Even if you have machine guards in place, some common mistakes can render your machine guard safety practices inadequate. Employees sometimes remove machine guards to save time, or they forget to put them back on after realignment or performing maintenance. Either way, it’s a serious issue. Machine guarding violations are among OSHA’s top 10 list of frequent citations each year.

OSHA and ANSI regulations exist to protect operators from hazards, but you need to go beyond just compliance to provide a truly safe environment for your workers. So, let’s take a look at seven of the most common machine guarding mistakes and some strategies for machine guard safety.

1.Using the Wrong Type of Guard

Different types of machine guarding safety equipment are designed for different situations. The wrong guard can cause problems, for example, using a fixed guard where an adjustable guard would allow for more flexibility or using a guard made of materials not strong enough to withstand impact.

To make sure you have the right type of guard:

Assess each machine individually to determine the most appropriate type.

Use the correct materials that can withstand the expected mechanical forces, temperature conditions, and potential impact.

. Inadequate Guarding for Hazardous Parts

Another common mistake is failing to fully protect exposed moving parts, such as gears, pulleys, or blades. Contact with these parts can result in serious injury.

Recommendations include conducting regular inspections to identify any exposed parts and missing guards. Make sure you provide the proper training for operators so they don’t bypass protection and they comply with OSHA standards for machine guarding.

2.Improper Guard Installation

Machine guard safety requires proper installation, but it’s not uncommon to find guards that are not fastened securely or come loose during machine operation.

Testing and regular inspections can help uncover guards that come loose. Other strategies include:

Training employees on how to check and maintain guards as part of regular machine maintenance.

Using safety devices like tamper-proof screws or bolts to prevent guards from being removed or altered without authorization.

3.Guards That Restrict Visibility or Access

If machine guards obstruct visibility, it might discourage workers from following the proper machine guarding safety procedures. When they can’t see the machine’s operation clearly, it can be tempting to bypass safety measures to perform their tasks.

Guards should be designed with both protection and visibility in mind. For example, transparent material creates better visibility. Ergonomics plays a role, too. When workers can perform their tasks comfortably, they are less likely to try to modify machine operations.

4.Poor Maintenance Habits

Guards can be damaged, worn out, or removed for maintenance, without being replaced. Failing to perform regular maintenance and safety checks puts workers at risk.

Preventative maintenance is key to avoiding problems, including regular inspections. Any damaged guards should be replaced or repaired before operations restart. Routine safety audits from a certified machine guard safety expert can help ensure proper operation and mitigate your risks.

5.Inadequate Lockout/Tagout Procedures

Another item in OSHA’s list of top citations involves lockout/tagout procedures. These procedures are critical to protect workers from the release of stored energy or unexpected operations. This is especially important when servicing machines or systems. OSHA points to examples like a jammed conveyor suddenly releasing and crushing a worker trying to clear the jam, or internal wiring that shorts out, shocking the person doing repairs.

Preventing these kinds of incidents requires implementing clear lockout/tagout procedures to ensure that machines are safely powered down before maintenance begins. Regular inspections of lockout/tagout devices should be incorporated into preventative maintenance programs along with training of employees.

6.Overlooking Training and Awareness

Even with proper guarding in place, employees need to be trained to use the machines safely and understand the importance of guards. Initial training is essential along with regular refreshers to keep safety top of mind.

Get Machine Safety Consultants

Even with the best intentions and the right equipment, mistakes happen. Companies should conduct regular testing, training, and inspections to ensure their machines are working correctly and operators are using them properly.

The machine safety experts at Pacific Blue Engineering can help. Our certified Functional Safety Engineers and Machine Safety Consultants can help you design and integrate a safe work environment for your team.

Contact Pacific Blue Engineering for turnkey machine safety solutions.