines in your shop and performing necessary guarding, you should be confident that the machines are guarded to the relevant standards. If you are not sure that they are, it may be time to seek help from an expert.

The purpose of hiring an expert is to help you provide a workplace free of machine hazards. Working with your safety committee, the machine guarding company will provide a thorough assessment of machine hazards. Next, they will implement a machine-guarding program that meets all manufacturing and regulatory requirements.

The result is an enhanced bottom line due to the increased productivity, efficiency and morale of your company’s most valuable asset, your employees.
Motor controls are another important item to review when performing a safety audit on a cutting or turning machine.

The first step is to determine if the machine’s motor controls meet current standards. OSHA and ANSI standards require that machines have an emergency stop within the operator’s reach. It should be red, latch when pushed and have a yellow background. The standards also require that there must be a way to disconnect power coming to the machine. The switch must be able to be pad-locked in the off position.

All machines must be equipped with a power outage device that does not allow the machine to restart automatically after a power outage. The operator must take an action, such as pushing the start button to restart the machine. Image the possibilities if a machine were to restart by itself when the power turns back on.

The safety expert you choose will help you provide a safe workplace with OSHA Compliant Hazard Guards and encourage employee involvement through a custom machine guarding program. The result is an enhanced bottom line due to the increased productivity, efficiency and morale of your company's most valuable asset, your employees.

More information at http://www.lovegreen.com/