The Idiots Guide To Machine Safety

The Idiots Guide to Machine Safety
Authored By
Kannan Makino
Preface
Irrespective of nature of industry, (petrochemical or fertilizer or
general manufacturing) the machines are ever presenting risk to
human life.
As much as the machines are good, they are increasing the risk of
injury, ill health and accidents rates too.
In order to control the accidents arising from the machineries, it
is essential for every safety practitioners to update themselves
with the technological options.
If you are a health and safety practitioner, wish to update your selves with
the various technological options that available to control the machine
accidents, this book is made for you.
For Any Doubts & Feedbacks leave Your Thoughts either through
Kannanmakino@gmail.com
Comment at www.kannanmakino.com
Get more HSE Books @ www.kannanmakino.com

About Author:
Thanks for Grabbing my Book.
My self Kannan Makino, a former mechanical engineering student and

passionate health and safety engineer lives in Chennai, India.
I love learning, writing, blogging, training and Practicing HSE.
Professionally i have been qualified in HSE, with more than 3+ Health and
safety Diplomas and 10+ International HSE Qualifications.
With an Initial Intention, I have started HSE Blogging at

www.kannanakino.com,in 2014, where i used to blog in a regular manner.
I believe, the curiosity and passion about the job is everything irrespective
of the situation we are living in.
I have experienced in Construction, Manufacturing and Now am working as

a professional HSE Trainer & Consultant in a private organization.
Occasionally i used to involve in HSE External Audits, inspections and other

professional HSE Services.
Yet now, I have given, HSE Trainings for more than 10+ Industrial staffs
and workforce.
You can friend me in Facebook or else you can feed the comments in my
Personal blog.

Introduction to Machine Safety:

Imagine, if the bike was designed without the following elements,
The Bike with only flashing turn indicator without any audible sound
The Bike which is made up of 4 or 2 feet height
The Bike, which has its brakes near to the wheels
What will happen?
The visual signal will not attract and indicate the risk in the day
time, or else the people may not give attention to the light when it
is required.
The bike will not be suitable to most of the people
There are more chances for the entanglements and resulting
injury.

The concept is, machine safety is not alone, focusing on the annual
maintenances and the outlook or the presence of Guards.
Moreover, its starts with the design itself.
Every employer is having a legal duty to protect their own employees and
others who are intended to use their products or machine.
In order to protect the employees, it is essential that, we should be familiar

with various health and safety principles that lay behind the machineries
and equipments.
Introduction to Legal Requirements
Irrespective of the country, region, designation, every human beings are

subjected to certain legal requirements amended by the national
governments.
As a Health and safety practitioner, learning and interpreting health and

safety regulations are highly recommended and must.
The Regulations are different between every country and region, for
example;
In U.K
Supply of machinery (safety ) regulations 2008

Provision of use of work equipment regulations 1998
Are the sample regulations that applicable related to machinery.
In India / United States, and in any other country, the name of legislation /
regulation may tend to be different.

But,
All the regulations are amended in order to protect the employees and end
users.
And the concepts are also same, by which
The machine must be designed, implemented, operated, maintained, and

cleaned safely without causing risk to health and safety of any kind of
human.
Introduction to Machine hazards:
Would you believe, the machines are producing and presenting all kind of
hazards during its Operation and even in Circumstances when its still?
The Machines are capable of producing different kind of hazards and risk to
human (Both to health and Safety), when their Safety principles are not
followed.
The Machine itself can cause cut, crush, entanglement, trap, and friction,
ejection of parts, noise, heat, radiation, hazardous chemicals, and even
ergonomic al issues.
As i mentioned earlier the machine must be designed, installed, used and

maintained safely to prevent risk to health and safety of employee.
In This Part - 1 Guide, I have given short summary of machine safety and
quick briefing about Machine safety design controls, which is highly
beneficial to you.

Introduction to Engineering Controls
Fixed Guard
Interlocking Guard
Interlocking Guard with Guard locking
Adjustable Guard
Self-Adjusting Guard
Two Hand Operating Control
Pull Back Device
Restraint Device
Safety Edges
Trip Bars
Presence sensing Device
Presence sensing Mats
Feeding & Ejection Systems
Work holding Equipment
Hold to run control
Emergency stop control
Limited Movement Control ( Movement Control Device)
Deterring / Impeding Device
Time Delay Device
Safe Motion Control

Fixed Enclosing Guard:
The Name itself describes "Fixed" , Simply a kind of physical barrier placed
permanently with a machinery ( Fixed either by Screws/ weld/ any
mechanism) that prevent persons contacting the moving dangerous parts
of machinery.
The Guard will not move & could not be removed by the hands, the
removal of guard will require the special tools like spanner or screw driver
etc.

Fixed Distance Guard:
Fixed Distance Guard, Is similar to the last type, Instead of enclosing the
dangerous parts, the barrier will be placed in a distance permanently , the
best example for the fixed distance guard would be a perimeter fence
around the robotic area.
Interlocking Guard:
The Guards are connected to the machine power controls either
mechanically / electrically or through any other means, which ensures,
The Machine will not run, if the guard is open
During the machine the guard could not be opened or opening the guard
will stop the machine immediately.

Interlocking Guard with Guard Locking:
The "Interlocking Guard with Guard locking" is similar to the "General

Interlocking Guards" but the guard needs to be closed & locked in order to
start the machine.
The Machine will not run,
When the Guard is open or

When the Guard is not locked
Adjustable Guard:
The Adjustable guards are the option, when the dangerous parts of the
machinery shall not be fully enclosed due to the nature of operation or any
other reasons.

Simply, the Size or length or position of the guard shall be adjusted by the
operators depending upon the nature of operation and work piece being
machined.
The Adjustable guards are being commonly found in wood working

machine, milling machine & laths.
Self-Adjusting Guard
"Self" describes clearly, that does not require the additional action to
change its length / size / position.
The Guard will automatically adjust its position depending on the machine
operation; the best example for the "Self adjusting Guard" would be the
"lower guard of portable wood cutting machine"
Normally the self-adjusting guards will be connected with the spring / any
other mechanism.
Two Hand Operating Control:

Two hand operating controls are the safety device that designed to protect
the operator's hands; Simply the person needs to continuously operate two
controls of the machinery in order to run the machine.
Removal of any hand from the control will stop the machine immediately.
Hold to Run Control:

The machine control needs to be activated continuously in order to operate
the machine, if the control being released the machine will stop.
The Best example would be the portable drilling machine that requires the
continuous action till the drilling action completed.
Restraint Device:

A series of cables attached to the fixed point and another end connected to
operator hands, wrists or arms that ensure the operator shall not reach the
dangerous part of machine.
The Cable will not involve any extension / retracting action.
Pull Back Device:
Pull back device similar to the restraint device, but its linked to the machine
motion & It involves extension and retracting actions.
A series of cables, that connected to the operator hands, wrists and arms,
and another end of cables are mechanically linked to the machinery. When
the machine cycle starts, the operators hands are automatically removed
from the dangerous area.

Presence sensing Device:
A Device interlocked to the machine control system, that stop the machine
operation when the sensing field (Photo electric or Radio frequency) is
disturbed by the machine operator.
Simply, a sensor that continuously senses the dangerous area, and stops
the machine when the person accesses the dangerous area.
Presence Sensing Mats:

A Pressure mat interlocked to the machine control, and when the person
enters & stands or walks over the mats (and the predetermined weight /
pressure being applied) the machine will stop.
Most suited to the robotic operational areas.
Safety Edges: (Type of Pressure Sensing Device)
The type of safety system that prevents the trapping of hands or person
between the machine parts or doors.
Have you ever seen? The passenger lift doors will retract, when you place
your hands between the doors while closing.
Alternatively, Instead of sensing device, a narrow strip is fitted to the

sliding doors / machine parts, when the pressure applied by the trapping
action, either the movement will stop or the doors will automatically
retract.

Trip Bars (Type of Pressure Sensing Device)

Trip bars are the type of Trip device that designed like a small bar. Shall be
positioned close to the dangerous part , and when the persons hands or
other part of body touches the trip bar, the machine will immediately stop.
For Example: If the Trip bar positioned close to the radial drill bit, if the
person touches the small trip bar during the entanglement, the motion will
immediately stop and further injury is protected.
Feeding / Ejection Systems:

Automatic Feeding & Ejection systems are the indirect safety system, which
minimize or eliminates the operators and other personals to keep their
hands & other parts of the body in the dangerous areas of the machine
during hazardous motion.
Work holding Devices:

Work holding devices are the machine parts that designed to hold the work
piece during operation, thus remove the need for operator
to place their hands / other parts in hazardous areas.
The Most common types would be clamps, jigs & fixtures.
Limited Movement Control:

An actuation of control, that allows only limited movement of travel /
operation.
The Movement control may be designed either by point-to-point basis or by

the basis of pressure or force.

Safe Motion Control Device:
Safe motion device is an advanced version of limited movement control

device, which integrates the overall movement of the machine parts.
A device that continuously monitors the speed, direction of movements &

other parameters of the machine as per the programmed Instructions.
Time Delay Device:

Most of the machine parts run even after the completion of process. In that
Situation the Time delay devices would be very much useful.
The Device, which delays the opening of machine guard, till the hazardous
movement of machine parts gets completed.
Deterring / Impeding Control:

A form of physical barrier, which can be placed between the dangerous
parts of the machinery and the person, without totally preventing the
hazardous zone.
It can be a partial barrier / Low barrier or any other physical barrier.

Emergency stop Control:
A type of push button / Pull rope, that brings the machine to safe condition
after immediate activation by the person.
The Main disadvantage is that, will only be activated after recognizing the
incident / hazardous situation and also It will not prevent / detect the
employee exposure to machine.

Summary:
A machine cannot be made safe by using single safety device and more
than that any engineering control would not guarantee zero accidents.
The zero accidents can be (while working on machineries) only achieved

through integration of different machine safety devices and safe behavior
along with rigorous administrative controls.
In this Part 1, I have listed you only the engineering controls and soon, I
will come back to you with more administrative and advanced safety
devices in part 2 of this book.
To get more Safety books and safety articles, stay in touch through
subscribing my HSE Blog.

Key Terms:
The Safety Devices are effective than administrative controls & PPE.
The Choice of Safety device depends on the nature of operation &
Machine design
The Single machine will have two or more number of safety devices
The Pullback devices are the series of cables that pull the hands
away from the dangerous area during operation
The Hold to run controls require the operator continuously hold the
control to operate the machine
The Two hand controls. require the operator to operate two control
switches at same time
The Limited movement controls are most useful during maintenance
& testing
The Safe motion controls are monitoring & controlling the movement
of machine during regular operations
Trip bars & safety edges are works by detecting the pressure applied
by either trip / entanglement.

References and Bibliography
Occupational Health and safety Administration (OSHA) Guidelines

Health and Safety Executive Guidelines

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Get more HSE Books @ www.kannanmakino.com

My self Kannan Makino, a former mechanical engineering student and

I love learning, writing, blogging, training and Practicing HSE.

With an Initial Intention, I have started HSE Blogging at

I have experienced in Construction, Manufacturing and Now am working as

Occasionally i used to involve in HSE External Audits, inspections and other

Get more HSE Books @ www.kannanmakino.com

Introduction to Machine Safety:

What will happen?

Get more HSE Books @ www.kannanmakino.com

Moreover, its starts with the design itself.

In order to protect the employees, it is essential that, we should be familiar

Introduction to Legal Requirements

Irrespective of the country, region, designation, every human beings are

As a Health and safety practitioner, learning and interpreting health and

Supply of machinery (safety ) regulations 2008

Get more HSE Books @ www.kannanmakino.com

And the concepts are also same, by which

The machine must be designed, implemented, operated, maintained, and

Introduction to Machine hazards:

As i mentioned earlier the machine must be designed, installed, used and

Get more HSE Books @ www.kannanmakino.com

Introduction to Engineering Controls

Get more HSE Books @ www.kannanmakino.com

Fixed Enclosing Guard:

Get more HSE Books @ www.kannanmakino.com

Fixed Distance Guard:

The Machine will not run, if the guard is open

Get more HSE Books @ www.kannanmakino.com

Interlocking Guard with Guard Locking:

The "Interlocking Guard with Guard locking" is similar to the "General

The Machine will not run,

When the Guard is open or

Get more HSE Books @ www.kannanmakino.com

The Adjustable guards are being commonly found in wood working

Two Hand Operating Control:

Get more HSE Books @ www.kannanmakino.com

Hold to Run Control:

Get more HSE Books @ www.kannanmakino.com

The Cable will not involve any extension / retracting action.

Pull Back Device:

Get more HSE Books @ www.kannanmakino.com

Presence sensing Device:

Presence Sensing Mats:

Get more HSE Books @ www.kannanmakino.com

Most suited to the robotic operational areas.

Safety Edges: (Type of Pressure Sensing Device)

Alternatively, Instead of sensing device, a narrow strip is fitted to the

Get more HSE Books @ www.kannanmakino.com

Trip Bars (Type of Pressure Sensing Device)

Feeding / Ejection Systems:

Work holding Devices:

The Most common types would be clamps, jigs & fixtures.

Limited Movement Control:

The Movement control may be designed either by point-to-point basis or by

Get more HSE Books @ www.kannanmakino.com

Safe Motion Control Device: