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In 2019, machine guarding ranked #9 on OSHA’s list of most frequently cited violations in the U.S. (OSHA, 2020).  Moving parts of machines have the potential to cause severe injuries in the workplace such as amputations, crushed fingers and more.  While these injuries are extremely serious, these injuries can be prevented with the use of proper safeguarding and controls.

OSHA- What do I report?

An amputation is the traumatic loss of all or part of a limb or other external body part.  This would include fingertip amputations with or without bone loss, medical amputations resulting from irreparable damage and amputations of body parts that have since been reattached.  If, and when, a health care professional's diagnosis is available, the employer should rely on that diagnosis (OSHA, 2020). 

Much like in-patient hospitalizations and eye loss, amputations must be reported to OSHA within 24 hours of the incident. 

Hazard Recognition

In order to prevent injuries resulting from improper guards, we must first be able to identify areas and machines where hazards are present.  Generally speaking, there are two areas that present the greatest hazards on a machine:

1. The parts that move or transmit power (i.e., belts, pulleys, gear wheels, etc.)
2. The parts that actually do the work (i.e., blades, saws, drills, etc.)

To identify these dangerous parts of a machine, look for signs of flying particles, shear points, crushing areas, cutting areas or any other areas where there is machine movement and potential for injury.

Guards

There are generally four types of guards:

Fixed - A fixed guard is a permanent part of a machine that is not dependent on movement.  These types of guards are relatively simple; however, they can be limited to specific operations since they cannot be moved.  Examples of fixed guards would be fences, cages or other barriers that separate workers from the intended hazard.    

Self-adjusting - These guards provide a barrier that moves according to the size of the stock entering the danger area.  These guards are often commercially available; however, they do always provide maximum protection and may interfere with visibility.  An example of these would be on an electric hand saw where the guard automatically adjusts to the size of material being cut.

Adjustable - Adjustable guards are self-explanatory.  These are guards that can be adjusted by the operator for maximum flexibility.  These guards can be constructed to suit different applications.  However, these guards have a greater chance of human error which can lead to increased injuries.  A common example of an adjustable guard would be a shield guard on a bench grinder, bandsaw or similar machine that allows for movement and flexibility depending on the job at hand.

Interlocked - Unlike fixed guards, interlocked guards can be moved or opened.  However, when an interlocked guard is not in place, the machine automatically shuts off and will not start again until the guard has been installed back in place.  Interlocked guards can provide maximum protection; however, they require careful adjustment and maintenance.  Examples of interlocked guards would be safety light curtains or a door/gate that automatically turns off the machine when opened. 

Summary

Proper machine guarding is an extremely important factor in preventing workplace injuries such as amputations, crushed limbs and more.  It is not just important to have guards in place but also to train and educate your employees on machine guarding and how to prevent accidents and injuries from those hazards.  As with any workplace hazard, administrative controls such as machine guard signage and PPE such as eye and hand protection, are also important controls to help prevent employee injuries.  If machine guarding is an area where you think your company can improve, the AlaCOMP Online Safety Library has several additional training materials and resources to assist you in your workplace safety needs.  

For more information on machine guarding, visit AlaCOMP’s FREE Online Safety Library with your company’s login credentials and click on topic index “Machinery Safety”. As always, the AlaCOMP Loss Control team is here to assist you in any way we can so please reach out to us if you have any questions or concerns. 

References: UNITED STATES DEPARTMENT OF LABOR. (n.d.). Retrieved January 08, 2021, from https://www.osha.gov/