Machine Guarding

  • Are the required SAFE forms (i.e. SAFF068.1.0-New Equipment Checklist; SAFF068.2.0-Machine Audit Checklist) being used? **Verify that the required forms are being used to document the machine guarding assessments.**

  • Was the facility machine guarding assessment completed during the last 12 month period? **Unless an initial assessment wasn't completed this should be just a verification of current status of guarding against the previously completed assessment. Verify th

  • Were machine audit checklists completed for all plant machines? **During the physical assessment, identify a sampling of equipment across the plant (i.e. 10 machines). Compare that list for inclusion in the machine guarding assessments, by identifying the

  • Has the installation of guarding retrofits on non-compliant machines been completed? **Interview the safety training manager to determine status. Verify by sampling (i.e. 10 machines) with guarding deficiencies identified during the plant assessments as d

  • Has a plan been developed to install guarding retrofits on non-compliant machines? **Interview the safety training manager (or as appropriate) to determine what plan for correcting deficiencies was developed following the assessments.**

  • Have risk assessments been completed for all machinery and equipment in use? **Have risk assessments been conducted using the machine guarding assessments as a baseline. Review the risk assessments. Are results available for all equipment included in the

  • Where significant risk has been identified by the risk assessment process have controls, including guarding, been identified and implemented?

  • Site has a documented preventative maintenance program to ensure guards are properly maintained to ensure their effectiveness. **Review documentation of preventative maintenance program. This will require reviewing the program in MRP II with the maintenan

  • Were all Managers and Supervisors trained on machine guarding during the Review Period of the audit? **This training must be completed within 365 days of the last training. The review period may range from 12 to 60 months and will be defined by the Lead A

  • Were all Affected Employees trained on machine guarding during the Review Period of the audit? **This training must be completed within 365 days of the last training. The review period may range from 12 to 60 months and will be defined by the Lead Auditor

  • Does the machine guarding training documentation for the Review Period of the audit include the date of training? (The review period may range from 12 to 60 months and will be defined by the Lead Auditor.) **Verify that the training dates for all trained

  • Does the machine guarding training documentation for the Review Period of the audit include the signature of trainer? (The review period may range from 12 to 60 months and will be defined by the Lead Auditor.) **Verify that the signatures of trainers for

  • Does the machine guarding training documentation for the Review Period of the audit include the signatures of trainees? (The review period may range from 12 to 60 months and will be defined by the Lead Auditor.) **Verify that the signatures of all trainee

  • Does the machine guarding training documentation for the Review Period of the audit include the topic of training? (The review period may range from 12 to 60 months and will be defined by the Lead Auditor.) **Verify that the topic of training for all trai

  • Does the machine guarding training documentation for the Review Period of the audit include the outline/description of what was covered? (The review period may range from 12 to 60 months and will be defined by the Lead Auditor.) **Verify that the outline/

  • Is compressed air not used for cleaning purposes except where reduced to less than 30 psi. and then only with effective chip guarding and PPE? **During the physical assessment, look for usages of compressed air. All air cleaning nozzles should be marked i

  • Abrasive blast cleaning nozzles are equipped with an operating valve which must be held open manually, with a support provided on which the nozzle may be mounted when not in use. **During the physical assessment, look at any sand/grit blasting equipment u

  • Are machines designed for a fixed location securely anchored to prevent walking or moving? **Are stationary tools such as drill presses, hydraulic presses, table saws, grinders, etc. secured to either the floor or structure?**

  • Are all portions of bandsaw blades enclosed or guarded, except for that portion between the bottom of guide rolls and the table? **During physical assessment, inspect each bandsaw for proper guarding. The only exposed, non-guarded portions of the blade sh

  • Are guards affixed to the machine where possible and secured elsewhere if for any reason attachment to the machine is not possible. The guard shall be such that it does not offer an accident hazard in itself. **During the physical assessment, look for fix

  • All guards are rigidly braced every 3 feet or fractional part of their height to some fixed part of machinery or building structure? **During physical assessment, inspect guards for secure mounting/reinforcement. Installations should be secure.**

  • When the periphery of the blades of a fan is less than seven (7) feet above the floor or working level, the blades are guarded. The guard having openings are no larger than ½ inch. **During the physical assessment, look for fans placed within 7' of the f

  • Is the point of operation of machines whose point of operation exposes an employee to injury properly guarded? **During the physical assessment look at points where actual work is done on the product or its intermediates. Does the guarding prevent access

  • Where employees are exposed, are flywheels located within seven feet of floor level properly guarded? **During the physical assessment, look for any instances where flywheels are located within 7 feet of the floor? Are the point either guarded with a fixe

  • Where employees are exposed, are pulleys located within seven feet of floor level properly guarded? **During the physical assessment, look for any instances where pulleys are located within 7 feet of the floor? Are the pulleys either guarded with a fixed

  • Mechanical power-transmission pulleys are kept in proper alignment to prevent belts from running off. **During physical assessment, review any belt systems for proper alignment, Example: an imaginary line drawn through the centerline of the drive belt sho

  • Where employees are exposed, are horizontal and vertical belt drives located within seven feet of floor level properly guarded? **During the physical assessment, look for any instances where belts drives are located within 7 feet of the floor? Are the bel

  • On mechanical power transmission components inspections are made of belts, lacings, and fasteners and such equipment kept in good repair.

  • Where employees are exposed, are sprocket wheels and chains located within seven feet of floor level properly guarded. **During the physical assessment, look for any instances where sprockets wheels and chains are located within 7 feet of the floor? Are t

  • Are all gears within 7 feet of the floor are not properly guarded? **During the physical assessment, look for any instances where flywheels are located within 7 feet of the floor. Are the gears within 7 feet of the floor either guarded with a fixed guard,

  • Are all vertical and/or horizontal shafting guarded? **During the physical assessment, look for any instances where shafts are located within 7 feet of the floor. Are the shafts either guarded with a fixed guard, a barrier, or with an electronic/mechanica

  • Are all motor couplings, key ways, and set screws guarded? **During the physical assessment observe all motor coupling, key ways, and set screws. These should be guarded to prevent access. Again Table 10 will give the details for openings, but a "gotcha s

  • Do projecting shaft ends present a smooth edge and the end does not project more than one-half the diameter of the shaft unless guarded by nonrotating caps or safety sleeves? **During the physical assessment look at rollers, gear shafts, etc. to determine

  • Are unused keyways on projecting shaft ends filled up or covered? Unfilled key ways/projecting keys on shafts require that either the shaft be trimmed flush or guarded with a cap or cover, otherwise they are non-compliant.

  • The regular oilers for mechanical power-transmission apparatus wear tight-fitting clothing or machinery is oiled when not in motion. **Interview the maintenance planner/scheduler to determine what equipment lubrication is scheduled during the audit. Durin

  • Special handtools for placing and removing material are provided to permit easy handling of material without the operator placing a hand in the danger zone. Such tools are not in lieu of other guarding required by this section, but are only used to supple

  • Program Major Finding. There are not sufficient minor findings that there is an overall program/section failure. **This is only used if: a. The complete lack of an entire regulatory required program or standard; b. No attempt to implement any of the requi

Machine Guarding Barrier Guarding

  • On barrier guards, is the opening between the bottom of the barrier and the floor less than or equal to 6 inches. **During the physical assessment verify that the distance between the bottom of all barrier guards and the floor does not exceed 6".**

  • On barrier guards, is the height of the barrier a minimum of 5'. **During the physical assessment verify that the minimum height of all barrier guards is 5'. Verify that the 8 foot rule condition is still being met. (The 8 foot rule is that the height of

  • On barrier guards, does the barrier guard completely enclose and prevent access to the hazards being guarded? **During the physical assessment, visually inspect the barrier guards for openings. Subpart O's Table 10 defines the maximum opening depending on

  • On barrier guards, any gated entry points are interlocked to machine power or openable only with a tool or through a keyed access lock. **During the physical assessment, verify that all gated openings in barrier guards are secured either with fasteners re

  • On barrier guards, any non-gated entry points are interlocked to machine power using a presence sensing device(s), such as a scanning laser, light curtain, or safety mat. **Any non physical gates (i.e. doors, panels) must be protected by a presence sensin

  • On card barrier guards, do entry gates have a 2 minute timer (non-adjustable) preventing release of trapped gate keys before timer has elapsed. **During the physical assessment, review the card barrier trapped keyed system, to determine if the 2 minute ti

Machine Guarding Emergency Stops

  • Are all machines equipped with a minimum of 1 Category 0 Emergency Stop? **Interview the plant engineer/electrical engineer to determine if provided emergency stops disconnect machine power. Additionally, verify that the provided emergency stop switches c

  • Are emergency stops installed at all locations where workers interact with machinery/equipment? **Look for an emergency stop located at all operator control stations. Additional emergency stops are required within 10 feet of all points where the operators

  • Are emergency stop buttons used for emergency stopping of machinery are red mushroom shaped buttons with a yellow background? **Emergency stop buttons shall be red in color and either mushroom shaped or the European "Cone" shaped configurations with a yel

  • Are the emergency stop buttons free of operating obstructions, i.e. hoods, cover, shrouds, etc.? **Full or partial cylinder button shrouds/hoods/protectors are not permitted. Recessed button installations are also not permitted.**

  • Emergency stop (cable pull) cable switches used for emergency stopping of machinery are safety rated emergency stop switches? **Safety rated cable pull switches will be so marked; an alternative markings is a circle containing an arrow. These should not b

  • Emergency stop cables are not obstructed/contacting the machine or adjacent structure/eyelets, etc. **Look for points in the emergency stop cable runs where the cable contact equipment framework/adjacent structure/vector and/or directional eyelets. This n

  • Emergency stop (cable pull) cables used for emergency stopping of machinery are red or labeled "emergency stop" in both English and Spanish? **All emergency stop switches should be red in color. If there is a mixing of cable color or if normal stop cable

  • Emergency stop (cable pull) cables are properly tensioned? **On those installations with cable switches having tension windows typically arrows must be aligned with cursor marking; with those color coded windows, indicator window should be green; on older

Machine Guarding Grinders

  • Are "ring test" conducted on all grinding wheels prior to mounting for use? **Ask this question of maintenance associates. Have them describe the test.**

  • Spindle speed of the machine is checked before mounting of the wheel? **Ask maintenance associates how they do this.**

  • Do all grinding wheels fit freely on the spindle and remain free under all grinding conditions? **Inspect on walkthrough.**

  • On bench grinders does the distance between the wheel periphery and the adjustable tongue or the end of the peripheral member at the top never exceed one-fourth inch? **Inspect on walkthrough.**

  • Are work rests on grinding machines kept adjusted closely to the wheel with a maximum opening of one-eighth inch to prevent the work from being jammed between the wheel and the rest, which may cause wheel breakage. **Inspect on walkthrough.**

  • On abrasive wheel machines (i.e. grinders) safety guards cover the spindle end, nut, and flange projections. **Inspect on walkthrough.**

  • Are grinding machines equipped with flanges which are at least one-third the diameter of the wheel and the flanges are in good condition? **Inspect on walkthrough.**

Machine Guarding Tufting Machines

  • On tufting machine exit roller guards, are the guards an approved Risk Management design/installation? **Inspect the guard installation to ensure that they are in compliance with table 10. Interview the plant engineer to determine if the documentation is

  • On tufting machine drive end guards, do the guards prevent access to all moving parts? **In the field, look at the drive end guard installations on a minimum of 5 tufting machines. Are any openings in the guards less than 8' from the floor in compliance w

  • On tufting machine drive end guards, the interlock switches on the hinged door are safety rated switches. **In the field, look at the interlock switches on the drive end guard hinged doors, are they safety rated switches. As a rule switches will be red in

Machine Guarding Woodworking

  • On woodworking machines means are provided for rendering motor controls or devices inoperative while repairs or adjustments are being made to the machines they control. **Ask operators how they do this.**

  • Woodworking machines are provided with mechanical or electrical power control on each machine to make it possible for the operator to cut off the power from each machine without leaving his position at the point of operation. **Have the operator explain h

  • Are all woodworking machinery and equipment such as table saws, drill presses, joiners, etc., suitably guarded? **Observe equipment for manufacturer's guards being in place and functioning. Observe for areas that do not have guards that might be hazardous

  • Is all woodworking machinery prevented from automatically restarting following a power failure? **Ask operator what happens if the power goes off and how they restart the machine.**

  • Do table saws have proper hood-type guards with spreaders and dogs intact? **Observe for manufactures guards.**

  • Do jointers have guards in place and operable? **Observe for hazardous areas and guards being in place.**

  • Do self-feed rip saws have anti-kick back fingers? **Look for this during walkthrough and have operator explain how they work.**

  • Do radial saws have hood and adjustable lower guard in place? **Observe during walkthrough and make sure guard retracts when lifted then recovers the blade when lowered.**

  • Cleanliness is maintained around woodworking machinery. particularly as regards the effective functioning of guards and the prevention of fire hazards in switch enclosures, bearings, and motors. **Observe during walkthrough.**

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