You are on page 1of 27

Occupational Health & Safety

Practitioner

Reading

CONTROLLING MACHINERY RISKS

January 2006

®
Contents
OVERVIEW .....................................................................................................................1

SECTION 1: INTRODUCTION.......................................................................................2

SECTION 2: HIERARCHY OF CONTROL.....................................................................5

SECTION 3: ISSUES FOR DESIGNERS ......................................................................7

SECTION 4: ENSURE DESIGN FAILS TO SAFETY...................................................11

SECTION 5: ISSUES FOR EMPLOYERS ...................................................................12

SECTION 6: TYPES OF GUARDS ..............................................................................15

SECTION 7: SELECTION OF SAFEGUARDS ............................................................21

SECTION 8: LEGAL REQUIREMENTS.......................................................................22

REFERENCES AND FURTHER READING..................................................................23


Published by WorkSafe,
Department of Consumer and
Employment Protection,
PO Box 294, WEST PERTH WA 6872.
Tel: Toll Free 1300 307 877.
Email: institute@worksafe.wa.gov.au

The SafetyLine Institute material has been prepared


and published as part of Western Australia’s
contribution to the National Occupational Health and
® Safety Skills Development Action Plan.
www.worksafe.wa.gov.au/institute

© 2006 State of Western Australia. All rights reserved.

Details of copyright conditions are provided at the SafetyLine Institute website.

Before using this publication, note should be taken of the Disclaimer, which is published at the
SafetyLine Institute website.

.
READING – CONTROLLING MACHINERY RISKS

Overview

This reading introduces students to the Hierarchy of Controls, the


common guards available and provides guidance on the selection
of the most appropriate guard for a particular application. A brief
precis of the legal situation is also included.

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

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 1


READING – CONTROLLING MACHINERY RISKS

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.

Anthropometric measurements of the human body -


Oxford Dictionary.

Hazard in relation to a person, means anything


with the potential to cause injury, or harm
to the health of the person.

Hazard is the process of identifying situations or


identification events that could give rise to the potential
of injury, or of harm to the health, of a
person.

MDF medium density fibreboard.

PCB (polychlorinated biphenyl) an electrically


insulating oil used for heat transfer in
transformers, capacitors and the like.

Risk in relation to any injury or harm, means the


likelihood of that injury or harm occurring.

Risk Assessment is the process of determining whether


there is a risk associated with an identified
hazard, that is whether there is any
likelihood of injury, or harm to health.

PAGE 2 SAFETYLINE INSTITUTE JANUARY 2006


READING – CONTROLLING MACHINERY RISKS

1.1 Unguarded machinery is hazardous


The number of machines being introduced to workplaces is
increasing exponentially. Initially machines were unguarded
probably because the hazards* were not fully appreciated and
community expectations were not as high as they are today.

You will no doubt have seen photographs of factories in the late


1800s and the early 1900s with line shafts running from one end to
the other with numerous pulleys and unguarded flat belts driving a
variety of different machines. The accidents that occurred with
such systems led to the realisation that action had to be taken to
protect workers. However, despite the fact that guarding has been
available for many decades, approximately 1140 workers are still
injured in Western Australia each year in incidents involving
machinery.

The following is a summary of machinery related injuries*:

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.

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 3


READING – CONTROLLING MACHINERY RISKS

1.2 Machines must be adequately guarded


In many cases workers remove guards because they perceive
some difficulty in performing their job efficiently with the guard in
place. Sometimes the guard is thought to slow work down,
sometimes the guard gets in the way of the workpiece or the job
just can't be done with the guard in place.

Sometimes workers complain that the guard restricts their view or


doesn't allow the degree of accuracy required when lining-up the
job for say a bending or pressing operation.

Employers and persons in charge of workplaces should treat all of


these concerns as genuine and in consultation with
KEY POINT
exposed workers attempt to find acceptable solutions.
However, as a good If a machine can't be
"rule of thumb" if a machine can't be adequately guarded adequately guarded for the
job in hand the machine
for the job in hand the machine being used is probably being used is probably not
not the right machine. the right machine.

In comparison with States like New South Wales and


Victoria, Western Australia's manufacturing industry is on a small
scale, making it difficult to justify jigging and tooling to automate
manufacturing processes with the associated improvement in
safety for machine operators.

This "economy of scale" problem also results in many old


machines remaining in service long after their genuine "use by
date" has expired. They are kept for those one or two jobs a year
that can then be done in house rather than sent out to a competitor
with a more appropriate / modern machine. As a result, it is
particularly necessary for those who work with and around
machines to be aware of the related hazards and the means of
controlling them.

This reading provides an introduction to an area that is rapidly


developing into a 'specialist' skill.

PAGE 4 SAFETYLINE INSTITUTE JANUARY 2006


READING – CONTROLLING MACHINERY RISKS

SECTION 2: HIERARCHY OF CONTROL

2.1 Hierarchy has the safest measures at the


top
In occupational safety and health there is a hierarchy of controls
that should be applied to any hazard. The hierarchy is in a
descending order from the control measure which gives the
greatest level of safety, but they may be used in combination.
Generally the order is:

• 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.

The other alternative is to remove the hazardous machine, ie. buy


sawn timber rather than having a circular saw on site. This solution
would eliminate the hazard associated with cutting the cord as well
as the hazard associated with the sharp blade of the saw.

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.

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 5


READING – CONTROLLING MACHINERY RISKS

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.

2.5 Engineering control


If the hazard cannot be eliminated, substituted or isolated,
engineering control is the next preferred option. It involves such
things as guards, introducing remote stop and start buttons,
introducing 'jogging' controls to facilitate cleaning of machines that
cannot be adequately cleaned when stationary and use of lead
sheeting or lead impregnated foam to reduce vibration and noise.

2.6 Administrative control


Administrative controls include the use of danger signs, work
practices that reduce the risk such as regular rest breaks for
keyboard operators and reduced exposure to noisy machines (by
job rotation), supervision and training. The introduction of written
procedures accompanied by associated training would also be
included in this control measure.

2.7 Personal protective equipment


Personal protective equipment (PPE) should be considered only
when other control measures are not practical, or to increase
protection. PPE associated with the use and
KEY POINT
maintenance of machinery includes, eye protection,
hearing protection, safety footwear, close fitting (without Administrative controls and
hampering movement) clothing, and gloves. The PPE should be considered
only as "back-up" control
provision of PPE must be accompanied by training in its measures.
proper use, fitting, cleaning and maintenance.

Administrative controls and PPE should be considered


only as "back-up" control measures. They should not be used as
long term controls.

PAGE 6 SAFETYLINE INSTITUTE JANUARY 2006


READING – CONTROLLING MACHINERY RISKS

SECTION 3: ISSUES FOR DESIGNERS

3.1 Intrinsic safety


This is a process by which the designer eliminates hazards at the
design stage. The designer considers the phases in the life cycle
of the machine, identifies the hazards related to each phase,
assesses the risk associated with each hazard and provides
design features to control all unacceptable risks.

The Life Cycle Phases that a designer should consider are:

• 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.

The designer could incorporate lifting eyes to ensure that slings


are located in positions that result in the lathe being level
(horizontal) when lifted.

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 7


READING – CONTROLLING MACHINERY RISKS

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.

Routine adjustments and lubrication should be designed to be


carried out with the machine stopped, but without the need for
removal of safeguards or dismantling of machine components.
Where frequent access is required, interlocked guards should be
used. Self-lubrication or central lubrication of parts should be
considered if access is difficult. Positive lock-off devices should be
provided to prevent unintentional restarting of machinery,
particularly after a machine has shut down unintentionally.

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.

PAGE 8 SAFETYLINE INSTITUTE JANUARY 2006


READING – CONTROLLING MACHINERY RISKS

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).

Sources of Plant Environment,


Consequences
Hazard & Work Processes

moving rotating, guillotine, entanglement,


parts stamping, conveyor crushing, trapping,
belt, lifting, moving cutting, stabbing,
plant puncturing,
shearing, abrasion,
tearing or stretching

hot and cold engines, freezers, burns, frost bite,


parts sterilisers, boiler heat stress, heat
plant, furnaces stroke

electrical generators, electrical shocks, burns,


parts motors, all electrocution
electrically operated
plant

radiation plant that produces burns, cancer,


electromagnetic damaged eye-sight,
waves, welding arc blindness
flashes, laser beams

toxic plant that exhaust toxic effect injuries


exhaust, toxic fumes as a by- such as burns,
toxic product, tankers that dermatitis,
content transport toxic respiratory illnesses,
leakage and chemicals, cranes cancer,
dangerous handling molten and environmental
material other kinds of pollution
spills dangerous materials

pressurised plant rupturing or injuries from flying


vessels exploding due to metal fragments and
failure of its shell or deadly substances if
welding seams to content is
contain the pressure hazardous. Can
cause fire and
explosion if content
is flammable,
equipment and
property damage

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 9


READING – CONTROLLING MACHINERY RISKS

inadequate tall standing plant fractures, bruises,


stability collapsing down or lacerations,
factor, toppling over dislocations,
structural because of structural concussion,
strength & failure or instability. permanent or fatal
components Dropping of heavy injuries from falls,
loads because of equipment and
component failure property damage

vibration vibrating type vibration white


and noise machines, heavy finger, hearing loss
engineering plant
with rotating parts,
reciprocating
engines, turbines

manual plant requiring sprains, strains,


operation manual control effort fractures,
eg. repetitive occupational
movements, overuse syndrome
overexertion, bad
ergonomic designs,
speed of processes

confined plant requiring contaminants,


spaces internal human inadequate oxygen
presence, eg., level,
construction process, claustrophobia,
inspections, repairs asphyxia
and maintenance

However, despite the best endeavours of designers, practical


considerations, such as cost and competition, frequently result in
residual risks having to be addressed by other means such as
guarding.

PAGE 10 SAFETYLINE INSTITUTE JANUARY 2006


READING – CONTROLLING MACHINERY RISKS

SECTION 4: ENSURE DESIGN FAILS TO SAFETY

Designers should ensure that machines fail to safety and not to


danger.

Examples of this are provision of arrester devices to prevent


unexpected strokes and movement (such as a falling
counterweight if a conveyor belt breaks), fitting of catches and
fallback devices, and fail-safe electrical limit switches.

Figure 1. Failure to Safety.

This arrangement prevents the switch being taped back and also
prevents the machine from operating if the guard is removed.

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 11


READING – CONTROLLING MACHINERY RISKS

SECTION 5: ISSUES FOR EMPLOYERS

5.1 Typical machinery hazards requiring


guarding
In circumstances where intrinsic safety through design is not
achieved, machinery guarding will be required to eliminate any
remaining hazards:

• 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 2. Guarding Typical Machinery Hazards

PAGE 12 SAFETYLINE INSTITUTE JANUARY 2006


READING – CONTROLLING MACHINERY RISKS

5.2 Consider all aspects


When considering the need for guarding, consider both operational
and non-operational parts of the machine when identifying
hazards.

Start with such obvious operational parts as:-

• Rolls (calendars, flour mills and the like)


• Saws (circular, band, etc)
• Drills and drill chucks
• Cutters in metal working machines including the blades
of guillotines and the tools of power presses
• Beaters

Then consider non-operational parts such as:-

• Chains and sprockets


• Belts and pulleys
• Gears (including rack and pinion sets)
• Shafts (plain or threaded)
• Flywheels

5.3 Safety by position


Parts of machines which are normally out of reach are called "safe
by position". However, employers must consider the likelihood of
dangerous parts normally out of reach becoming accessible in
some circumstances. An example of when this could happen is
during painting of a factory machinery area from elevating work
platforms.

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 13


READING – CONTROLLING MACHINERY RISKS

5.4 Machine layout


The way in which machines are arranged in the workplace can
reduce accidents significantly. A safe layout will take account of:

• Spacing - to facilitate access for operation, supervision,


maintenance, adjustment and cleaning
• Lighting - both general lighting to the workplace (natural or
artificial, but avoiding glare) and localised for specific
operations at machines
• Safe access for maintenance

Figure 3. Good Machine Layout.


Considerations of spacing, safe access for maintenance and good lighting are
important. (ILO illustration).

5.5 Select material for guards


The selection of the material from which the guards will be
constructed is determined by four main considerations. These are:

• Strength and durability.


• Effects on machine reliability (for example, a solid guard may
cause the machine to overheat eg. a guard of sheet material
such as MDF* or steel over an electric motor).
• Visibility (there may be operational and safety reasons for
needing a clear view of the danger area eg. the contact line
between the tool of an hydraulic press and workpiece).
• The control of other hazards (for example, the use of a material
that will not permit the ejection of molten metal).

PAGE 14 SAFETYLINE INSTITUTE JANUARY 2006


READING – CONTROLLING MACHINERY RISKS

SECTION 6: TYPES OF GUARDS

6.1 Fixed guards


A fixed guard should be fitted wherever practicable and should, by
design, prevent access to dangerous parts of machinery without
introducing a further hazard. It should be designed to withstand the
process and environmental conditions. The method of fixing and
the size of any openings, allowing for an adequate distance
between the opening and the danger point will determine its
effectiveness. This may be determined from anthropometric* data
found in national standards. The guard should only be removable
with the use of a special tool, such as a spanner, Allen key or
similar. Wing nuts and similar fixing devices that can be operated
with the fingers should not be used.

Figure 4. Fixed Guard. The design of guards may need to take into account the need to
adjust drive belts and transmission chains.

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 15


READING – CONTROLLING MACHINERY RISKS

6.2 Interlocked guards


The essential principles of an interlocked guard are that the
machine cannot operate until the guard is closed, and the guard
cannot be opened until the dangerous parts of the machine have
come fully to rest. Interlocked guards can be mechanical,
electrical, hydraulic, pneumatic or a combination of these.
Interlocked guards and their components have to be designed so
that any failure of them does not expose people to danger. Their
design needs to consider the possibility of a person being inside
the area covered by the guard when an attempt is made to start
the machine.

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.

PAGE 16 SAFETYLINE INSTITUTE JANUARY 2006


READING – CONTROLLING MACHINERY RISKS

6.3 Control guards


If the motion of the machine can be stopped quickly, control
guards can be used. The principle of control guarding is that the
machine must not be able to operate until the guard is closed.
When the operator closes the guard, the machine's operating
sequence is started automatically. If the guard is opened, the
machine's motion is stopped or reversed, so the machine must
come to rest or reverse its motion quickly for this technique to be
effective. Generally, this type of guard is not locked closed during
the operation of the machine.

6.4 Automatic guards


An automatic guard operates by physically eliminating from the
danger area any part of the body exposed to danger. It can only be
used where there is adequate time to do this without causing
injury, which limits its use to slow-moving machinery.

Figure 6. Automatic Guard. This system is limited to slow moving machinery.


The machine will only operate when guard is in the position shown: with the
operator unable to reach the danger area.

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 17


READING – CONTROLLING MACHINERY RISKS

6.5 Distance guards


A distance guard prevents any part of the body from reaching a
danger area. It could take the form of a fixed barrier or fence
designed to prevent access.

Figure 7. Distance Guard. Perimeter fence guard with fixed panels and
interlocking access door.

6.6 Adjustable guards


Where it is impracticable to prevent access to dangerous parts
(they may be unavoidably exposed during use), adjustable guards
(fixed guards with adjustable elements) can be used. The amount
of protection given by these guards relies heavily on close
supervision of the operator, operator training, correct adjustment of
the guard and its adequate maintenance.

PAGE 18 SAFETYLINE INSTITUTE JANUARY 2006


READING – CONTROLLING MACHINERY RISKS

6.7 Self adjusting guards


This guard is automatically opened by the movement of the
workpiece and returns to its closed position when the operation is
completed.

6.8 Trip devices


These automatically stop or reverse the machine before the
operator reaches the danger point. They rely upon sensitive trip
mechanisms and on the machine being able to stop quickly (which
may be assisted by a brake). Examples include trip wires and mats
containing switches that stop the machine when they are trodden
on.

Figure 8. Trip Device. Photoelectric device fitted to a pressbrake. The


machinery must be able to stop quickly after the device has been tripped
(usually assisted by a brake).

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 19


READING – CONTROLLING MACHINERY RISKS

6.9 Two hand control devices


These devices force the operator to use both hands to operate the
machine controls. However, they only provide protection for the
operator and are usually easy to defeat. They do
KEY POINT
not provide protection for anyone else who may
be near the danger point. Two-hand control devices
Guards should be arranged to protect all only give protection to the
operator and not to other
persons. Where these devices are provided, the persons near the hazard.
controls should be spaced well apart and/or The device is usually easily
shrouded. The machine should only operate defeated.
when both controls are activated together, and
the control system should require resetting
between each cycle of the machine. It should not be possible to
tape (or weigh) down one of the control buttons, nor should it be
possible to operate one button with the knee, elbow, forehead or
foot.

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.

PAGE 20 SAFETYLINE INSTITUTE JANUARY 2006


READING – CONTROLLING MACHINERY RISKS

SECTION 7: SELECTION OF SAFEGUARDS

7.1 Importance of fixed guards


KEY POINT
Fixed guards provide the highest standard of
protection, because they place a physical Fixed guards provide the
barrier between the operator and the danger highest standard of
area. For this reason they should be used protection and should be
used where access to the
where practicable ie. danger area is not required
where access to the danger area is not during normal operation.
required during normal operation.

The following gives guidance on the selection of safeguards (in


order of merit):

7.2 If access not required during normal


operation
Where access to the danger area is not required during normal
operation, the order of merit is:

1. Fixed guard (where practicable)


2. Distance guard
3. Trip device

7.3 If access required during normal


operation
Where access to the danger area is required during normal
operation, the order of merit is:

1. Interlocked guard
2. Automatic guard
3. Trip device
4. Adjustable guard
5. Self-adjusting guard
6. Two-hand control

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 21


READING – CONTROLLING MACHINERY RISKS

7.4 Design of guards


Guards should be designed, constructed and used to:

• Provide positive protection.


• Prevent access to the danger zone during operation.
• Withstand long use with minimum maintenance
• Resist normal wear and shock
• Not constitute a hazard or cause inconvenience or discomfort
to the operator.

SECTION 8: LEGAL REQUIREMENTS

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).

A person who decides to manufacture his/her own guard becomes


the designer and manufacturer and must undertake their
obligations.

The "National Standard for Plant" NOHSC:1010 (1994) (on which


most machinery related regulations are based) introduces a
hierarchy to the selection of guards similar to that described under
"Selection of Safeguards".

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.

An interlocked physical barrier is required where access to the


dangerous area is required during normal operation of the
machine. A physical barrier capable of removal using a tool or key
may be used if a permanently fixed or interlocked physical barrier
is impracticable.

Only if none of the above guards is practicable, may presence


sensing safeguarding systems be used.

PAGE 22 SAFETYLINE INSTITUTE JANUARY 2006


READING – CONTROLLING MACHINERY RISKS

Your feedback
WorkSafe is committed to continuous improvement. If you take
the time to complete the online Feedback Form at the SafetyLine
Institute website you will assist us to maintain and improve our
high standards.

REFERENCES AND FURTHER READING

National Standard for Plant [NOHSC : 1010(1994)] by WorkSafe


Australia.

Australian Standard AS4024 - Safeguarding of Machinery.

Australian Standard AS1219 - Power Presses - Safety


Requirements.

Australian Standard AS1755 - Conveyors.

Principles of Machine Guarding - MGI. WorkCover Authority


(NSW).

Controlling Risks from Plant (Machinery & Equipment) ACTU -


Occupational Health and Safety Unit.

Plant - Code of Practice - Division of Workplace Health and Safety


(Qld).

Code of Practice for Plant - Health and Safety Organisation (Vic).

Plant Design - Making it Safe - WorkSafe WA.

Plant in the Workplace - Making it Safe - WA.

JANUARY 2006 SAFETYLINE INSTITUTE PAGE 23

You might also like