Machine Safeguarding at The Point of Operation: A Guide For Finding Solutions To Machine Hazards

WORKER HEALTH AND SAFETY
Machine safeguarding
at the point of operation
A guide for finding solutions
to machine hazards
Oregon OSHA
Machine safeguarding
at the point of operation
A guide for finding solutions
to machine hazards
About this guide

“Machine safeguarding at the point of operation” is an Oregon OSHA
Standards and Technical Resources publication.
Piracy notice:
Reprinting, excerpting, or plagiarizing this publication is fine with
us as long as it’s not for profit! Please inform Oregon OSHA of your
intention as a courtesy.
Table of Contents
The importance of machine safeguarding......................4 Portable jigsaw.................................................................... 31
Abrasive wheel grinder .......................................................6 Power press.......................................................................... 32
Horizontal band saw.............................................................9 Power press brake.............................................................. 36
Vertical band saw............................................................... 10 Power roll forming and bending machine................... 39
CNC turning machine.........................................................11 Radial-arm saw....................................................................40
Compacting and baling equipment.............................. 13 Robots................................................................................... 41
Cut-off saws......................................................................... 15 Belt sander........................................................................... 42
Drill press ............................................................................. 17 Disk sander........................................................................... 43
Ironworker............................................................................ 18 Scroll (jig) saw...................................................................... 45
Jointer.................................................................................... 19 Shaper/Router.....................................................................46
Metal lathe........................................................................... 20 Shear...................................................................................... 47
Wood lathe........................................................................... 22 Table saw.............................................................................. 49
Milling machine.................................................................. 23 Power-transmission apparatuses.................................... 51
CNC router and cutting tables........................................ 24 Lockout/Tagout.................................................................. 53
Planer..................................................................................... 26 Risk Reduction Hierarchy.................................................. 54
Plastic injection molding machinery............................. 27 Training guidelines............................................................. 55
Portable abrasive grinder................................................. 28 Basic safety principles....................................................... 56
Portable belt sander.......................................................... 29 Glossary of terms................................................................ 57
Portable circular saw.......................................................... 30 Oregon OSHA Services...................................................... 58
3
The importance of machine safeguarding
Most of us have heard the adage about how machinery doesn’t discriminate between product and
people – it will do the same to both. Many people discover this through unfortunate means: an
injured machine operator sharing the details of his or her accident or a family member reflecting on
the circumstances that took a loved one.
Recent statistics that About this guide

support the concern This guide focuses on point-of-operation hazards and
safeguarding methods and offers a comprehensive
National look at equipment and machinery commonly found
Contact with objects and equipment (caught in, on, in various Oregon workplaces. It does not specify
or under equipment or machinery only) all machine guarding requirements or all types of
• More than 690 fatalities per year machinery or equipment. The reference section
addresses typical hazards and guarding solutions
• More than 137,600 lost workday injuries per year related to power transmission devices, lockout/
• 1,400 amputations per year tagout, and general safety principles for operating or
maintaining machines and equipment.
Oregon This guide also refers to many American National
Contact with objects and equipment (caught in and Standards. The American National Standards Institute
struck by/against) (ANSI) publishes voluntary consensus standards
• 13 compensable fatalities per year on the care and use of machinery. ANSI standards
provide guidance for complying with Oregon OSHA
• 29 percent of all fatalities standards. ANSI standards are sometimes incorporated
• 4,120 accepted disabling injuries into Oregon OSHA regulations and employers are
accountable for complying with the version specified.
Machines with moving parts and workers who operate Oregon OSHA generally recommends, however, that
them have an uneasy relationship. Machines make employers follow the most recent ANSI standards.
workers more productive and enable them to form Of course, all original equipment operating manuals
and shape material in ways that would be impossible (OEMs) and other manufacturer suggestions must be
with hand tools. Technology can make machines strictly adhered to.
safer, but as long as workers need machines to help
them process material – to cut, shear, punch, bend, or In addition to ANSI, the International Organization for
drill – they will be exposed to moving parts that could Standardization (ISO) standards provide requirements
harm them. Much of the danger occurs at the point of for personnel safety in the design, construction, and
operation, where the work is performed and where the integration of machinery. ISO standards are voluntary.
machine cuts, shears, punches, bends, or drills.
4
Oregon OSHA standards related to machinery and machine guarding
General Industry Construction
Division 2/Subdivision I, Personal Protective
• Division 3/Subdivision E, Personal Protective and
•
Equipment Life Saving Equipment
Division 2/Subdivision J, General Environmental
• Division 3/Subdivision I, Tools – Hand and Power
•
Controls (Lockout/Tagout)
Agriculture
Division 2/Subdivision N, Material Handling and
• Division 4/Subdivision I, Protective Equipment
•
Storage
Division 4/Subdivision J, Work Environment
•
Division 2/Subdivision O, Machinery and Machine
• (Lockout/Tagout)
Guarding
Division 4/Subdivision N, Material Handling
•
• Division 2/Subdivision P, Hand and Portable
Powered Tools Division 4/Subdivision O, Equipment Guarding
•
• Division 2/Subdivision R, Special Industries Division 4/Subdivision P, Small Tools
•
(sawmills, pulp and paper mills, etc.) Forest Activities
• Oregon OSHA Program Directive A-280, National Division 7/Subdivision D, Personal Protective
•
Emphasis Program on Amputations Equipment and Programs
Division 7/Subdivision H, Machines Used in Forest
•
Activities
Oregon fatalities
Operator pulled into a machine by a moving belt
Worker caught in an irrigation spool
Lathe operator hit by rotating bar stock
Operator caught in keyed shaft (loose-fitting shirt contributed)
Worker caught in a glue line conveyor
5
Abrasive wheel grinder
Abrasive wheels and grinding machines come in many styles, sizes, and designs. Both bench-style and
pedestal (stand) grinders are commonly found in many industries. These grinders often have either
two abrasive wheels or one abrasive wheel and one special-purpose wheel such as a wire brush,
buffing wheel, or sandstone wheel.
These types of grinders normally come with the manufacturer’s safety guard covering most of the
wheel, including the spindle end, nut, and flange projection. These guards must be strong enough to
withstand the effects of a bursting wheel. In addition, a work rest and transparent shields are often
provided.
Tool rest
DEWALT Industrial Tool Co.
Exposed spindle end, flange, and nut. No tool/workrest.
Hazard In addition, the wheels found on these machines

(abrasive, polishing, wire, etc.) often rotate at several
Bench-style and pedestal grinders create special thousand revolutions per minute. The potential for
safety problems due to the potential of the abrasive serious injury from shooting fragments and the rotating
wheel shattering; exposed rotating wheel, flange, and wheel assemblies (including the flange, spindle end,
spindle end; and a naturally occurring nip point and nut) is high. To ensure that grinding wheels are
that is created by the work rest. This is in addition safely used in your workplace, know the hazards and
to such concerns as flying fragments, sparks, air how to control them.
contaminants, etc. Cutting, polishing, and wire
buffing wheels can create many of the same Solution
hazards.
Abrasive wheels used on bench and pedestal grinding
Grinding machines are powerful and designed to machines must be equipped with safety guards. The
operate at high speeds. If a grinding wheel shatters safety guard encloses most of the wheel – covering
while in use, the fragments can travel at more than 300 the flange, spindle end, and nut projection – while
miles per hour.
Wherever the nature

This exposure begins
of the work requires
at a point not more
contact with the
than 65 degrees
wheel below the
above the horizontal
horizontal plane
plane of the wheel
of the spindle, the
spindle.
exposure must not
exceed 125 degrees.
6
allowing maximum exposure of the wheel periphery.
The exposure of the wheel should not exceed 90
degrees or one-fourth of the periphery (see diagram
on Page 6). Because the safety guard is designed to
restrain the pieces of a shattered grinding wheel,
the distance between the safety guard and the
top periphery of the wheel must not be more than
1/4-inch. If this distance is greater because of the
decreased size of the abrasive wheel, then a “tongue
guard” must be installed to protect workers from flying
fragments in case of wheel breakage. This tongue
guard should be adjustable to maintain the maximum
1/4-inch distance between it and the wheel.
An adjustable work rest must also be installed and
maintained at a maximum clearance of 1/8-inch
between it and the face of the wheel. Spindle guard Tool rest Tongue guard
In addition to offering a stable working position, this
small clearance must be maintained to prevent the • Proper exposure angle (90 degrees)
• Adjustable tongue guards (1⁄4-inch)
operator’s hands or the work from being jammed • Adjustable tool/work rest (1⁄8-inch)
between the wheel and the rest, which may cause
serious injury or the wheel to break. Plastic glass (Plexiglas) shields are optional. They are not a substitute
for eye and face protection and are not included as a part of the
All abrasive wheels must be closely inspected and guard (unless they are adjusted accordingly and have strength equal
ring-tested before mounting to ensure that they are to that of the safety guard).
free from cracks or other defects. Wheels should be
suspended from the center mounting hole and tapped
gently with a light, nonmetallic instrument. A stable
and undamaged wheel will give a clear metallic tone
or “ring.” If a wheel sounds dead or dull, it may be
cracked. Do not use it. This is known as the ring test.
The spindle speed of the machine must also be
checked before mounting the wheel to be certain that
it does not exceed the maximum operating speed
marked on the wheel.
Always follow the manufacturer’s recommendations.
References
General Industry
Oregon OSHA Division 2/Subdivision O,
•
1910.215
Construction
Oregon OSHA Division 3/Subdivision I,
•
1926.300(b)(7) & 1926.303
Agriculture
Oregon OSHA Division 4/Subdivision O, OAR
•
437-004-2100
American National Standards Institute
ANSI B7.1, Safety Code for the Use, Care, and
•
Protection of Abrasive Wheels
ANSI B11.9, Safety Requirements for Grinding
•
7
Worker’s Fatal Injury Leads to OSHA Citations,
Penalties for Milwaukee Foundry
Company Faces $156,500 Fine
for Safety Shortcomings
MILWAUKEE, WI – Fatal injuries sustained by a foundry worker at Grede

Foundries, Inc., Milwaukee Steel Foundry, Milwaukee, might have been
avoided if safety procedures for abrasive grinding machinery had been
followed, according to the Occupational Safety and Health Administration of
the U.S. Department of Labor. OSHA proposed a $156,500 fine.
“Protecting the health and safety of workers in America is a chief goal of the
U.S. Department of Labor,” said U.S. Secretary of Labor Elaine L. Chao. “OSHA’s
standards prescribe excellent methods to keep workers safe from the hazards
associated with grinding wheels, and we will make certain standards are
followed.”
OSHA’s Milwaukee area office director, George Yoksas, said the agency opened
an inspection of the foundry following the Jan. 7, 2003, accident that occurred
when an abrasive wheel on a stand grinder exploded, propelling fragments
that struck the grinder operator. The wheel guard was unable to contain the
fragments from the 30-by-2-inch abrasive wheel.
As a result of that investigation, OSHA proposed willful and serious citations
alleging the lack of a preventative maintenance program, failure to ensure
the grinder was running at an appropriate speed within the grinding wheel
tolerance, and issues involving machine guarding and other adjustments to
the machine.
Source: Federal OSHA Regional News Release, July 7, 2003
8
Horizontal band saw
A horizontal band saw uses a thin, flexible, continuous metal band with cutting teeth on one edge.
Horizontal band saws are used primarily for cutting metal stock, such as angle iron and other round
and flat stock. The blade runs horizontally on two pulleys through two separate guides.
The operator secures the stock on the table and manually assists the saw as it cuts.
Hazard
Serious cuts or amputations can occur if the operator
contacts the blade. Extreme caution is necessary
because the operator’s hands may come close to the
saw blade, and the entire run of the blade cannot be
fully guarded.
Solution
Guard the entire blade, except at the point of
operation (the working portion of the blade between
the two guides). Band saw wheels must be fully
encased. Make sure the saw includes a tension-control
device to indicate proper blade tension.
References RL Johnson Co.
General Industry
• Oregon OSHA Division 2/Subdivision O,
1910.212, General Requirements for All Machines Horizontal band saw blade guard.

• ANSI B11.1, Metal Sawing Machines
9
Vertical band saw
A vertical band saw uses a thin, flexible, continuous metal band with cutting teeth on one edge. It is a
versatile saw used to cut both wood and metal stock and also to cut and trim meat. The blade runs on
two pulleys, driver and idler, and through a work table where material is fed manually.
In order to cut, the operator is required to hand-feed and manipulate the stock against the blade. The
operator must also keep the stock flat on the work table and exert the proper amount of force.
Hazard
Serious cuts or amputations can occur if the operator
contacts the blade. Extreme caution is necessary
because the operator’s hands may come close to the
saw blade and a band saw cannot be fully guarded.
Solution
Guard the entire blade, except at the point of
operation (the working portion of the blade between
the bottom of the sliding guide rolls and the table).
Use an adjustable guard for the portion of the blade
above the sliding guide rolls so that it raises and lowers
with the guide. Properly adjust the blade guide to fit
the thickness of the stock and ensure the guard is as
close as possible to the stock.
Vertical band saw
Band saw wheels must be fully enclosed.
References
General Industry
•
1910.213(i)
Agriculture
•
OAR 437-004-2000(4)
Large portion of exposed blade at point of operation.
ANSI 01.1, Woodworking Machinery – Safety
•
Requirements
ANSI B11.10, Metal Sawing Machines
•
University of British Columbia
Blade guard.
10
CNC turning machine
Computer numerically controlled (CNC) machining centers cut and shape an assortment of precision
products from automobile parts to general machine parts. Operating in either horizontal or vertical
positions, CNC machinery includes machining tools such as lathes, multi-axis spindles, and milling
and boring machines; the functions formerly performed by human operators are performed by a
computer-control module. CNC machinery is either hand loaded or automatically fed.
Most CNC machinery is partially or totally enclosed by metal enclosures equipped with thermoplastic
vision panels, most commonly polycarbonate.
Hazard
Two primary hazards arise from CNC turning
operations: Entanglement and the ejection of parts.
Serious lacerations, fractures, amputations, or even
death can occur if an operator contacts or becomes
entangled in or between the tooling or rotating work
piece. Similar injuries or death can also occur from
being struck by ejected parts (e.g., cutters or other
tools, chucks, or the work piece).
Although the risk of injury from ejected parts
is lessened due to the interlocked enclosure CNC control panel Determine if the polycarbonate
of CNC machinery, recent research has shown vision panels are strong enough to
that polycarbonate materials used in the unit’s contain ejected parts.
vision panels can degrade after exposure to the
metalworking fluids and lubricants used in the To prevent injury from ejected parts, make sure the
machining process. polycarbonate vision panels are strong enough to
contain ejected parts. Also, verify the appropriate
Over time, vision panels may not be able to contain rotational speed for the particular work piece and
ejected parts. Most ejections at CNC turning machines inspect the chuck jaw assemblies, work piece clamps,
are caused by a setup error or failing to properly and all component parts of the turning fixtures.
maintain work-holding devices.
Unexpected movement or startup caused by faults in References
the control system can also cause serious injury.
General Industry
Solution • Oregon OSHA Division 2/Subdivision O,
1910.212, General Requirements for All Machines
To prevent access into the point-of-operation area,
ensure the CNC machine is fully enclosed and • HSE Engineering Information Sheet #33, “CNC
equipped with an interlocked guard (door). The turning machines: Controlling risks from ejected parts”
cutting tools should not start unless the door is in • ANSI B11.22, Safety Requirements for Turning
a closed position and should stop when the door is Center and Automatic Numerically Controlled Turning
opened. Many machines lock the guard in position Machines
during operation and can be opened only when the • ANSI B11.23, Safety Requirements for Machining
tooling stops. If access into the point of operation Centers and Automatic Numerically Controlled Milling,
is infrequent, install a fixed enclosure that can be Drilling, and Boring Machines
removed only for maintenance activities.
• OSHA Safety Hazard Information Bulletin 00-06-
Automatic loading and unloading methods and 23, “Potential Hazards Associated with the Use of
automatic tool changing further reduce the exposure Replacement Materials for Machine Guarding” (June
to the point of operation. 23, 2000)
11
WORKER HEALTH AND SAFETY
A Division of the
Department of Consumer
and Business Services
Hazard alert
CNC Lathe Safety
What happened?
A machinist died when he was struck by a 40-pound
pump rotor he was turning in a vertical CNC metal
lathe. The rotor was a different size than others he
had worked on and the chuck jaws were not properly
extended to secure it. While he was standing in Le
win xan
dow
front of the machine’s Lexan viewing window, the

rotor suddenly dislodged from the chuck jaws, broke
through the window, and struck him in chest. The force
of the blow knocked him back 27 feet off the work
platform and onto a concrete floor.
How to prevent similar injuries

Ensure that the parts being machined are the
27
appropriate size so that they engage properly with the

Fee
chuck and the cutting tool.

t
Remember
Lexan windows are not guards. Do not rely on them to
protect you if a part ejects from the chuck.
For more information:

Potential Hazards Associated with the Use of
Replacement Materials for Machine Guarding
(OSHA Hazard Information Bulletin 00-06-23)
Photo of the accident

site: The CNC lathe is in
the upper left.
Salem Central Office Phone: 503-378-3272

osha.oregon.gov 350 Winter St. NE Toll-free: 800-922-2689
Oregon OSHA OR-OSHA 2993-15 (1/20) Salem, OR 97301-3882 Fax: 503-947-7461
12
Compacting and baling equipment
Compacting and baling equipment reduces large amounts of solid waste to smaller, more
manageable units by means of powered rams. In general, compactors compress refuse into containers
for transport. Baling equipment is designed to compress material (e.g., cardboard boxes) and produce
a bale (bound or unbound) that is handled as a unit.
A wide range of hazards exists simply due to the size, configuration, and operation of compactors
and balers. Some machines allow direct access to the compression chamber, while others have a
hopper or chute through which material feeds into the machine. Machines may operate in a manual,
semiautomatic, or automatic mode. The rams may move vertically or horizontally.
Hazard Whenever unjamming,

adjusting, cleaning,
Workers can be crushed by the ram motion if guarding repairing, or performing
is missing or bypassed, or if lockout procedures are other maintenance tasks,
not followed during maintenance activities. Older the machine must be
compacting equipment may not have appropriate isolated from all its energy
interlock guarding or may not have enough guarding sources and “locked out.” If
to enclose the chamber or point-of-operation area conveyors are used, they
completely. should be interconnected
Severe injury and death can also occur during service so that a single, lockable
or maintenance tasks on or inside an energized or device can de-energize
jammed machine if the machine cycles automatically and isolate the power to Pacific Compactor Corporation
or if the machine is activated by another worker who is both machines. Lockout
unaware that someone is inside the chamber. Because procedures are further explained on Page 58.
ram motion stops during a jam, workers may not Follow permit-required confined space entry
recognize that the machine remains energized and procedures whenever working inside these machines.
that the ram could activate unexpectedly. Similarly, if
conveyors are used to feed material into a compactor Also, refer to Oregon OSHA’s rules for Stationary
or baler, workers may mistakenly believe that shutting Compactors, Self-Contained Compactors, and Balers for
down the conveyor also prevents the compactor or specific control, marking, and signage requirements.
baler from operating.
In addition to the hazardous-energy potential, working
References
inside these machines may also present confined- General Industry
space hazards such as hazardous atmospheres and • Oregon OSHA Division 2/Subdivision O, OAR
engulfment. 437-002-0256, Stationary Compactors,
Self-Contained Compactors, and Balers
Solution • Oregon OSHA Division 2/Subdivision J,
Access covers and point-of-operation guarding must 1910.147, The Control of Hazardous Energy
be interlocked in such a manner that the compactor (Lockout/Tagout)
cannot be operated if the guard or loading door is • Oregon OSHA Division 2/Subdivision J, 437-002-
removed or opened. Most compactors and balers 0146, Confined Spaces
today prevent workers from reaching into the point
of operation by configuration, cycling controls, and • ANSI Z245.2, Stationary Compactors – Safety
interlock guarding that interrupt or reverse the ram’s Requirements
motion if the compression chamber doors are opened. • ANSI Z245.5, Baling Equipment – Safety
However, older equipment may not have these features. Requirements
Employers should consult with the manufacturer • NIOSH Publication No. 2003-124, Preventing
for possible retrofits or upgrades or others who are Deaths and Injuries While Compacting or
qualified to assess and perform such work. Baling Refuse Material
13
Sixteen-year-old produce-market worker
dies from crushing injuries
Caught in a vertical downstroke baler
A 16-year-old male produce-market worker died from crushing injuries after being caught
in the vertical downstroke baling machine that he was operating. The victim, working alone
in the basement of a small produce market, was crushing cardboard boxes when at some
point in the compacting process he was caught by the machine’s hydraulic ram. The victim was
discovered by an exterminator spraying the basement, who told the store manager to call
police and emergency medical services (EMS).
Subsequent examination by investigators revealed that the safety interlock had been
bypassed, allowing the machine to operate with the loading door in the open position. The
victim may have reached into the baling chamber during a compression cycle to adjust a tie
wire or a liner box and was caught by the ram platen.
• NIOSH investigators concluded that, to help prevent similar incidents, employers should:
• Ensure that all safety devices on baling machines are functioning correctly and enforce
proper operation.
• Ensure that employees, including management personnel, know and understand
the importance of the machine’s safety features.
• Comply with child labor laws that prohibit youths under the age of 18 from operating
or assisting in operation of paper balers.
• Develop and implement a comprehensive employee safety program that includes training
in the safe operation of machinery and the importance of the machine’s safety devices.
Source: NIOSH FACE Report 2000
14
Cut-off saws
Although there are many specific types of cut-off saws, they are all circular saws designed to
cross-cut stock at exact lengths and angles. The following are some of the common cut-off saws
used today.
Miter saw
Miter saw Chop saw
A miter saw is a versatile circular power saw mounted
on a hinged frame and designed to make accurate
angle cuts. When the blade is lowered in a chopping
motion, the blade cuts through the work piece,
passing through a slot in the base.
Chop saw
A chop saw is a lightweight circular saw mounted on a
spring-loaded pivoting arm and supported by a metal DEWALT Industrial Tool Inc. DEWALT Industrial Tool Inc.
base. The operator clamps the stock to the fence, pulls
the blade through the work piece, and guides the saw
back to its upright position. Chop saws typically do not Although not as common as with ripsaws, hazardous
have the cutting capacity of miter saws. kickbacks might also occur.
Swing saw Solution

Swing saws, both overhead and inverted, are swung Overtable cut-off saws (miter, chop, and overhead
from a pivot, either above or below the saw arbor. The swing saws) must be provided with fixed hood guards
operator positions the stock, pulls the saw across to that enclose the arbor and top half of the saw. These
make the cut, and then returns the saw to its original saws also must be equipped with a self-adjusting
position. lower blade guard that automatically adjusts itself to
the thickness of the material being cut and provides
Jump saw continuous protection from the blade. Most guards
supplied by manufacturers are designed to move out
Similar to an inverted swing saw, a jump saw (also of the way as the blade nears the cut. If a guard seems
called an up-cut saw) is a circular saw located slow to return to its normal position, adjust or repair it
underneath the stock and hold down (clamp) and is immediately.
attached on an arm that pivots from behind the saw
arbor at approximately the same height. After the stock
is positioned, the blade comes up, cuts the stock, and
drops below the table surface.
These “undertable” saws are normally operated by a
knee or foot pedal.
Hazard
Severe cuts to or amputations of the fingers or hands
can occur if they come in contact with the saw blade.
If the rotating blade is not properly guarded, exposure
can occur during operation or when the saw is idling.
Overhead swing saws can pose additional hazards
if the return device fails, if the saw bounces forward
from a retracted position, or if the saw blade is able to
go past the edge of the table, possibly contacting the
operator’s body. Miter saw, unguarded
15
Overhead swing saws must be provided with a device
(i.e., counterweight) to return the saw automatically
to the back of the table when released at any point
of its travel. Limit chains must also be provided to
keep the saw from swinging beyond the front or back
edges of the table.
Furthermore, swing saws and jump saws must have
a “nose guard” affixed to the saw table in front of the
hood guard (or another method providing equivalent
protection) and additional point-of-operation
guarding to prevent accidental entry of fingers or
hands into the path of the saw blade from the front Overhead swing saw missing a lower blade guard and extending
and sides (Oregon OSHA Hazard Alert, Aug. 1, 2018). beyond table edge.
References
General Industry
•
1910.213(g), Swing saw
•
1910.213(h)(1), Miter/chop saw
Construction
•
1926.304(g)(1), Miter/chop saw
Agriculture
•
OAR 437-004-2000(5)
ANSI O1.1, Woodworking Machinery – Safety
•
Requirements
Properly guarded jump saw.
Missing “nose guard” and additional point of operation guarding on a

jump saw.
16
Drill press
The drill press is a versatile machine that uses a multiple-cutting-edged drill bit secured in a rotating
chuck to bore and drill holes, usually into wood, metal, or plastic stock. Either in floor or bench-top
designs, drill presses are usually arranged vertically, requiring the operator to raise and lower an
operating handle in order to control the drill bit. These machines also have variable speeds and some
have multiple spindles for gang drilling. The most commonly used drill press is a single-spindle, floor-
mounted, belt-driven machine for nonproduction drilling.
Hazard
Serious lacerations and entanglement can occur if
operators contact the rotating bit or chuck, operators
try to hold the stock by hand when drilling, or if there
is contact with unguarded rotating belts and pulleys
above the motor. If not adequately secured, the stock
can spin violently and contact the operator and others
nearby. Also, injuries can occur from a projected chuck
key if it is left in the chuck.
Solution
Use jigs or fixtures to fasten the stock to the bed and
stabilize the work piece. This allows the stock to be
secured for drilling and the operator’s free hand to be
positioned away from the rotating chuck and drill bit.
The drill bit is more likely to grab and twist an unstable
work piece.
In many repetitive drilling applications, specially
designed guards or shields are installed to protect the
operator from the potential exposure to rotating drill
chucks and drill bits. A fixed universal-type shield can
be used on larger gang drills.
Securely anchor the drill press to prevent walking or
moving during operation, and tipping over.
When replacing the belts or adjusting drill speed,
always turn off the switch and unplug the drill press
to prevent accidental startup. Ensure all protective
guards and covers are in place before using.
Vertical drill press with vise (to prevent stock from spinning).
References
General Industry
1910.213(l)
• Oregon OSHA Division 2/Subdivision O
19110.219(d)
• ANSI 01.1, Woodworking Machinery – Safety
Requirements
17
Ironworker
Ironworkers are versatile, multi-station metal fabricating machines that offer component tooling
options to perform punching, shearing, notching-coping, and, sometimes, bending operations. The
workstations can work singly or simultaneously and all tooling moves vertically. Ironworkers are
normally powered hydraulically.
Hazard
Severe crushing injuries or amputations can occur if an
operator makes contact with any of the pinch or shear
points this machine provides.
Flying or ejected parts from either the stock or the
tooling can strike operators and other workers in the
area. Punches are hardened and will not bend as they
collide with dies. If a punch is out of alignment, it is
more likely to flake or even explode, causing serious
harm to the operator.
Unprotected foot pedals can also introduce the
possibility of accidental cycling.
Solution
Guard all pinch and shear points with fixed or
adjustable guarding. Guards should be adjusted down
to within ¼ inch from the top of the material to the
bottom of the guard (or stripper when punching). Scotchman Industries, Inc.
Most newer machines are equipped with adjustable
restrictors that surround the material in-going areas
and should allow just enough clearance for the
material to enter.
Beware of machines with automatic urethane hold-
downs. These hold-downs, if not adjusted properly,
also come down with many tons of force and can be
hazardous pinch points.
Ensure adequate die-enclosure guarding, and proper
alignment of the punch and dies. Cover foot pedals to
prevent accidental cycling.
References
General Industry
• ANSI B11.5, Safety Requirements for the
Construction, Care, and Use of Iron Workers
“Strippers” are designed to hold the material down

and hold the punch tip rigid as it punches the hole
in the work piece. Strippers may also provide some
protection from the punch hazard.
18
Jointer
Jointers face and straighten wood and are used primarily to square edges. The operator passes stock
over a cylindrical, multiple-knife cutting head while keeping the stock flush against a guide.
Hazard
Severe lacerations or amputations can occur if the
operator’s hands and fingers come in contact with the
knives. This can happen when operating an unguarded
machine, jointing narrow lengths of stock when
not using a jig or other holding device, or when the
operator’s fingers ride along the surface of the jointer
and through the self-adjusting guard while feeding
the wood. Also, stock may kick back and expose the
operator’s hands to the cutter head.
Solution
A spring-loaded, self-adjusting guard must be
provided to enclose the horizontal cutting head when Photo: University of Utah
stock is not being fed. The guard automatically adjusts Jointer
to cover the unused portion of the head and remains
in contact with the stock at all times. A guard must also
cover the section of cutting head behind the fence
(gauge). For vertical-head jointers, completely enclose
the cutter head except for the slot to apply the stock.
This guard can be part of the local exhaust system.
The knife projection on the cutting head must not be
more than 1/8 inch beyond the cylindrical body of
the head. The clearance between the edge of the rear
table (infeed) and the cutting head must not exceed
1/8-inch. The opening in the table must be kept as
small as possible.
Hold-down push shoes and sticks are recommended
when using the jointer.
References Unique Projects
• O regon OSHA Division 2/Subdivision O,

1910.213(j)
Requirements
19
Metal lathe
A metal lathe is a precision turning machine that rotates a metal rod or irregular-shaped material
while a tool cuts into the material at a preset position. Similar to the wood lathe, the metal lathe
normally consists of a headstock and base that houses one or more spindles on which a work-
holding device (chuck) can drive the stock and the cutting tools can remove metal, producing mainly
cylindrical and conical shapes.
There are basically two main types of metal lathes: Lathes for shaft work (material supported at
two or more locations) and lathes for bar (bar stock introduced through the spindle) or chucking
work (individual pieces secured at the chuck). Shaft lathes include engine lathes, vertical-shaft
lathes, and turning centers. Bar and chucking lathes include turret lathes (vertical and horizontal) and
vertical boring mills.
Hazard
Severe injuries and death can occur primarily from
being caught in or struck by rotating parts. An operator
can be pulled into the lathe from working perilously
close (e.g., polishing a slotted shaft with emery cloth)
or wearing gloves, loose clothing, loose hair, jewelry,
etc. Trapping spaces are also created between the
cutting tool, its mounting, and the work piece or
chuck.
Projected parts or material such as chuck keys or
unsecured work pieces can also strike nearby operators.
Flying chips and coolant also present hazards to the
operator.
Solution
Avoid wearing gloves, loose clothing, long hair,
jewelry, or other dangling objects near lathe
RDM Industrial Services Ltd.
operations. Pay close attention to work pieces that
have keyway slots or other surface profiles that may
increase the risk of entanglement. Assess the need to rule is to never take your hand off the chuck key until
manually polish (e.g., emery cloth) rotating material. If you set it back onto a table. Consider using a spring-
necessary, consider milling keyways or other profiles loaded wrench.
after polishing or use emery cloth with the aid of a Provide a chip/coolant shield unless another guard
tool or backing boards. Always use a brush or tool to or shield already provides protection. This does not
remove chips. replace the need for eye and face protection, however.
Cover work-holding devices (chucks) and tool trapping Note: Guards or shields used to protect lathe operators
space hazards (especially in automatic or semiautomatic from projected parts must either be from the
modes) with secured fixed or movable guards or shields. manufacturer or, if fabricated in-house, meet or exceed
Vertical lathes and controlled turning centers are normally the same impact-resistance specifications as the
provided with fixed or interlocked guarding that prevents original manufactured part. Various materials (such as
access during the automatic cycle. polycarbonates) may possess different and less-effective
Make sure all work pieces and work-holding devices impact-resistance characteristics than the original
are secure and free from defects. Remove the chuck key materials used by the manufacturer.
from the chuck after securing the material. A good
20
In one case, an operator was killed when the bell casting
on a lathe came loose while the lathe was turning and
was propelled through two, 1/2-inch-thick Plexiglas
windows. The Plexiglas was installed as a replacement
for the manufacturer’s original composite window on the
machine’s door frame. The operator was fatally struck
in the head and neck as he was looking through the
window.
The manufacturer’s original observation window was
made of a 1/4-inch-thick laminated glass plate with
a 1/2-inch-thick polycarbonate window, separated
by an approximately 1/4-inch air space. The original
window was replaced with Plexiglas material that had a
lower impact resistance than the polycarbonate shield
originally supplied by the machine manufacturer.
Hazardous exposures are present simply due to the operator’s close
Polycarbonates are a family of various polymers that proximity to the lathe’s rotating parts.
includes Macrolux, Lexan, Relex, Replex, Dynaglass,
Exolite, Verolite, Cyrolon, and Makrolon. These materials
have different impact-resistance characteristics for
different thicknesses and surface areas. It is important
to note that increasing the thickness beyond a certain
level does not always improve or increase the impact
resistance. Some studies have shown polycarbonate
degrades due to age and prolonged contact with
metalworking fluids and lubricants.
References
General Industry
• Oregon OSHA Division 2/Subdivision O, Chipmakers Metalworking World
• Oregon OSHA Program Directive A-236,
Guarding: Metal Lathe Chucks (Engine Lathes)
• OSHA Safety Hazard Information Bulletin
00-06-23, Potential Hazards Associated with the Use
of Replacement Materials for Machine Guarding (June
23, 2000)
• HSE Engineering Information Sheet #33, CNC
turning machines: Controlling risks from ejected parts
• HSE Engineering Information Sheet #2, Accidents
at metalworking lathes using emery cloth
• ANSI B11.6, Lathes – Safety Requirements for
Construction, Care, and Use
Fabricated quill-mounted guard to enclose cathead.
21
Wood lathe
While most tools rotate or move a blade or bit to cut, the wood lathe moves the work piece being
cut. The wood lathe is used to turn stock into round objects by securing the stock between two
centers: the headstock and tailstock (spindle turning), or by securing the work to the headstock only
with a faceplate (facing). Spindle turning is used for long objects such as table and chair legs, while
facing is used for cups, bowls, and plates.
The stock rotates rapidly while the operator applies a single-point tool to the wood. The operator holds
the tool on a tool rest and advances it along the length of the tool rest to shape the stock as desired.
Hazard
Due to its unique operation of rotating the stock being
cut, the lathe presents several concerns. The primary
hazards arise when using a hand tool against the
rotating stock and the close proximity of the operator
to the rotating parts.
Serious injuries can occur if the tool becomes caught
between the rest and the rotating stock, bringing the
operator’s hands in with it. Also, hands, arms, clothing,
hair, or jewelry may be caught on the rotating parts
and pulled into the machine simply because of the
close distance the operator is from the machine’s
components.
Projected or broken work pieces can be another Delta Inc.
hazard if not secured between the centers or if the
work piece is defective. Furthermore, chuck keys can
eject if left in the chuck. Flying wood chips from the
turning operation also can pose a hazard on wood
lathes. Remove chuck keys or
adjusting wrenches.
Solution Develop the habit of
never letting go of the
Cover all rotating parts and points of operation with chuck key or wrench
shields. when you are using
Cover lathes used for turning long stock with long, it. Consider using a Make sure the tool rest is secure and
set close to the stock.
curved guards that extend over the top of the lathe. spring-loaded chuck
These shields, or guards, must protect the operator wrench.
if the stock comes loose and is thrown from the Check to make sure that the chuck is secured before
machine. turning the lathe on.
Make sure the tool rest is secure and set close to the Never permit operators to wear loose clothing, long
stock (1/8 inch). Rotate the stock by hand to make hair, jewelry, dangling objects, or gloves.
sure it clears the tool rest before turning the lathe
on. Guide the turning tool on the rest only – do not
attempt to support the tool with your hands. References
The work piece must be secured and should be free of General Industry
cracks, splits, knots, and other defects. Check for weak • Oregon OSHA Division 2/Subdivision O,
glue joints. 1910.213(o)
Requirements
22
Milling machine
A milling machine removes material from a work piece by rotating a cutting tool (cutter) and moving
it into the work piece. Milling machines, either vertical or horizontal, are usually used to machine flat
and irregularly shaped surfaces of metal and other tough materials, and can be used to drill, bore, and
cut gears, threads, and slots.
The vertical mill, or “column and knee” mill, is the most common milling machine found in machine
shops today. The general construction of this mill includes the quill, which moves vertically in the
head and contains the spindle and cutting tools. The knee moves up and down by sliding parallel to
the column. The column holds the turret, which allows the milling head to be positioned anywhere
above the table. Hand wheels move the work table to the left and right (X axis), in and out (Y axis),
in addition to moving the knee, saddle, and worktable up and down (Z axis).
Hazard
Serious injuries and entanglement can occur if the
operator contacts the rotating cutter. Metal shavings
and lubricating/cooling fluids might also present a risk
from the point of operation area.
Material might spin and strike an operator if the
material is not secured to the table. Injuries can also
occur from a projected wrench if it is left in the spindle.
Solution
Secure the work piece, either by clamping it onto
the work table or by clamping it securely in a vise that Georgia Tech Research Institute Illinois Institute of Technology
is clamped tightly to the table.
Vertical “column and knee” mill.
Note: Computer numerical controlled (CNC) mills are rapidly
replacing manually fed machines, mainly for versatility and
production reasons. The increased automation does not
normally require the operator to move the hand wheels (like
the traditional machines), so operators must always keep their
hands away from the point of operation. A guard or shield
that encloses the cutter head or milling bed may be considered
to protect the operator from the cutting area, flying metal
shavings, and lubricating or cooling fluids.
Make sure the tightening wrench is removed from
the mill.
References
General Industry
• Oregon OSHA Division 2/Subdivision O, Ball State University
1910.212, General Requirements for All Machines In some cases, a polycarbonate shield can provide an operator
• ANSI B11.8, Drilling, Milling, and Boring Machines protection from the cutter, as well as from metal shavings and metal
working fluids.
23
CNC router and cutting tables
Computer numerical controlled (CNC) routers remove material
from a work piece by rotating a cutting tool (cutter) and moving
it into the work piece, but operate at higher speeds than milling
machines. CNC routers are usually used to cut or shape more
ornate designs into thinner and softer materials such as wood,
plastic, and soft metals like aluminum.
CNC cutting tables use plasma, lasers, or high-powered waterjets
instead of a rotating tool, to cut and engrave metal, and other
hard or soft materials.
CNC routers and cutting tables, either vertical or horizontal, are commonly found in wood shops and
metal fabrication shops, and vary in size to accommodate smaller work pieces, or large sheet stock.
The general construction of these highly automated machines consists of a stationary table or bed
featuring a turret (Z axis) with a spindle or cutting tip that moves back and forth on the rails (X axis) of a
moving gantry (Y axis) above the work piece.
Depending on size and application, CNC routers and cutting tables can be completely open, or
partially or totally enclosed by interlocked metal enclosures equipped with thermoplastic vision
panels. Operators initiate start/stop sequences from a control console that is usually a safe distance
away from the point of operation.
Hazard Crushing injuries can occur if an operator, or any part

of the body is caught between the stationary and
Serious lacerations, fractures, burns, and amputations moving parts of the machine. The operator, or others
can occur if an operator contacts the rotating cutting in the area, can be struck by the traveling gantry.
tool, or cutting tip/nozzle during operation. Fractures,
lacerations, and even death can occur to the operator Unexpected movement or startup caused by faults in
and others in the area from being struck by ejected the control system can also cause serious injury when
material, parts, and tooling. changing tools and moving material and parts.
Metal shavings and lubricating/cooling fluids might Solution
also present a risk from the point of operation area.
When CNC routers are not fully or partially enclosed,
Plasma and laser cutting produces toxic fumes and fixed barrier guards can protect the operator and
particulates, and also produces intense light and/or others in the area from point of operation hazards at
radiation that can cause eye damage and skin burns. the cutting tool and from ejected parts.
Sparks and hot slag from these hot processes can
ignite nearby combustibles. A potential for shock and Automatic loading and unloading methods, automatic
electrocution hazards exists due to the high operating tool changing, light curtains, or pressure sensitive
voltages of plasma and laser cutters. mats that shut off the machine can further reduce the
exposure to the point of operation from unexpected
Dust accumulation from the laser cutting of titanium, movement or startup.
aluminum, zinc, and their alloys can cause a thermite
reaction when mixed with the dust of oxidized iron or Safe distance, barrier guards, or electronic safety
copper, and cause a combustible dust explosion. devices can prevent others in the area from getting to
close to the moving gantry, and other moving parts of
Water used in high-powered jet cutting is the machine.
compressible at the pressures involved and can store
energy just as compressed air does. The use of pool/ Ensure adequate ventilation is provided to exhaust
spa chemicals to control bacteria in the water tanks of hazardous fumes and particulates.
waterjet cutters can cause eye injuries.
24
Keep dust collectors clean. Do not allow the Establish a laser safety program and appoint a Laser
accumulation of flammable or combustible materials Safety Officer in accordance with ANSI Z 136.1 when
and debris such as metal dust, baled paper, bulk sulfur, workers use or are exposed to Class IIIB or Class IV lasers.
and oily rags. Keep a fire extinguisher readily available
in the immediate area. References
Use proper personal protective equipment to protect General Industry
operators and others from hazards caused by hot • Oregon OSHA Division 2/Subdivision O,
processes such as hearing protection, safety glasses 1910.212, General Requirements for All Machines
and/or face shields, shock resistant gloves, and
welding curtains. • Oregon OSHA Division 2/Subdivision Q, Welding,
Cutting, and Brazing
• Oregon OSHA Division 2/Subdivision I, 437-002-
0134 Personal Protective Equipment
• ANSI B 11.23, Safety Requirements for Machining
Centers and Automatic Numerically Controlled Milling,
Drilling and Boring Machines
• ANSI B11.25, Safety Requirements for Large
Machines
• ANSI Z 136.1, Safe Use of Lasers
• ANSI O 1.1, Safety Requirements for CNC Machining
Centers for the Woodworking Industry
CNC router table equipped with a dust collection system around the
cutting tool.
Machine operator dies

Shirt sleeve was caught by the rotating bit of a milling machine
On June 16, 1999, a 57-year-old male supervisor/mill operator was fatally injured after his shirt
sleeve was caught by the rotating bit of the milling machine he was operating. The rotating bit
tightened the shirt around his neck, strangling him.
The victim, working alone, was clamping 8-inch by 8-inch by 1/2-inch-thick steel plates to the
table while the bit was rotating. A co-worker was passing by and noticed the victim caught in the
running mill press. The co-worker shut off the machine as another co-worker arrived to help. Both
co-workers were trying to hold up the victim while a third co-worker went to call for emergency
assistance.
The victim was transported to the hospital where he was pronounced dead. The investigation
concluded that to prevent similar occurrences in the future, employers should:
• Guard moving machine parts to prevent employee contact with them.
• Instruct employees to have the drill spindle engaged only when ready to start drilling.
• Ensure that drill presses, milling machines, and similar equipment have emergency stops and
convenient and accessible switches.
• Develop, implement, and enforce a comprehensive safety program that includes, but is not limited
to, training on all equipment used to complete tasks.
Source: NIOSH FACE Report 1999
25
Planer
Planers are most frequently used to produce smooth faces on boards and to mill them to particular
thicknesses. Planers are different from jointers because of their capacity to plane wider surfaces and
the capability to control thickness.
Planers have automatic feed systems that pull the work through the horizontally rotating blades and
out the back.
Hazard
Severe lacerations, amputations, or avulsions (tearing
away) can occur if the operator’s hand or arm is fed
through the machine and contacts the cutting heads.
Serious injury can also occur from kickback. A
kickback can occur when lowering the table with the
power on and the stock still in the machine, feeding
stacked boards, or planing boards shorter than the
manufacturer’s recommendation.
Solution
Keep the machine guards in place at all times.
Keep your hands out of the machine feeding area and
allow the planer to pull the stock through. DEWALT industrial Tool Co.
Never lower the table during operation and never

feed stacked boards. Also, follow manufacturer’s
recommendations for allowable material dimensions.
Keep your body to the side of the stock.
References
General Industry
1910.213(n)
Requirements
Cornell University
26
Plastic injection molding machinery
Plastic injection molding machines produce plastic parts by converting plastic pellets into molten
material, injecting the molten plastic into a mold, and cooling the plastic material. One half of the
mold is connected to a movable platen (clamp) and the other is connected to a stationary platen. As
the machine prepares to inject molten plastic into the mold, the platens close and press the mold
halves tightly together. When the plastic is cooled, the movable platen retracts, and the solidified
plastic parts are removed.
Hazard
Crushing injuries, avulsions, and amputations can
result from the numerous moving parts and pinch
points. Severe burns can also occur from the hot
temperatures. Such injuries can result from safeguards
that are missing, improperly installed, removed, or
bypassed.
Solution
Since these machines are complex pieces of
equipment, well-designed and effective guarding is
a must. An interlocked movable barrier (operator’s
door or “gate”) should be installed to block operator
access to moving parts while the machine is in OSHA SPI Alliance
normal production. The safety interlocks (mechanical,
electrical, hydraulic) prevent the mold from closing
when the door is open. Install guarding if a person can
reach over the machine into the mold area.
References
General Industry
• O regon OSHA Division 2/Subdivision O
• ANSI/SPI B151.1, Safety Requirements for Horizontal
Injection Molding Machines
• ANSI/SPI B151.27, Safety Requirements for the
Integration of Robots with Injection Molding Machines
• OSHA Machine Guarding eTool, Plastics Machinery OSHA
• SPI/OSHA Alliance,
• OSHA Alliance Program Products: www.osha.gov
• Worker Health and Safety Resources: www.
plasticsindustry.org
• I
RSST Publication, Horizontal Plastic Injection
Molding Machine - Safety Checklists
27
Portable abrasive grinder
One of the most common portable tools found in virtually any shop, the portable grinder is incredibly
useful for grinding and finishing material of all shapes and sizes.
Hazard
The hazards associated with portable grinders are
similar to those of pedestal or bench grinders. First of
all, serious abrasion or cuts can occur from contacting
the rotating abrasive stone. There is also the potential
for the abrasive stone to shatter, plus the dangers of
exposure to the rotating wheel, flange, and spindle
end from kickback. Finally, other concerns, such
as flying fragments and sparks, are present during
portable grinding operations.
Solution
These types of grinders normally come with the
manufacturer’s safety guard covering most of the
wheel. Abrasive grinder exposure must not exceed a
maximum angle of 180 degrees and the top half of the
wheel must be enclosed at all times. The guard must
be mounted so it maintains proper alignment with the
wheel.
References
General Industry
Vertical “right angle” grinders must have a 180-degree
guard between the operator and wheel. The guard • Oregon OSHA Division 2/Subdivision P,
must be adjusted so that pieces of a broken wheel 1910.243(c)
will be deflected away from the operator. The above Construction
picture depicts a properly guarded “right angle” • Oregon OSHA Division 3/Subdivision I, 1926.303
grinder.
Agriculture
Cup wheel grinders must be guarded as described • Oregon OSHA Division 4/Subdivision P, OAR
above or be provided with special “revolving cup 437-004-2230(3)
guards,” which mount behind the wheel and turn with it.
There are exceptions for guarding based on work
practices and for other grinders [Oregon OSHA • ANSI/UL 45, Portable Electric Tools
Division 2/Subdivision P, 1910.243(c)(1)]. Natural • A
NSI B7.1, Safety Code for the Use, Care, and
sandstone wheels and metal, wooden, cloth, or paper Protection of Abrasive Wheels
discs that have a layer of abrasive on the surface are
• A
NSI B11.9, Safety Requirements for Grinding
not covered by Oregon OSHA’s portable abrasive
grinder rule. Machines
All abrasive wheels must be closely inspected and

“ring-tested” before mounting to ensure that they are
free from cracks or other defects. The spindle speed of
the machine also must be checked before mounting
the wheel to be certain that it does not exceed the
maximum operating speed marked on the wheel.
Always follow the manufacturer’s recommendations.
28
Portable belt sander
The portable belt sander is a general-purpose finishing tool. The belt is looped around two or more
pulleys. The belt sander’s linear motion makes it an excellent tool for sanding with the grain of the wood.
Hazard
Serious abrasion can occur from contacting the
moving belt.
In-running nip points – created where the belt meets
the pulley – can be present on the side of the tool.
Nip points allow fingers, clothing, or hair to become
caught in the tool.
Solution
Both hands should be used to operate the portable
belt sander, one on the trigger switch and the other on
the front handle.
Guard the unused runs of the sanding belt and all
in-running nip points. This is normally accomplished
by the tool’s casing, enclosing the top portion of the
belt and much of the side. The enclosure, or guard, on
the sides must prevent the operator from contacting
the nip points.
References
General Industry
Oregon OSHA Division 2/Subdivision P,
•
1910.243(a)(3)
Agriculture
Oregon OSHA Division 4/Subdivision P,
•
OAR 437-004-2230(1)(d)
29
Portable circular saw
The portable circular saw is probably the most commonly used power saw. Circular saws are versatile
and used to crosscut, rip, and bevel cut. The operator adjusts the saw to the proper cutting depth and
pushes the tool through the wood.
Hazard should be positioned so

that the weight of the
Severe cuts and amputations can occur if the operator cutoff keeps the saw
contacts the saw blade. Many injuries occur when kerf open as the cut
the lower portion of the blade is fully exposed during is being made. Also,
operation or when the operator places his or her hand make sure you are
under the base plate (shoe) of the saw. not cutting uphill
Kickbacks can also present a significant hazard. They – even the slightest
occur when the saw blade binds in the cut and the saw incline can cause the
kicks back toward the operator. Binding most often saw to bind. The saw
occurs when the piece being cut off is not allowed to must always move in Never pin back the blade guard.
fall down, if cutting on an incline, or between two saw a straight line. If the
horses and either the weight of the saw or the forward blade wanders from its
motion causes the saw kerf (line of cut) to close. straight path, the rear
of the blade can bind
Solution against the side of the
kerf. If the saw has to be
All saws with a blade diameter greater than two inches turned off in the middle
must be equipped with guards above and below the of a cut, make sure
base plate (shoe). The upper guard must cover the saw the blade has stopped
to the depth of the teeth, except for the minimum arc spinning before taking
required to permit the base to be tilted for bevel cuts. your hand off the saw. Always keep your body out of
The lower guard must enclose the teeth as much as the line of potential kickback.
possible and cover the unused portion of the blade
when cutting. Use two hands whenever possible, one on the trigger
switch and the other on a front knob handle. Avoid
When the tool is withdrawn from the work, the lower holding onto smaller work pieces with one hand while
guard must automatically and instantly return to the operating the saw with the other. Secure work being
covering position. Check that the retracting lower guard cut to avoid movement.
has returned to its starting position before laying down
the saw. If the saw is set down with the guard open, it References
usually spins in a tight circle – sometimes cutting its own
cord or possibly contacting the worker’s foot. General Industry
In addition, the lower guard must be equipped with a • Oregon OSHA Division 2/Subdivision P,
lug or lever, located safely away from the blade teeth, 1910.243(a)(1)(i)
that will permit the operator to shift the guard safely • Oregon OSHA Division 2/Subdivision P, OAR
for starting unusual cuts. Never hold or force the 437-002-0266(1)
retracting lower guard in the open position and never
pin the guard up. Construction
•
Kickbacks can be minimized by setting the proper blade 1926.304(d)
depth so that the lowest tooth extends no more than
1/8 inch beyond the bottom of the material. This limits Agriculture
the area of the blade in the kerf and also exposes less of • Oregon OSHA Division 4/Subdivision P, OAR
the blade if the saw does kick back. 437-004-2230(1)(a)
It’s also important to keep the saw kerf open, reducing American National Standards Institute
the chance for the saw to bind. The board being cut ANSI/UL 45, Portable Electric Tools
•
30
Portable jigsaw
Handheld jigsaws are useful for cutting intricate curves and patterns in thin stock. They have thin
blades that move rapidly up and down through the saw’s guide plate. The blade is held in a chuck. The
operator either holds the saw with one hand while the other hand is used to secure the stock, or the
saw is held with both hands if the stock is already secured.
Hazard
Serious cuts can occur when the operator contacts the
reciprocating blade. Much of the blade is exposed by
design and contact can be made before or after the
cut, or during the cut if the operator’s hand is securing
the material underneath the stock and in the path of
the blade.
Solution
Ensure the portion of the blade above the guide plate
is adequately guarded. This may require setting it to an
appropriate height.
Secure the work piece and use two hands whenever
possible. Be aware of the portion of the blade below
the stock, especially if you are using one hand to
secure the material.
Make turns slowly and use a narrow blade for sharp
turns.
References
General Industry
• Oregon OSHA Division 2/Subdivision P,
1910.243
• ANSI/UL 45, Portable Electric Tools
Construction
• Oregon OSHA Division 3/Subdivision I, 1926.300
Agriculture
• Oregon OSHA Division 4/Subdivision P, DEWALT Industrial Tool Co.
437-004-2230
31
Power press
Power presses are metalworking machines used primarily to cut, punch,
or form metal using tooling (dies) attached to the slide (ram) and bed. The
slide has a controlled reciprocating motion toward and away from the bed
surface and at right angles to it. It is guided in the frame of the machine –
either a “C” frame [open back inclined (OBI)] or straight side frame – to give a
definite path of motion.
The two most common types of power presses are mechanically and
hydraulically powered. Though these two share common features, the
mechanical power press has been the most widely used throughout
industry and has been the subject of most of the research done, primarily
due to its tenure in industry and the number of injuries associated with it. Rockford Systems Inc.
The main components for power transmission on a mechanical power press are the clutch, flywheel, and
crankshaft. The slide is attached to a crankshaft with connecting rods (“pitmans”) and the crankshaft is
coupled to the flywheel, which always rotates when the motor is running. A clutch is used to connect the
spinning flywheel to the crankshaft. The crankshaft converts the rotary motion of the flywheel to the
downward and upward motions of the press slide.
Two different types of clutches are used on mechanical power presses: full-revolution and part-
revolution clutches. Full revolution clutches, when tripped, cannot be disengaged until the crankshaft
has completed a full revolution and the press slide has completed a full stroke. Presses equipped with
full-revolution clutches are typically older and more hazardous due to their cycling operation. A part-
revolution clutch can be disengaged at any point before the crankshaft has completed a full revolution
and the press slide has completed a full stroke. The majority of part revolution clutch presses use air
and a brake. When air is trapped and compressed in chambers, the clutch is engaged and the brake is
disengaged. To stop the press, the reverse takes place.
Manually fed presses are cycled either by foot or by two-hand controls or trips. With foot controls, the
press is activated by pressing down on a foot switch or pedal, leaving the hands free during the cycling
of the press. This freedom of hand movement places operators using foot controls at a greater risk of
sustaining an injury at the point of operation. Approximately twice as many press injuries are from foot-
controlled presses. With two-hand controls or trips, once a work piece is positioned in the press, both
hands must be removed from the point of operation to depress the buttons.
The other major aspect of press operation involves safely installing, removing, and transferring the dies.
Hazard Flying or ejected parts from either the stock or the

dies can also strike operators and other workers in the
A machine that punches metal in a blink of an eye operation area.
leaves little to the imagination as to what it can do
to body parts. Severe crushing injuries, amputations, Unprotected operating controls, especially foot pedals,
and even death can occur in the point of operation or also can introduce the possibility of accidental cycling.
while performing servicing tasks such as die setting or
troubleshooting. Solution
According to Federal Bureau of Labor and Statistics, The point of operation of all power presses must be
approximately 7,000 amputations occur each year and safeguarded. Safeguarding is accomplished either
many are from mechanical and hydraulic presses. by barrier guarding or the use of devices. Barrier
32
guarding prevents entry into the die area by physically Fixed barrier guards are, as the term implies, firmly
enclosing the point of operation. Devices control entry fixed to the frame of the press or the bolster plate, and
by allowing the operator to reach into the die area to do not have hinged, movable, or adjustable sections.
feed or remove parts and will either prevent a machine Interlocked press barrier guarding has hinged or
cycle, stop the hazardous down-stroke, or pull the movable sections interlocked with the clutch/brake
operator’s hands out if his or her hands are detected control so that the clutch cannot be engaged unless
or remain in the point of operation. Guarding is not the guard sections are in proper position. When the
required if the point of operation opening is 1/4 inch interlocked guard section is opened, the press slide must
or less. either stop immediately or have already completed the
die-closing portion of the stroke (full revolution clutch
Safeguarding choices for mechanical power presses
presses normally cannot be equipped with interlocked
depend on the clutch systems. Feasible methods for
guarding). Adjustable barrier guarding can be adjusted
full-revolution presses include fixed or adjustable
for different material widths and thicknesses and still
barrier guarding, two-hand trips, pullbacks, restraints,
meet the acceptable guard opening distances (Table
or type “A” gates. Part-revolution presses are usually
O-10).
equipped with barrier guarding, presence-sensing
devices, two-hand controls or trips, type “A” or “B” Devices can be effective safeguards at the point of
gates, pullbacks, or restraints. The safeguarding operation. They include presence-sensing devices,
options for a part-revolution press also can be installed two-hand controls or trips, gates, pullbacks, or
on hydraulic presses. restraints. Presence-sensing devices (photoelectric
“light curtains” are most commonly used) create an
invisible sensing field and are designed to detect an
operator’s hand, arm, or other body part entering
the hazard area and either prevent a machine cycle
or stop the hazardous motion of the machine. They
are a versatile and popular method of safeguarding
because they do not create a physical barrier between
the operator and the point of operation, they allow
complete visibility, and they can be “blanked” or
“muted” (certain channels are bypassed) to allow
material movement. They must be located at the
proper safety distance (see Page 36) from the point of
operation and can only be used on part revolution
presses and hydraulic presses that are capable of
Fixed, interlocked, or adjustable barrier guarding is

best for applications where the operator does not
need frequent access to the point of operation, for
example, on a mechanical power press in continuous
mode. An advantage to using barrier guarding is that
it presents a physical barrier between people (the
operator and other workers) and the machine’s pinch
point, in addition to capturing any flying parts from
either the stock or the die.
Barrier guarding must be designed and constructed
so that people cannot reach over, under, around, or Rockford Systems Inc.
through the guard and reach the pinch-point hazard. If
Barrier guarding on an OBI mechanical power press.
there are openings in the barrier guard, the openings
must be in compliance with the OSHA (or ANSI) quickly stopping hazardous motion.
guard-opening requirements. The following are the
maximum permissible openings as listed in Table O-10
of OSHA’s Mechanical Power Press Standard.
33
Distance of opening from Maximum width
point of operation hazard of opening (in.):
(in.):
⁄2 to 11⁄2
1 1
⁄4
11⁄2 to 21⁄2 3
⁄8
21⁄2 to 31⁄2 1
⁄2
31⁄2 to 51⁄2 5
⁄8
51⁄2 to 61⁄2 ⁄4
3
61⁄2 to 71⁄2 ⁄8
7
71⁄2 to 121⁄2 1 ⁄4
1
Rockford Systems Inc.
121⁄2 to 151⁄2 11⁄2 It is important to check the “safe distance” of the

151⁄2 to 171⁄2 17⁄8 guard opening to the point of operation. A guard
opening scale, like the one above, can be used to
171⁄2 to 311⁄2 21⁄8 easily determine compliance.
The various openings are such that for average-size hands, an
operator’s fingers will not reach the point of operation. Rockford Systems Inc.
Two-hand controls are also used on part-revolution

or hydraulic presses and require the use of both of
the operator’s hands to concurrently depress two
individual palm buttons to cycle the machine. These
controls must also require the operator to hold them
down through the die-closing portion of the stroke
(downstroke). Two-hand trips are similar to two-hand
controls, but are usually equipped on full-revolution Rockford Systems In
presses. Trips require only momentary actuation of
the palm buttons, and once the buttons have been Adjustable barrier guarding. Photoelectric “light curtain” on a
hydraulic press.
actuated, they can be released quickly and the machine
will make one full cycle or stroke. Of course, locating brake monitor or a portable stop-time measurement
two-hand controls or trips at their proper safety device. The ANSI formula takes more factors into account
distances (see below) are critical for operator safety. and normally results in a larger safety distance.
Also, they must incorporate both anti-tiedown and
anti-repeat features. Anti-tiedown prevents “tying” Gates are movable barriers that enclose (in combination
one button down and still being able to cycle the with barrier guards) the point of operation before the
machine by depressing the other. Anti-repeat prevents machine cycle can be started, and remain closed until
continuous cycling. If more than one operator is the downstroke has completed. There are two types:
operating a press, each operator must have his or her Type “A” gate remains closed during the entire cycle and
own set of controls/trips. type “B” gate remains closed during the downstroke only.
Gates are normally constructed of clear polycarbonate
Safety distance, as applied to press safeguarding using and powered by air and gravity.
presence-sensing devices, two-hand controls, two-hand
trips, and interlocked barrier guards, is a calculation Pullback devices use a series of cables attached to the
to determine where these devices must be located operator’s hands or wrists. Slack is taken up during the
from the point-of-operation hazard so that hazardous downstroke cycle, pulling the operator’s hands from
motion is effectively stopped or prevented before the point of operation, if they are still there. Restraint
contact can be made. Safety distance is calculated with (holdout) devices are also attached to the operator using
an equation using the maximum speed that someone cables or straps, but must be anchored and adjusted so
can approach the hazard (63 inches/second) and the the operator’s hands can never reach into the point of
total time it takes to stop hazardous motion (seconds). operation.
Additional factors such as, but not limited to, depth There is no retracting action involved. Consequently,
penetration (presence sensing) and reaction times of hand-feeding tools are often necessary if the operation
the control system and safeguard interface are also involves placing small material into the dies.
included. Stopping time is normally measured using the
34
It’s important to remember that most devices do not
provide protection from flying parts. Also, control
reliability (see Glossary) and a brake monitor (see
Glossary) must be incorporated in part revolution
mechanical power presses using a presence sensing
device, two-hand control, type “B” gate, or interlocked
barrier guarding.
Full-revolution mechanical power presses must Rockford Systems Inc.
incorporate a single-stroke (or anti-repeat) feature that
Two-hand controls on a part revolution press.
allows the clutch to engage and the press to cycle only
once each time the foot control or two-hand trips are
depressed.
To prevent accidental cycling, effectively cover or guard
all hand and foot controls. Foot pedals must be attached
to a nonslip surface to prevent the pedal from sliding.
Hand tools can be used for placing and removing
material, but they do not replace guarding.
Appropriate die-setting procedures must be established
and followed to ensure the safe design, handling,
installation, and removal of the dies. Safety blocks must
be used and enforced. Weekly inspections and regular
maintenance of presses, parts, auxiliary equipment, and
safeguards must be followed and documented.
If the back of the press presents a hazard to others,
prevent access with a barricade.
Notification of mechanical power press injury:
All point-of-operation injuries associated with a
mechanical power press must be reported to Oregon Type “A” gate.
OSHA within 30 days of occurrence. Information such
as the type of press, task performed, type of safeguards,
cause of injury, and feeding method must be provided.
References
General Industry
•
1910.217, Mechanical Power Presses
•
ANSI B11.1, Safety Requirements for Mechanical
•
Power Presses
ANSI B11.19, Safeguarding When Referenced by
•
the Other B11 Machine Tool Safety Standards –
Performance Criteria for the Design, Construction, Press restraints.
care, and Operation
NIOSH Publication No. 87-107, “Injuries and
•
Amputations Resulting From Work With Mechanical
Power Presses” (May 22, 1987)
Oregon OSHA Program Directive A-291, Machine
•
Guarding: Mechanical Power Presses
35
Power press brake
These metalworking machines bend and form
parts through the use of tooling (dies) attached
to a ram or slide and a bed. Metalworking
occurs by placing stock, primarily sheet metal,
on a bottom die and pressing it with a top die
attached to the movable ram.
Press brakes are mechanically or hydraulically
powered, or both (hydra-mechanical brakes
combine both). Mechanical (flywheel) press
brakes use either mechanical friction or air
Press brake
friction clutches that can be disengaged at any
point before the crankshaft has completed a full revolution and the press slide has completed a full
stroke. By inching and slipping the clutch, these presses allow the operator to drop the slide to the
work piece and stop, adjust, or align the work piece, and then complete the stroke. Hydraulic press
brakes can normally be stopped at any point in their cycle and the force exerted by the dies can be
varied. Operating speeds are normally slower than mechanical presses; however, because of their
slower operating speeds, they are normally not fully automated. Hydra-mechanical press brakes
combine hydraulic and mechanical operations into one system.
Regardless of how the press is powered, the basic operation involves the operator feeding or placing
the stock on the bottom die, positioning the stock properly, and activating the press cycle with hand
or foot controls. However, one important difference between mechanical and hydraulic brakes is there
is no way to reverse the stroke on mechanical brakes. Although it can be stopped or inched, the stroke
must be completed.
Note: When operating a mechanical press brake, if the ram is not brought back up to or past top dead center (crankshaft
rotation), the ram may drift back down the wrong way before the clutch re-engages. Not knowing where the ram is in
relationship to the stroke is a reason some press brake operators lose fingers.
Operating the press brake is only half of the overall operation – the other half involves installing,
removing, and transferring the dies.
Hazard
If the press brake can bend metal with ease, it is obvious
that this same capacity can cause serious injuries to
operators, including severed or broken arms, hands,
fingers, or any other part of the body. Although the
actual operation of the press brake does not require
the operator to place his or her hands or any part of the
body into the point of operation, the close exposure to Steve D. Benson
thefabricator.com
the closing dies still creates a significant risk. In addition,
the stock can sometimes “whip” or bend up, creating a
pinch-point hazard between it and the front face of the must place his or her hands between the two dies. The
slide (A) or possibly “slapping” the operator if he or she is operator’s hands or arms can be severely crushed if the
in the path of the rising material (B). ram fell during setup.
Installing and removing tooling provides the most Unprotected operating controls, especially foot pedals,
direct exposure in the point of operation as the operator can also introduce the possibility of accidental cycling.
36
Solution Pullbacks and restraints offer another safeguarding
option; these use straps and wristlets to keep the
Due to the flexibility needed to fabricate metal on operator’s hands out of the die area by either “pulling
press brakes, it comes as little surprise that these back” the arms and hands during the downstroke or
machines are difficult to guard. Fixed or adjustable simply “restraining” or keeping the operator’s arms and
barrier-type guarding at the point of operation hands from entering the die area. Hand-feeding tools
is usually not practical because of the fabrication are often necessary when using restraints due to the
process, though barrier-type guarding can be used to limited range of movement.
prevent exposure to the unused portions and ends
of tooling. However, feasible safeguarding methods,
including presence-sensing devices, two-hand
controls, pullbacks, or restraints, can often be used to
safeguard the point of operation without reducing
productivity.
Presence-sensing devices (light curtains and lasers)
and two-hand controls are the most common types of
press brake safeguarding. A presence-sensing device
prevents the machine from cycling when the sensing
field is obstructed before cycle initiation and stops
the downstroke when the sensing field is obstructed
after cycle initiation. Two-hand controls (palm buttons)
are designed to keep the operator’s hands from the die
area by requiring concurrent and constant pressure to Cincinnati Inc.
cycle the machine. Both presence-sensing devices and Plastic shield (“end barrier”) preventing entry to the unused portion of
two-hand controls must be located at a proper “safety full-length dies. Two-hand controls used.
distance” – the distance from the pinch-point hazard
so that hazardous motion is stopped or prevented Note: Please refer to the power press document (Page 33)
before the operator can enter the point of operation. for more information on the above safeguards.
If the use of physical barriers or devices is not feasible,
safeguarding by “safe distance” is permitted if the
employer meets the conditions described in Oregon
OSHA Program Directive A-217 “Guarding: Power
Press Brakes.” This safeguarding by maintaining a
“safe distance” is limited to one-time-only fabrication
of made-to-order or custom-made piece parts, such
as small-quantity runs typically performed in “job
shop” establishments. A “small-quantity run” means
fabrication of more than one of the same piece part
over a continuous timeframe of no more than four
hours per month.
Under this instruction, the operator and helpers
must not approach closer than necessary and, in no
case, closer than four inches to the brake’s point of
operation. The minimum safe distance of four inches
Presence-sensing device (light curtain) used. must be measured from the exterior point of contact
of the brake’s die closest to the worker’s fingers
Note: When using presence-sensing devices, make sure holding and supporting a piece part. Finally, this
there is no space between the device and the point of “Safe Distance Safeguarding” program must contain
operation where an operator can stand undetected. If written exposure prevention procedures, training, and
this is possible while maintaining an adequate safety enforcement criteria.
distance, additional protection is required such as a
second light curtain installed horizontally, a pressure-
sensitive mat, or a physical barrier preventing access.
37
If more than one person is needed to operate, only
one should be designated as the operator and controls
should be furnished for each person. The operator
should always make certain that any helpers are clear
of the press before beginning the operation.
To avoid being pinched or struck by the work piece
“whipping” up, never hold the material over the top
of a previous bend, keep your hands underneath the
work piece, and always keep your face and upper body
out of the material’s path.
Before any tooling can be installed, the ram should
be locked in the shut height position with the ram in
its most extended position (on the upstroke). Once
the press is locked into that position, the tooling
can slide safely into the press. The gap between the
QMF Solutions
ram and the bed should be just big enough to allow
easy installation without the tooling falling out. Use Qualified and attentive operators are a must in
safety blocks where tooling permits. Make sure the maintaining safe press brake operations.
back gauge is high enough to prevent the piece part
from slipping over the top of it, which can bring the
operator’s hands and arms into the die.
References
General Industry
To prevent accidental cycling, effectively cover all hand
and foot controls. • Oregon OSHA Division 2/Subdivision O,
As with any power press, a “no hands in die” policy
should always be encouraged. Of course, there are • Oregon OSHA Program Directive A-217, Guarding:
times during setup Power Press Brakes
where this exposure • ANSI B11.3, Power Press Brakes – Safety
will occur and effective Requirements for Construction, Care, and Use
die setting procedures • ANSI B11.19, Safeguarding When Referenced by
or energy-control the Other B11 Machine Tool Safety Standards –
procedures will address Performance Criteria for the Design, Construction,
this. Furthermore, Care, and Operation
the safeguarding
devices and strategies
mentioned here should
keep the operator’s
hands and other body Rockford Systems Inc.
parts out of the die area

during operation. Never reach between the tooling for
any reason – reach around or walk behind the press
brake when necessary. Barricade the back of the press
to restrict access.
Note: Consider feasible safeguarding or proper material
holding techniques if operating a press brake within a
stationary ram and a sliding bed.
38
Power roll forming and bending machine
Conventional metal forming and bending machines, also known as plate bending rolls, produce
smooth, circular bends in sheet, strip, or coiled stock. Metal is fed between successive pairs of rolls
that progressively bend and form it until the desired shape and cross section is obtained. The radius
of the bend can be adjusted by changing the location of the rolls. These machines are normally
equipped with instant start, stop, and reverse controls.
Hazard
Severe crushing injuries, amputations, and even death
can occur if a worker is caught and drawn into the
counter-rotating infeed rolls. The risk of injury is high
during the initial feeding of the stock.
Wearing gloves with fingertips and loose clothing also
increase the risk of entanglement.
Workers can also be struck by the moving work piece
or pinned between it and a fixed structure.
Solution
Installing fixed or adjustable barrier guarding at the Imagine what this machine can do to arms and hands if it can bend
metal like this.
point of operation is usually not practical, primarily
due to the flexibility needed to bend various sizes of
stock. Some protection for the operator and anyone
near the machine can be provided by using devices
such as safety trip cables (emergency stop) and hold-
down controls; however, these safety devices do not
directly prevent entanglement or entrapment. They
are intended to help prevent or minimize injury by
stopping the machine quickly.
Hold-down button or foot controls are designed to Gulfstream Steel & Supply
actuate roll movement only when held in the run Safety trip cable running the entire length on this roll bending
position. The control should automatically return to machine.
the stop position when released.
A trip device (bar, tensioned wire/cable, or kick panel) being fed to prevent close proximity to the point of
is interlocked with the machine’s control circuit and operation. Whenever practical, use feed or roller tables.
positioned so that it may be easily actuated by any Consider wearing gloves without fingertips, or palm
person caught or drawn toward the rolls and will stop protection only.
the machine before serious injury can occur. It should
run the entire length of the machine at the front and in Prohibit loose-fitting clothing.
the back. Also, ensure the braking system is adequate, Maintain adequate distance from the work piece being
as the safety devices are effective only if the dangerous formed to prevent being struck by it.
parts of the machine stop quickly.
In addition to the measures detailed above, an References
emergency stop button should be provided at the General Industry
machine control console and at any remote work
station. If more than one person is needed to operate Oregon OSHA Division 2/Subdivision O,
•
the machine, controls should be furnished for each 1910.212, General Requirements for All Machines
person. Stock should be held sufficiently far back from ANSI B11.12, Safety Requirements for Roll Forming &
•
the edge Roll Bending Machines
39
Radial-arm saw
Radial-arm saws are circular saws that are normally used to cut against the grain of wood (crosscut)
but can also cut with the grain (rip). For crosscutting, the operator pushes the wood against a fence
and pulls the saw into the cut. For rip cuts, the blade is set parallel to the fence, and the stock is
pushed through.
Hazard
Severe cuts and amputations can occur if the operator
contacts the rotating blade.
If the saw blade is able to go past the edge of the table,
the blade can contact the operator’s body.
Stock can be thrown back at the operator if unsecured,
caught in the blade, or fed in the wrong direction.
Solution
Enclose the upper half of the saw (top of the blade to
the arbor) with a fixed hood.
Guard the sides of the bottom half of the blade with a Bottom half of saw blade is unguarded.
self-adjusting guard that automatically adjusts to the
thickness of the stock and remains in contact with For ripping, install non-kickback fingers on both sides
the stock throughout the cut. The lower guard must of the saw blade and use a spreader to prevent the cut
guard the full perimeter of the blade on both in the wood from immediately closing and binding the
sides during the cutting cycle and in the rest position. blade.
It must guard all of the saw teeth. Oregon OSHA allows
radial saws to be guarded by a device or devices (jigs,
work holders, guides, or stops) that provide protection
References
equal to that mentioned above. General Industry
Make sure the cutting head has a return device and an • Oregon OSHA Division 2/Subdivision O,
adjustable stop to prevent the leading edge of the 1910.213(h) and OAR 437-002-0242(4)
saw from passing the front edge of the table, or extend • ANSI 01.1, Woodworking Machinery – Safety
the table edge. Requirements
Securely fasten material to avoid unwanted movement • Oregon OSHA Program Directive A-38,
during cuts. Guarding: Radial Arm Saws
Construction
•
1926.304(g)
Agriculture
Oregon OSHA Division 4/Subdivision O, OAR
•
437-004-2000(5)
Benson Polytechnic High School
40
Robots
The industry standard, ANSI/RIA R15.06, defines an industrial robot as an automatically controlled,
reprogrammable multipurpose manipulator, programmable in three or more axes, which can be
either fixed in place or mobile for use in industrial automation applications.
Furthermore, an industrial robot system comprises the robot (hardware and software) and consists of
the control system, the end-effectors, and any associated machinery and equipment supporting the
robot performing its task. An industrial robot system is usually not a stand-alone machine, but rather
part of a larger system (or cell) interacting with other equipment.
Hazard
Although hazards associated with robots are well
recognized, the actual hazard sources are often unique
to a particular robot system and directly related to the
nature of the automation process and the way it is
installed, programmed, operated, and maintained.
Hazards involving robots range from being struck
by moving components and projectiles to trapping
or crushing hazards, and dangers from inadvertent
operation.
Also, not recognizing risks from stored energy, faulty
design or installation, and point-of-operation hazards OSHA SPI Alliance
from the end-effector add to the list.
Solution References
Safeguarding robots and robot systems is normally General Industry
accomplished through fixed barrier guards (fencing), Oregon OSHA Division 2/Subdivision O,
•
interlocked movable barrier guards, presence sensing 1910.212, General Requirements for All Machines
devices (e.g., light curtains, laser scanners, pressure-
Industry Standards
sensitive mats, and edges), and two-hand controls.
• ANSI/RIA R15.06, American National Standard for
A risk assessment should be conducted to best evaluate Industrial Robots and Robot Systems
all of the hazards, most designed safeguards, and
robot limits and functions. The risk assessment should • ISO 10218 Robots and Robotic Devices – Safety
identify each type of hazard and estimate the risk level Requirements for Industrial Robots
based on frequency of exposure, and the probability Risk Assessment
and severity of injury. Emphasis should be placed on ANSI B11.TR3, Risk Assessment and Risk Reduction
•
intended operations (e.g., teaching, verification, and
maintenance), unexpected startup, access from all ISO 12100, Risk Reduction and Risk Assessment
•
directions (space restrictions – operating, restricted, Methodology
and safeguarded), foreseeable misuse, and the effect
of failure in the control system. The documented risk
assessment should confirm if the existing safeguards
are satisfactory and if additional safety measures are
needed.
41
Belt sander
The belt sander is a general-purpose finishing tool. The belt is looped around two or more pulleys
and the linear motion makes it effective for sanding with the grain of wood. Abrasive belts of various
grades also make the belt sander useful for shaping.
Belt sanders can be found in upright, vertical, and horizontal positions. When using a belt sander in an
upright or vertical position, the work should be supported on a table.
Hazard
Serious abrasion can occur from contacting the
moving belt. Small work should not be abraded on the
belt sander as the small piece can easily be dislodged
from the operator’s hands and allow contact with the
belt.
Nip points are created when a belt passes over or
under a pulley or roller, and are often close to the point
of operation. If nip points are not guarded, fingers,
clothing, or hair can become caught in the machine. Nip points
On vertical belt sanders, the gap created between an
Belt sander missing guards over in-running nip points and belt edge.
improperly adjusted work table and the down-running
portion of the sanding belt can trap the operator’s
fingers.
Solution
Guard the unused runs of the sanding belt.
Do not sand the face of pieces that are less than
¾-inch thick unless you use a push shoe or some other
means of supporting the stock.
Guard all nip points. This can normally be
accomplished by enclosing the edge of the sanding
belt and the ends of the pulleys. Ensure the work table
is as close as possible to the sanding belt.
Coffee Creek Correctional Facility
References
General Industry
• Oregon OSHA Division 2/Subdivision O, This vertical belt sander
1910.213(p)(4) is equipped with
guards on the sides to
• ANSI 01.1, Woodworking Machinery – Safety effectively cover the nip
Requirements Nip point points created by the
belt running onto the
pulleys. The work table is
properly positioned close
to the belt – minimizing
the nip point created by
the distance between the
belt and table.
42
Disk sander
The disk sander provides rotary sanding. The table (rest) on a disk sander can be at a fixed, level
position or adjusted to various angles. One-half of the top half of the vertical disk is used – the half
that rotates toward the table.
Hazard
Serious abrasions to the fingers and hands can occur if
the operator contacts the abrasive sanding disk.
Stock can violently kick back if pressed against the
portion of the sanding disk that is rotating away from
the table (e.g., right side of the disk in the diagram
above).
A nip point can be created if the distance between the
table and the downward portion of the disk is such
that the operator can be pulled into it.
Solution
Keep hands away from the abrasive surface and use
only the downward side of the disk so that the wood is
driven onto the table by the machine’s rotation.
Do not sand pieces that are of a shape or size that can
become wedged between the disk and the work table.
Hold small or thin pieces of stock in a jig or holding
device to prevent abrasion to the fingers or hands.
Each disk sanding machine must have an exhaust
hood (or other guard if no exhaust system is installed)
that encloses the rotating disk, except for the portion
of the disk above the table. This also applies to drum
(spindle) sanders.
References University of British Columbia
Disk sanders are also used for metal work. Provisions outlined in this
General Industry section apply.
•
1910.213(p)(3), Disk Sanders & 1910.213(p)(2) –
Drum Sanders
•
Requirements
The Hobbyist’s Machine Shop
43
Wood Dust
Hazards and precautions
Wood dust consists of tiny particles of wood produced during processing and handling of
wood, chipboard, hardboard, etc. Sanding, shaping, routing, sawing, and using compressed air
generally produce the greatest amount of dust.
Exposure to wood dust has long been associated with a variety of adverse health effects,
including dermatitis and other allergic reactions, mucosal and nonallergic respiratory effects,
and cancer. A hypersensitivity reaction leading to asthma, pneumonitis, and chronic bronchitis
has been associated with exposure to wood dust, commonly from western red cedar, cedar of
Lebanon, oak, mahogany, and redwood. Dust from both hardwood and softwood has also been
reported to cause cancer. The three types of cancers associated with wood dust exposure are
nasal and sinus cavity cancer, lung cancers, and Hodgkin’s disease.
Other common symptoms from wood dust include eye irritation, nasal dryness and obstruction,
prolonged colds, and frequent headaches. Health effects can come from biological organisms
such as mold and fungi that grow on the wood, or from chemicals used in some wood
processing, such as formaldehyde, copper naphthanate, and pentachlorophenol.
In addition to the health effects, airborne wood dust can create the potential for fire or
explosion.
Airborne dust can be adequately controlled by using dust-minimizing equipment and tools,
in addition to dust control equipment such as local or central exhaust ventilation. Proper
maintenance and housekeeping practices are also important. Keep ventilation ducts free from
blockages and maintain ducts, filters, and other collection equipment in accordance with
manufacturer’s recommendations. Suitable respiratory protection must be worn if dust levels
cannot be reduced to acceptable levels.
Check that the design and installation of dust-control equipment incorporates explosion
precautions and control potential ignition sources such as heaters, overheated electric motors,
electric sparks, and sparks from other sources such as open wood burning stoves and cigarettes.
Regulations
• Oregon OSHA Division 2/Subdivision Z, OAR 437-002-0382 Oregon Rules for Air
Contaminants
• Permissible Exposure Limit (PEL) = Wood Dust (non-allergenic) TWA 10mg/m3; Particulates
not otherwise regulated: Total Dust TWA 10mg/m3, Respirable Fraction TWA 5mg/m3
• ACGIH Threshold Limit Value (TLV) = TWA 1 mg/m3 (certain hard woods such as beech and
oak), TWA 5 mg/m3 (softwood); Short Term Exposure Limit (TLV-STEL) = 10 mg/m3 (softwood)
• NIOSH Recommended Exposure Limit (REL) = TWA 1 mg/m3
• NFPA 664: Standard for Prevention of Fires and Explosions in Wood Processing and
Woodworking Facilities
* TWA = Time Weighted Average
44
Scroll (jig) saw
Scroll saws are useful for cutting intricate curves and patterns in thin stock. They have thin blades
that move rapidly up and down through the opening in the saw table. The blade is held in upper and
lower chucks that pull it tight and keep it from bending. A hold-down device adjusts to the thickness
of the wood being cut. The material is pushed through the moving blade.
Hazard
Serious cuts to the fingers and hand can occur if the
operator contacts the blade.
The blade can bind or break if stock is lifted during the
upstroke of the reciprocating blade or if the stock is
moved aggressively.
Solution
Guard the blade above the work piece with an
adjustable guard.
Use an adjustable holddown device to oppose
the lifting tendency of the work piece from the
reciprocating blade.
Make turns slowly. Use a narrow blade for sharp turns.
Consider using aids to push material through the blade.
References
General Industry
1910.213(r)(4)
• ANSI 01.1, Woodworking Machinery –
Safety Requirements
Southwest Idaho JDC
Safety guard/holddown installed.
45
Shaper/Router
Woodworking shapers and routers are machines that cut various straight and irregularly shaped
(contour) profiles such as tonguing and grooving, and decorative molding. Although there are slight
differences in operation, both routers and shapers use one or more cutting heads mounted on a
rotating, vertical spindle. Shaper spindles are normally mounted below the stock and router spindles
are often mounted above the stock.
The primary difference in operation is how stock is fed into the cutter. Routers commonly cut either
stationary or moving stock and shapers cut only moving stock. On manually-fed shapers, the operator
feeds and manipulates the stock against the rotating cutter while keeping the stock flat on the table.
Guides can be used for irregular cuts and fences are often used for straight line shaping.
Hazard
Amputations or severe lacerations can occur if the
operator contacts the cutter head. Also, loose clothing
or gloves can become entangled in the rotating cutter
or spindle simply due to the operator’s proximity to
the cutting head.
Routers and shapers rotate at tremendous speeds Exposed cutting head on shaper.
– many operating in excess of 10,000 rpm. Any
imbalance or vibration of the spindle and cutter
presents a significant flying object hazard.
Hazardous kickbacks of the stock also can occur.
Solution
Ensure that the spindle is enclosed by the machine
table or a guard. The table opening for shapers must Guard
provide support for the stock to within ¼ inch of the
largest diameter cutter (inserts must be provided for Fence and barrier-type guarding used for straight-line shaping.
smaller diameter cutters).
dimensioned stock. Avoid wearing loose-fitting
All sections of the cutter must be safeguarded, except clothing or gloves.
for the opening to allow stock to pass. For straight-line
shaping, a fence must be provided to limit the depth To minimize hazardous kickback, use extra care when
of the cut and enclose the nonworking side of the shaping stock that contains cross grains or knots.
cutter. The fence should contain as small an opening as Use a secure stop block where an interrupted cut is
possible for the cutter and extend on either side of the made. Do not back up the stock (check to see that the
spindle. The fence or an additional guarding provision direction of rotation is as expected).
must also protect the operator from above the cutter by Ensure the cutting head is stable and does not
extending beyond the largest diameter cutting head. vibrate excessively when operated at maximum
For contour (free-hand) shaping, a “ring” guard or recommended speeds.
other type of adjustable guarding must be provided
to protect the operator from the exposed cutter (see References
accompanying illustration). If properly set up, this General Industry
guard may also hold down the work, minimizing
kickback. Oregon OSHA Division 2/Subdivision O,
•
1910.213(m)(1)
Use templates, jigs/fixtures, featherboards, or push
•
blocks to distance the operator’s hands from the
Requirements
point of operation and to aid when shaping smaller
46
Shear
Power squaring shears and plate shears cut sheets of metal using either mechanical or hydraulic-
driven rams for the shearing action. The ram moves a nonrotary blade at a constant rate past the edge
of a fixed blade.
The operator feeds or places the stock between the blades, ensures it is properly positioned, and
activates the cutting cycle with either foot or hand controls. The material hold-down devices, exerting
a tremendous amount of force, clamp the stock immediately before the shearing action.
Two other types of shears are also used in industry: alligator and guillotine shears. Both of these types
are used to cut metal stock and scrap metal. Guillotine shears also are used for paper and plastic.
Hazard
Like all machines that have operating cycles, shears
present the possibility of placing a hand in the danger
zone. And in the case of a shear, the consequences are
severe.
The primary hazard of the point of operation is the
shear hazard. Since shears use blades to sever many
forms and various sizes of stock, there is no doubt
what can happen to hands or fingers.
The hold-down devices on power squaring shears CPMFAB.com
also create a serious pinch point, which can lead to

amputation or fractures to the hands or fingers.
Injuries can occur from the reciprocating, or up-and-
down motion of the ram and back gauge assembly
behind the shear.
Serious lacerations can also occur from handling the
blades.
Solution
The shear blades are normally safeguarded by the
equipment manufacturer’s barrier guard. If not, a
barrier guard, capable of adjusting to the thickness of Gensco Equipment
the stock, must be installed in front of the shear blades.

The jagged-edge barrier guard behind the hold-down
devices in the picture (right) is the shear blade guard. Properly guarded alligator shear.
An adjustable barrier guard must also be provided
in front of the hold-down devices to protect the
operator from the pinch point hazard.
These guards must meet the safe opening
requirements found on Page 35. They must be
adjustable so that operators can feed the stock but
cannot get their hands or fingers into the hazard
area.
Unguarded hold-down devices on a power squaring shear.
47
On mechanical shears equipped with a part-revolution The back of the shear, where sheared debris drops,
clutch or for those that are hydraulically powered, light should be barricaded.
curtain presence-sensing devices or two-hand control
devices can also be considered to be safeguarding References
options.
General Industry
Wear gloves when handling the stock. In addition to Oregon OSHA Division 2/Subdivision O,
•
gloves, appropriate mechanical devices or assistance 1910.212, General Requirements for All Machines
should be used when removing, handling, and
installing the blades. ANSI B11.4, Shears – Safety Requirements for
•
Construction, Care, and Use
Hand/foot controls should be enclosed or shrouded to
eliminate accidental cycling.
Adjustable barrier-type guarding for the hold-down devices must If the C-frame throat is open on either side of a power squaring shear,
accommodate stock, not fingers. the gap must be guarded. Cincinnati Inc.
Georgia-Pacific (Wauna Mill)
Adjustable barrier-type guard. Barricade or restrict the area behind the shear.
48
Table saw
Table saws are versatile saws used for cutting across (crosscut) and with (rip) the wood grain. They are
most commonly used to rip.
After adjusting the height and angle of the blade, the operator pushes the stock into the blade to
make the cut. When making a rip cut, a fence is used to maintain a straight cut parallel to the blade.
Hazard
Severe cuts and amputations to the fingers or hands
can occur if the operator contacts the saw blade.
Many serious injuries are the result of using the
table saw without the point-of-operation guarding.
These injuries are often a direct result of operating
an unguarded machine in combination with other
hazardous practices, such as placing hands very close
to the blade to guide stock (e.g., not using a push stick
to guide stock through a cut), not firmly holding the
stock causing the hands to slip off, diverting attention
away from the cut (e.g., focusing on something other
than the cutting operation), or removing small scraps
(tailings) or finished pieces of stock from around the DEWALT Industrial Tool Co.
blade while the blade is moving.
Although not at the point of operation, contact with
the saw blade (and often a belt drive) may also be
made from behind and underneath the table saw.
Kickbacks also offer a significant hazard and occur
when the blade catches the stock and throws it back
toward the operator. Kickbacks, more likely to occur
during ripping, can result if the blade height is not
correct, if the blade is not maintained properly, or if
safeguards are not used.
Kickbacks can also occur if the operator stops guiding
the stock during the cut. For example, material
remaining on the table behind the saw can cause an
obstruction with the stock and require the operator to
stop mid-cut.
Table saw equipped with self-adjusting blade guard.
Solution These guards must be used under sufficient
The most common blade guard is a self-adjusting supervision and in accordance with manufacturer’s
guard that encloses the portion of the saw above instructions.
the table and above the stock being cut. The guard
automatically adjusts to the thickness of the material Prevent exposure to the blade (and belt drive) located
being cut and remains in contact with it during the cut. underneath and behind the table saw with a fixed
guard.
Fixed enclosures, fixed barrier guards, or manually
adjusted guards (e.g., Brett-Guards) can also be used as Use a push stick for small pieces of wood and for
point-of-operation guarding, provided its protection pushing stock past the blade. Consider using large or
is equivalent to the protection of self-adjusting guards well-designed push sticks that not only provide a
and it prevents employee exposure to the saw blade. firm and stable grip of the stock, but also effectively
push the stock through while keeping your hand
49
away from the blade. Combs (featherboards) or
suitable jigs can be used when a standard guard
cannot be used during dadoing, grooving, jointing,
moulding, or rabbeting.
Turn off the power, wait for the blade to stop, and
lower the blade before removing scraps or finished
pieces of stock from around the blade.
Use a spreader and anti-kickback fingers to prevent
material from squeezing the saw blade and kicking
back during ripping. Ensure enough clearance behind
the blade to allow the stock to completely pass
through the cut. Also, provide support for material that
will pass beyond the table.
Note: Table saws that use digital signal processing Manually adjustable “Brett-Guard.”
technology to stop the spinning saw blade if contact is
made with a body part (like “Saw Stop” table saws) must
still be used with a self-adjusting blade guard.
References
General Industry
•
1910.213(c) & (d)
Oregon OSHA Program Directive A-107,
•
Guarding: Woodworking Machinery
•
Requirements
Construction Biesemeyer Products/Delta Machinery

• Guard removed to show spreader device.
1926.304(h) & (i)
Agriculture
• Oregon OSHA Division 4/Subdivision O, OAR
437-004-2000(6)
50
Power-transmission apparatuses
Power-transmission apparatuses include all components of the mechanical system that transmit
energy to machines and equipment. Flywheels, couplings, pulleys, belts, cams, cranks, spindles,
shafts, gears, chains, and sprockets are common examples of these components.
Hazard Ensure projecting shaft ends are smooth, and unused

keyways are filled or covered. Provide a nonrotating
Power-transmission apparatuses consist of parts that cap or safety sleeve when the shaft end projects
move in order to transmit energy, and provide a variety more than one-half the diameter of the shaft. When
of hazards to operators and other workers, other measuring the length of the shaft end, include the
than point of operation hazards. The most common portion of the shaft that passes through the collar and
hazard is the rotating motion from these components. rotates with the shaft.
Entanglement can occur from a single part (e.g.,
shaft) or parts rotating closely together, producing Ensure guarding over belt, rope, and chain drives,
“in-running nip points.” In-running nip points are pulleys, sprockets, chains, and gears (except hand-
caused when parts rotate against a fixed object (e.g., operated adjustment gears) that are seven feet or less
screw conveyor), parts rotate in the same direction above the floor.
(e.g., v-belt and pulley), or when their axes are parallel,
but rotate in opposite directions (e.g., gears).
Rotating collars, couplings, cams, clutches, flywheels,
shaft ends, and spindles can grip clothing or
otherwise force a body part into a dangerous location.
Projections such as screws or burrs on the rotating part
increase the likelihood of injury.
Other components that move while the machine
is operating, such as reciprocating and transverse
moving parts, can create hazardous areas. Parts that
move back-and-forth or up-and-down (reciprocating
motion) can strike or entrap a worker between a
moving part and a fixed object. Parts that move in a
straight, continuous line (transverse motion) can strike
or catch a worker in a pinch or shear point created by
the moving part and a fixed object.
If A (length) is equal to or less than B (1/2 the diameter), then no
guarding is required. If A (length) is greater than B (1/2 the diameter),
Solution than guarding is required.
It is usually not difficult to guard these components.
As a general rule, a power-transmission apparatus is Use barricades and signs to keep workers out of areas
best protected by fixed barrier guards that enclose where they could come in contact with components
the danger. Guards should be made of expanded that move while the a machine is operating.
metal, sheet or perforated metal, or other substantial Specific guarding requirements are found in Oregon
material, and securely fastened to the frame of the OSHA Division 2/Subdivision O, 1910.219 – Mechanical
machine, or the floor. Wood guards may be used only Power Transmission Apparatus.
in the woodworking and chemical industries.
Guard all shafting seven feet or less above the floor
(except maintenance runways) with a stationary
casing, or a trough covering the sides, and top or
bottom as needed.
51
Georgia-Pacific Wauna Mill Georgia Pacific Wauna Mill
Fixed guard covering a shaft end. Fixed guard enclosing several belt drives.
Power transmission components may also be References

guarded by location or distance. Basically, this means
that all moving parts are positioned so that the General Industry Oregon
hazardous areas are not accessible or do not present • OSHA Division 2/Subdivision O, 1910.219,
a hazard during normal operation; examples include Mechanical Power Transmission Apparatus
positioning them above workers or behind a wall, • ANSI B11.19, Performance Requirements for
barrier, or fence. Generally, guarding is not required Safeguarding
when moving parts are more than seven feet above
the floor, or are in a basement. However, the following
questions should be asked before considering this
strategy:
Can components be easily accessed?
Can pieces or parts break and fall?
Are sparks or other flying debris being
produced?
52
Lockout/Tagout
Safe work practices during
service and repair
Many serious injuries and fatalities occur when
somebody mistakenly thinks a machine is safely
isolated from its energy sources or stored energy has
been relieved or blocked. Approximately 120 workers
are killed in the U.S. every year from a failure to
effectively isolate hazardous energy.
Oregon OSHA’s Hazardous Energy Control standard,
commonly referred to as “lockout/tagout,” covers the
maintenance of machinery and equipment where
unexpected startup, movement, or the release of
stored energy can cause injury to workers. In general,
the standard requires that all energy sources for
machinery and equipment be turned off, isolated
(disconnected), and physically locked out. Bleeding,
relieving, or blocking other stored and residual
energy must also be done to ensure isolation. The
final important step before service begins is to verify
all energy has been de-energized and isolated. These References
procedures, along with training and periodic audits,
must be established and enforced. General Industry and Construction
Oregon OSHA Division 2/Subdivision J,
•
Minor tool changes and adjustments, and other 1910.147, The Control of Hazardous Energy
minor servicing activities, which take place during (Lockout/Tagout)
normal production operations, are not covered by this
standard if they are routine, repetitive, and integral Oregon OSHA Program Directive A-156, Control
•
to the use of the equipment for production, provided of Hazardous Energy – Enforcement Policy and
the work is performed using alternative measures Inspection Procedures” (Lockout/Tagout)
that provide effective protection. Selection of an ISO 13849-1
•
alternative control method must be based on a risk Oregon OSHA Publication, Lockout/Tagout:
•
assessment of the machine, equipment, or process. Oregon OSHA’s guide to controlling hazardous energy
The risk assessment must consider existing safeguards
provided with the machine, equipment, or process Agriculture
that may need to be removed or modified to perform OAR 437-004-1275, The Control of Hazardous
•
a given task. For example, when control circuits are Energy (Lockout/Tagout)
used as part of the safeguarding system, the system
must be designed to ensure protection as effective American National Standards Institute
as a mechanical disconnect switch or master shutoff ANSI/ASSE Z244.1, Control of Hazardous Energy
•
valve. A control-reliable dual-channel hardwired (Lockout/Tagout and Alternative Methods)
circuit of industrially rated components that satisfies ANSI B11.19, Safeguarding when Referenced by
•
the design features as specified in ANSI B11.19, with the other B11 Machine Tool Safety Standards –
a safety relay or safety PLC (programmable logic Performance Criteria for Safeguarding
controllers) to ensure integrity and performance of
the safeguarding system, must be used. Under all
circumstances, the individual must have exclusive
personal control over the means to maintain the
state of the control circuit in a protective mode.
53
Risk Reduction Hierarchy
A hierarchical approach is recommended when both sense and switch (to instantly provide safety).
first approaching the safeguarding of a machine or It is imperative the control circuit meets appropriate
operation. Safeguarding principles should be based performance levels related to functional safety.
on preventing access during dangerous motion or
For many years, the term “control reliability” has been
preventing dangerous motion during access.
mainly defined by ANSI B11.19 addressing the safety
performance of control circuits. However, the use
1. Eliminate the hazard or of the term has declined in recent years due to the
exposure to the hazard widespread acceptance of European Directives and
International Standards such as ISO 13849 and IEC
• D
esign/redesign the operation to remove
62061. These standards provide a more complete and
exposure (e.g., automatic feeding/ejection,
verifiable means of specifying the safety performance
designed enclosures)
level of control circuits [further defining five circuit
• L ocate the hazard where it is not accessible due categories and five performance levels based
to its location or distance on redundancy (duplication), diversity (different
techniques), and monitoring (self-checking)]. Safety-
• Reduce energy
related functions, safety-related control system, or
• Replace/substitute functional safety are other terms commonly used
these days.
2. Prevent exposure
• Fastened barrier guarding 4. Use administrative controls
• Metal or plastic enclosures and aids to supplement
• F ixed metal or plastic enclosures, guarding, other controls
screens, fence, etc. • Reduce the occurrences of the task
• Adjustable guarding • P
rovide information, instructions (i.e., manuals)
and warnings (e.g., signs, symbols, markings,
• Self-adjusting guarding lights, alarms, awareness barriers)
• I nterlocked, fixed barrier guarding (interlock • A
ppropriate hand tools, jigs, holders, push
or other inputs meeting safety-related sticks, etc.
performance levels)
• P
rovide hands-on training and effective
3. Safeguard exposure supervision
• Devices that require adjustment or actuation by • E nforce safe work practices (e.g., safe job
the user procedure, job hazard analysis)
• P
resence-sensing devices (e.g., light curtains,
scanners, mats) References
• O regon OSHA www.orosha.org
• Gates
• OSHA www.osha.gov
• Two-hand controls and trips
• National Institute of Occupational Safety and
• Pullbacks and restraints Health (NIOSH) www.cdc.gov/niosh
• S afety-related control system meeting • Industry Standards ANSI B11.19, Performance
appropriate performance levels related to Criteria for Safeguarding
functional safety (ANSI B11.19; ISO 13849; IEC • ISO 12100, Safety of Machinery
62061)
Remember, control inputs like presence-sensing
devices and interlocks do not restrict or prevent access
but only “sense” it. They rely entirely on their ability to
54
Training guidelines
An important step in machine safeguarding – a step Training and relevant retraining must be provided for
often overlooked – is providing safety instruction and new operators and maintenance/setup employees.
training on the various types of equipment the worker Also, retrain affected employees when new or altered
is expected to operate and the safeguarding the safeguards are used, when an employee is assigned
worker is expected to use. to a new machine or operation, and whenever worker
deficiencies are discovered.
At a minimum, this education Safeguarding strategies must include adequate
should include: management controls, such as accountability,
enforcement, inspection, and maintenance. This
• D
iscussion of hazardous exposures and control
can ensure clean and roomy work areas, properly
measures
maintained safeguards, and that lockout/tagout
• H
azardous motions (rotating, reciprocating, and procedures are followed, to name a few. Finally, don’t
transverse) forget personal disabilities (e.g., color blindness,
hearing impairment) if relying on visual warnings
• H
azardous actions (cutting, bending, drilling, and
(colors) or audible warnings (machine startup).
punching, etc.)
• Potential of flying or ejected material or parts
• E ffective safeguarding methods or other control
measures (automatic/semi-automatic feeding/
ejection, guarding by location/distance, etc.)
• E rgonomics (awkward posture, vibration, repetitive
motion, forceful exertion, etc.)
• F ire or combustion hazards (dust, lubricants, hot
processes, hydraulic fluid, etc.)
• A
ppropriate personal protective equipment and
clothing
• Health hazards
− Air quality (dust, fumes or smoke from certain
metals, mist from fluids, etc.) Nova Scotia Agricultural College
− Noise and vibration

− Metalworking fluids (danger to skin, lungs, etc.)
Equipment-specific training
(hands-on)
• Proper operation of safeguards
• Limitations
• Maintenance and care
• Inspection
• Adjustment and placement
• Clarification of manufacturer requirements
• P
rocedures to follow when safeguard is discovered
damaged, missing, etc.
55
Basic safety principles
Although this guide addresses point-of-operation
safeguarding for specific machinery, it is also
Work practices
important to establish and enforce safe work • Use only tools you can control easily
practices when operating and maintaining all types of • Make sure hands are kept at a safe distance
equipment and machinery.
• F ollow safe procedures as outlined in the operator’s
The following list includes basic rules that apply to manual
portable and fixed machinery:
• A
lways wear eye and face protection and other
Equipment (parts include blades, appropriate personal protective equipment
bits, sanding belts, dies, grinding • D
o not wear loose clothing or long hair that may
become entangled
stones)
• C
heck to see that power cords are kept away from
• F ollow the equipment manufacturer’s the line of cut and other moving parts
recommendations
• F ollow proper lockout/tagout procedures during
• U
se equipment only for the purpose for which its service and repair
design is intended
• Never defeat the guard to expose the blade
• O
perate the tool at the speed and tension specified
by the manufacturer • N
ever reach under the saw, work piece, or any place
you can’t see clearly
• Inspect the equipment visually before use
• Direct the operation away from your body
• R
emove unadjusted, defective, cracked, or worn
parts from service
Work environment
• Maintain sharp and clean parts • P
ractice good housekeeping – avoid crowded,
• W
hen provided, use equipment with an exhaust or cluttered conditions
dust-collection system • M
ake sure combustible or flammable material is
• U
se the appropriate size and type of part for the located away from spark-producing operations
material and cutting action • P
rovide adequate ventilation to reduce dust and
• C
heck to see that guards, guides, and other air contaminants
counterweights are properly adjusted and operable • M
onitor noise levels and provide hearing protection
• Avoid overheating the equipment when necessary
56
Glossary of terms
Adjustable barrier guard – A physical barrier requiring • Must not create a pinch point between it and
manual adjustment for various jobs. moving machine parts
• Must be affixed to the machine and remain secure
Brake monitor – A sensor designed, constructed, and • Must facilitate its own inspection and allow for
arranged to monitor the effectiveness of the press maintenance and lubrication
braking system. • Must offer maximum visibility of the point of
operation consistent with the other requirements
Competent person – One who is capable of identifying • Must conform to other appropriate standards (ANSI,
existing and predictable hazards in the surroundings manufacturer specifications, etc.)
or working conditions which are unsanitary, hazardous,
or dangerous to employees, and who has authorization Interlocked guard – A barrier that, when opened or
to take prompt corrective measures to eliminate them. removed, trips a control mechanism that stops a cycle
or prevents a cycle until the guard returns to its safe
Control reliability (also called performance of safety- position.
related functions) – A part of the system that controls
hazardous motion of a machine. It ensures the Point of operation – The area on a machine where
machine will stop when required in the event of a work is actually performed upon the material being
single component failure within the system. processed.
Device – A control or attachment that: Safety distance – A calculation of how far a person’s
• Prevents a cycle if the operator’s hands are hand can move from the time it activates a device until
inadvertently in the point of operation the slide stops moving.
• Maintains the operator’s hands at a safe distance
during the hazardous portion of a cycle Self-adjusting guard – A physical barrier that adjusts
• Restrains the operator from inadvertently reaching by the movement of stock and returns to its rest
into the point of operation position after the stock passes through.
• Automatically withdraws the operator’s hands from
the point of operation as the dies close Qualified person – One who, by possession of a
recognized degree, certificate, or professional
Fixed (barrier) guard – A guard that provides standing, or who by extensive knowledge, training,
a physical restriction to a hazard. and experience, has successfully demonstrated an
ability to solve or resolve problems relating to the
Guard – A physical barrier that prevents entry of the subject matter, the work, or the project.
operator’s hands or fingers into the point of operation.
A guard:
• Must prevent any contact to the machine hazard
and must be installed to prevent contact from
around, over, through, or under the guard
• Must not allow objects to fall into moving parts or
be ejected toward a worker
57
Oregon OSHA Services
Oregon OSHA offers a wide variety of safety and health services to
employers and employees:
Enforcement Appeals
503-378-3272; 800-922-2689 503-947-7426; 800-922-2689
[email protected] [email protected]
• Offers pre-job conferences for mobile employers in • Provides the opportunity for employers to hold
industries such as logging and construction. informal meetings with Oregon OSHA on concerns
• Inspects places of employment for occupational about workplace safety and health.
safety and health hazards and investigates workplace • Discusses Oregon OSHA’s requirements and clarifies
complaints and accidents. workplace safety or health violations.
• Provides abatement assistance to employers who • Discusses abatement dates and negotiates settlement
have received citations and provides compliance and agreements to resolve disputed citations.
technical assistance by phone.
Conferences
Consultative Services • 503-378-3272; 888-292-5247, Option 1
503-378-3272; 800-922-2689 [email protected]
[email protected] • Co-hosts conferences throughout Oregon that enable
• Offers no-cost, on-site safety and health assistance employees and employers to learn and share ideas
to help Oregon employers recognize and correct with local and nationally recognized safety and health
workplace safety and health problems. professionals.
• Provides consultations in the areas of safety, industrial
hygiene, ergonomics, occupational safety and health
Public Education
programs, assistance to new businesses, the Safety and • 503-947-7443; 888-292-5247, Option 2
Health Achievement Recognition Program (SHARP), [email protected]
and the Voluntary Protection Program (VPP). • Provides workshops and materials covering
management of basic safety and health programs,
Standards and Technical Resources safety committees, accident investigation, technical
503-378-3272; 800-922-2689, topics, and job safety analysis.
[email protected]
• Develops, interprets, and gives technical advice on
Oregon OSHA’s safety and health rules.
• Publishes safe-practices guides, pamphlets, and other
materials for employers and employees.
• Manages the Oregon OSHA Resource Center, which
offers safety videos, books, periodicals, and research
assistance for employers and employees.
58
Need more information?
Call your nearest Oregon OSHA office.
Salem Central Office Pendleton
350 Winter St. NE 200 SE Hailey Ave.
Salem, OR 97301-3882 Pendleton, OR 97801-3056
Phone: 503-378-3272 541-276-9175
Toll-free: 800-922-2689 Consultation: 541-276-2353
Fax: 503-947-7461
en Español: 800-843-8086 Portland
Website: osha.oregon.gov Durham Plaza
Bend 16760 SW Upper Boones Ferry Road, Suite 200
Tigard, OR 97224-7696
Red Oaks Square 503-229-5910
1230 NE Third St., Suite A-115 Consultation: 503-229-6193
Bend, OR 97701-4374
541-388-6066 Salem
Consultation: 541-388-6068 1340 Tandem Ave. NE, Suite 160
Eugene Salem, OR 97301
503-378-3274
1500 Valley River Drive, Suite 150 Consultation: 503-373-7819
Eugene, OR 97401-4643
541-686-7562
Consultation: 541-686-7913
Medford
1840 Barnett Road, Suite D
Medford, OR 97504-8250
541-776-6030
Consultation: 541-776-6016
Salem Central Office
350 Winter St. NE
Salem, OR 97301-3882
Phone: 503-378-3272
Toll-free: 800-922-2689
Fax: 503-947-7461
en Español: 800-843-8086
Website: osha.oregon.gov
440-2980 (2/20/COM)

Machine Safeguarding at The Point of Operation: A Guide For Finding Solutions To Machine Hazards

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Machine Safeguarding at The Point of Operation: A Guide For Finding Solutions To Machine Hazards

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WORKER HEALTH AND SAFETY

About this guide

Abrasive wheel grinder .......................................................6 Power press.......................................................................... 32

Horizontal band saw.............................................................9 Power press brake.............................................................. 36

Vertical band saw............................................................... 10 Power roll forming and bending machine................... 39

CNC turning machine.........................................................11 Radial-arm saw....................................................................40

Compacting and baling equipment.............................. 13 Robots................................................................................... 41

Cut-off saws......................................................................... 15 Belt sander........................................................................... 42

Drill press ............................................................................. 17 Disk sander........................................................................... 43

Ironworker............................................................................ 18 Scroll (jig) saw...................................................................... 45

Metal lathe........................................................................... 20 Shear...................................................................................... 47

Wood lathe........................................................................... 22 Table saw.............................................................................. 49

Milling machine.................................................................. 23 Power-transmission apparatuses.................................... 51

CNC router and cutting tables........................................ 24 Lockout/Tagout.................................................................. 53

Planer..................................................................................... 26 Risk Reduction Hierarchy.................................................. 54

Plastic injection molding machinery............................. 27 Training guidelines............................................................. 55

Portable abrasive grinder................................................. 28 Basic safety principles....................................................... 56

Portable belt sander.......................................................... 29 Glossary of terms................................................................ 57

Portable circular saw.......................................................... 30 Oregon OSHA Services...................................................... 58

Recent statistics that About this guide

Worker caught in an irrigation spool

Lathe operator hit by rotating bar stock

Operator caught in keyed shaft (loose-fitting shirt contributed)

Worker caught in a glue line conveyor

Hazard In addition, the wheels found on these machines

Wherever the nature

MILWAUKEE, WI – Fatal injuries sustained by a foundry worker at Grede

Source: Federal OSHA Regional News Release, July 7, 2003

References RL Johnson Co.

American National Standards Institute

University of British Columbia

front of the machine’s Lexan viewing window, the

How to prevent similar injuries

appropriate size so that they engage properly with the

chuck and the cutting tool.

For more information:

Photo of the accident

Salem Central Office Phone: 503-378-3272

Hazard Whenever unjamming,

Source: NIOSH FACE Report 2000

Swing saw Solution

Missing “nose guard” and additional point of operation guarding on a

“Strippers” are designed to hold the material down

References Unique Projects

• O regon OSHA Division 2/Subdivision O,

Fabricated quill-mounted guard to enclose cathead.

Hazard Crushing injuries can occur if an operator, or any part

Machine operator dies

Never lower the table during operation and never

All abrasive wheels must be closely inspected and

Hazard should be positioned so

Hazard Flying or ejected parts from either the stock or the

Fixed, interlocked, or adjustable barrier guarding is

121⁄2 to 151⁄2 11⁄2 It is important to check the “safe distance” of the

Two-hand controls are also used on part-revolution

parts out of the die area

Benson Polytechnic High School

References University of British Columbia

The Hobbyist’s Machine Shop

* TWA = Time Weighted Average

Southwest Idaho JDC

Safety guard/holddown installed.