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January 2006
®
Contents
OVERVIEW .....................................................................................................................1
SECTION 1: INTRODUCTION.......................................................................................2
Before using this publication, note should be taken of the Disclaimer, which is published at the
SafetyLine Institute website.
.
READING – CONTROLLING MACHINERY RISKS
Overview
Objectives
After reading this information you should be able to recall the
methods available to control risks associated with common
manufacturing machinery with particular emphasis on guards.
Author
F. John Randall
M.I.E. Australia CP Eng
Section 1: INTRODUCTION
Glossary of terms
When they are first used, glossary terms are indicated with an
asterisk (*). Make sure that you are familiar with the Glossary of
terms before going any further.
Percentage
Average Percentage
Type of injury of all lost
number of resulting in
time injuries
lost time 30 or more
injuries in last 5 days off
each year years work
Being trapped by
moving machinery 609 13% 26%
or equipment
Being trapped
between stationary
529 12% 22%
and moving
objects
* Based on workers’ compensation claim data for claims lodged between 1999-00
and 2003-04.
• ELIMINATION
• SUBSTITUTION
• ISOLATION
• ENGINEERING CONTROL
• ADMINISTRATION CONTROL
• PERSONAL PROTECTIVE EQUIPMENT
2.2 Elimination
Machinery can be made safe by eliminating the cause of the
danger. For instance, if the use of a portable circular saw creates
an electrocution hazard through cutting the power cord, use a
bench saw with built-in fixed wiring. Whilst the electricity is still
present the chance of electrocution as a result of the saw cutting
the wiring is eliminated.
2.3 Substitution
Substitution involves replacing a hazardous machine or hazardous
work practice with a less hazardous one. Using a cordless drill
rather than a drill with a cord for instance.
2.4 Isolation
Isolation involves separating the hazard from persons at risk of
being injured by it. In the case of machinery it might involve
installing a fence around a dangerous machine.
• MANUFACTURE
• TRANSPORT
• INSTALLATION
• COMMISSIONING
• USE
• MAINTENANCE
• STORAGE
• DISPOSAL
3.2 Manufacture
Examples of hazards that might be foreseen by the designer
include the replacement of spoked gears with gears having a solid
disc to eliminate a shear hazard; or building a housing around
obvious hazards rather than relying on fitting guards later.
3.3 Transport
A machine such as a metal lathe that could be delivered fully
assembled would be much heavier on the headstock end than the
tailstock end. In this example, the designer might foresee the
potential for the lathe to slip out of its lifting slings and injure
someone.
3.4 Installation
To minimise hazards during installation a designer might organise
the design of a large machine so that it is supplied in large
modules that can be placed in position by a crane, to avoid the
need for installers to work at height (with the risk of falling).
3.5 Commissioning
To avoid problems with inadvertent energising of various areas of
a machine, a designer might build in to the machine test points for
instruments and alarms.
3.6 Use
The designer should consider such issues as how the operator will
safely operate the machine. If the operator is to be seated this
could involve ergonomic considerations such as seating and the
ease with which controls can be reached and operated. If it is a
large machine that requires the operator to move around it,
consideration might be given to provision of a portable emergency
stop button.
3.7 Maintenance
Maintenance considerations should include ready access to areas
identified during design as requiring regular maintenance such as
for cleaning, lubrication and adjustment.
3.8 Storage
Storage considerations would include how to "mothball" a machine
so that it doesn't present hazards in storage or when started after a
period of inactivity. It might also include safe breakdown for
storage procedures.
3.9 Disposal
The designer should consider hazards to persons breaking down
machines for scrap. Such considerations could include hazards
associated with potential energy (springs and pressure devices),
and hazardous substances incorporated into the design (PCBs
and asbestos for instance).
This arrangement prevents the switch being taped back and also
prevents the machine from operating if the guard is removed.
• Cutting
KEY POINT
• Shearing
• Stabbing and puncturing Machine guarding should
ensure any remaining
• Impact hazards are eliminated.
• Entanglement
• Friction and abrasion
• Crushing
• Shearing or crushing nip-points
• Projectiles (flying particles of the machine or material)
• Release of potential energy
Figure 4. Fixed Guard. The design of guards may need to take into account the need to
adjust drive belts and transmission chains.
Figure 5. Interlocked Guard. When the door is opened the circuit is broken and the
revolving cylinder stops. In this type of arrangement, opening the door may also
mechanically activate a brake to stop the cylinder.
Figure 7. Distance Guard. Perimeter fence guard with fixed panels and
interlocking access door.
Figure 9. Two-Hand Control Device. Protection is only provided to the operator and not
to other persons near the hazard. The device is usually easily defeated.
1. Interlocked guard
2. Automatic guard
3. Trip device
4. Adjustable guard
5. Self-adjusting guard
6. Two-hand control
8.1 Legislation
In Australia designers, manufacturers, importers and suppliers
have a duty to ensure that their equipment is safe, so far as is
reasonably practicable (occupational safety and health legislation).
8.2 Requirements
A permanently fixed physical barrier is required where no access
to the dangerous area, during normal operation of the machine, is
required.
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