An Introduction to Machine Guarding

The Occupational Safety and Health Administration has established a set of standards regarding machine guarding, which are designed to protect employees from workplace injuries and accidents. 

The purpose of machine guarding protocols is to limit hazards created during the regular operation of a machine. Some of these hazards include—but are not limited to—ingoing nip points, rotating parts, reciprocating, traversing, and/or flying chips and sparks.

Depending on the machine, moving parts have the potential to cause severe injuries. Examples may entail:

●      Crushed fingers or hands

●      Amputations

●      Burns

●      Blindness

●      Lacerations

●      Abrasions

When incidents like this occur, they can have a life-changing impact on the individuals involved. In order to minimize operator and employee risk, any machine part, function, or process that might cause injury is required to have a safeguard.

The Relationship Between Safety and Productivity

Many business owners worry that improved workplace safety measures will negatively impact productivity. However, safe working environments with minimal job hazards have been proven to help increase productivity and profits.

The proper workplace safeguards offer a wide range of benefits, such as the following:

●      Minimize lost working hours

●      Makes for engaged employees

●      Improves access to safety information and education

●      Increased employee satisfaction

By following the three pillars (as follows), business owners are more likely to establish an effective working environment. Like any operational component, safety, quality, and productivity must be considered in unison.

Safety

Proper safety measures help improve both the quality and productivity of a workplace. Unsafe environments are typically poorly managed, and, therefore, do not run as efficiently as they could. When this happens, both quality and productivity tend to suffer.

Quality

Higher quality work means better results and effective productivity. The conscientious execution of safety tactics ensures operations are performed according to the set standards required. This allows everyone to work under the same conditions with peace of mind, thus improving productivity.

Productivity

Carelessness is one of the biggest barriers to effective productivity. When the appropriate safety processes are in place, employees can ensure corners are not cut, which in turn helps guarantee the overall quality of both the products and workflow.

The Types of Machine Guarding

Fixed Guards

Fixed guards are a style of machine guard that gets permanently attached to a machine or tool itself. They typically do not have any moving parts, and cannot be moved while the machine is in use.

Key Features:

●      Permanent

●      Non-moving

●      Enclose the point of operation

●      Must be disassembled and removed to perform any kind of adjustment or maintenance

Adjustable Guards 

Similar to fixed guards, adjustable guards are also permanent. However, they can be adjusted to allow the machine to handle different sizes of material as needed. Operators must be properly trained on how to manually adjust and lock these guards into place before operating the machinery.

Key Features:

●      Adjustable

●      Require training

●      Can fail if improperly adjusted or locked

Self-Adjusting Guards

Serving the same purpose as an adjustable guard, self-adjusting guards are designed to automatically adapt to the size of the material. They often take a resting position when the machine is not in use, and then return to their working position once it is turned on.

Key Features:

●      Automatic adjustment

●      Have built-in safety guards for non-use

●      Commonly found on table saws and woodworking tools

Interlocking Guards

Also known as barrier guards, interlocking guards are meant to automatically shut off or disengage the power source when the guard is open or removed. This design is ideal for machinery where the operator may be required to remove any jams or obstructions that occur during standard operations.

Key Features: 

●      Automatically shut off the power source

●      Allow safe access to interior parts

●      Can sometimes open on accident

The Benefits of Proper Machine Guarding

1.   Improves employee morale

Whether an employee feels an employer cares about their well-being or not has a direct impact on work performance. The more publicly you display your concern for employee safety, the higher quality work they are likely to provide. Machine guarding is an easy and effective way to do this.

2.   Compliance

Regardless of how an employer may feel about safety guidelines and their effect on productivity, machine guards are required by law for any rotating parts or nip hazards. These features help ensure your business is compliant with the necessary safety regulations. This, in turn, minimizes the risk of unnecessary closures or pauses in work.

3.   Additional usage

An unknown fact is that when the dangerous components of machinery are protected, operators are actually able to use the machine in more extensive ways than before. This allows for greater functionality and productivity across the board.

Implementing Effective Machine Guarding

1.   Conduct a risk assessment

Before implementing any machine guarding components, you must first conduct a complete risk assessment. This process involves identifying all potential hazards associated with operating machinery and assessing the possibility of mild to severe injuries. It’s important to include workers in this process to ensure any unique insights about the operation are taken into account.

2.   Choose the right type

Considering there are several types of guarding restraints available, it’s crucial you select the correct one. The type of guarding restraint required will depend on the equipment being used, the hazards associated with that equipment, and the level of risk identified during the risk assessment.

3.   Ensure proper installation

Proper installation includes ensuring the guard is securely attached to the equipment while confirming there is no way to bypass or remove the guard. A properly positioned guard will prevent workers from coming into contact with moving parts or equipment.

4.   Provide adequate training

Before an operator can start using any machinery, they must first be properly trained on the use of machine safeguards. The training should include information about the following:

●      The purpose and function of guarding restraints

●      How to properly use and adjust them

●      How to inspect them for defects

●      The consequences of failing to use guarding restraints properly

Measuring and Improving Operational Efficiency

Although measuring operational efficiency may look different between businesses, it is still a crucial factor in determining how well things are running. Efficiency is separate from productivity in that it focuses on comparing the output to the input. 

For example, in addition to considering the quality and quantity of products, efficiency measurements also take into account how much it costs to produce a specific product output.

Some ways to measure operational efficiency are:

1. Line efficiency: The quantity of units a production line produces in a certain time; this is usually measured by the hour.

2. Energy efficiency: Measured in revenue per kilowatt-hour (kWh), and can be improved by using more energy-efficient systems.

3. Marketing efficiency: This can be measured in the cost of acquiring a new customer or retaining existing ones.

4. Asset efficiency: An example would be the occupancy rate of a hotel, which can show how investments and assets are bringing in revenue.

The way your business measures operational efficiency will depend on the industry, type of processes, and size, among other variables. Operational efficiency can be improved in a few simple steps:

1. Determine the organization’s current state of operational efficiency.

2. Determine the areas where performance is lacking compared to revenue.

3. Implement an organization-wide effort towards improving operational efficiency.

Create a Safe Workplace With Machine Guarding

Machine guarding is a necessary safeguard for protecting workers against dangerous and moving machine parts. Openly addressing safety concerns within the work environment allows business owners to reduce the risk of injury, shows employees that employers care about their well-being, and increases overall productivity. Prioritizing machine guarding can help you develop a better job site for everyone.