Introduction Amputations are among the most severe and disabling 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. Approximately
forty-four percent (44%) of all workplace amputations occurred
in the manufacturing sector and the rest occurred across the
construction, agriculture, wholesale and retail trade, and
service industries.) These injuries result from the use and
care of machines such as saws, presses, conveyors, and bending,
rolling or shaping machines as well as from powered and non-powered
hand tools, forklifts, doors, trash compactors and during materials
handling activities.
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. Primary safeguarding, as used in this
publication, includes control methods that protect (e.g., prevent
employee contact with hazardous machine areas) employees from
machine hazards through effective machine guarding techniques.
In addition, a hazardous energy control (lockout/tagout) program
needs to complement machine safeguarding methods in order to
protect employees during potentially hazardous servicing and
maintenance work activities.
This guide can help you, the small business employer, identify
and manage common amputation hazards associated with the operation
and care of machines. The first two sections of the document, Recognizing
Amputation Hazards and Controlling Amputation Hazards,
look at sources of amputations and how to safeguard machinery
and control employee exposure to hazardous energy (lockout/
tagout) during machine servicing and maintenance activities.
The section on Specific Machinery Hazards and Safeguarding
Methods identifies the hazards and various control methods
for machinery associated with workplace amputations, such as:
mechanical power presses, press brakes, conveyors, printing
presses, roll-forming and roll-bending machines, shears, food
slicers, meat grinders, meat-cutting band saws, drill presses,
milling machines, grinding machines, and slitting machines.
The information in this booklet does not specifically address
amputation hazards on all types of machinery in general industry,
construction, maritime and agricultural operations; however,
many of the described safeguarding techniques may be used to
prevent other amputation injuries. Additionally, while this
manual concentrates attention on concepts and techniques for
safeguarding mechanical motion, machines obviously present
a variety of other types of energy hazards that cannot be ignored.
For example, pressure system failure could cause fires and
explosions. Machine electrical sources also pose electrical
hazards that are addressed by other OSHA standards, such as
the electrical standards contained in Subpart S. Full discussion
of these matters is beyond the scope of this publication. For
compliance assistance purposes, references and the appendices
are provided on applicable OSHA standards, additional information
sources, and ways you may obtain OSHA assistance.
OSHA Standards Although this guide recommends ways to safeguard and lockout/tagout
energy sources associated with machinery hazards, there are
legal requirements in OSHA standards that you need to know
about and comply with. The following OSHA standards are a few
of the regulations that protect employees from amputation hazards.
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. For detailed information about
machine guarding and lockout/tagout, see the following resources:
National Consensus Standards OSHA recognizes the valuable contributions of national consensus
standards and these voluntary standards may be used as guidance
and recognition of industry accepted practices. For example,
the American National Standards Institute (ANSI) publishes
numerous voluntary national consensus standards on the safe
care and use of specific machinery. These consensus standards
provide you with useful guidance on how to protect your employees
from machine amputation hazards and the control methods described
may assist you in complying with OSHA performance-based standards.
Furthermore, OSHA encourages employers to abide by the more
current industry consensus standards since those standards
are more likely to be abreast of the state of the art than
an applicable OSHA standard may be. However, when a consensus
standard addresses safety considerations, OSHA may determine
that the safety practices described by that consensus standard
are less protective than the requirement(s) set forth by the
pertinent OSHA regulations. OSHA enforcement policy regarding
the use of consensus standards is that a violation of an OSHA
standard may be deemed de minimis in nature if the
employer complies with a consensus standard (that is not incorporated
by reference) rather than the OSHA standard in effect and if
the employer's action clearly provides equal or greater
employee protection. (Such de minimis violations require
no corrective action and result in no penalty.)
For example, the OSHA point-of-operation guarding provisions,
contained in paragraph 1910.212(a)(3), require the guarding
device to…be in conformance with any appropriate
standards thereof, or in the absence of applicable specific
standards, shall be so designed and constructed as to prevent
the operator from having any part of his body in the danger
zone during the operating cycle. The terms applicable
standards or appropriate standards, as used in the context
of 29 CFR 1910.212, are references to those private consensus
standards that were adopted (source standards) or incorporated
by reference in the OSHA standards.
In some instances, a specific national consensus standard
(that is not incorporated by reference or a source standard),
such as an ANSI standard for a particular machine, may be used
for guidance purposes to assist employers in preventing an
operator from having any body part in the machine danger zone
during the operating cycle. Also, OSHA may, in appropriate
cases, use these consensus standards as evidence that machine
hazards are recognized and that there are feasible means of
correcting the hazard. On the other hand, some national consensus
standards may sanction practices that provide less employee
protection than that provided by compliance with the relevant
OSHA provisions. In these cases, compliance with the specific
consensus standard provision would not constitute compliance
with the relevant OSHA requirement.
Recognizing Amputation Hazards To prevent employee amputations, you and your employees must
first be able to recognize the contributing 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.
Point of Operation is the area of the machine
where the machine performs work – i.e., mechanical actions
that occur at the point of operation, such as cutting, shaping,
boring, and forming.
Power-Transmission Apparatus is all components
of the mechanical system that transmit energy, such as flywheels,
pulleys, belts, chains, couplings, connecting rods, spindles,
cams, and gears.
Other Moving Parts are the parts of the
machine that move while the machine is operating, such as reciprocating,
rotating, and transverse moving parts as well as lead mechanisms
and auxiliary parts of the machine.
Hazardous Mechanical Motions A wide variety of mechanical motion is potentially hazardous.
Here are the basic types of hazardous mechanical motions:
Rotating Motion (Figure 1) is
circular motion such as action generated by rotating collars,
couplings, cams, clutches, flywheels, shaft ends, and spindles
that may grip clothing or otherwise force a body part into
a dangerous location. Even smooth surfaced rotating machine
parts can be hazardous. Projections such as screws or burrs
on the rotating part increase the hazard potential.
Reciprocating Motion (Figure 2)
is back-and-forth or up-and-down motion that may strike or
entrap an employee between a moving part and a fixed object.
Transversing Motion (Figure 3)
is motion in a straight, continuous line that may strike or
catch an employee in a pinch or shear point created by the
moving part and a fixed object.
Punching Action (Figure 5) begins
when power causes the machine to hit a slide (ram) to stamp
or blank metal or other material. The hazard occurs at the
point of operation where the employee typically inserts, holds,
or withdraws the stock by hand.
Shearing Action (Figure 6) involves
applying power to a slide or knife in order to trim or shear
metal or other materials. The hazard occurs at the point of
operation where the employee typically inserts, holds, or withdraws
the stock by hand.
Bending Action (Figure 7) is power
applied to a slide to draw or stamp metal or other materials
in a bending motion. The hazard occurs at the point of operation
where the employee typically inserts, holds, or withdraws the
stock by hand.
In-Running Nip Points (Figure 8),
also known as “pinch points,” develop when two
parts move together and at least one moves in rotary or circular
motion. In-running nip points occur whenever machine parts
move toward each other or when one part moves past a stationary
object. Typical nip points include gears, rollers, belt drives,
and pulleys.
Hazardous Activities Employees operating and caring for machinery perform various
activities that present potential amputation hazards.
Machine set-up/threading/preparation,*
Machine inspection,*
Normal production operations,
Clearing jams,*
Machine adjustments,*
Cleaning of machine,*
Lubricating of machine parts,* and
Scheduled and unscheduled maintenance.*
* These activities are servicing and/or maintenance activities.
Hazard Analysis You can help prevent workplace amputations by looking at
your workplace operations and identifying the hazards associated
with the use and care of the machine. A hazard analysis is
a technique that focuses on the relationship between the employee,
the task, the tools, and the environment. When evaluating work
activities for potential amputation hazards, you need to consider
the entire machine operation production process, the machine
modes of operation, individual activities associated with the
operation, servicing and maintenance of the machine, and the
potential for injury to employees.
The results from the analysis may then be used as a basis
to design machine safeguarding and an overall energy control
(lockout/tagout) program. This is likely to result in fewer
employee amputations; safer, more effective work methods; reduced
workers' compensation costs; and increased employee productivity
and morale.
Controlling Amputation Hazards Safeguarding is essential for protecting employees from needless
and preventable injury. A good rule to remember is:
Any machine part, function, or process that may cause
injury must be safeguarded.
In this booklet, the term primary safeguarding methods refers
to machine guarding techniques that are intended to prevent
or greatly reduce the chance that an employee will have an
amputation injury. Refer to the OSHA general industry (e.g.,
Subpart O) and construction (e.g., Subparts I and N) standards
for specific guarding requirements. Many of these standards
address preventive methods (such as using barrier guards or
two-hand tripping devices) as primary control measures; while
other OSHA standards allow guarding techniques (such as a self-adjustable
table saw guard) that reduce the likelihood of injury. Other
less protective safeguarding methods (such as safe work methods)
that do not satisfactorily protect employees from the machine
hazard areas are considered secondary control methods.
Machine safeguarding must be supplemented by an effective
energy control (lockout/tagout) program that ensures that employees
are protected from hazardous energy sources during machine
servicing and maintenance work activities. Lockout/tagout plays
an essential role in the prevention and control of workplace
amputations. In terms of controlling amputation hazards, employees
are protected from hazardous machine work activities either
by: 1) effective machine safeguarding, or 2) lockout/tagout
where safeguards are rendered ineffective or do not protect
employees from hazardous energy during servicing and maintenance
operations.
Additionally, there are some servicing activities, such as
lubricating, cleaning, releasing jams and making machine adjustments
that are minor in nature and are performed during normal production
operations. It is not necessary to lockout/ tagout a machine
if the activity is routine, repetitive and integral to the
production operation provided that you use an alternative control
method that affords effective protection from the machine's
hazardous energy sources.
Safeguarding Machinery The employer is responsible for safeguarding machines and
should consider this need when purchasing machinery. Almost
all new machinery is available with safeguards installed by
the manufacturer, but used equipment may not be.
If machinery has no safeguards, you may be able to purchase
safeguards from the original machine manufacturer or from an
after-market manufacturer. You can also build and install the
safeguards in-house. Safeguarding equipment should be designed
and installed only by technically qualified professionals.
If possible, the original equipment manufacturer should review
the safeguard design to ensure that it will protect employees
without interfering with the operation of the machine or creating
additional hazards.
Regardless of the source of safeguards, the guards and devices
used need to be compatible with a machine's operation
and designed to ensure safe operator use. The type of operation,
size, and shape of stock, method of feeding, physical layout
of the work area, and production requirements all affect the
selection of safeguards. Also, safeguards should be designed
with the machine operator in mind as a guarding method that
interferes with the operation of the machine may cause employees
to override them. To ensure effective and safe operator use,
guards and devices should suit the operation.
The Performance Criteria for Safeguarding [ANSI B11.19-2003]
national consensus standard provides valuable guidance as the
standard addresses the design, construction, installation,
operation and maintenance of the safeguarding used to protect
employees from machine hazards. The following safeguarding
method descriptions are, in part, structured like and, in many
ways are similar to this national consensus standard.
Primary Safeguarding Methods Two primary methods are used to safeguard machines: guards
and some types of safeguarding devices. Guards provide physical
barriers that prevent access to danger areas. Safeguarding
devices either prevent or detect operator contact with the
point of operation or stop potentially hazardous machine motion
if any part of an individual's body is within the hazardous
portion of the machine. Both types of safeguards need to be
properly designed, constructed, installed, used and maintained
in good operating condition to ensure employee protection.
Guards Guards usually are preferable to other control methods because
they are physical barriers that enclose dangerous machine parts
and prevent employee contact with them. To be effective, guards
must be strong and fastened by any secure method that prevents
the guard from being inadvertently dislodged or removed. Guards
typically are designed with screws, bolts and lock fasteners
and usually a tool is necessary to unfasten and remove them.
Generally, guards are designed not to obstruct the operator's
view or to prevent employees from doing a job.
In some cases, guarding may be used as an alternative to
lockout/tagout because employees can safely service or maintain
machines with a guard in place. For example, polycarbonate
and wire-mesh guards provide greater visibility and can be
used to allow maintenance employees to safely observe system
components. In other instances, employees may safely access
machine areas, without locking or tagging out, to perform maintenance
work (such as machine cleaning or oiling tasks) because the
hazardous machine components remain effectively guarded.
Guards must not create additional hazards such as pinch points
or shear points between guards and other machine parts. Guard
openings should be small enough to prevent employees from accessing
danger areas. (See Table 1 and Figures 9 through
12 for commonly used machine guards.)
Barrier that allows for
stock feeding but does not permit operator to reach the
danger area.
Can be constructed
to suit many applications.
Permanently encloses
the point of operation or hazard area.
Provides
protection against machine repeat.
Allows simple,
in-plant construction, with minimal maintenance.
Sometimes not practical
for changing production runs involving different size
stock or feeding methods.
Machine adjustment and
repair often require guard removal.
Other means
of protecting maintenance personnel often required (lockout/tagout).
Adjustable
Barrier that adjusts for
a variety of production operations.
Can be constructed
to suit many applications.
Can be adjusted to
admit varying stock sizes.
May require frequent
maintenance or adjustment.
Operator may make guard
ineffective.
Self-Adjusting
Barrier that moves according
to the size of the stock entering point of operation.
Guard is in place when machine is at rest and pushes
away when stock enters the point of operation.
Off-the-shelf guards
are often commercially available.
Does not provide
maximum protection.
May require frequent maintenance
and adjustment.
Interlocking Barrier Guards
Shuts off or disengages
power and prevents machine start-up when guard is open.
Should allow for inching of machine.
Allows access for
some minor servicing work, in accordance with the lockout/tagout
exception, without time-consuming removal of fixed guards.
May require periodic
maintenance or adjustment.
Movable sections cannot
be used for manual feeding.
Some designs may be
easy to defeat.
Interlock control circuitry may
not be used for all maintenance and servicing work.
Safeguarding Devices Safeguarding devices are controls or attachments that, when
properly designed, applied and used, usually prevent inadvertent
access by employees to hazardous machine areas by:
Preventing hazardous machine component operation if your
hand or body part is inadvertently placed in the danger area;
Restraining or withdrawing your hands from the danger
area during machine operation;
Requiring the use of both of your hands on machine controls
(or the use of one hand if the control is mounted at a safe
distance from the danger area) that are mounted at a predetermined
safety distance; or
Providing a barrier which is synchronized with the operating
cycle in order to prevent entry to the danger area during
the hazardous part of the cycle.
These types of engineering controls, which either prevent
the start of or stop hazardous motion, may be used in place
of guards or as supplemental control measures when guards alone
do not adequately enclose the hazard. In order for these safeguarding
devices to accomplish this requirement, they must be properly
designed and installed at a predetermined safe distance from
the machine's danger area. Other safeguarding devices
(probe detection and safety edge devices) that merely detect,
instead of prevent, inadvertent access to a hazard are not considered primary safeguards.
(See Table 2 and Figures 13 through 17 for
the types of safeguarding devices.)
Cords connected to operator's
wrists and linked mechanically to the machine automatically
withdraw the hands from the point of operation during
the machine cycle.
Allows the hands
to enter the point of operation for feeding and removal.
Provides
protection even in the event of mechanical repeat.
Close
supervision ensures proper use and adjustment. Must be
inspected prior to each operator change or machine set-up
Limits
operator's movement and may obstruct their work
space.
Operator may easily make device ineffective
by not adjusting the device properly.
Restraint Devices
Wrists are connected by
cords and secured to a fixed anchor point which limit
operator's hands from reaching the point of operation
at any time.
Simple, few moving
parts; requires little maintenance.
Operator cannot
reach into the danger area.
Little risk of mechanical
failure; provides protection even in the event of mechanical
repeat.
Close
supervision required to ensure proper use and adjustment.
Must be inspected prior to each operator change or machine
set-up.
Operator must use hand tools to enter
the point of operation.
Limits the movement of
the operator; may obstruct work space around operator.
Operator
may easily make device ineffective by disconnecting the
device.
Presence-Sensing Devices
Interlock into the machine's
control system to stop operation when the sensing field
(photoelectric, radio frequency, or electromagnetic)
is disturbed.
Adjusts to fit different
stock sizes.
Allows access to load and unload
the machine.
Allows access to the guarded area
for maintenance and set-up activities.
Restricted
to machines that stop operating cycle before operator
can reach into danger area (e.g., machines with partial
revolution clutches or hydraulic machines).
Must
be carefully maintained and adjusted.
Does not
protect operator in the event of a mechanical failure.
Operator
may make device ineffective.
Presence-Sensing Mats
Interlock into machine's
control system to stop operation when a predetermined
weight is applied to the mat. A manual reset switch must
be located outside the protected zone.
Full visibility and
access to the work area.
Install as a perimeter
guard or over an entire area.
Configure for many
applications.
Restricted
to machines that stop operating cycle before operator
can reach into danger area (e.g., machines with part-revolution
clutches or hydraulic machines).
Some chemicals
can degrade the mats.
Does not protect operator
during mechanical failures.
Two-Hand Control
Requires concurrent and
continued use of both hands, preventing them from entering
the danger area.
Operator's
hands are at a predetermined safety distance.
Operator's
hands are free to pick up new parts after completion
of first part of cycle.
Requires a partial
cycle machine with a brake and anti-repeat feature.
Operator
may make devices without anti-tie-down ineffective.
Protects
the operator only.
Two-Hand Trip
Requires concurrent use
of both hands, prevents them from being in danger area
when machine cycle starts.
Operator's
hands are at a predetermined safety distance.
Can
be adapted to multiple operations.
No obstruction
to hand feeding.
Operator may make
devices without anti-tie-down ineffective.
Protects
the operator only.
Sometimes impractical because
distance requirements may reduce production below acceptable
level.
May require adjustment with tooling changes.
Requires
anti-repeat feature.
Type “A” Gate
(moveable barrier)
Applicable to mechanical
power presses. Provides barrier between danger area and
operator (or other employees) until completion of machine
cycle.
Prevents operator
from reaching into danger area during machine cycle.
Provides
protection from machine repeat.
May require frequent
inspection and regular maintenance.
May interfere
with operator's ability to see work.
Type “B” Gate
(moveable barrier)
Applicable to mechanical
power presses and press brakes. Provides a barrier between
danger area and operator (or other employees) during
the downstroke.
May increase production
by allowing the operator to remove and feed the press
on the upstroke.
Can only be used
on machines with a part-revolution clutch or hydraulic
machines.
May require frequent inspection and
regular maintenance.
May interfere with the operator's
ability to see work.
Secondary Safeguarding Methods Other safeguarding methods, such as those described in the Performance
Criteria for Safeguarding(ANSI B11.19-2003), may also
provide employees with some protection from machine hazards.
Detection safeguarding devices, awareness devices, safeguarding
methods and safe work procedures are described in this section.
These methods provide a lesser degree of employee protection
than the primary safeguarding methods and they are considered
secondary control measures as they do not prevent employees
from placing or having any part of their bodies in the hazardous
machine areas.
Secondary safeguarding methods are acceptable only when guards
or safeguarding devices (that prevent you from being exposed
to machine hazards) cannot be installed due to reasons of infeasibility.
Where it is feasible to use primary safeguarding methods, secondary
safeguarding methods may supplement these primary control measures;
however, these secondary safeguarding methods must not be used
in place of primary safeguarding methods.
Probe Detection and Safety Edge Devices A probe detection device (sometimes referred to as a ring
guard) detects the presence or absence of a person's
hand or finger by encircling all or part of the machine hazard
area. The ring guard makes you aware of your hand's
entry into a hazardous area and usually stops or prevents
a hazardous machine cycle or stroke, thereby reducing the
likelihood of injuring yourself in the point of operation.
These types of detection devices are commonly used on spot
welders, riveters, staplers and stackers because primary
safeguarding methods are not possible. However, probe detection
devices do not prevent inadvertent access to the point-of-operation
danger area; rather, they serve as a warning mechanism and
may prevent the initiation of or stop the machine cycle if
an employee's hand or finger(s) is too close to the
hazard area.
A safety edge device (sometimes called a bump switch)
is another type of safeguard that detects the presence of an
employee when they are in contact with the device's sensing
edge. A safety edge device protects employees by initiating
a stop command when the sensing surface detects the presence
of a person; however, they do not usually, when used by themselves,
prevent inadvertent access to machine danger areas. Therefore,
additional guarding or safeguarding devices must be provided
to prevent employee exposure to a machine hazard.
Awareness Devices Awareness devices warn employees of an impending, approaching
or present hazard. The first type is an awareness barrier which
allows access to machine danger areas, but it is designed to
contact the employee, creating an awareness that he or she
is close to the danger point. Awareness signals, through the
use of recognizable audible or visual signals, are other devices
that alert employees to an approaching or present hazard. Lastly,
awareness signs are used to notify employees of the nature
of the hazard and to provide instructions and training information.
OSHA standard 1910.145 provides design, application, and use
specifications for accident prevention (danger, caution, safety
instruction) signs and (danger, caution, warning) tags.
Safeguarding Methods Safeguarding methods protect employees from hazards by the
physical arrangement of distance, holding, openings or the
positioning of the machine components to ensure that the operator
cannot reach the hazard. Some safeguarding work methods include
safe distance safeguarding, safe holding safeguarding and safe
opening safeguarding. Requirements for these secondary control
measures may be found in ANSI B11.19-2003. Proper training
and supervision are essential to ensure that these secondary
safeguarding methods are being used properly. Safeguarding
work methods may require the use of awareness devices, including
the use of accident prevention signs where there is a need
for warning or safety instruction.
Safe Distance Safeguarding
Safeguarding by safe distance (by location) may involve an
operator holding and supporting a work-piece with both hands
at a predetermined minimum safe distance or, if both hands
cannot be used to hold the work-piece at a distance so that
the operator cannot reach the hazard with the free hand. For
example, the feeding process itself can create a distance safeguard
if the operators maintain a safe distance between their hands
and the point of operation. Additionally, where material position
gauges are used, they need to be of sufficient height and size
to prevent slipping of the material past the gauges.
Another example of a safe distance safeguarding method is
the use of gravity feed methods that reduce or eliminate employee
exposure to machine hazards as the part slides down a chute
into the point of operation. Automatic and semiautomatic feeding
and ejection methods can also protect the employee by minimizing
or eliminating employee exposure with potentially hazardous
machinery components. An employee places the part in a magazine
which is then fed into the point of operation. Automatic and
semiautomatic ejection methods include pneumatic (jet of air),
magnetic, mechanical (such as an arm), or vacuum. Figures
18 and 19 illustrate different types of automatic feeding
and ejecting methods.
Operator's hands are maintained away from the hazardous
portion of the machine cycle by requiring that both hands are
used to hold or support the work-piece, or by requiring that
one hand holds the work-piece while the other hand operates
the machine. For instance, if the stock is several feet long
and only one end of the stock is being worked on, the operator
may be able to hold the opposite end while performing the work.
The operator's body parts are out of the machine hazard
area during the hazardous portion of the machine cycle. However,
this work method only protects the operator.
Safe Opening Safeguarding
This method limits access to the machine hazardous areas
by the size of the opening or by closing off the danger zone
access when the work-piece is in place in the machine. Operators
are prevented from reaching the hazard area during the machine
operation; however, employee access to the danger area is not
adequately guarded when the work-piece is not in place.
Safe Work Procedures Safe work procedures are formal, written instructions which
describe how a task is to be performed. These procedures should
incorporate appropriate safe work practices, such as prohibiting
employees from wearing loose clothing or jewelry and requiring
the securing of long hair with nets or caps. Clothing, jewelry,
long hair, and even gloves can get entangled in moving machine
parts.
Complementary Equipment Complementary equipment is used in conjunction with selected
safeguarding techniques and it is, by itself, not a safeguarding
method. Some common complementary equipment used to augment
machine safeguarding include:
Emergency Stop Devices
Emergency stop devices are designed to be used in reaction
to an incident or hazardous situation and, as such, are not
considered machine safeguarding. These devices, such as buttons,
rope-pulls, cable-pulls, or pressure-sensitive body bars, neither
detect nor prevent employee exposure to machine hazards; rather
they initiate an action to stop hazardous motion when an employee
recognizes a hazard and activates them. (See Figure 20.)
Work-holding equipment is not used to feed or remove the
work-piece, but rather to hold it in place during the hazardous
portion of the machine cycle. Clamps, jigs, fixtures and back
gauges are examples of work-holding equipment. This equipment
may be used to reduce or eliminate the need for an employee
to place their hands in the hazard area.
Feeding and Ejection Systems
A feeding and ejection system (e.g., a gravity fed chute;
semi-automatic and automatic feeding and ejection equipment),
by itself, does not constitute secondary safeguarding. However,
the use of properly designed feed and ejection mechanisms can
protect employees by minimizing or eliminating the need for
them to be in a hazard area during the hazardous motion of
the machine.
Hand-Feeding Tools
Operators can use tools to feed and remove material into
and from machines so as to keep their hands away from the point
of operation. However, this must be done only in conjunction
with the guards and safeguarding devices described previously.
Hand tools are not point-of-operation guarding or safeguarding
devices and they need to be designed to allow employees' hands
to remain outside of the machine danger area. Using hand tools
requires close supervision to ensure that the operator does
not bypass their use to increase production. It is recommended
that these tools be stored near the operation to promote their
use.
To prevent injury and repetitive trauma disorders, hand-feeding
tools should be shatterproof and ergonomically designed for
the specific task being performed. (Figure 21 shows
typical handfeeding tools.)
Foot controls that are not securely fixed at a safe distance
do not constitute machine safeguarding because they do not
keep the operator's hands out of the danger area. If
you use foot-actuated controls that are not single-control
safeguarding devices, they will need to be used with some type
of guard or other safeguarding device.
Improperly used foot-actuated controls may increase productivity,
but the freedom of hand movement increases the risk of a point-of-operation
injury or amputation. Foot controls must be guarded to prevent
accidental activation by another employee or by falling material.
Do not ride the foot pedal. Ensure that the machine control
circuit is properly designed to prevent continuous cycling.
(See Figure 22 for an example of a properly guarded
foot control.)
Administrative Issues As an employer, you need to consider housekeeping practices,
employee apparel, and employee training. Implement good housekeeping
practices to promote safe working conditions around machinery
by doing the following:
Remove slip, trip, and fall hazards from the areas surrounding
machines;
Use drip pans when oiling equipment;
Remove waste stock as it is generated;
Make the work area large enough for machine operation
and maintenance; and
Place machines away from high traffic areas to reduce
employee distraction.
Employees should not wear loose-fitting clothing, jewelry,
or other items that could become entangled in machinery, and
long hair should be worn under a cap or otherwise contained
to prevent entanglement in moving machinery.
Adequate instruction in the safe use and care of machines
and supervised on-the-job training are essential in preventing
amputation injuries. Only trained employees should operate
machinery.
In addition to employee instruction and training, employers
need to provide adequate supervision to reinforce safe practices.
Take disciplinary action to enforce safe work practices and
working conditions.
Inspection and Maintenance Good inspection, maintenance and repair procedures contribute
significantly to the safety of the maintenance crew as well
as to the operators. To ensure the integrity of the machinery
and machine safeguards, a proactive, versus a break-down maintenance
program needs to be established based upon the:
Manufacturer's recommendations;
Good engineering practice; and
Any applicable OSHA provisions (such as the mechanical
power press inspection and maintenance requirements, contained
in 1910.217(e)).
Lockout/Tagout OSHA's lockout/tagout (LOTO) standard, 29 CFR 1910.147,
establishes minimum performance requirements for controlling
hazardous energy and it is intended to complement and augment
machine safeguarding practices. The lockout/tagout standard
applies only if employees are exposed to hazardous energy during
servicing/maintenance activities. An employer may avoid the
requirements of the LOTO standard if the safeguarding method
eliminates your employees' exposure to the machine danger
area during the servicing or maintenance work by using Machinery
and Machine Guarding methods in accordance with the requirements
contained in 29 CFR 1910, Subpart O.
Additionally, because some minor servicing may have to be
performed during normal production operations, an employer
may be exempt from LOTO in some instances. Minor tool changes
and adjustments and other minor servicing operations, which
take place during normal production operations, are not covered
by lockout/tagout if they are routine, repetitive and integral
to the use of the machine for production and if work is performed
using alternative effective protective measures that provide
effective employee protection.
In short, a hazardous energy control program is a critical
part of an overall strategy to prevent workplace amputations
during machine servicing and maintenance activities, such as
during the setting up of machines for production purposes,
bypassing guards to clear jams or lubricate parts, and inspecting,
adjusting, replacing, or otherwise servicing machine parts.
Machine amputations occur when an employer does not have or
fails to implement practices and procedures to disable and
control a machine's energy sources during machine servicing
and maintenance work.
Specific Machine Hazards and Safeguarding Methods As discussed earlier, 8,450 known non-fatal amputation cases
(involving days away from work) occurred in 2005 for all of
private industry. The most prevalent injury source was, by
far, machinery, which accounted for approximately 60% (5,080
instances) of the amputation cases. 1 The machinery listed
here cause amputation injuries, and appropriate safeguarding
and hazardous energy control (lockout/tagout) methods are addressed
in this section. Employers need to consult the OSHA standard
for specific machinery to ensure compliance with all requirements.
For other types of hazardous sources of injury, see Appendix
B.
Hazards of Mechanical Power Presses Although there are three major types of power presses—mechanical,
hydraulic, and pneumatic— the machinery that accounts
for a large number of workplace amputations are mechanical
power presses.
In mechanical power presses, tools or dies are mounted on
a slide, or ram, which operates in a controlled, reciprocating
motion toward and away from the stationary bed or anvil containing
the lower die. When the upper and lower dies press together – to
punch, shear or form – the work-piece, the desired piece
is produced. Once the downstroke is completed, the re-formed
work-piece is removed either automatically or manually, a new work-piece
is fed into the die, and the process is repeated. (See Figure
23.)
For safeguarding purposes, part-revolution mechanical power
presses can be equipped with presence-sensing devices, but
full-revolution mechanical power presses cannot.
NOTE: Likewise, most hydraulic power presses and their associated
control systems are similar to part-revolution mechanical power
presses in that the slide can be stopped at any point in the
cycle. In order to ensure the integrity of the safety-related
functions, safeguarding devices (such as presence-sensing devices)
may only be used on hydraulic power presses that are properly
designed and constructed (in accordance with good engineering
practice) to accommodate the safeguarding system. Refer to
OSHA's Machine Guarding eTool for additional information
on hydraulic presses.
Amputations occurring from the point of operation hazards
are the most common types of injuries associated with mechanical
power presses. Improperly applied safeguarding methods (such
as using a guard with more than maximum allowable openings
or 2-hand palm buttons that are mounted within the safety distance
of the press) may allow operators unsafe access to the press's
hazardous area. These unsafe conditions may result in an amputation
when an operator, for example, instinctively reaches into the
point of operation to adjust a misaligned part or release a
jam. Also, amputations occur when an operator's normal
feeding rhythm is interrupted, resulting in inadvertent placement
of the operator's hands in the point of operation. Such
injuries usually happen while the operator is riding the foot
pedal. Additionally, some amputations are linked to mechanical
(such as the failure of a single-stroke linkage), electrical
(such as a control relay failure), or pneumatic (such as the
loss of air pressure to the clutch/brake) machine component
failure.
Examples of inadequate or ineffective safeguarding and hazardous
energy control practices include the following:
Guards and devices disabled to increase production, to
allow the insertion of small-piece work, or to allow better
viewing of the operation.
Two-hand trips/controls bridged or tied-down to allow
initiation of the press cycle using only one hand.
Devices such as pullbacks or restraints improperly adjusted.
Controls of a single-operator press bypassed by having
a coworker activate the controls while the operator positions
or aligns parts in the die, or repairs or troubleshoots the
press.
Failure to properly disable, isolate press energy sources,
and lockout/tagout presses before an employee performs servicing
or maintenance work.
Safeguarding Mechanical Power Presses Mechanical power presses are extremely versatile and selecting
appropriate safeguarding methods depends on the specific press
design and use. You should consider the press, the type of
clutch used, the stock size, the length of production runs,
and the method of feeding.
You can use primary safeguarding methods, such as guards
or safeguarding devices, to prevent injuries. For example,
29 CFR 1910.217 requires employers to provide and ensure the
use of point of operation guards or properly installed devices
on every operation performed on a press when the die opening
is greater than 1 / 4 inch.
In addition, guards must conform to the maximum permissible
openings of Table O-10 of 29 CFR 1910.217. Guards must prevent
entry of hands or fingers into the point of operation through,
over, under, or around the guard.
Other Controls for Mechanical Power Press Servicing and Maintenance Secondary safeguarding methods may be used alone or in combination
(to achieve near equivalent protection) only when the employer
can show that it is impossible to use any of the primary safeguarding
methods. The following are some work practices, complementary
equipment and energy control measures that may be used to supplement
primary safeguarding:
If employees operate presses under a “no-hands-in-die” policy
using complementary feeding methods such as hand-tool feeding,
employers still must protect operators through the use of primary
safeguarding methods, such as a properly applied two-hand control
or trip safeguarding device. Hand-tool feeding alone does not
ensure that the operator's hands cannot reach the danger
area. (Figure 24 illustrates the use of hand-feeding
tools in conjunction with pullbacks on a power press.)
Removing scrap or stuck work with tools is required even
when hand feeding is allowed according to 29 CFR 1910.217(d)(1)(ii).
Employers must furnish and enforce the use of hand tools
for freeing or removing work or scrap pieces from the die
to reduce the amount of time an operator's hand is
near the point of operation.
Control point of operation hazards created when guards
are removed for set-up and repair by operating the machine
in the inch mode. This involves using two-hand controls (or
a single control mounted at a safe distance from the machine
hazards) to gradually inch the press through a stroke when
the dies are being tested on part-revolution clutch presses.
Observe energy control procedures and practices for press
servicing and maintenance work. For example, the changing
of dies on a mechanical power press requires the employer
to establish a die-setting procedure that employs point-of-operation
safeguarding method(s) such as the safe usage of an inch or jog safety
device for die set-up purposes together with LOTO. These
devices safely position the mechanical power press slide
utilizing a point-of-operation safeguarding technique. Thus,
an energy control procedure for these types of presses would need to integrate both point-of-operation safeguarding method(s) for slide positioning as well as LOTO procedures for the die setting operation.
Additional power press energy control precautions (e.g., use
of safety blocks; LOTO the press disconnect switch if re-energization
presents a hazard) will be necessary if employees need to place
their hands/arms in a press working area (the space between the
bolster plate and the ram/slide) to perform the servicing and/or
maintenance activity (such as adjusting, cleaning or repairing
dies) because the inch or jog safety device
will not protect employees from ram movement due to potential
mechanical energy (resulting from the ram/slide position and
associated gravitational force), press component or control system
malfunction, or press activation by others.
Training Training is essential for employee protection. As an employer,
you should:
Train operators in safe mechanical press operation and
hazardous energy control (lockout/ tagout) procedures and
techniques before they begin work on the press.
Supervise operators to ensure that correct procedures
and techniques are being followed.
Additional Requirements In addition, work practices such as regular mechanical power
press inspection, maintenance, and reporting are essential.
29 CFR 1910.217(e)(1)(i) requires a program of periodic
and regular inspections of mechanical power presses to ensure
that all of the press parts, auxiliary equipment and safeguards
are in safe operating condition and adjustment. Inspection
certification records must be maintained.
29 CFR 1910.217(e)(1)(ii) requires you to inspect and
test the condition of the clutch/brake mechanism, anti-repeat
feature, and single-stroke mechanism on at least a weekly
basis for presses without control reliability and brake system
monitoring. Certification records must be maintained of these
inspections and the maintenance performed.
29 CFR 1910.217(g)(1) requires the reporting of all point
of operation injuries to operators or other employees within
30 days to either the Director of the Directorate of Standards
and Guidance, OSHA, U.S. Department of Labor, Washington,
DC 20210, or the state agency administering a plan approved
by OSHA. You can also use the Internet to report injuries
(www.osha.gov/pls/powerpress/mechanical.html).
Power Press Brakes Power press brakes are similar to mechanical power presses
in that they use vertical reciprocating motion and are used
for repetitive tasks. Press brake operation is either mechanical
or hydraulic.
Press brakes are either general-purpose or special-purpose
brakes, according to ANSI B11.3-2002, Safety Requirements
for Power Press Brakes. General purpose press brakes have
a single operator control station. A servo-system activates
the special purpose brake, which may be equipped with multiple
operator/helper control stations. (See Figure 25 for
a power press brake operation.)
Hazards of Power Press Brakes As with mechanical power presses, point of operation injuries
are the most common type of injury associated with power press
brakes. Here are some frequent causes of amputations from power
press brakes:
Foot controls being inadvertently activated while the
operator's hand is in the point of operation. The likelihood
of this type of injury increases as the size of stock decreases
and brings the operator's hands closer to the point
of operation.
Parts of the body caught in pinch points created between
the stock and the press brake frame while the bend is being
made.
Controls of a single-operator press bypassed by having
a coworker activate the controls while the operator positions or aligns stock or repairs or troubleshoots
the press.
Failure to properly lockout/tagout presses during the
necessary tasks of making adjustments, clearing jams, performing
maintenance, installing or aligning dies, or cleaning the machine.
Safeguarding Power Press Brakes Primary safeguarding methods, such as physical guards and
point of operation safeguarding devices (movable barrier devices,
presence-sensing devices, pull-back devices, restraint devices,
single-and two-hand devices) can be used to effectively guard
power press brakes. (Figure 26 shows a general-purpose
power press brake used in conjunction with pullbacks.) Some
safeguarding methods, such as presence-sensing devices, may
require muting or blanking to allow the bending of material.
Always ensure that these safety devices are properly installed,
maintained, and used in accordance with the manufacturer's
guidelines for the specific stock and task to be performed.
Failure to do so could leave sensing field channels "blanked
out" and expose operators to point-of-operation hazards
as the safeguarding device's safety distance increases
when blanking is used.
In other instances, such as with special-purpose power press
brakes, machines are equipped with advanced control systems
that are adaptable to all forms of safeguarding concepts and
devices, such as two-hand controls and multiple operator/helper
actuating controls. For example, two-hand down, foot through
(actuation) methods are used to safeguard employees while
they operate press brakes. With this safeguarding system, an
operator uses a two-hand control to lower the press brake ram,
for example, to within 1 / 4 inch or less of the lower die
(which is considered a safe opening). The operator then has
the ability to maneuver and align the work-piece within this
1 / 4 inch safe opening area and he or she is protected from
the amputation hazard. Then the foot control is used by the
operator to safely actuate the machine to produce the desired
product.
Because of constraints imposed by certain manufacturing or
fabricating processes, safeguarding by maintaining a safe
distance from the point of operation may be acceptable.
However, this is permitted only when safeguarding by barrier
guard or safeguarding devices is not feasible (impossible) – that
is, where the use of primary safeguarding method (such as a
restraint device) is not feasible. Additional information about
a safe distance safeguarding program can be found
in OSHA Instruction 02-01-025 [CPL 2-1.25] – Guidelines
for Point of Operation Guarding of Power Press Brakes.
Other Controls for Power Press Brakes The following are some secondary safeguarding methods and
complementary equipment that may be used to supplement primary
safeguarding or alone or in combination when primary safeguarding
methods are not feasible:
Safe distance safeguarding,
Safe holding safeguarding,
Safe work procedures,
Work-holding equipment (such as back gauges),
Properly designed and protected foot pedals, and
Hand-feeding tools.
Ensure that proper safeguarding and lockout/ tagout procedures
are developed and implemented for power press brakes. Train
and supervise employees in these procedures and conduct periodic
inspections to ensure compliance.
Hazards of Conveyors Conveyors are used in many industries to transport materials
horizontally, vertically, at an angle, or around curves. Many
conveyors have different and unique features and uses, so that
hazards vary due to the material conveyed, the location of
the conveyor, and the proximity of the conveyer to the employees.
Types include unpowered and powered, live roller, slat, chain,
screw, and pneumatic. Conveyors eliminate or reduce manual
material handling tasks, but they present amputation hazards
associated with mechanical motion. (See Figures 27 through
30 for examples of common conveyors.)
Conveyor-related injuries typically involve a employee's
hands or fingers becoming caught in nip points or shear points
on conveyors and may occur in these situations:
Cleaning and maintaining a conveyor, especially when it
is still operating.
Reaching into an in-going nip point to remove debris or
to free jammed material.
Allowing a cleaning cloth or an employee's clothing
to get caught in the conveyor and pull the employee's
fingers or hands into the conveyor.
Other conveyor-related hazards include improperly guarded
gears, sprocket and chain drives, horizontal and vertical shafting,
belts and pulleys, and power transmission couplings. Overhead
conveyors warrant special attention because most of the conveyor's
drive train is exposed. Employees have also been injured or
killed while working in areas underneath conveyors and in areas
around lubrication fittings, tension adjusters, and other equipment
with hazardous energy sources.
Safeguarding Conveyors As conveyor hazards vary depending on the application, employers
need to look at each conveyor to evaluate and determine what
primary safeguarding methods and energy control (lockout/tagout)
practices are required. Where necessary for the protection
of employees, conveyors need to have mechanical guards that
protect the employee from nip points, shear points, and other
moving parts, including power-transmission apparatus. Guards
may include barriers, enclosures, grating, fences, or other
obstructions that prevent inadvertent physical contact with
operating machine components, such as point of operation areas,
belts, gears, sprockets, chains, and other moving parts. A
brief description of the hazards and recognized safeguarding
methods is presented for common types of conveyors.
Other Controls for Conveyors The following are some secondary safeguarding methods, work
practices, and complementary equipment that may be used to
supplement primary safeguarding or alone or in combination
when primary safeguarding methods are not feasible:
Safeguarding by safe distance (by location) — locating
moving parts away from employees to prevent accidental contact
with the hazard point—is one option for safeguarding
conveyors. It is particularly difficult, however, to use this
method when employees need to be at or near unguarded moving
parts.
Use prominent awareness devices, such as warning signs
or lights, to alert employees to the conveyor operation.
Allow only trained individuals to operate conveyors and
only trained, authorized staff to perform servicing and maintenance
work.
Visually inspect the entire conveyor and immediate work
area prior to start-up to determine that the actuation will
not cause an employee hazard.
Inspect and test conveyor safety mechanisms, such as its
alarms, emergency stops, and safeguarding methods.
Do not use any conveyor which is unsafe until it is made
safe.
Forbid employees from riding on conveyors.
Prohibit employees working with or near conveyors from
wearing loose clothing or jewelry, and require them to secure
long hair with a net or cap.
Install emergency stop devices on conveyors where
employees work when they cannot otherwise control the movement
of the conveyor. This recognized safety feature provides
employees with the means to shut off the equipment in the
event of a hazardous situation or emergency incident.
For emergency stop devices, you will need these engineering
controls:
Equip conveyors with interlocking devices that shut them
down during an electrical or mechanical overload such as
product jam or other stoppage. Emergency devices need to
be installed so that they cannot be overridden from other
locations.
When conveyors are arranged in a series, all should automatically
stop whenever one stops.
Equip conveyors with emergency stop controls that require
manual resetting before resuming conveyor operation.
Install clearly marked, unobstructed emergency stop buttons
or pull cords within easy reach of employees.
Provide continuously accessible conveyor belts with emergency
stop cables that extend the entire length of the conveyor
belt to allow access to the cable from any point along the
belt.
Ensure that conveyor controls or power sources can accept
a lockout/tagout device to allow safe maintenance practices.
Perform servicing and maintenance under an energy
control program in accordance with the Control of hazardous
energy (lockout/tagout), 29 CFR 1910.147, standard. For
example, instruct employees to lubricate, align, service, and
maintain conveyors when the conveyor is locked or tagged out
if the task would expose them to an area of the conveyor (or
adjacent machinery) where hazardous energy exists.
Hazards of Printing Presses Printing presses vary by type and size, ranging from relatively
simple manual presses to the complex large presses used for
printing newspapers, magazines, and books. Printing presses
are often part of a larger system that also includes cutting,
binding, folding, and finishing equipment. Many modern printing
presses rely on computer controls, and the high speeds of such
equipment often require rapid machine adjustments to avoid
waste.
This section discusses amputation hazards associated with
two common types of printing presses: web-fed and sheet-fed
printing press systems. Web-fed printing presses are fed by
large continuous rolls of substrate such as paper, fabric or
plastic; sheet-fed printing presses, as their name implies,
are fed by large sheets of substrate. In both types, the substrate
typically feeds through a series of cylinders containing printing
plates and supporting cylinders moving in the opposite direction.
(Figures 31 and 32 illustrate a roll-to-roll offset
printing press and a sheet-fed offset printing press.)
As with other machines, printing press-related amputations
occur during servicing and maintenance activities. For example,
amputations occur when employees get their fingers or hands
caught in the in-going nip points created between two rollers
while:
Hand-feeding the leading edge of paper into the in-running
rollers during press set-up while the machine is operating;
Adjusting ink flow on a press;
Cleaning ink off the press while it is operating;
Attempting to free material from the rollers;
Straightening misaligned sheets of paper in the press;
Jogging the printer and making adjustments to the equipment
(such as adjusting the nip wheel on a sheeter);
Using rags to clean machinery adjacent to unguarded rollers.
Safeguarding Printing Presses As with most machinery, you can rely on primary safeguarding
methods to protect employees against injuries when using printing
presses. For example, some primary safeguarding methods include
the following:
Install guards on all mechanical hazard points that are
accessible during normal operation -such as accessible in-going
nip points between rollers and power-transmission apparatus
(chains and sprockets).
Safeguard nip point hazards with barrier guards or nip
guards. Nip guards need to be designed and installed without
creating additional hazards.
Install fixed barrier guards, with tamper-proof fasteners,
at rollers that do not require operator access.
Properly designed, applied, and maintained safeguarding
devices (such as presence-sensing devices and mats) may also
be used to keep your body out of machine danger areas. However,
these control circuit devices are no substitute for lockout/tagout.
Use hold-to-run controls (such as inch or reverse) that
protect employees from machine mechanical hazards by either:
1) requiring the use of both hands for control initiation
purposes; or 2) are mounted at a safe distance so that an
employee cannot inch or reverse the press and simultaneously access any unguarded danger area or otherwise
reach into the danger zone while the press is operating.
Other Controls for Printing Presses The following are some secondary safeguarding methods, work
practices, and complementary equipment that may be used to
supplement primary safeguarding or alone or in combination
when primary safeguarding methods are not feasible:
Make sure that printing presses attended by more than
one operator or ones outside of the operator's viewing
area are equipped with visual and audible warning devices
to alert employees regarding the press's operational
status—in operation, safe mode, or impending operation.
Install visual warning devices of sufficient number and
brightness and locate them so that they are readily visible
to press personnel.
Ensure that audible alarms are loud enough to be heard
above background noise.
Provide a warning system that activates for at least 2
seconds prior to machine motion.
Use additional secondary safeguarding methods such as
safeguarding by location and safe work (operating) procedures
for printing presses.
Ensure that all press operators receive appropriate training
and supervision until they can work safely on their own.
Prohibit employees working with or near printing presses
from wearing loose clothing or jewelry and require them to
secure long hair with a net or cap.
Conduct periodic inspections to ensure compliance.
Perform servicing and maintenance under an energy control
program in accordance with the Control of hazardous energy
(lockout/tagout), 29 CFR 1910.147, standard.
Hazards of Roll-Forming and Roll-Bending Machines Roll-forming and roll-bending machines primarily perform
metal bending, rolling, or shaping functions. Roll-forming
is the process of bending a continuous strip of metal to gradually
form a predetermined shape using a self-contained machine.
Roll-forming machines contain a series of rolls that may or
may not have braking systems. Roll-forming machines may also
perform other processes on the metal, including piercing holes,
slots, or notches; stamping; flanging; and stretch-bending.
Roll-bending machines usually have three rolls arranged like
a pyramid and they perform essentially the same process as
roll-forming, except that the machine produces a bend across
the width of flat or pre-formed metal to achieve a curved or
angular configuration.
Roll-forming and roll-bending machines frequently are set
up and operated by one person. (Figure 33 illustrates
a roll-forming machine producing a finished product. Figure
34 illustrates the in-feed section of a roll-forming machine.)
The most common type of amputation hazard associated with
roll-forming and roll-bending machines are point of operation
hazards created by in-running nip points. Amputations occur
when the hands of the operator feeding material through the
rolls get caught and are then pulled into the point of operation.
Causes of amputations related to roll-forming and roll-bending
machines can occur from the following:
Having an unguarded or inadequately guarded point of operation;
Locating the operator control station too close to the
process;
Activating the machine inadvertently; and
Performing cleaning, clearing, changing, or inspecting
tasks while the machine is operating or is not properly locked
or tagged out.
Safeguarding Roll-Forming and Roll-Bending Machines Roll-forming and roll-bending machines are available in a
wide variety of sizes and designs, and safeguarding methods
must be tailored for each machine. Several factors affect the
ways to safeguard the equipment, including whether a machine
has a brake system, its size, operating speed, thickness of
product, length of production runs, required production accuracy,
sheet feeding methods, and part removal methods. Depending
on the size and type of machine, a number of different primary
safeguarding methods may be required to adequately protect
the operator as well as other employees nearby. For example,
you can do the following:
Install fixed or adjustable point of operation barrier
guards at the in-feed and out-feed sections of machines. If
the stock or end-product does not differ greatly from run to
run, a fixed guard may be preferable. If the stock or end-product
is variable, however, an adjustable guard may be more suitable.
Install fixed point of operation guards to cover the sides
of the rollers to prevent entry of clothing and parts of
your body into the in-going nip points of the rollers.
Install fixed or interlocked guards to cover any other
rotating parts, such as power-transmission apparatus.
Install and use properly applied presence-sensing safeguarding
devices (light curtains, safety mats) on roll-forming and
roll-bending machines (those equipped with brakes) to protect
you from hazardous machine areas during normal production
operations.
Install and use properly applied two-hand control safeguarding
devices to protect you from the machine hazards during roll-bending
production operations.
Ensure that operators use the jog mode during feeding
operations, if appropriate, and that the control station
requires the use of both hands or is mounted at a safe distance
from the machine's danger areas.
Allow only one control station to operate at any one time
when a single machine has more than one set of operator controls.
This does not apply to the emergency stop controls, which
must be operable from all locations at all times, such as
accessible in-going nip points between rollers and power-transmission
apparatus (chains and sprockets).
Other Controls for Roll-Forming and Roll-Bending Machines The following are some secondary safeguarding methods, work
practices, and complementary equipment that may be used to
supplement primary safeguarding or alone or in combination
when primary safeguarding methods are not feasible:
Use proper lighting and awareness barrier devices (such
as interlocking gates around the perimeter of the machine
to prevent unauthorized entry), awareness signals and signs.
Position (safeguard by location) operating stations in
a way that ensures that operators are not exposed to the
machine's point of operation.
Locate foot pedal controls away from the point of operation
and guard them in such a way as to prevent inadvertent activation.
Some foot controls use dead-man (hold-to-run) features so
that the rolls stop turning (via a brake and clutch
assembly) when you release the foot switch
Develop and implement safe work (operating) procedures
for roll-forming and roll-bending machines.
Safeguard operator control stations to prevent inadvertent
activation by unauthorized employees.
Ensure that all operators receive appropriate on-the-job
training under the direct supervision of experienced operators
until they can work safely on their own.
Prohibit employees working with or near printing presses
from wearing loose clothing or jewelry and require them to
secure long hair with a net or cap.
Install safety trip controls, such as a pressure-sensitive
body bar or safety tripwire cable, on the in-feed section
of the machine to shut down the machine if an employee gets
too close to the point of operation.
Install emergency stop controls that are readily accessible
to the operator.
Conduct periodic inspections to ensure compliance.
Perform servicing and maintenance under an energy control
program in accordance with the Control of hazardous energy
(lockout/tagout), 29 CFR 1910.147, standard.
Hazards of Shearing Machines Mechanical power shears contain a ram for their shearing
action. The ram moves a non-rotary blade at a constant rate
past the edge of a fixed blade. Shears may be mechanically,
hydraulically, hydra-mechanically, pneumatically, or manually
powered and are used to perform numerous functions such as
squaring, cropping, and cutting to length.
In the basic shear operation, stock is fed into the point
of operation between two blades. A hold-down may then be activated
that applies pressure to the stock to prevent movement. One
complete cycle consists of a downward stroke of the top blade
until it passes the lower fixed blade followed by an upward
stroke to the starting position. (See Figures 35 and 36 for
examples of alligator and power squaring shears.)
The two primary point-of-operation hazards on shears are
the shear blade and the material hold-downs. Amputations may
occur in the following situations:
The foot control inadvertently activates while the operator's
hands are in the point of operation. Such amputations usually
relate to foot-activated, stand-alone manual shears that
require the use of both hands to feed the stock.
A tripping device located on the back side of the shear's
mouth operates the shear but does not prevent the operator
from reaching into the hazard area. Such tripping devices,
commonly found on stand-alone manual shears, may increase
productivity but must be used in conjunction with primary
safeguards.
When there is no hold-down and stock being fed into a
stand-alone manual shear kicks out and strikes the operator's
hands or fingers.
Safeguarding Shearing Machines Because shears have a wide variety of applications, safeguarding
methods must be determined individually for each machine based
on its use. A number of different safeguarding methods may
be necessary to adequately protect the operator as well as
other employees nearby. For example, you will need to consider
the machine size, operating speed, size and type of material,
length of production runs, required accuracy of the work, methods
for material feeding and removal, operator controls, and clutch
type.
Here are some primary safeguarding options for protecting
employees from the shear's point of operation during
feeding activities at the front of the machine:
Install a properly applied fixed or adjustable point of
operation guard at the in-feed of the shearing machine to
prevent operator contact with the shear's point of
operation as well as the pinch point of the hold-down. The
guard's design must prevent the employee from reaching
under or around it.
Install and arrange two-hand trips and controls so that
the operator must use both hands to initiate the shear cycle.
Two-hand trips and controls need to be designed so that they
cannot be defeated easily. The Safety Requirements for Shears
(ANSI B11.4-2003) standard recommends the installation of
additional safeguarding when two-hand controls are used on
part-revolution shears, based on the nature of the shearing
operation. This national consensus standard specifies the
use of guards on full-revolution shears.
Use a properly applied presence-sensing device, such as
a light curtain, on shears that are hydraulically powered
or equipped with a part-revolution clutch.
Mount guarded foot-pedal controls at a safe distance (single
control safeguarding devices) away from the point of operation
to protect the operator during the operating cycle.
Use pull-backs or restraints for stand-alone manual shears
when other guarding methods are not feasible or do not adequately
protect employees. (These devices may not be appropriate
if the job requires employees' mobility.)
Use automatic-feeding devices such as conveyors with stand-alone
manual shears when the material is uniform in size and shape.
Equip mechanical shears with either a part-revolution
or full-revolution clutch. Methods of safeguarding depend
on the type of clutch in use. Shears equipped with full-revolution
clutches used in single-stroke operations must be equipped
with an anti-repeat feature.
Other Controls for Shearing Machines The following are some secondary safeguarding methods, work
practices, and complementary equipment that may be used to
supplement primary safeguarding or alone or in combination
when primary safeguarding methods are not feasible:
Install guarded operating stations at a safe distance
(safeguarding by location) from the shear's point of
operation to prevent inadvertent activation.
Develop and implement safe work (operating) procedures
for shearing machines and conduct periodic inspections to
ensure compliance.
Use proper lighting and awareness devices, such as awareness
barriers and warning signs, to warn employees of the hazard.
Install hold-down (work-holding) devices that prevent
the work piece from kicking up and striking the operator.
Hold-down devices may eliminate the need for employees to
hold the material near the point of operation.
Instruct operators to use distancing tools when their
hands might otherwise reach into the point of operation because
of the size of the material being cut.
Where it is possible to stop the shear during its operating
cycle, install an emergency stop device—such as a pressure-sensitive
body bar, safety tripod, or safety tripwire cable—at
the in-feed section of the shear.
Install an awareness barrier or a safety trip control
(safety tripwire or safety tripod) on the back side of the
shear.
Ensure that all operators receive on-the-job training under the direct supervision of experienced operators
until they can work safely on their own.
Instruct employees to perform routine maintenance on the
clutch and braking systems.
Instruct employees to inspect all guarding to ensure that
it is in place properly before the machine is operated.
Instruct supervisors to ensure that operators keep their
hands out of the shear's point of operation at all
times while the machine is energized and not properly locked
out.
Instruct employees not to perform activities on the back
side of a shear while it is operating or still energized.
Prohibit employees from riding the foot activation pedal.
Perform servicing and maintenance under an energy control
program in accordance with the Control of hazardous energy
(lockout/tagout), 29 CFR 1910.147, standard.
Hazards of Food Slicers Food slicers are electrically powered machines typically
equipped with a rotary blade, an on/off switch, thickness adjustment,
and a food holder or chute. A pushing/guarding device or plunger
may be used to apply pressure to the food against the slicer
blade, or pressure may be applied by gravity and/or by an attachment
connected to the food holder. (See Figure 37.)
Amputations resulting from work with food slicers can occur
as follows:
When the operator adjusts or services the slicer while
it is still operating or while it is switched off but still
plugged in, or energized. In the latter case, amputations
occur when the operator accidentally switches the slicer
on.
When the operator fails to use the sliding attachment
on the food-holding device, especially when slicing small
pieces of meat.
When the operator hand-feeds food into a chute-fed slicer
without using the proper pushing/guarding device or plunger.
Safeguarding and Other Controls for Food Slicers Food slicers must be used with guards that cover the unused
portions of the slicer blade on both the top and bottom of
the slicer. You should buy slicers already equipped with a
feeding attachment on the sliding mechanism of the food holder
or purchase the attachment separately and install it before
use. Instruct employees to use a pushing/guarding device with
chute-fed slicers.
The following are some secondary safeguarding methods, work
practices and complementary equipment that may be used to supplement
primary safeguarding or alone or in combination when primary
safeguarding methods are not feasible:
Develop and implement safe work (operating) procedures
for slicers and conduct periodic inspections to ensure compliance.
Ensure that all operators receive on-the-job training
under the direct supervision of experienced operators until
they can work safely on their own.
Use warning signs to alert employees of the hazard and
safety instructions.
Instruct operators to use plungers to feed food into chute-fed
slicers. For other slicers, they should use the feeding attachment
located on the food-holder.
Never place food into the slicer by hand-feeding or hand
pressure.
Instruct operators to retract the slicer blade during
cleaning operations.
Instruct operators to turn off and unplug slicers when
not in use or when left unattended for any period of time.
Perform servicing and maintenance under an energy control
program in accordance with the Control of hazardous energy
(lockout/tagout), 29 CFR 1910.147, standard. You can
avoid slicer lockout/tagout if the equipment is cord-and-plug
connected equipment simply by having exclusive control over
the attachment plug after you shut the slicer off and unplug
it from the energy source.
Hazards of Meat Grinders Electric meat grinders typically have a feeding tray attached
to a tubular throat, a screw auger that pushes meat to the
cutting blade and through the cutting plate, an on/off switch,
a reverse switch, and a plunger. (See Figure 38.)
The operator reaches into the throat of the grinder while
it is still operating or while it is switched off but still
plugged in (energized). In the latter case, amputations can
occur when the operator accidentally switches the grinder
back on.
The operator fails to use the attached feeding tray and
throat.
Defective meat grinders, such as ones with holes in the throat
or screw auger area, are also a source of workplace amputations
and must be taken out of service.
Safeguarding and Other Controls for Meat Grinders Meat grinders must be retrofitted with a primary safeguard,
such as a properly designed tapered throat or fixed guard,
in cases where the machine design is such that an employee's
hand may come in contact with the point-of-operation (that
is the auger cutter area). You should buy meat grinders already
equipped with this primary safeguard.
The following are some other secondary safeguarding methods,
work practices, and complementary equipment that may be used
to supplement primary safeguarding or alone or in combination
when primary safeguarding methods are not feasible:
Develop and implement safe work (operating) procedures
for meat grinders to ensure that the guards are adequate
and in place, and that the grinder feeding methods are performed
safely. Conduct periodic inspections of grinder operations
to ensure compliance.
Use warning signs to alert employees of the hazard and
safety instructions.
Ensure that all operators receive appropriate on-the-job
training under direct supervision of experienced operators
until they can work safely on their own.
Provide operators with properly sized plungers to eliminate
the need for their hands to enter the feed throat during
operation.
Instruct operators to use the proper plunger device to
feed meat into grinders. No other device should be used to
feed the grinder.
Instruct employees to operate grinders only with feeding
trays and throats installed.
Instruct operators to use the meat grinder only for its
intended purpose.
Instruct operators to turn off and unplug grinders when
not in use or when left unattended for any period of time.
Perform servicing and maintenance under an energy control
program in accordance with the Control of hazardous energy (lockout/tagout), 29
CFR 1910.147, standard. You can avoid slicer lockout/tagout
if the equipment is cord-and-plug connected equipment simply
by having exclusive control over the attachment plug after
you shut the slicer off and unplug it from the energy source.
Hazards of Meat-Cutting Band Saws Band saws can cut wood, plastic, metal, or meat. These saws
use a thin, flexible, continuous steel strip with cutting teeth
on one edge that runs around two large motorized pulleys or
wheels. The blade runs on two pulleys (driver and idler) and
passes through a hole in the work table where the operator
feeds the stock. Blades are available with various teeth sizes,
and the saws usually have adjustable blade speeds.
Unlike band saws used in other industries, meat-cutting band
saws are usually constructed of stainless steel for sanitary
purposes and for easy cleaning. The table, which may slide
or roll, has a pushing guard installed to protect the operator
while feeding the saw. Meat-cutting band saws may also be equipped
with a fence and pushing guard to feed the meat through the
band saw. (See Figure 39.)
Amputations occur most frequently when operators' hands
contact the running saw blade while feeding meat into the saw.
The risk of amputation is greatest when operators place their
hands too close to the saw blade, in a direct line with the
saw blade, or beneath the adjustable guard during feeding operations.
Here are some common causes of amputations involving meat-cutting
band saws:
The operator's hand slips off the meat or otherwise
accidentally runs through the blade.
The operator attempts to remove meat from the band saw
table while the blade is still moving.
The operator's gloves, jewelry, or loose-fitting
clothing became entangled in the saw blade.
Install a self-adjusting guard over the entire blade,
except at the working portion, or point of operation of the
blade. The guard must be adjustable to cover the unused portion
of the blade above the meat during cutting operations.
Enclose the pulley mechanism and motor completely.
The following are some secondary safeguarding methods,
work practices, and complementary equipment that may be
used to supplement primary safeguarding or alone or in
combination when primary safeguarding methods are not feasible:
Develop and implement safe work (operating) procedures
for meat-cutting band saws to ensure that the guards are
adequate and in place and that operators safely perform feeding
methods.
Ensure that all operators receive adequate on-the-job
training under the direct supervision of experienced operators
until they can work safely on their own.
Use warning signs to alert employees of the hazard and
safety instructions.
Install a brake on one or both wheels to prevent the saw
blade from coasting after the machine is shut off.
Provide a pushing guard or fence to feed meat into the
saw blade.
Instruct operators to use the pushing guard or fence to
feed the saw, especially when cutting small pieces of meat.
Instruct operators to adjust the point of operation guard
properly to fit the thickness of the meat.
Instruct operators to use only sharp meat-cutting blades
and to tighten blades to the appropriate tension with the
machine's tension control device.
Instruct operators not to wear gloves, jewelry, or loose-fitting
clothing while operating a band saw and to secure long hair
in a net or cap.
Prohibit operators from removing meat from the band saw
while the saw blade is still moving.
Instruct operators to turn off and unplug band saws when
not in use or when left unattended for any period of time.
Conduct periodic inspections of the saw operation to ensure
compliance.
Perform servicing and maintenance under an energy control
program in accordance with the Control of hazardous energy
(lockout/tagout), 29 CFR 1910.147, standard. You can
avoid slicer lockout/tagout if the equipment is cord-and-plug
connected equipment simply by having exclusive control over
the attachment plug after you shut the band saw off and unplug
it from the energy source.
Hazards of Drill Presses Electric drill presses use a rotating bit to drill or cut
holes in wood or metal. The holes may be cut to a desired preset
depth or completely through the stock. A basic drill press
operation consists of selecting an appropriate drill bit, tightening
the bit in the chuck, setting the drill depth, placing the
material on the drill press bed, securing the work to the bed
so that it will not rotate during drilling, turning the drill
press on, and pulling the drill press lever down so that the
drill bit will be lowered into the stock. (See Figure 40.)
Amputations typically occur when the operator's gloves,
loose-fitting clothing, or jewelry become entangled in the
rotating drill bit. Here are some other causes of drill press-related
amputations:
Inadequately guarding points of operation or power-transmission
(such as belt and pulleys) devices;
Removing a part from a drill press while wearing gloves;
Making adjustments to the drill press, such as setting
the depth, securing the material to the drill press bed,
and repositioning the wood or metal, while the drill bit
is still rotating;
Changing the drill bit with the operating control unprotected
so that a falling object or otherwise bumping the switch
can accidentally start up the press spindle and tool assembly;
Performing servicing and maintenance activities, such
as changing pulleys and belts, without de-energizing and
locking/tagging out the drill press.
Safeguarding and Other Controls for Drill Presses For drill presses, you must be protected from the rotating
chuck and swarf that is produced by the drill bit. Guarding
at the point-of-operation is difficult because of the nature
of the drilling press. The following primary safeguarding methods
can be installed to guard the operator and other employees
from rotating parts, flying chips, and cuttings:
Specifically designed shields can be attached to the quill
and used to guard this area. For example, telescopic shielding
that retracts as the drill bit contacts the piece or a more
universal-type shield can be applied.
Automatic machines and high-production machines could
have enclosures designed and installed to guard the employee
from the entire drilling operation.
Install guarding over the motor, belts, and pulleys.
Install an adjustable guard to cover the unused
portion of the bit and chuck above the material being worked.
The following are some secondary safeguarding methods,
work practices, and complementary equipment that may be
used to supplement primary safeguarding or alone or in
combination when primary safeguarding methods are not feasible:
Automatic machines and high-production machines could
use barricades to separate the employee from the entire drilling
operation.
Develop and implement safe work (operating) practices,
such as removing the chuck immediately after each use, for
drill press operations and conduct periodic inspections to
ensure compliance.
Train and supervise all operators until they can work
safely on their own.
Use the drill press only for its intended purposes.
Instruct employees not to wear gloves, jewelry, or loose-fitting
clothing while operating a drill press and to secure long
hair in a net or cap.
Make sure that operators secure material to the drill
press bed with clamps (work-holding equipment) before drilling,
so that the material will not spin and strike the operator.
The operator should not manually secure the work to the drill
press bed while drilling holes.
Do not adjust the drill press while the drill bit is still
rotating.
Replace projecting chucks and set screws with non-projecting
safety-bit chucks and set screws.
Cover operator controls so that the drill press cannot
be turned on accidentally.
Shut off the drill press when not in use or when left
unattended for any period of time.
Perform servicing and maintenance under an energy control
program in accordance with the Control of hazardous energy
(lockout/tagout), 29 CFR 1910.147, standard.
Hazards of Milling Machines Electric milling machines cut metal using a rotating cutting
device called a milling cutter. These machines cut flat surfaces,
angles, slots, grooves, shoulders, inclined surfaces, dovetails,
and recessed cuts. Cutters of different sizes and shapes are
available for a wide variety of milling operations.
Milling machines include knee-and-column machines, bed-type
or manufacturing machines, and special milling machines designed
for special applications. Typical milling operations consist
of selecting and installing the appropriate milling cutter,
loading a work-piece on the milling table, controlling the
table movement to feed the part against the rotating milling
cutter, and callipering or measuring the part. (See Figure
41.)
Some frequent causes of amputation from milling machines
include:
Loading or unloading parts and callipering or measuring
the milled part while the cutter is still rotating;
Operating milling machines with the safety door selector
switch on bypass;
Inspecting the milling machine gearbox with the machine
still operating;
Manually checking the machine for loose gears (by removing
the gearbox cover) while computerized cutting software program
was operating;
Performing servicing and maintenance activities such as
setting up the machine, changing and lubricating parts, clearing
jams, and removing excess oil, chips, fines, turnings, or
particles either while the milling machine is stopped but
still energized, or while the cutter is still rotating; and
Getting jewelry or loose-fitting clothing entangled in
the rotating cutter.
Install guards (fixed, movable, and interlocked) that
enclose the milling cutter's point-of-operation;
Install properly applied safeguarding devices, such as
presence-sensing devices and two-hand control methods;
Install guards around the machine's power
transmission components (such as drive mechanisms).
The following are some secondary safeguarding methods,
work practices, and complementary equipment that may be
used to supplement primary safeguarding or alone or in
combination when primary safeguarding methods are not feasible:
Use other safeguarding devices such as splash shields,
chip shields, or barriers if they provide effective protection
to the operator and when it is impractical to guard cutters
without interfering with normal production operations or
creating a more hazardous situation.
Install awareness devices, such as barriers and warning
signs, around the milling table.
Instruct operators not to use a jig or vise (workholding
equipment) that prevents the point of operation guard from
being adjusted appropriately.
Develop and implement safe (operating) work procedures
for machine operators, such as safe work procedures for installing
and using fixtures and tooling.
Instruct operators to place the jig or vise locking arrangement
so that force must be exerted away from the cutter.
Ensure that all operators receive appropriate safe work
procedure training by experienced operators until they can
work safely on their own.
Instruct operators to move the work-holding device back
to a safe distance when loading or unloading parts and callipering
or measuring the work and not to perform these activities
while the cutter is still rotating unless the cutter is adequately
guarded.
Instruct employees not to wear gloves, jewelry, or loose-fitting
clothing while operating a milling machine and to secure
long hair in a net or cap.
Prohibit operators from reaching around the cutter or
hob to remove chips while the machine is in motion or not
locked or tagged out.
Conduct periodic inspections to ensure compliance.
Perform servicing and maintenance under an energy control
program in accordance with the Control of hazardous energy
(lockout/tagout), 29 CFR 1910.147, standard.
Hazards of Grinding Machines Grinding machines primarily alter the size, shape, and surface
finish of metal by placing a work-piece against a rotating
abrasive surface or wheel. Grinding machines may also be used
for grinding glass, ceramics, plastics, and rubber.
Examples of grinding machines include abrasive belt machines,
abrasive cutoff machines, cylindrical grinders, centerless
grinders, gear grinders, internal grinders, lapping machines,
off-hand grinders, surface grinders, swing frame grinders,
and thread grinders. (See Figure 42.)
Amputation injuries can occur when the operator's hands
enter the point of operation during the following activities:
Bypassing the grinding machine safety switch feature in
order to clean the machine while it is running;
Wearing gloves while grinding, where it is possible to
have the glove get caught between the revolving disc and
the table;
Fixing a jammed grinder machine by turning the machine
off, removing the blade guard and reaching into the danger
area before the blades stop turning;
Operating a grinding machine with non-functional interlocks
and without the guard in place;
Using an incorrectly adjusted or missing work rest or
a poorly maintained or unbalanced abrasive wheel;
Adjusting the work rest, balancing the wheel, cleaning
the area around the abrasive wheel and loading and unloading
parts or measuring parts while the abrasive wheel is still
rotating;
Attempting to stop a rotating abrasive wheel by hand.
Install safety guards that cover the spindle end, nut,
and flange projections or otherwise ensure adequate operator
protection;
Install adjustable and rigid work rests on offhand grinding
machines; and
Install guards over power belts and drives.
The following are some secondary safeguarding methods,
work practices, and complementary equipment that may be
used to supplement primary safeguarding or alone or in
combination when primary safeguarding methods are not feasible:
Develop and implement safe work procedures for grinding
machine operations.
Install warning and safety instruction signs.
Ensure that all operators receive appropriate on-the-job
training and supervision until they can work safely on their
own.
Use abrasive discs and wheels that are correctly rated
for the grinder's maximum operating spindle speed.
The disc or wheel rating is marked on the disc or wheel in
surface feet per minute.
Inspect and sound test the grinding wheel to ensure that
it is not defective, unbalanced, loose, or too small.
Adjust the work rest to within 1 / 8 inch of the wheel.
Do not wear gloves, jewelry, or loose-fitting clothing
while operating grinding machines and secure long hair in
a net or cap.
Do not adjust the guard or clean the grinding machine
while the abrasive wheel is still rotating.
Conduct periodic inspections to ensure compliance.
Perform servicing and maintenance under an energy control
program in accordance with the Control of hazardous energy
(lockout/tagout), 29 CFR 1910.147, standard.
Hazards of Slitters Slitters use rotary knives to slit flat rolled metal, plastic
film, paper, plastic, foam, and rubber as well as other coiled
or sheet-fed materials. Slitters range from small hand-fed
paper slitters to large-scale automated metal slitters, complete
with metal processing and handling units such as unwinders
and rewinders. Both light and heavy gauge slitters are available.
(See Figure 43.)
Amputations often occur when clothing or body parts come in contact with slitter blades or get caught in the movement of coils and rolls. Here are some examples:
Employees can inadvertently get their fingers and hands caught
in the in-going nip points of the slitter or associated machinery such as rewinders.
Gloves, jewelry, long hair and loose clothing can get entangled in in-going
nip points or in the rotary knives of the slitter.
Employees can suffer an amputation when clearing, adjusting, cleaning,
or servicing the slitter while it is either still operating, or shut off but
still plugged in (energized).
Safeguarding and Other Controls for Slitters The following primary safeguards may be used to protect employees from the hazardous portions of the slitter and auxiliary equipment:
Install a fixed or adjustable point-of-operation guard
to prevent inadvertent entry of body parts into a hazardous
area of the slitter system.
Install a fixed point of operation guard to cover the
sides of the unwinder or rewinder to prevent an employee's
hands or clothing from entering into the rollers.
Properly applied presence-sensing devices (such as light
curtains, radio-frequency devices, safety mats) may be used
to control employee exposure to certain types of hazards (such as the slitter knives' point-of-operation hazard) by stopping or preventing machine system operation in the event any part of an employee's body is detected in a sensing field.
Install fixed or interlocked guards to cover other moving parts of the machine such as the power-transmission apparatus.
The following are some secondary safeguarding methods, work practices, and complementary equipment that may be used to supplement primary safeguarding or alone or in combination when primary safeguarding methods are not feasible:
Use awareness devices, such as an awareness barrier or fence (with an interlocking gate) and hazard warning/safety instruction signs around the perimeter of the machine to alert people of the hazard and prevent unauthorized entry.
Awareness signals may also be used to alert you of an existing or approaching hazard as these devices issue a warning sound or provide a visible warning light.
Restrict employee access to hazardous areas through the application of safeguarding by location techniques – such as utilizing the facility layout (walls) and equipment location (elevation) for isolation purposes.
Develop and implement safe work procedures for machine operators and conduct periodic inspections to ensure compliance.
Develop an operator training program to ensure that all operators are knowledgeable and proficient in the safeguarding methods and work procedures. Employees need
to be supervised on a regular basis to ensure that they are following the safety program requirements.
Perform servicing and maintenance under an energy control
program in accordance with the Control of hazardous energy
(lockout/tagout), 29 CFR 1910.147, standard.
OSHA Assistance OSHA can provide extensive help through a variety of programs,
including technical assistance about effective safety and health
programs, state plans, workplace consultations, voluntary protection
programs, strategic partnerships, training and education, and
more. An overall commitment to workplace safety and health
can add value to your business, to your workplace, and to your
life.
Safety and Health Program Management Guidelines
Effective management of employee safety and health protection
is a decisive factor in reducing the extent and severity of
work-related injuries and illnesses and their related costs.
In fact, an effective safety and health program forms the basis
of good employee protection and can save time and money (about
$4 for every dollar spent) and increase productivity and reduce
employee injuries, illnesses, and related workers' compensation
costs.
To assist employers and employees in developing effective
safety and health programs, OSHA published recommended Safety
and Health Program Management Guidelines (54 Federal Register
(16): 3904-3916, January 26, 1989). These voluntary guidelines
can be applied to all places of employment covered by OSHA.
The guidelines identify four general elements critical to
the development of a successful safety and health management
system:
Management leadership and employee involvement,
Worksite analysis,
Hazard prevention and control, and
Safety and health training.
The guidelines recommend specific actions, under each of
these general elements, to achieve an effective safety and
health program. The Federal Register notice is available
online at www.osha.gov.
State Programs
The Occupational Safety and Health Act of 1970(OSH
Act) encourages states to develop and operate their own job
safety and health plans. OSHA approves and monitors these plans.
Twenty-four states, Puerto Rico and the Virgin Islands currently
operate approved state plans: 22 cover both private and public
(state and local government) employment; Connecticut, New Jersey,
New York and the Virgin Islands cover the public sector only.
States and territories with their own OSHA-approved occupational
safety and health plans must adopt standards identical to,
or at least as effective as, the Federal OSHA standards.
Consultation Services
Consultation assistance is available on request to employers who want help in establishing and maintaining a
safe and healthful workplace. Largely funded by OSHA, the service
is provided at no cost to the employer. Primarily developed
for smaller employers with more hazardous operations, the consultation
service is delivered by state governments employing professional
safety and health consultants. Comprehensive assistance includes
an appraisal of all mechanical systems, work practices, and
occupational safety and health hazards of the workplace and
all aspects of the employer's present job safety and
health program. In addition, the service offers assistance
to employers in developing and implementing an effective safety
and health program. No penalties are proposed or citations
issued for hazards identified by the consultant. OSHA provides
consultation assistance to the employer with the assurance
that his or her name and firm and any information about the
workplace will not be routinely reported to OSHA enforcement
staff.
Under the consultation program, certain exemplary employers
may request participation in OSHA's Safety and Health
Achievement Recognition Program (SHARP). Eligibility for participation
in SHARP includes receiving a comprehensive consultation visit,
demonstrating exemplary achievements in workplace safety and
health by abating all identified hazards, and developing an
excellent safety and health program.
Employers accepted into SHARP may receive an exemption from
programmed inspections (not complaint or accident investigation
inspections) for a period of 1 year. For more information concerning
consultation assistance, see OSHA's website at www.osha.gov.
Voluntary Protection Programs (VPP)
Voluntary Protection Programs and on-site consultation services,
when coupled with an effective enforcement program, expand
employee protection to help meet the goals of the OSH Act.
The VPPs motivate others to achieve excellent safety and health
results in the same outstanding way as they establish a cooperative
relationship between employers, employees, and OSHA.
For additional information on VPP and how to apply, contact
the OSHA regional offices listed at the end of this publication.
Strategic Partnership Program
OSHA's Strategic Partnership Program, the newest member
of OSHA's cooperative programs, helps encourage, assist,
and recognize the efforts of partners to eliminate serious
workplace hazards and achieve a high level of employee safety
and health. Whereas OSHA's Consultation Program and VPP
entail one-on-one relationships between OSHA and individual
worksites, most strategic partnerships seek to have a broader
impact by building cooperative relationships with groups of
employers and employees. These partnerships are voluntary,
cooperative relationships between OSHA, employers, employee
representatives, and others (e.g., trade unions, trade and
professional associations, universities, and other government
agencies).
For more information on this and other cooperative programs,
contact your nearest OSHA office, or visit OSHA's website
at www.osha.gov.
Alliance Program
The Alliance Program enables organizations committed to workplace
safety and health to collaborate with OSHA to prevent injuries
and illnesses in the workplace. OSHA and the Alliance participants
work together to reach out to, educate, and lead the nation's
employers and their employees in improving and advancing workplace
safety and health.
Groups that can form an Alliance with OSHA include employers,
labor unions, trade or professional groups, educational institutions
and government agencies. In some cases, organizations may be
building on existing relationships with OSHA that were developed
through other cooperative programs.
There are few formal program requirements for Alliances and
the agreements do not include an enforcement component. However,
OSHA and the participating organizations must define, implement,
and meet a set of short- and long-term goals that fall into
three categories: training and education; outreach and communication;
and promotion of the national dialogue on workplace safety
and health.
OSHA Training and Education
OSHA area offices offer a variety of information services,
such as compliance assistance, technical advice, publications,
audiovisual aids and speakers for special engagements. OSHA's
Training Institute in Arlington Heights, IL, provides basic
and advanced courses in safety and health for Federal and state
compliance officers, state consultants, Federal agency personnel,
and private sector employers, employees, and their representatives.
The OSHA Training Institute also has established OSHA Training
Institute Education Centers to address the increased demand
for its courses from the private sector and from other federal
agencies. These centers are nonprofit colleges, universities,
and other organizations that have been selected after a competition
for participation in the program.
OSHA also provides funds to nonprofit organizations, through
grants, to conduct workplace training and education in subjects
where OSHA believes there is a lack of workplace training.
Grants are awarded annually. Grant recipients are expected
to contribute 20 percent of the total grant cost.
For more information on grants, training, and education,
contact the OSHA Training Institute, Office of Training and
Education, 2020 South Arlington Road, Arlington Heights, IL
60005, (847) 297-4810, or see Outreach on OSHA's
website at www.osha.gov. For further information on any OSHA
program, contact your nearest OSHA regional office listed at
the end of this publication.
Information Available Electronically
OSHA has a variety of materials and tools available on its
website at www.osha.gov. These include electronic compliance
assistance tools, such as Safety and Health Topics, eTools,
Expert Advisors; regulations, directives and publications;
videos and other information for employers and employees. OSHA's
software programs and compliance assistance tools walk you
through challenging safety and health issues and common problems
to find the best solutions for your workplace.
A wide variety of OSHA materials, including standards, interpretations,
directives and more can be purchased on CD-ROM from the U.S.
Government Printing Office, Superintendent of Documents, toll-free
phone (866) 512-1800.
OSHA Publications
OSHA has an extensive publications program. For a listing
of free or sales items, visit OSHA's website at www.osha.gov
or contact the OSHA Publications Office, U.S. Department of
Labor, 200 Constitution Avenue, NW, N-3101, Washington, DC
20210: Telephone (202) 693-1888 or fax to (202) 693-2498.
Contacting OSHA
To report an emergency, file a complaint, or seek OSHA advice,
assistance, or products, call (800) 321OSHA or contact your
nearest OSHA Regional or Area office listed at the end of this
publication. The teletypewriter (TTY) number is (877) 889-5627.
Written correspondence can be mailed to the nearest OSHA
Regional or Area Office listed at the end of this publication
or to OSHA's national office at: U.S. Department of Labor,
Occupational Safety and Health Administration, 200 Constitution
Avenue, N.W., Washington, DC 20210.
By visiting OSHA's website at www.osha.gov, you can
also:
file a complaint online,
submit general inquiries about workplace safety and health
electronically, and
find more information about OSHA and occupational safety
and health.
Appendix A. Amputation Hazards Not Covered in this Guide The following amputation hazards and related activities are
not specifically covered in detail in this document. They are
either covered in other OSHA publications or specific OSHA
standards. While you may find the general hazard recognition
and machine guarding concepts presented in the
Recognizing Amputations Hazards and Controlling Amputation
Hazards sections of this document helpful, please refer
to the applicable topic-specific resources and standards
listed in the reference section of this publication for a
complete discussion of these hazards.
Amputation Hazards Associated with Saws
Saws are the top source of amputations in wholesale and retail
trade and in the construction industry. Stationary saws, such
as band, radial arm and table saws, account for a substantial
number of amputations in the workplace. Sawing machinery used
for woodworking applications is not specifically addressed
in this guide.
You can find specific guidance on these saws in OSHA Publication
3157, A Guide for Protecting Workers from Woodworking Hazards;
29 CFR 1910.213, Woodworking machinery requirements;
29 CFR 1910.243, Guarding of portable powered tools;
and 29 CFR 1926.304, Woodworking tools. For additional
information on how to safeguard saws and implement hazardous
energy control practices, you can find guidance at OSHA's
Machine Guarding eTool section for Saws (http://www.osha.gov/SLTC/etools/machineguarding/saws.html) Also, the national consensus standard, ANSI O1.1-2004, Safety
Requirements for Woodworking Machinery, may provide you
with valuable information on how to prevent amputations.
Amputation Hazards Associated with Plastics Machinery
Plastics processing machines are complex pieces of equipment
that require safeguarding and a hazardous energy control program.
Serious injuries, including fatalities, amputations, avulsions,
burns and cuts can occur, especially during servicing and maintenance
work. You can find specific guidance at OSHA's “Machine
Guarding” eTool section for “Plastics Machinery” (http://www.osha.gov/dcsp/products/etools/machineguarding/plastics/h_injectmold.html).
Amputation Hazards in Agriculture and Maritime Operations
Requirements for machine guarding in agriculture operations
are contained in the Standards for Agriculture, 29 CFR Part
1928 Subpart D—Safety for Agricultural Equipment,
and requirements for machine guarding in maritime operations
can be found in the Shipyard Employment Standards, 29 CFR Part
1915 Subpart H—Tools and Related Equipment,
the Marine Terminals Standard, 29 CFR Part 1917 Subpart G—Machine
Guarding, and the Longshoring Standard, 29 CFR Part 1918
Subpart I—General Working Conditions.
Additional Health and Safety Hazards
Other health and safety hazards associated with using stationary
machines, but not addressed in this guide, include noise, vibration,
ergonomic stresses, exposure to hazardous chemicals (e.g.,
metalworking fluids) and dust, electric hazards, and flying
objects.
Please visit the OSHA website at www.osha.gov for more information
on how to recognize and control these hazards.
Powered and Non-Powered Hand Tools. Portable hand tools, such
as saws, grinders, shears, and bolt cutters are associated with amputations in
the construction, retail trade, and services industries.
Material Handling. Amputations related to manual
material handling tasks often result when heavy or sharp objects fall from
an elevated surface or shift during transfer. Amputation often occurs
when the employee attempts to limit the movement of, or damage
to, material as it shifts or falls.
Forklifts. Amputation hazards related to
forklift operation and use include employees being trapped
or pinned between the forklift and another object; struck or
run over by the forklift; struck by falling or shifting loads
or overturning forklifts.
Doors and Covers. Amputation hazards are not limited to mechanical equipment or heavy loads. Doors also have the potential to amputate fingers. These injuries typically result when a door closes while a person's hands are in the doorjamb. Manhole covers, commercial garbage disposal covers, and tank or bin covers can also amputate fingers and toes.
Trash Compactors. Many businesses use small trash compactors for reducing the volume of wastes such as cardboard. Often these compactors are not properly guarded and employees are not properly trained in their use. The majority of these amputations result from employees being struck by the ram/piston either during the initiating stroke or the return stroke. The ram/piston should be guarded if any part of an operator's body is exposed to the danger area during the operating cycle. Likewise, before reaching into any trash compactor the operator should de-energize and lock out the machine.
(IA,* KS, MO, NE) City Center Square 1100 Main Street, Suite 800 Kansas City, MO 64105 (816) 426-5861
Region VIII
(CO, MT, ND, SD, UT,* WY*) 1999 Broadway, Suite 1690 PO Box 46550 Denver, CO 80202-5716 (720) 264-6550
Region IX
(American Samoa, AZ,* CA,* HI,* NV,* Northern Mariana Islands) 71 Stevenson Street, Room 420 San Francisco, CA 94105 (415) 975-4310
Region X
(AK,* ID, OR,* WA*) 1111 Third Avenue, Suite 715 Seattle, WA 98101-3212 (206) 553-5930
* These states and territories operate their own OSHA-approved
job safety and health programs and cover state and local government
employees as well as private sector employees. The Connecticut,
New Jersey, New York and Virgin Islands plans cover public
employees only. States with approved programs must have standards
that are identical to, or at least as effective as, the Federal
standards.
Note: To get contact information for OSHA
Area Offices, OSHA-approved State Plans and OSHA Consultation
Projects, please visit us online at www.osha.gov or call us
at 1-800-321-OSHA.
This is one in a series of informational fact sheets highlighting OSHA programs, policies or
standards. It does not impose any new compliance requirements. For a comprehensive list of
compliance requirements of OSHA standards or regulations, refer to Title 29 of the Code of Federal
Regulations. This information will be made available to sensory impaired individuals upon request.
The voice phone is (202) 693-1999; teletypewriter (TTY) number: (877) 889-5627.
For more complete information:
Occupational
Safety and Health
Administration
U.S. Department of Labor www.osha.gov (800) 321-OSHA