• band saws,
• circular saws,
• guillotine shears,
• punching and shearing machines,
• meatpacking or meat-processing machines, and certain power-driven machines:
  - paper products machines,
  - woodworking machines,
  - metal forming machines, and
  - meat slicers.

• Point of Operation is the area of the machine where the machine performs work. Mechanical actions that occur at the point of operation, including cutting, shaping, boring, and forming.
• Power-Transmission Apparatuses are all components of the mechanical system that transmit energy such as flywheels, pulleys, belts, chains, couplings, connecting rods, spindles, cams, and gears.
• Other Moving Partsare the parts of the machine that move while the machine is operating, such as reciprocating, rotating, and transverse moving parts as well as lead mechanisms and auxiliary parts of the machine.

• Rotating Motion (Figure 1) is circular motion such as action generated by rotating collars, couplings, cams, clutches, flywheels, shaft ends, and spindles, that may grip clothing or otherwise force a body part into a dangerous location. Projections such as screws or burrs on the rotating part increase the hazard potential.
  
  Figure 1. Rotating Motion
  
  
• Reciprocating Motion (Figure 2) is back-andforth or up-and-down motion that may strike or entrap a worker between a moving part and a fixed object.
  
  Figure 2. Reciprocating Motion
  
  
• Transversing Motion (Figure 3) is motion in a straight, continuous line that may strike or catch a worker in a pinch or shear point created by the moving part and a fixed object.
  
  Figure 3. Transversing Motion
  
  
• Cutting Action (Figure 4) occurs by sawing, boring and drilling, milling, and slicing or slitting machinery.
  
  Figure 4. Cutting Action
  
  
• Punching Action (Figure 5) begins when power causes the machine to hit a slide (ram) to stamp or blank metal or other material. The hazard occurs at the point of operation where the worker inserts, holds, or withdraws the stock by hand.
  
  Figure 5. Punching Action
  
  
• Shearing Action (Figure 6) is powered slide or knife movement used to trim or shear metal or other materials generates the motion. The hazard occurs at the point of operation where the worker inserts, holds, or withdraws the stock by hand.
  
  Figure 6. Shearing Action
  
  
• Bending Action (Figure 7) is power applied to a slide to draw or stamp metal or other materials generates the motion. The hazard occurs at the point of operation where the worker inserts, holds, or withdraws the stock by hand.
  
  Figure 7. Bending Action
  
  
• In-Running Nip Points (Figure 8), also known as "pinch points," develop when two parts move together and at least one moves in rotary or circular motion. In-running nip points occur whenever machine parts move toward each other or when one part moves past a stationary object.
  
  Typical nip points include gears, rollers, belt drives, and pulleys.
  
  Figure 8. Inrunning Nip Points

• Machine set-up/threading/preparation,
• Normal operation,
• Clearing jams,
• Machine adjustments,
• Cleaning of machine,
• Lubricating of machine parts, and
• Scheduled and unscheduled maintenance.

• Prevents worker contact with the hazard area during the operating cycle.
• Avoids creating additional hazards.
• Is secure, tamper-resistant, and durable.
• Avoids interfering with normal operation of the machine.
• Allows for safe lubrication and maintenance.

What Are Guards?

Guards are physical barriers that enclose dangerous machine parts and prevent worker contact with them. Guards must be secure and strong. Workers should not be able to bypass, remove, or tamper with guards. To prevent tampering, guards typically require a tool to unfasten and remove them. Guards should not create additional hazards such as pinch points or shear points between guards and other machine parts. Guards should not obstruct the operator's view or prevent workers from doing a job. Metal bars, Plexiglass™, or similar guards are suitable. Guard openings should be small enough to prevent workers from accessing danger areas. (See Table 1 and Figures 9 through 12 for commonly used machine guards.)


Figure 9. Fixed Guard on a Power Press


Figure 10. Power Press with Adjustable Barrier Guard

Table 1. Commonly Used Machine Guards

Figure 11. Self-Adjusting Guard on a Radial Saw


Figure 12. Interlocked Guard on Roll Make-up Machine

What Are Some Safeguarding Devices I Can Use?

Safeguarding devices typically help prevent operator contact with the point of operation. They may be used in place of guards or as a supplemental control when guarding alone does not adequately enclose the hazard. Safeguarding devices either (1) interrupt the normal cycle of the machine if the operator's hands are at the point of operation, (2) prevent the operator from reaching into the point of operation, or (3) withdraw the operator's hands if they are located in or near the point of operation when the machine cycles. (See Table 2 and Figures 13 through 18 for the types of safeguarding devices.)


Figure 13. Pullback Device on a Power Press

Table 2. Types of Safeguarding Devices (Continued)

Figure 14. Restraint Device on Power Press	Figure 16. Safety Tripod on a Rubber Mill
Figure 15. Presence Sensing Device on a Power Press	Figure 17. Two-Hand Control
Figure 18. Power Press with Gate	Figure 19. Power Press with Plunger Feed

Are There Other Ways to Safeguard Machines?

Yes, other methods for safeguarding machines include guarding by location or distance and by feeding methods that prevent operator access to the point of operation.

What Is Guarding by Location?

Safeguarding by location involves positioning or designing a machine so that the hazardous parts are away from areas where employees work or walk, or alternatively, installing enclosure walls or fences that restrict access to machines.

What Is Safeguarding by Feeding Methods?

The feeding process can be safeguarded by distance if the operators maintain a safe distance between their hands and the point of operation. For instance, if the stock is several feet long and only one end of the stock is being worked on, the operator may be able to hold the opposite end while performing the work. Safeguarding by distance is sometimes used during power press brake operations to ensure its effectiveness. This method of safeguarding requires close supervision and training.

Automatic and semiautomatic feeding and ejection methods can protect the worker by minimizing or eliminating direct contact with machinery. These methods typically require frequent maintenance, however, and are only protective for normal machine operation.

Examples of semiautomatic feeding methods include gravity feeds, where the part slides down a chute into the point of operation and magazine feeding, where the worker places the part in a magazine which is then fed into the point of operation. Automatic and semiautomatic ejection methods include pneumatic (jet of air), magnetic, mechanical (such as an arm), or vacuum. Figures 19 and 20 illustrate different types of automatic feeding and ejecting methods.


Figure 20. Shuttle Ejection Mechanism

Can Workers Use Hand-Feeding Tools?

Operators can use tools to feed work pieces into equipment to keep their hands away from the point of operation, but this should be done only in conjunction with the guards and devices described previously. Using hand tools requires close supervision to ensure that the operator does not bypass their use to increase production. Tools should be stored near the operation to encourage their use. To prevent repetitive trauma disorders, hand-feeding tools should be ergonomically designed for the specific task being performed. (Figure 21 shows typical hand-feeding tools.)


Figure 21. Typical Hand Feeding Tools

Are Foot Controls Another Option?

Foot controls are not safeguards because they do not keep the operator's hands out of the danger area. If you use them, they will need some type of guard or device, such as barriers or pullouts with interlocks capable of controlling the start up of the machine cycle. Using foot controls may increase productivity, but the freedom of hand movement allowed while the machine is operating increases the risk of a point of operation injury. Foot controls must be guarded to prevent accidental activation by another worker or by falling material and not allow continuous cycling. They work best when the operator is in a sitting position. Always avoid the hazard of riding the pedal (keeping the foot on the pedal while not actively depressing it.) (See properly guarded and positioned foot control in Figure 22.)


Figure 22. Properly Guarded Foot Control

What About Controls for Machines with Clutches?

Certain machines can be categorized based on the type of clutch they use -- full-revolution or part-revolution. Differing modes of operation for these two clutches determine the type of guarding that can be used.

Once activated, full-revolution clutches complete a full cycle of the slide (lowering and raising of the slide) and cannot be disengaged until the cycle is complete. So, presence-sensing devices may not work and a worker must maintain a safe distance when using two-hand trips. Machines incorporating full-revolution clutches, such as power presses, must also incorporate a single-stroke device and anti-repeat feature.

The part-revolution clutch can be disengaged at any time during the cycle to stop the cycle before it completes the down stroke. For example, part-revolution presses can be equipped with presence-sensing devices, but full-revolution presses cannot. Likewise, hydraulic presses can be stopped at any point in the cycle, and their safeguarding is similar to guarding for part-revolution clutch presses.

Do I Need to Safeguard Machinery?

You are responsible for safeguarding machines and should consider this need when purchasing machinery. Most new machinery is available with safeguards installed by the manufacturer, but used equipment may not be.

In cases where machinery has no safeguards, you can purchase safeguards from the original machine manufacturer or an after-market manufacturer. You can also build and install the safeguards in-house. Safeguarding equipment should be designed and installed only by technically qualified professionals. In addition, the original equipment manufacturer should review the safeguard design to ensure that it will protect employees without interfering with the operation of the machine or creating additional hazards.

Regardless of the source of safeguards, the guards and devices you use should be compatible with a machine's operation and designed to ensure safe operator use. The type of operation, size, and shape of stock; method of feeding; physical layout of the work area; and production requirements all affect the selection of safeguards. Also, safeguards should be designed with the machine operator in mind. To ensure effective and safe operator use, guards and devices should suit the operation. For example, if an operation is prone to jamming, installing a fixed guard may not work. An interlocked guard or presence-sensing device may be a more practical solution.

What Administrative Issues Must Be Considered When Safeguarding Machinery?

As an employer, you need to consider housekeeping practices, employee apparel, and employee training. Implement good housekeeping practices to promote safe working conditions around machinery by doing the following:

• Remove slip, trip, and fall hazards from the areas surrounding machines;
• Use drip pans when oiling equipment;
• Remove waste stock as it is generated;
• Make the work area large enough for machine operation and maintenance; and
• Place machines away from high traffic areas to reduce worker distraction.

• All hazards in the work area, including machine-specific hazards;
• Safe work practices and machine operating procedures;
• The purpose and proper use of machine safeguards; and
• All procedures for responding to safeguarding problems such as immediately reporting unsafe conditions such as missing or damaged guards and violations of safe operating practices to supervisors.

• 1910.211 -- Definitions.
• 1910.212 -- General requirements for all machines.
• 1910.213 -- Woodworking machinery requirements.
• 1910.215 -- Abrasive wheel machinery.
• 1910.216 -- Mills and calenders in the rubber and plastics industries.
• 1910.217 -- Mechanical power presses.
• 1910.218 -- Forging machines.
• 1910.219 -- Mechanical power-transmission apparatus.

• 1926.300 -- General requirements.
• 1926.301 -- Hand tools.
• 1926.302 -- Power-operated hand tools.
• 1926.303 -- Abrasive wheels and tools.
• 1926.304 -- Woodworking tools.
• 1926.305 -- Jacks -- lever and ratchet, screw, and hydraulic.
• 1926.306 -- Air receivers.
• 1926.307 -- Mechanical power-transmission apparatus.

1. Mechanical Power Presses
2. Power Press Brakes
3. Powered and Non-Powered Conveyors
4. Printing Presses
5. Roll-Forming and Roll-Bending Machines
6. Shearing Machines
7. Food Slicers
8. Meat Grinders
9. Meat-Cutting Band Saws
10. Drill Presses
11. Milling Machines
12. Grinding Machines
13. Slitters

What Are Mechanical Power Presses and Their Hazards?

Although there are three major types of power presses -- mechanical, hydraulic, and pneumatic -- the machinery that accounts for a large number of workplace amputations are mechanical power presses.

In mechanical power presses, tools or dies are mounted on a slide, or ram, which operates in a controlled, reciprocating motion toward and away from the stationary bed or anvil containing the lower die. When the upper and lower dies press together on the workpiece, a re-formed piece is produced. Once the downstroke is completed, the re-formed workpiece is removed either automatically or manually, a new workpiece is fed into the die, and the process is repeated. (See Figure 23.)


Figure 23. Part Revolution Mechanical Power Press with Two-Hand Control

Amputations occurring from point of operation hazards are the most common types of injuries associated with mechanical power presses. Inadequate safeguarding allows the operators to inadvertently activate the power press's tripping mechanism while their fingers are in the die (point of operation). For example, amputations can occur when an operator instinctively reaches into the point of operation to adjust a misaligned part or release a jam. Amputations also occur when an operator's normal feeding rhythm is interrupted, resulting in inadvertent placement of the operator's hands in the point of operation. Such injuries typically happen while the operator is riding the foot pedal. Examples of inadequate or ineffective safeguarding include the following:

• Guards and devices disabled to increase production, to allow the insertion of small-piece work, or to allow better viewing of the operation.
• Two-hand trips/controls bridged or tied-down to allow initiation of the press cycle using only one hand.
• Devices such as pullbacks or restraints improperly adjusted to fit the specific operator.
• Controls of a single-operator press by-passed by having a co-worker activate the controls while the operator positions or aligns parts in the die, or repairs or troubleshoots the press.
• Failure to properly lockout/tagout presses or to have a special method in place for making adjustments, clearing jams, performing maintenance, installing or aligning dies, or cleaning the machine.

• Prevent or stop the normal press stroke if the operator's hands are in the point of operation; or
• Prevent the operator from reaching into the point of operation as the die closes; or
• Withdraw the operator's hands if inadvertently placed in the point of operation as the die closes; or
• Prevent the operator from reaching the point of operation at any time; or
• Require the operator to use both hands for the machine controls that are located at such a distance that the slide completes the downward travel or stops before the operator can reach into the point of operation; or
• Enclose the point of operation before a press stroke can be started to prevent the operator from reaching into the danger area before die closure or enclose the point of operation prior to cessation of the slide motion during the downward stroke.

What Work Practices and Administrative Controls Should I Use?

"No Hands in Die" Policy
A "no hands in die" policy should be implemented and followed whenever possible. Under this policy, operators never place their hands in the point of operation (die area). Adherence to this policy would eliminate point of operation amputations.

The types of work practices and administrative controls you provide can make a big difference in reducing the potential for amputation hazards. For example, if workers operate presses under a "no hands in die" policy using feeding methods such as hand-tool feeding, safeguarding (two-hand trip, Type A and B gates, or presence-sensing device) you still must protect operators. Hand-tool feeding alone does not ensure that the operator's hands cannot reach the danger area. (Figure 24 illustrates the use of hand feeding tools in conjunction with pullbacks on a power press.)


Figure 24. Hand Feeding Tools Used in Conjunction with Pullbacks on a Power Press

Removing scrap or stuck work with tools is required even when hand feeding is allowed according to 29 CFR 1910.217(d)(1)(ii). You must furnish and enforce the use of hand tools for freeing or removing work or scrap pieces from the die to reduce the amount of time an operator's hand is near the point of operation.

What Other Controls Pertain to Mechanical Power Press Die Set-Up and Maintenance?

For example, always do the following:

• Control point of operation hazards created when guards are removed for set-up and repair by operating the machine in the inch mode. This involves using two-hand controls to gradually inch the press through a stroke when the dies are being tested on part-revolution clutch presses.
• Avoid making machine repairs or modifications while the machine can be stroked.
• Prevent stroking by using die blocks or interlocked barrier guards.
• Disconnect or remove foot controls while die work is being performed if they are used to initiate the stroke.

• Train operators in safe mechanical press operation procedures and techniques before they begin work on the press.
• Supervise operators to ensure that correct procedures and techniques are being followed.

• 29 CFR 1910.217(e)(1)(i) requires a program of periodic and regular inspections of mechanical power presses. You must inspect and test the condition of the clutch/brake mechanism, anti-repeat feature, and single-stroke mechanism and maintain records of these inspections and the maintenance performed.
• 29 CFR 1910.217(g), requires the reporting of all point of operation injuries within 30 days to either the Director of the Directorate of Safety Standards Programs, OSHA, U.S. Department of Labor, Washington, DC 20210, or the state agency administering a plan approved by OSHA.
• 29 CFR 1910.147 requires the performance of servicing and maintenance activities under an energy control program.

• 29 CFR 1910.217, Mechanical power presses.
• 29 CFR 1910.219, Mechanical powertransmission apparatus.
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

• OSHA Instruction CPL 2-1.24A, National Emphasis Program on Amputations
• OSHA publication 3067, Concepts and Techniques of Machine Safeguarding (http://www.osha.gov/Publications/osha3067.pdf)
• OSHA Technical Links -- Machine Guarding (http://www.osha.gov/SLTC/machineguarding/index.html)
• OSHA Lockout/Tagout Interactive Training Program (http://www.osha.gov/dts/osta/lototraining/index.html)
• NIOSH CIB 49, Injuries and Amputations Resulting From Work With Mechanical Power Presses (May 22, 1987)
• OSHA Instruction STD 1-12.21 -- 29 CFR 1910.217, Mechanical Power Presses, Clarifications (10/30/78)
• ANSI B11.1-1988 (R1994), Machine Tools -- Mechanical Power Presses, Safety Requirement for Construction, Care, and Use

• Foot controls being inadvertently activated while the operator's hand is in the point of operation. The likelihood of this type of injury increases as the size of stock decreases and brings the operator's hands closer to the point of operation.
• Parts of the body caught in pinch points created between the stock and the press brake frame while the bend is being made.
• Controls of a single-operator press bypassed by having a coworker activate the controls while the operator positions or aligns stock or repairs or troubleshoots the press.
• Failure to properly lockout/tagout presses or to have an alternative measure that provides effective protection for safety during the necessary tasks of making adjustments, clearing jams, performing maintenance, installing or aligning dies, or cleaning the machine.

Case History #3
An operator was bending small parts using an 80-ton unguarded press brake. This required the employee's fingers to be very close to the point of operation and consequently, the operator lost three fingers when his hand entered the point of operation. The operator on the previous shift had reported to the supervisor that the operator placed his fingers close to the point of operation, but was told nothing could be done but that the operator should be careful.

Case History #4
An operator was bending metal parts using a 36-ton part-revolution power press brake that was foot-activated and equipped with a light curtain. About 3-4 inches of the light curtain had been "blanked out" during a previous part run. While adjusting a part at the point of operation, the employee accidentally activated the foot pedal and amputated three finger tips.

How Can I Safeguard Power Press Brakes?

Engineering controls, work practices, and administrative controls can be used to effectively guard power press brakes. Engineering controls such as presence-sensing devices are sometimes used to safeguard power press brakes. When installed on special-purpose press brakes, these devices may require muting or balancing to allow the bending material to move through the protected zone. Always ensure that these devices are properly adjusted for the specific stock and task to be performed. Failure to adjust the device could leave it "blanked out" in certain areas and expose operators to point of operation hazards.

Be sure to safeguard general-purpose power press brakes by location, or by barrier guard, pullbacks, or restraints when operated by a single operator and helper. (Figure 26 shows a general-purpose power press brake used in conjunction with pullbacks.) Other forms of helper safeguarding are ineffective and not applicable to general-purpose power press brakes. Special-purpose power press brakes are equipped with advanced control systems that are adaptable to all forms of safeguarding concepts and devices, such as two-hand controls and multiple operator/helper actuating controls. Use anti-repeat devices to protect operators at the point of operation on special-purpose power press brakes to comply with ANSI B11.3.


Figure 26. Two Person Power Press Brake Operation with Pullbacks

Under some conditions, absolute safeguarding of power press brakes may be impractical. This is especially true for press brakes used to process small-quantity runs involving the fabrication of unique pieces. When absolute physical guarding is impractical or infeasible for small quantity runs, OSHA recognizes the use of a "safe distance" as an alternative safeguarding method. Additional information about a "safe distance" safeguarding program can be found in OSHA CPL 2-1.25 -- Guidelines for Point of Operation Guarding of Power Press Brakes.

What About Work Practices and Administrative Controls for Power Press Brakes?

• Implement the following work practices to ensure safe operation of power press brakes with foot pedals, especially when the operator is working with small parts:
  • Use foot pedals only with other guards or devices but keep a safe distance between the operator's hand and the point of operation when the use of such safeguards is not feasible.
  • Be certain that the stock size is large enough to ensure that the operator is unable to reach into the point of operation during the down stroke when a foot control is used to stroke the press brake.
  • Don't ride the foot pedal.
  • Protect foot pedals from accidental activation and continuous cycling.
  • Use hand-feeding tools for operations when the operator's hands come closer to the point of operation as the size of stock decreases.
• Ensure that all power press brake operators receive appropriate training from experienced operators and supervision until they can work safely on their own.
• Develop and implement safe operating procedures for power press brakes and conduct periodic inspections to ensure compliance.
• Require workers to perform servicing and maintenance activities under an energy control program in accordance with 29 CFR 1910.147.

• 29 CFR 1910.212, General requirements for all machines.
• 29 CFR 1910.219, Mechanical powertransmission apparatus.
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

• OSHA publication 3067, Concepts and Techniques of Machine Safeguarding (http://www.osha.gov/Publications/Mach_SafeGuard/intro.html)
• OSHA Technical Links -- Machine Guarding (http://www.osha.gov/SLTC/machineguarding/index.html)
• OSHA Lockout/Tagout Interactive Training Program (http://www.osha.gov/dts/osta/lototraining/index.html)
• OSHA Directive - CPL 2-1.25, Guidelines for Point of Operation Guarding of Power Press Brakes
• OSHA Interpretation - 1910.212, Point of Operation Guarding on Power Press Brakes (03/25/1983)
• ANSI B11.3-1982 (R1994), Power Press Brakes, Safety Requirements for the Construction, Care, and Use of

• Cleaning and maintaining a conveyor especially when it is still operating.
• Reaching into an in-going nip point to remove debris or to free jammed material.
• Allowing a cleaning cloth or an employee's clothing to get caught in the conveyor and pull the worker's fingers or hands into the conveyor.

Figure 27. Belt Conveyor	Figure 28. Screw Conveyor
Figure 29. Chain Driven Live Roller Conveyor	Figure 30. Slat Conveyor

• Install guards for all sprockets, chains, rollers, belts, and other moving parts. Guarding by location -- locating moving parts away from employees to prevent accidental contact with the hazard point -- is one option for guarding conveyors. It is particularly difficult, however, to use this method when guarding the in-going nip points on certain conveyors such as roller conveyors because the exposed rollers are crucial to the function of the conveyor.
• Use prominent warning signs or lights to alert workers to the conveyor operation when it is not feasible to install guarding devices because they interfere with the conveyor's operation.
• Ensure that all conveyor openings such as wall and floor openings, and chutes and hoppers, have guards when the conveyor is not in use.
• Ensure that start buttons have guards to prevent accidental operation.
• Ensure that conveyor controls or power sources can accept a lockout/tagout device to allow safe maintenance practices. For crossovers, aisles, passageways, you need to do the following:
• Ensure that all accesses and aisles that cross over or under or are adjacent to the conveyor have adequate clearance and hand rails or other guards.
• Place crossovers in areas where employees are most likely to use them.
• Ensure that all underpasses have protected ceilings.
• Post appropriate hazard warning signs at all crossovers, aisles, and passageways.
• Considering emergency egress when determining placement of crossovers, aisles, and passageways. For emergency stops or shut-offs, you will need these engineering controls:
• Equip conveyors with interlocking devices that shut them down during an electrical or mechanical overload such as product jam or other stoppage. When conveyors are arranged in a series, all should automatically stop whenever one stops.
• Equip conveyors with emergency stop controls that require manual resetting before resuming conveyor operation.
• Install clearly marked, unobstructed emergency stop buttons or pull cords within easy reach of workers.
• Provide continuously accessible conveyor belts with emergency stop cables that extend the entire length of the conveyor belt to allow access to the cable from any point along the belt.

• Develop and implement safe operating procedures for conveyors and conduct periodic inspections to ensure compliance.
• Allow only trained individuals to operate conveyors and only trained, authorized staff to perform maintenance.
• Train employees working with or near conveyors regarding the location and use of emergency stopping devices and the proper procedures for conveyor operation.
• Forbid employees to ride on conveyors.
• Instruct employees to cross over or under conveyors only at properly designed and safeguarded passageways.
• Instruct employees to lubricate, align, and maintain conveyors when the conveyor is stopped. If this is impractical, advise workers to perform this work at a safe distance from any in-going nip points or pinch points. Installing extended oiler tubes and adjusting screws will help in these instances.
• Prohibit employees working with or near conveyors from wearing loose clothing or jewelry, and require them to secure long hair with nets or caps.
• Perform servicing and maintenance under an energy control program in accordance with 29 CFR 1910.147.

• 29 CFR 1926.555, Conveyors.
• ANSI B20.1-57, Safety Code for Conveyors, Cableways, and Related Equipment [incorporated by reference in 1926.555 (a)(8)]
• 29 CFR 1910.212, General requirements for all machines
• 29 CFR 1910.219, Mechanical power-transmission apparatus
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout)

• OSHA publication 3067, Concepts and Techniques of Machine Safeguarding (http://www.osha.gov/Publications/Mach_SafeGuard/intro.html)
• OSHA Technical Links -- Machine Guarding (http://www.osha.gov/SLTC/machine guarding/index.html)
• OSHA Lockout Tagout Interactive Training Program (http://www.osha.gov/dts/osta/lototraining/index.html)
• ANSI/ASME B20.1-1996, Safety Standard for Conveyors and Related Equipment
• ANSI/CEMA 350-1988, Screw Conveyors
• ANSI/CEMA 402-1992, Unit Handling Conveyors -- Belt Conveyors
• ANSI/CEMA 404-1985, Unit Handling Conveyors -- Chain Driven Live Roller Conveyors
• ANSI/CEMA 403-1985, Unit Handling Conveyors -- Belt Driven Live Roller Conveyors
• ANSI/CEMA 401-1994, Unit Handling Conveyors -- Roller Conveyors -- Non-powered
• ANSI/CEMA 405-1985, Package Handling Conveyors -- Slat Conveyors

What Are the Hazards from Printing Presses?

Printing presses vary by type and size, ranging from relatively simple manual presses to the complex large presses used for printing newspapers, magazines, and books. Printing presses are often part of a larger system that also includes cutting, binding, folding, and finishing equipment. Many modern printing presses rely on computer controls, and the high speeds of such equipment often require rapid machine adjustments to avoid waste.

This section discusses amputation hazards associated with two common types of printing presses: web-fed and sheet-fed printing press systems. Web-fed printing presses are fed by large continuous rolls of substrate such as paper, fabric or plastic; sheet-fed printing presses, as their name implies, are fed by large sheets of substrate. In both types, the substrate typically feeds through a series of cylinders containing printing plates and supporting cylinders moving in the opposite direction. (Figures 31 and 32 illustrate a roll-to-roll offset printing press and a sheet-fed offset printing press.)


Figure 31. Roll-to-Roll Offset Printing Press


Figure 32. Sheet-Fed Offset Printing Press

As with other machines, many printing press-related amputations occur during cleaning and maintenance activities. For example, amputations frequently occur when workers get their fingers or hands caught in the in-going nip points created between two rollers while performing these tasks:

• Cleaning or attempting to free material from the rollers.
• Hand-feeding substrate into the in-running rollers during press set-up while the machine is operating.

• Install guarding on all hazard points, including all accessible in-going nip points between rollers and power-transmission apparatus (such as chains and sprockets), that are accessible during normal operation.
• Safeguard nip point hazards with barrier guards or nip guards. Nip guards should be designed and installed without creating additional hazards. For example, the distance between the nip guard and the adjacent roller/cylinder should be minimized. Additionally, to prevent wedging, the angle between the nip guard and the surface of the roller should not be less than 60 degrees.
• Install fixed barrier guards at rollers that do not require operator access.
• Use fixed guards that can only be opened with tools (to prevent tampering) at points requiring operator access once per shift or less.
• When you need more frequent access to the press, use interlocked guards, which are designed to stop the printing press when opened or moved, instead of fixed guards. Interlocked guards should not allow normal operation of the press while open.
• Use an inch or reverse function to perform actions such as substrate feeding, machine adjustment, and lubrication when one or more interlocked guards is moved to allow operator access. The speed and distance of the inch function should be designed to ensure that it does not pose a hazard if not otherwise guarded.
• Require press operators to perform normal startup procedures before the press can be operated. Replacing an interlocked guard should not automatically trigger machine operation.
• Use additional safeguarding methods such as guarding by location as well as devices for stopping the printing press such as trip bars and pull cords.
• Remember that interlocks and stops do not stop the press immediately and that non-driven idler rollers may continue to rotate when the press is stopped and can cause injury.

• Make sure that printing presses attended by more than one operator or ones outside of the operator's viewing area be equipped with visual and audible warning devices to alert workers regarding the press's operational status -- in operation, safe mode, or impending operation.
• Install visual warning devices of sufficient number and brightness and locate them so that they are readily visible to press personnel.
• Ensure that audible alarms are loud enough to be heard above background noise.
• Provide a warning system that activates for at least 2 seconds prior to machine motion.

• Develop and implement safe operating procedures for printing presses and conduct periodic inspections to ensure compliance.
• Ensure that all press operators receive appropriate training and supervision until they can work safely on their own.
• Instruct workers to lubricate, align, and maintain printing presses only when presses are stopped. If this is impractical, advise employees to maintain a safe distance from any in-going nip points. Installing extended oiler tubes and adjusting screws will help in these instances.
• Prohibit employees working with or near printing presses from wearing loose clothing or jewelry and require them to secure long hair with a net or cap.
• Perform servicing and maintenance activities under an energy control program in accordance with 29 CFR 1910.147.

• 29 CFR 1910.212, General requirements for all machines.
• 29 CFR 1910.219, Mechanical powertransmission apparatus.
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

• OSHA publication 3067, Concepts and Techniques of Machine Safeguarding (http://www.osha.gov/Publications/Mach_SafeGuard/intro.html)
• OSHA Technical Links -- Machine Guarding (http://www.osha.gov/SLTC/machine guarding/index.html)
• OSHA Lockout Tagout Interactive Training Program (http://www.osha.gov/dts/osta/lototraining/index.html)
• ANSI B65.1-1995, Safety Standard-Printing Press Systems

What Are the Hazards from Roll-Forming and Roll-Bending Machines?

Roll-forming and roll-bending machines primarily perform metal bending, rolling, or shaping functions. Roll forming is the process of bending a continuous strip of metal to gradually form a predetermined shape using a self-contained machine. Roll-forming machines may also perform other processes on the metal, including piercing holes, slots, or notches; stamping; flanging; and stretch-bending. Roll bending is essentially the same process, except that the machine produces a bend across the width of flat or pre-formed metal to achieve a curved or angular configuration.

Roll-forming and roll-bending machines frequently are set up and operated by one person. (Figure 33 illustrates a roll-forming machine producing a finished product. Figure 34 illustrates the in-feed section of a roll-forming machine.)


Figure 33. Roll-Forming Machine


Figure 34. Infeed Area of a Roll-Forming Machine

The most common type of amputation hazard associated with roll-forming and roll-bending machines are point of operation hazards created by in-running nip points. Amputations occur when the hands of the operator feeding material through the rolls get caught and are then pulled into the point of operation. Causes of amputations related to roll-forming and roll-bending machines can occur from the following:

• Having an unguarded or inadequately guarded point of operation;
• Locating the operator control station too close to the process;
• Activating the machine inadvertently; and
• Performing cleaning, clearing, changing, or inspecting tasks while the machine is operating or is not properly locked or tagged out.

• Install fixed or adjustable point of operation guards at the in-feed and out-feed sections of machines. If the stock or end-product does not differ greatly from run to run, a fixed guard may be preferable. If the stock or end-product is variable, however, an adjustable guard may be more suitable.
• Install fixed point of operation guards to cover the sides of the rollers to prevent an employee from reaching into the in-going nip points of the rollers.
• Install fixed or interlocked guards to cover any other rotating parts, such as a power- transmission apparatus.
• Install safety trip controls, such as a pressure-sensitive body bar or safety tripwire cable on the in-feed section of the machine to shut down the machine if an employee gets too close to the point of operation.
• Install emergency stop controls that are readily accessible to the operator.
• Use an awareness barrier guard with an interlocking gate around the perimeter of the machine to prevent unauthorized entry.
• Locate foot pedal controls away from the point of operation and guard them in such a way as to prevent inadvertent activation.
• Allow only one control station to operate at any one time when a single machine has more than one set of operator controls, this does not apply to the emergency stop controls which must be operable from all locations at all times.
• Position operating stations in a way that ensures operators are not exposed to the machine's point of operation.
• Safeguard operator control stations to prevent inadvertent activation by unauthorized employees.

• Develop and implement safe operating procedures for roll-forming and roll-bending machines and conduct periodic inspections of the operation to ensure compliance.
• Ensure that all operators receive appropriate on-the-job training under direct supervision of experienced operators until they can work safely on their own.
• Ensure that operators use the jog mode during feeding operations if appropriate; and that they maintain a safe distance from the machine's rollers.
• Require workers to perform servicing and maintenance activities under an energy control program in accordance with 29 CFR 1910.147.

• 29 CFR 1910.212, General requirements for all machines.
• 29 CFR 1910.219, Mechanical powertransmission apparatus.
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

• OSHA publication 3067, Concepts and Techniques of Machine Safeguarding (http://www.osha.gov/Publications/Mach_SafeGuard/intro.html)
• OSHA Technical Links -- Machine Guarding (http://www.osha.gov/SLTC/machine guarding/index.html)
• OSHA Lockout Tagout Interactive Training Program (http://www.osha.gov/dts/osta/lototraining/index.html)
• ANSI B11.12-1996 Roll-Forming and Roll-Bending Machines -- Safety Requirements for Construction, Care, and Use

What Are Shearing Machines and Their Hazards?

Mechanical power shears contain a ram for their shearing action. The ram moves a non-rotary blade at a constant rate past the edge of a fixed blade. Shears may be mechanically, hydraulically, hydra-mechanically, pneumatically, or manually powered and are used to perform numerous functions such as squaring, cropping, and cutting to length.

In the basic shear operation, stock is fed into the point of operation between two blades. A hold-down may then be activated that applies pressure to the stock to prevent movement. One complete cycle consists of a downward stroke of the top blade until it passes the lower fixed blade followed by an upward stroke to the starting position. (See Figures 35 and 36 for examples of alligator and power squaring shears.)


Figure 35. Hydraulic Alligator Shear


Figure 36. Power Squaring Shear

Shears can be categorized as stand-alone manual shears, stand-alone automatic shears, and process-line shears.

Stand-alone manual shears. An operator controls them from a control station. The operator feeds the shear either by hand or by activating the automatic loading mechanism and activates the equipment using hand or foot controls or a tripping device on the back side of the shear. An example is an alligator shear.

Stand-alone automatic shears. These feed and stroke automatically and continuously. The operator uses hand-activated or foot activated controls to initiate the operation requiring limited additional operator interaction. An example is a guillotine shear.

Process-line shears. These are integrated into an automated production process and are controlled automatically as part of the process. Examples include crop shears and cut-to-length shears.

The primary hazard associated with shears is the shearing action at the point of operation. Amputations may occur in the following situations:

• The foot control inadvertently activates while the operator's hands are in the point of operation. Such amputations usually relate to foot-activated, stand-alone manual shears that require the use of both hands to feed the stock.
• A tripping device located on the back side of the shear's mouth operates the shear but does not prevent the operator from reaching into the hazard area. Such tripping devices, commonly found on stand-alone manual shears, may increase productivity but must be used in conjunction with appropriate safeguards.
• When there is no hold-down and stock being fed into a stand-alone manual shear kicks out and strikes the operator's hands or fingers.
• The shear is not equipped with either a full-revolution or a part-revolution clutch. Even after it is shut down, a shear that is not equipped with either type of clutch continues to cycle until its energy is exhausted.

• Use automatic-feeding devices such as conveyors with stand-alone manual shears when the material is uniform in size and shape.
• Equip mechanical shears with either a part-revolution or full-revolution clutch. Methods of safeguarding depend on the type of clutch in use. Shears equipped with full-revolution clutches used in single-stroke operations must be equipped with an anti-repeat feature.

• Install a fixed or adjustable point of operation guard at the in-feed of the shearing machine to prevent operator contact with the shear's point of operation as well as the pinch point of the hold-down. The guard's design should prevent the employee from reaching under or around it.
• Install a safety trip control device -- such as a pressure-sensitive body bar, safety tripod, or safety tripwire cable -- at the in-feed section of the shear.
• Install a presence-sensing device, such as a light curtasin, near the in-feed area of a stand- alone automatic or process-line shear.
• Install hold-down devices that prevent the work piece from kicking up and striking the operator.
• Install and arrange two-hand trips and controls so that the operator must use both hands to initiate the shear cycle. Two-hand trips and controls should be designed so they cannot be defeated easily. The ANSI B11.4 Shears -- Safety Requirements for Construction, Care, and Use standard recommends the installation of additional safeguarding when two-hand controls are used on part-revolution shears, based on the nature of the shearing operation. ANSI specifies the use of guards on full-revolution shears.
• Use restraints for stand-alone manual shears when other guarding methods are not feasible or do not adequately protect employees. These devices may not be appropriate if the job requires employees mobility.
• Install guarded operating stations at a safe distance from the shear's point of operation to prevent inadvertent activation.
• Mount guarded foot pedal controls at a safe distance away from the point of operation to prevent accidental activation.

• Install fixed guards on the back side of shears.
• Install an awareness barrier guard with an interlocking gate, a presence-sensing device (light curtain), or a safety trip control (safety tripwire cable or safety tripod) on the back side of the shear.

• Develop and implement safe operating procedures for shearing machines and conduct periodic inspections to ensure compliance.
• Instruct operators to use distancing tools when their hands might reach into the point of operation because of the size of the material being cut.
• Instruct employees to perform routine maintenance on the clutch and braking systems.
• Instruct employees to inspect all guarding to ensure that it is in place properly before the machine is operated.
• Instruct supervisors to ensure that operators keep their hands out of the shear's point of operation at all times while the machine is energized and not properly locked out.
• Instruct employees not to perform activities on the back side of a shear while it is operating or still energized.
• Prohibit employees from riding the foot activation pedal.
• Ensure that all operators receive on-the-job training under the direct supervision of experienced operators until they can work safely on their own.
• Require workers to perform servicing and maintenance activities under an energy control program in accordance with 29 CFR 1910.147.

• 29 CFR 1910.212, General requirements for all machines.
• 29 CFR 1910.219, Mechanical powertransmission apparatus.
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

What Are the Hazards Associated with Food Slicers?

Food slicers are electrically powered machines typically equipped with a rotary blade, an on/off switch, thickness adjustment, and a food holder or chute. A pushing/guarding device or plunger may be used to apply pressure to the food against the slicer blade, or pressure may be applied by gravity and/or by an attachment connected to the food holder. (See Figure 37.)


Figure 37. Meat Slicer

Amputations resulting from work with food slicers can occur as follows:

• When the operator adjusts or services the slicer while it is still operating or while it is switched off but still plugged in, or energized. In the latter case, amputations occur when the operator accidentally switches the slicer on.
• When the operator fails to use the sliding attachment on the food-holding device, especially when slicing small pieces of meat.
• When the operator hand-feeds food into a chute-fed slicer without using the proper pushing/ guarding device or plunger.

• Install guards that cover the unused portions of the slicer blade on both the top and bottom of the slicer.
• Buy slicers already equipped with a feeding attachment on the sliding mechanism of the food holder or purchase the attachment separately and install it prior to use.
• Instruct employees to use a pushing/guarding device with chute-fed slicers.
• Provide employees with a plunger for chute-fed slicers that are not equipped with a pushing/guarding device.

• Develop and implement safe operating procedures for slicers and conduct periodic inspections to ensure compliance.
• Ensure that all operators receive on-the-job training under the direct supervision of experienced operators until they can work safely on their own.
• Instruct operators to turn off and unplug slicers when not in use or when left unattended for any period of time.
• Instruct operators to use plungers to feed food into chute-fed slicers. For other slicers, they should use the feeding attachment located on the food-holder. Never place food into the slicer by hand-feeding or hand pressure.
• Tell operators that, although not required, wire mesh gloves may be worn while operating the slicer or cleaning the slicer's blade.
• Instruct operators to retract the slicer blade during cleaning operations.
• Instruct employees to perform servicing and maintenance activities under an energy control program in accordance with 29 CFR 1910.147. If the slicer is cord-and-plug connected equipment for which exposure to the hazards of unexpected energization or start up of the equipment is controlled by the unplugging of the equipment from the energy source and by the plug being under the exclusive control of the employee performing the servicing and maintenance, 1910.147 does not apply.

• 29 CFR 1910.212, General requirements for all machines.
• 29 CFR 1910.219, Mechanical power-transmission apparatus.
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

What Are the Hazards of Using Meat Grinders?

Electrically powered meat grinders typically have a feeding tray attached to a tubular throat, a screw auger that pushes meat to the cutting blade and through the cutting plate, an on/off switch, a reverse switch, and a plunger. (See Figure 38.)


Figure 38. Stainless Steel Meat Grinder

Amputations can occur when:

• The operator reaches into the throat of the grinder while it is still operating or while it is switched off but still plugged in (energized). In the latter case, amputations occur when the operator accidentally switches the grinder back on.
• The operator fails to use the attached feeding tray and throat.

• Equip meat grinders with properly sized throats that prevent the operator's hands from inadvertently reaching the point of operation.
• Provide operators with properly sized plungers to eliminate the need for their hands to enter the feed throat during operation.

• Develop and implement safe operating procedures for meat grinders to ensure that the guards are adequate and in place, and that the grinder feeding methods are performed safely. Conduct periodic inspections of grinder operations to ensure compliance.
• Ensure that all operators receive appropriate on-the-job training under direct supervision of experienced operators until they can work safely on their own.
• Instruct operators to turn off and unplug grinders when not in use or when left unattended for any period of time.
• Instruct operators to use the proper plunger device to feed meat into grinders. No other device should be used to feed the grinder.
• Instruct employees to operate only grinders with feeding trays and throats installed.
• Instruct operators to use the meat grinder only for its intended purpose.
• Perform appropriate servicing and maintenance activities under an energy control program in accordance with 29 CFR 1910.147. If the slicer is a cord and plug connected equipment for which exposure to the hazards of unexpected energization or start up of the equipment is controlled by the unplugging of the equipment from the energy source and by the plug being under the exclusive control of the employee performing the servicing and maintenance, 1910.147 does not apply.

• 29 CFR 1910.212, General requirements for all machines.
  
• 29 CFR 1910.219, Mechanical power transmission apparatus.
  
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

How Do Meat-Cutting Band Saws Pose Hazards?

Band saws can cut wood, plastic, metal, or meat. These saws use a thin, flexible, continuous steel strip with cutting teeth on one edge, that runs around two large motorized pulleys or wheels. The blade passes through a hole in the work table where the operator feeds the stock. Blades are available with various teeth sizes, and the saws usually have adjustable blade speeds.

Unlike band saws used in other industries, meat-cutting band saws are usually constructed of stainless steel for sanitary purposes and for easy cleaning. The table, which may slide or roll, has a pushing guard installed to protect the operator while feeding the saw. Meat-cutting band saws may also be equipped with a fence and pushing guard to feed the meat through the band saw. (See Figure 39.)


Figure 39. Stainless Steel Meat-Cutting Band Saw

Amputations occur most frequently when operators' hands contact the running saw blade while feeding meat into the saw. The risk of amputation is greatest when operators place their hands too close to the saw blade, in a direct line with the saw blade, or beneath the adjustable guard during feeding operations. Here are some common causes of amputations involving meat-cutting band saws:

• The operator's hand slips off the meat or otherwise accidentally runs through the blade.
• The operator attempts to remove meat from the band saw table while the blade is still moving.
• The operator's gloves, jewelry, or loose-fitting clothing became entangled in the saw blade.

• Install a guard over the entire blade, except at the working portion, or point of operation of the blade. The guard must be adjustable to cover the unused portion of the blade above the meat during cutting operations.
• Enclose the pulley mechanism and motor completely.
• Install a brake on one or both wheels to prevent the saw blade from coasting after the machine shut off.
• Provide a pushing guard or fence to feed meat into the saw blade.

• Develop and implement safe operating procedures for meat-cutting band saws to ensure the guards are adequate and in place and that operators safely perform feeding methods. Conduct periodic inspections of the saw operation to ensure compliance.
• Ensure that all operators receive adequate on-the-job training under the direct supervision of experienced operators until they can work safely on their own.
• Instruct operators to adjust the point of operation guard to admit only the meat.
• Instruct operators to use the pushing guard or fence to feed the saw, especially when cutting small pieces of meat.
• Instruct operators to use only sharp meat-cutting blades and to tighten blades to the appropriate tension.
• Instruct operators not to wear gloves, jewelry, or loose-fitting clothing while operating a band saw and to secure long hair in a net or cap.
• Prohibit operators from removing meat from the band saw while the saw blade is still moving.
• Instruct operators to turn off and unplug band saws when not in use or when left unattended for any period of time.
• Instruct employees to perform servicing and maintenance activities under an energy control program in accordance with 29 CFR 1910.147. If the band saw is a cord and plug connected equipment for which exposure to the hazards of unexpected energization or start up of the equipment is controlled by the unplugging of the equipment from the energy source and by the plug being under the exclusive control of the employee performing the servicing and maintenance, 1910.147 does not apply.

• 29 CFR 1910.212, General requirements for all machines.
• 29 CFR 1910.213, Woodworking machinery requirements.
• 29 CFR 1910.219, Mechanical powertransmission apparatus.
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

What About Drill Presses and Related Hazards?

Electrically powered drill presses use a rotating boring bit to drill or cut holes in wood or metal. The holes may be cut to a desired preset depth or completely through the stock. A basic drill press operation consists of selecting an appropriate drill bit, tightening the bit in the chuck, setting the drill depth, placing the material on the drill press bed, securing the work to the bed so that it will not rotate during drilling, turning the drill press on, and pulling the drill press lever down so that the drill bit will be lowered into the stock. (See Figure 40.)


Figure 40. Drill Press with Transparent Drill Shield

Amputations typically occur when the operator's gloves, loose-fitting clothing, or jewelry become entangled in the rotating drill bit. Here are some other causes of drill press-related amputations:

• Inadequately guarding points of operation or power-transmission devices.
• Performing servicing and maintenance activities such as changing pulleys and belts, changing or tightening drill bits, lubricating the drill press, and cleaning the drill press without de-energizing the drill press.
• Making adjustments to the drill press such as setting the depth, securing the material to the drill press bed, and repositioning the wood or metal while the drill bit is still rotating.

• Install guarding over the motor, belts, and pulleys.
• Install an adjustable guard to cover the unused portion of the bit and chuck above the material being worked.
• Replace projecting chucks and set screws with non-projecting safety-bit chucks and set screws.
• Cover operator controls so that the drill press cannot be turned on accidentally.
• Develop and implement safe work practices for drill-press operations and conduct periodic inspections to ensure compliance.
• Train and supervise all operators until they can work safely on their own.
• Instruct employees not to wear gloves, jewelry, or loose-fitting clothing while operating a drill press and to secure long hair in a net or cap.
• Make sure operators secure material to the drill press bed with clamps before drilling, so that the material will not spin and strike the operator. The operator should not manually secure the work to the drill press bed while drilling holes.
• Do not adjust the drill press while the drill bit is still rotating.
• Use the drill press only for its intended purposes.
• Shut off the drill press when not in use or when left unattended for any period of time.
• Remove the chuck immediately after each use.
• Perform appropriate servicing and maintenance activities under an energy control program in accordance with 29 CFR 1910.147.

• 29 CFR 1910.212, General requirements for all machines.
• 29 CFR 1910.213, Woodworking machinery requirements.
• 29 CFR 1910.219, Mechanical power-transmission apparatus.
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

What About Milling Machines and Related Hazards?

Electrically powered milling machines cut metal using a rotating cutting device called a milling cutter. These machines cut flat surfaces, angles, slots, grooves, shoulders, inclined surfaces, dovetails, and recessed cuts. Cutters of different sizes and shapes are available for a wide variety of milling operations.

Milling machines include knee-and-column machines, bed-type or manufacturing machines, and special milling machines designed for special applications. Typical milling operations consist of selecting and installing the appropriate milling cutter, loading a work piece on the milling table, controlling the table movement to feed the part against the rotating milling cutter, and calipering or measuring the part. (See Figure 41.)


Figure 41. Bed Mill

There are some frequent causes of amputation from milling machines:

• Loading or unloading parts and calipering or measuring the milled part while the cutter is still rotating.
• Performing servicing and maintenance activities such as setting up the machine, changing and lubricating parts, clearing jams, and removing excess oil, chips, fines, turnings, or particles while the milling machine is either stopped but still energized, or while the cutter is still rotating.
• Getting jewelry or loose-fitting clothing entangled in the rotating cutter.

• Install self-closing guards that enclose the milling cutter when the table has been withdrawn.
• Install an interlocked barrier guard around the table. When equipped with a cutter blade brake, the brake should be applied when opening or removing the interlocked barrier guard.
• Use other safeguarding devices such as splash shields, chip shields, or barriers if they provide effective protection to the operator and when it is impractical to guard cutters without interfering with normal production operations or creating a more hazardous situation.
• Instruct operators not to use a jib or vise that prevents the point of operation guard from being adjusted appropriately.
• Develop and implement safe work practices for machine operators and conduct periodic inspections to ensure compliance.
• Ensure that all operators receive appropriate on-the-job training by experienced operators until they can work safely on their own.
• Instruct operators to move the work holding device back to a safe distance when loading or unloading parts and calipering or measuring the work and not to perform these activities while the cutter is still rotating unless the cutter is adequately guarded.
• Prohibit operators from reaching around the cutter or hob to remove chips while the machine is in motion or not de-energized.
• Instruct operators to remove fines, turnings, or particles only with a brush while the cutter is stopped.
• Instruct operators to place the jib or vise locking arrangement so that force must be exerted away from the milling cutter.
• Instruct operators not to leave the cutter exposed after withdrawing work piece.
• Instruct operators to turn off the milling machine when not in use or when left unattended for any period of time.
• Instruct employees not to wear gloves, jewelry, or loose-fitting clothing while operating a milling machine and to secure long hair in a net or cap.
• Instruct operators to perform servicing and maintenance activities under an energy control program in accordance with 29 CFR 1910.147.

• 9 CFR 1910.212, General requirements for all machines.
• 9 CFR 1910.219, Mechanical power-transmission apparatus.
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

• Grinding on the side of the wheel not designed for grinding.
• Using an inadequately guarded grinding wheel.
• Using an incorrectly adjusted or missing work rest or a poorly maintained or unbalanced abrasive wheel.
• Wedging a tool between the work rest and the abrasive wheel, causing the wheel to break into flying particles.
• Adjusting the work rest, balancing the wheel, cleaning the area around the abrasive wheel, attempting to stop a rotating abrasive wheel by hand, and loading and unloading parts or measuring parts while the abrasive wheel is still rotating.

Figure 42. Horizontal Surface Grinder

Case History #23
After grinding a piece of steel on an offhand grinder, an employee turned off the machine and tried to stop the wheel with a piece of scrap steel. His hand slipped and hit the rotating abrasive wheel, amputating the tip of his left middle finger.

Case History #24
An employee was operating a large surface grinder to grind a groove into a steel part in a large pump repair shop. The part was secured with a vise and placed on a magnetic table. The employee was trying to measure the groove while the table was moving back and forth beneath the grinding wheel. The safe practice, both written and customary, is to disengage the hydraulics for the table and stop the wheel before reaching in to measure or remove a part. Though experienced at operating this machine and aware of the strict rule, the employee attempted to take measurements while the table and wheel were moving and ground off part of his left index finger.

How Can I Safeguard Grinding Machines?

You can help prevent worker accidents and injuries by using guards and other engineering controls. Here are some examples:

• Install safety guards that cover the spindle end, nut, and flange projections or otherwise ensure adequate operator protection.
• Install adjustable and rigid work rests on offhand grinding machines.
• Install guards on foot-operated controls to prevent accidental activation.
• Instruct operators to use hand tools to maintain a safe distance between the operator and the point of operation when needed.

• Develop and implement safe work practices for grinding machine operations and conduct periodic inspections to ensure compliance. ¹U.S. Department of Labor, OSHA, Office of Statistics, 1999. Based on BLS Annual Survey data for the number of amputations by source and type of event for various industry divisions and industries with high rates and high numbers of amputations in 1995.
• Ensure that all operators receive appropriate on-the-job training and supervision until they can work safely on their own.
• Instruct operators to inspect the grinding wheel to ensure that it is not defective, unbalanced, loose, or too small.
• Instruct operators to inspect the point of operation guard and to adjust it if necessary prior to each use.
• Instruct operators to adjust the work rest to within 1/8 inch from the wheel.
• Instruct employees not to wear gloves, jewelry, or loose-fitting clothing while operating grinding machines and to secure long hair in a net or cap.
• Instruct employees to keep their hands as far away as possible from the point of operation while feeding work into an offhand grinder.
• Instruct employees not to adjust the guard or clean the grinding machine while the abrasive wheel is still rotating.
• Instruct employees to perform servicing and maintenance activities under an energy control program in accordance with 29 CFR 1910.147.

• 29 CFR 1910.215, Abrasive wheel machinery.
• ANSI B7.1-70, Safety Code for the Use, Care and Protection of Abrasive Wheels [incorporated by reference in 1910.215(b)(12)]
• 29 CFR 1926.303, Abrasive wheels and tools.
• 29 CFR 1910.219, Mechanical power-transmission apparatus.
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

• Workers can inadvertently get their fingers and hands caught in the in-going nip points of the slitter or associated machinery such as rewinders.
• Gloves, jewelry, and loose clothing can get entangled in in-going nip points or in the rotary knives of the slitter.
• Workers can suffer an amputation when clearing, adjusting, cleaning, or servicing the slitter while it is either still operating, or shut off but still plugged in (energized).

Figure 43. Paper Slitter

Case History #25
An employee was operating a precision slitting machine to slit a roll of aluminum. As the employee reached into the machine to make an adjustment because the aluminum was not being slit properly, the employee's right arm got caught in the slitter. A set of rollers pulled his arm and amputated his right thumb and forefinger.

Case History #26
An employee was feeding cardboard strips onto slit steel as it was being coiled on a slitter machine. While the machine was operating, the employee was placing the cardboard strips on the coils. After reaching over the steel strips, the coiled steel on the mandrel pulled his right arm into the machine and amputated it.

What Are Some Ways to Safeguard Slitter Machines?

You can use guards and other engineering controls such as the following:

• Install a fixed or adjustable point of operation guard at the in-feed and out-feed section of the machine.
• Install a fixed point of operation guard to cover the sides of the unwinder/rewinder to prevent an employee's hands or clothing from entering into the rollers.
• Install fixed or interlocked guards to cover other moving parts of the machine such as the power-transmission apparatus.
• Use an awareness barrier guard with an interlocking gate around the perimeter of the machine to prevent unauthorized entry.
• Provide guards for operator control stations to prevent inadvertent activation.

• Develop and implement safe work procedures for machine operators and conduct periodic inspections to ensure compliance.
• Ensure that all operators receive appropriate on-the-job training and supervision until they can work safely on their own.
• Instruct employees to perform servicing and maintenance activities under an energy control program in accordance with 29 CFR 1910.147.

• 29 CFR 1910.212, General requirements for all machines.
• 29 CFR 1910.219, Mechanical power-transmission apparatus.
• 29 CFR 1910.147, The control of hazardous energy (lockout/tagout).

• Management leadership and employee involvement,
• Worksite analysis,
• Hazard prevention and control, and
• Safety and health training.

ANSI B5.52M-1980 (R1994), Presses, General Purpose, Single Point, Gap Type, Mechanical Power (Metric) ANSI B5.37 -- 1970 (R1994), External
Cylindrical Grinding Machines -- Centerless
ANSI B5.42 -- 198 (R1994), External
Cylindrical Grinding Machines -- Universal
ANSI B7.1 -- 2000, Use, Care, and Protection of Abrasive Wheels ANSI B11.1-1988 (R1994), Machine Tools --

ANSI B11.3-1982 (R1994), Power Press
Brakes, Safety Requirements for the
Construction, Care, and Use of
ANSI B11.9 -- 1975 (R1997), Grinding
Machines, Safety Requirements for the
Construction, Care, and Use of
ANSI B11.12-1996 Roll-Forming and Roll-Bending Machines -- Safety Requirements for Construction, Care, and Use ANSI B11.4-1993, Shears -- Safety Requirements for Construction, Care, and Use ANSI B20.1-57, Safety Code for Conveyors, Cableways, and Related Equipment [incorporated by reference in 1926.555 (a)(8)] ANSI B65.1-1995, Safety Standard -- Printing Press Systems

ANSI/CEMA 401-1994, Unit Handling Conveyors -- Roller Conveyors -- Non-powered ANSI/CEMA 402-1992, Unit Handling
Conveyors -- Belt Conveyors
ANSI/CEMA 403-1985, Unit Handling Conveyors -- Belt Driven Live Roller Conveyors

• National Safety Council, Accident Prevention Manual for Industrial Operations: Engineering and Technology. 9th. Ed. Itasca, IL
• National Safety Council, Accident Prevention Manual for Business and Industry: Engineering and Technology 11th Ed. Itasca, IL

• 29 CFR 1910.147 -- The control of hazardous energy (lockout/tagout).
• 29 CFR 1910.211 -- Definitions.
• 29 CFR 1910.212 -- General requirements for all machines.
• 29 CFR 1910.213 -- Woodworking machinery requirements.
• 29 CFR 1910.215 -- Abrasive wheel machinery.
• 29 CFR 1910.217 -- Mechanical power presses.
• 29 CFR 1910.219 -- Mechanical power-transmission apparatus.
• 29 CFR 1926.300 -- General requirements.
• 29 CFR 1926.301 -- Hand tools.
• 29 CFR 1926.302 -- Power-operated hand tools.
• 29 CFR 1926.303 -- Abrasive wheels and tools.
• 29 CFR 1926.304 -- Woodworking tools.
• 29 CFR 1926.307 -- Mechanical power -- transmission apparatus.
• 29 CFR 1926.555 -- Conveyors.

• OSHA Instruction CPL 2-1.24A, National Emphasis Program on Amputations
• OSHA Instruction STD 1-12.21 -- 29 CFR 1910.217, Mechanical Power Presses, Clarifications (10/30/78)
• OSHA Directive -- CPL 2-1.25, Guidelines for Point of Operation Guarding of Power Press Brakes
• OSHA Directive STD 1-7.3, The Control of Hazardous Energy (Lockout/Tagout) -- Inspection Procedures and Interpretive Guidance

• OSHA Publication 3067- Concepts and Techniques of Machine Safeguarding (http://www.osha.gov/Publications/Mach_SafeGuard/)
• OSHA Publication 3120- Control of Hazardous Energy (Lockout/Tagout)
• OSHA publication 3157- A Guide for Protecting Workers from Woodworking Hazards

• Material Handling. Amputations related to manual material handling tasks often result when heavy or sharp objects fall from an elevated surface or shift during transfer. Amputation often occurs when the employee attempts to limit the movement of, or damage to, material as it shifts or falls.
• Forklifts. Amputation hazards related to forklift operation and use include employees being trapped or pinned between the forklift and another object; struck or run over by the forklift; struck by falling or shifting loads or overturning forklifts.
• Doors and Covers. Amputation hazards are not limited to mechanical equipment or heavy loads. Doors also have the potential to amputate fingers. These injuries typically result when a door closes while a person's hands are in the door jamb. Manhole covers, commercial garbage disposal covers, and tank or bin covers can also amputate fingers and toes.
• Trash Compactors. Many businesses use small trash compactors for reducing the volume of wastes such as cardboard. Often these compactors are not properly guarded and employees are not properly trained in their use. The majority of these amputations result from employees being struck by the ram/piston either during the initiating stroke or the return stroke. The ram/ piston should be guarded if any part of an operator's body is exposed to the danger area during the operating cycle. Likewise, before reaching into any trash compactor the operator should deenergize and lock out the machine.