Machinery GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR

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1 GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR Machinery TO MEET THE REQUIREMENTS OF THE HEALTH AND SAFETY IN EMPLOYMENT ACT 1992 AND REGULATIONS 1995 OCCUPATIONAL SAFETY & HEALTH SERVICE LABOUR DEPARTMENT OF TE TARI MAHI

2 Foreword The Health and Safety in Employment Act 1992 reformed the law and provided, for the first time, comprehensive coverage and a consistency of approach to the management of safety and health in all New Zealand workplaces. Since its introduction on 1 April 1993 the new law has proven to be innovative and effective. It has not only been successfully enforced through the courts, but more importantly has improved attitudes throughout all industries. Regulations have now been passed which contain standards for matters not specifically addressed in the Act. Hon. Doug Kidd Minister of Labour The importance of enforcing the law can't be ignored. However, there is also a real need for industry-specific information for employers and employees. These guidelines are an important part of this process, and they provide further information on means of compliance with the Act and the regulations. My intention in publishing these guidelines is that they will be another step towards the ultimate goal of the legislation which is to constructively change people's attitudes and responses to workplace health and safety. Hon Doug Kidd Minister of Labour

3 Contents Foreword 2 About these guidelines 4 Content of the guidelines 4 Application of reference information 4 Terminology 6 Definitions 6 Part 1: Machine hazards and general guarding principles 1.1 Examples of machinery hazards Prime movers Transmission machinery Other machinery Machine guarding and ergonomics 12 Part 3: Safe operation of machinery and other responsibilities 3.1 Restrictions relating to young people Long hair, loose clothing and machinery use Cleaning and maintenance of machinery Training and supervision of machine operators Responsibilities of machine operators Operating speeds and dangerous vibration Machinery stability and security Electrical safety of machinery Isolation, hold cards and lock-out devices Noise control 28 Appendix 1: OSH publications relating to machinery 30 Appendix 2: NZ and overseas Standards relating to machinery Guarding types 13 Part 2: Design and construction of machinery and guards 2.1 Construction of machinery Construction of machinery guards Power controls Duties of designers Duties of manufacturers and suppliers of machinery and plant 20

4 About these guidelines These guidelines apply to machinery in places of work covered by the Health and Safety in Employment Act 1992 and its regulations. They are not intended to apply to machinery that is subject to any other Act or regulation that specifically provides for its inspection or safe use. Separate legislation covers amusement devices, boilers, cranes, lifts, mining, petroleum, pressure vessels, passenger ropeways and tractor safety frames. The guidelines are part of a series intended for different industries. The other guidelines currently available are: Agriculture Commercial and industrial premises Construction Forestry Woodworking machinery. These general guidelines will assist those with machinery-related responsibilities under the Health and Safety in Employment Act They are a guide to the regulations and to good practice in particular situations or hazards. Guidance on the Act is available from other OSH publications, such as A Guide to the Health and Safety in Employment Act 1992, or A Guide to Managing Health and Safety to Meet the Requirements of the Health and Safety in Employment Act Content of the guidelines The guidelines contain three categories of information on safety and health: Relevant sections of the Health and Safety in Employment Act 1992 and regulations. The guidelines themselves based in part on standards contained in former legislation and on generally accepted good practice; and References to further information in support of the guidelines. Application of reference information 1. Approved codes of practice Any work carried on in a place of work for which there as been issued an approved code of practice under section 20 of the Act, should be carried out in accordance with that code. GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER

5 LEGISLATIVE PROVISIONS THAT RELATE SPECIFICALLY TO THE SUBJECT OF THE GUIDELINE. The most relevant sections of the Act and regulations are listed separately. Often the section of the Act referred to contains general provisions, but has been quoted because it is most likely that any prosecution would be taken under it. Regulations are reproduced as appropriate, and their observance is mandatory where they apply. THE GUIDELINES THEMSELVES. These guidelines contain recommendations for employers and others on means of compliance with the Health and Safety in Employment Act They describe good practices for specific work situations, and as such support the Act and regulations. Where appropriate they refer the reader on to Codes of Practice approved by the Minister of Labour under the Act, Standards, regulations made under other Acts of Parliament, and other recognised statements of good practice relevant to the particular area. They are, however, guidelines, and while every effort has been made towards completeness and accuracy at the time of publication they should at any time be read in conjunction with the legislation and other documents referred to. REFERENCES TO IN SUPPORT OF THE GUIDELINES. (i) There are no practicable steps that may be taken to isolate it from the employees; or (ii) All practicable steps to isolate it from the employees have been taken, but it has not been isolated, the employer shall take the steps set out in subsection (2) of this section. (2) The steps are (a) To take all practicable steps to minimise the likelihood that the hazard will be a cause or source of harm to the employees; and (b) To ensure that there is provided for, accessible to, and used by the employees suitable clothing and equipment to protect them from any harm that may be caused by or may arise out of the hazard; and (c) To monitor the employees exposure to the hazard; and d) To take all practicable steps to obtain the employees consent to the monitoring of their health in relation to the hazard; and (e) With their informed consent, to monitor the employees health in relation to exposure to the hazard. OSH publication Guidance Notes for Electrical Interlocking for Safety in Industrial Processes 3.10 Noise control Employers operating machinery should take all practical steps to reduce noise produced by machinery to levels below the exposure limits (elimination). Where it is not practical to do this, then all practical steps should be taken to isolate the excessive noise from people. Where both are not practical, systems should be put in place to ensure that people exposed to the remaining excessive noise are unlikely to suffer harm Further information on the management of noise hazards are contained in the OSH publication Guidelines for the Provision of Facilities and General Safety and Health in Commercial and Industrial Premises OSH publications Noise Abatement for Circular Saws Reduction of Noise from Multi Head Woodworking Planers Guidelines for the Provision of Facilities and General Safety in Commercial and Industrial Premises Noise Induced Hearing Loss: A Message to Employees Noise Induced Hearing Loss: A Message to Employees These include New Zealand and other Standards, Occupational Safety and Health Service publications, other publications, and other sources of information which support the guidelines. GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER Standards These guidelines frequently refer to New Zealand and other Standards that provide technical guidance and specifications for employers and others. In addition, standards may be specified in particular regulations as having application to any place or type of work, equipment, plant, activity, or any other thing, covered by the regulations. In these cases, employers shall comply with the requirements of that Standard unless otherwise advised by an inspector. 3. OSH Handbook for health and safety inspectors This resource has been developed and maintained primarily for the use of Occupational Safety and Health Service employees. It has not been referred to in these guidelines but is a source of further information for people in industry, it may be sighted at any branch office of the Occupational Safety and Health Service. 4. Legislation The following parts of the Health and Safety in Employment Act 1992 and the Health and Safety in Employment Regulations 1995 will apply to almost every section of these guidelines: Section 6: Employers to ensure the safety of employees generally; and Regulation 66: Duties of designers of plant; and Regulation 67: Duties of manufacturers and suppliers. 5 GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER 1995I

6 Terminology In this document the terms shall and should are used. Shall is used in places where there is a technical requirement to achieve the desired result. It is used to alert the reader to the need to for the safeguard to have that element. Should is used as a way of indicating a preference. It does not indicate a mandatory requirement as other alternatives may achieve an equivalent result. Definitions All practicable steps is defined in the Health and Safety in Employment Act Briefly, it means doing what is reasonably able to be done in the circumstances, taking into account: The severity of any injury or harm to health which may occur; The degree of risk or probability of that injury or harm occurring; How much is known about the hazard and the ways of eliminating, reducing or controlling it; and The availability, effectiveness and cost of the possible safeguards. Inching means limited motion of machinery where dangerous parts of machinery are exposed during cleaning, setting, adjustment or feeding material and, depending on the machine and industry, may include the terms jog, crawl and pulse. Machinery means an engine, motor, or other appliance that provides mechanical energy derived from compressed air, the combustion of fuel, electricity, gas, gaseous products, steam, water, wind, or any other source; and includes- (a) Any plant by or to which the motion of any machinery is transmitted; and (b) A lifting machine, a lifting vehicle, a machine whose motive power is wholly or partly generated by the human body, and a tractor. Plant includes any- (a) Appliance, equipment, fitting, furniture, implement, machine, machinery, tool, and vehicle; and (b) Part of any plant, the controls of any plant, and any thing connected to any plant. Prime mover means an engine, motor, or other appliance that provides mechanical energy derived from steam water, wind, electricity, gas, gaseous products, or any other source, and includes any device which converts stored or potential energy into movement or mechanical energy. GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER

7 Securely fenced means so guarded that the arrangements provided ensure that the dangerous part is no longer dangerous in the sense that there is no longer a reasonably foreseeable risk of injury to any person employed or working in the place of work, even a person who is careless or inattentive while in the vicinity of a machine or using a machine. Safe by position means so positioned that any person cannot reach or gain access to the dangerous parts. A supplier with regard to the responsibilities they have in relation to machinery includes any person who sells or hires plant or who offers plant for sale or hire. Transmission machinery means any shaft, wheel, drum, pulley, system of fast and loose pulleys, gearing, coupling, clutch, driving belt, chain, rope, band, or other device by which the motion of a prime mover is transmitted to or received by any machine or appliance. 7 GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER 1995I

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9 PART 1 Machine hazards and general guarding principles

10 Legislation Control of hazards ACT 6. Employers to ensure safety of employees Every employer shall take all practicable steps to ensure the safety of employees while at work; and in particular shall take all practicable steps to... (c) Ensure that plant used by any employee at work is so arranged, designed, made, and maintained that it is safe for the employee to use; and... Duties of Employers in Relation to Hazard Management 7. Identification of hazards (1) Every employer shall ensure that there are in place effective methods for (a) Systematically identifying existing hazards to employees at work; and (b) Systematically identifying (if possible before, and otherwise as, they arise) new hazards to employees at work; and (c) Regularly assessing each hazard identified, and determining whether or not it is a significant hazard. (2) Where there occurs any accident or harm in respect of which an employer is required by section 25 (1) of this Act to record particulars, the employer shall take all practicable steps to ensure that the occurrence is so investigated as to determine whether it was caused by or arose from a significant hazard. 8. Significant hazards to employees to be eliminated if practicable Where there is a significant hazard to employees at work, the employer shall take all practicable steps to eliminate it. 9. Significant hazards to employees to be isolated where elimination impracticable Where (a) There is a significant hazard to employees at work; and (b) Either (i) There are no practicable steps that may be taken to eliminate it; or (ii) All practicable steps to eliminate it have been taken, but it has not been eliminated, the employer shall take all practicable steps to isolate it from the employees. 10. Significant hazards to employees to be minimised, and employees to be protected, where elimination and isolation impracticable (1) Where (a) There is a significant hazard to employees at work; and (b) Either (i) There are no practicable steps that may be taken to eliminate it; or (ii) All practicable steps to eliminate it have been 1.1 Examples of machinery hazards The hazards listed below are examples only, and the list should not be considered as exhaustive. Trapping hazards Closing nips between platen motions. In-running nips between pairs of revolving parts. In-running nips of the belt and pulley type. Moving balance weights and dead weights. Nips between connecting rods or links and rotating wheels, cranks or discs. Nips between fixed parts and uni-directional moving parts. Nips between gears and rack strips. Nips between reciprocating and fixed parts, other than tools and dies. Nips between revolving control handles and fixed parts. Nips between revolving wheels or cylinders in pans or on tables. Pawl and notched wheel devices for intermittent feed motions. Projecting belt fasteners and running belts. Reciprocating tools and dies. Impact and entanglement hazards Automatic guided vehicles. Discontinuous rotating parts. Moving robot arms and assemblies. Projections on revolving parts. Revolving beaters, spiked cylinders and drums. Revolving drums and cylinders uncased. Revolving high-speed cages in casings. Revolving mixer arms in casings. Revolving shafts, spindles, mandrels, and bars. Friction/cutting hazards Abrasive wheels. GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER

11 Cutting edges of endless-band cutting machines. Reciprocating knives and saws. Revolving cutting tools. Revolving worms and spirals in casings. Projectile hazards Breakage of high-speed cutting tools. Disintegration of abrasive wheels. Robot arm gripper (or clamp) failure. Other hazards Electrical equipment. Hot metal parts. Ionising radiation, such as x-rays. taken, but it has not been eliminated; and (c) Either (i) There are no practicable steps that may be taken to isolate it from the employees; or (ii) All practicable steps to isolate it from the employees have been taken, but it has not been isolated, the employer shall take the steps set out in subsection (2) of this section. (2) The steps are (a) To take all practicable steps to minimise the likelihood that the hazard will be a cause or source of harm to the employees; and (b) To ensure that there is provided for, accessible to, and used by the employees suitable clothing and equipment to protect them from any harm that may be caused by or may arise out of the hazard; and (c) To monitor the employees exposure to the hazard; and d)to take all practicable steps to obtain the employees consent to the monitoring of their health in relation to the hazard; and e) With their informed consent, to monitor the employees health in relation to exposure to the hazard. Noise. Radiation such as microwaves, ultraviolet light, laser beams and radio waves. OSH publication Dangerous Parts of Machinery and its Guarding (to be produced) 1.2 Prime movers Every flywheel directly connected to any prime mover and every moving part of any prime mover should be securely fenced, unless it is safe by position or by construction, so as to be safe to every person in the place of work. Legislation Prime movers ACT Section 6(c) applies. It is reproduced in section 1.1 of these guidelines. Regulations 66 and 67 also apply. They are reproduced in sections 2.4 and 2.5. Prime movers include the head and tail race of water wheels, water turbines, electric generators, electric motors, and electric rotary converters. OSH publication Dangerous Parts of Machinery and its Guarding (to be produced) 1.3 Transmission machinery Every part of any transmission machinery should be securely fenced unless it is in such a position or of such construction as to be safe to every person as it would be if securely fenced. Legislation Transmission machinery ACT Section 6(c) applies. It is reproduced in section 1.1 of these guidelines. Regulations 66 and 67 also apply. They are reproduced in sections 2.4 and GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER 1995I

12 Where belts or pulleys are used in connection with any machinery, the machinery should have belt shifters or other safe mechanical contrivances for the purpose of moving the belts to and from fast and loose pulleys, and any such contrivances should be so constructed, placed and maintained as to prevent the driving belt from creeping back on to the fast pulley. No driving belt should be allowed when not in use to rest or ride upon a revolving shaft which forms part of the transmission machinery. Efficient devices or appliances should be provided and maintained in every room or place of work by which the power can promptly be cut off from the transmission machinery. Legislation Other machinery ACT Section 6(c) applies. It is reproduced in section 1.1 of these guidelines. Regulations 66 and 67 also apply. They are reproduced in sections 2.4 and 2.5. OSH publication Dangerous Parts of Machinery and Its Guarding (to be produced) 1.4 Other machinery Every dangerous part of any machinery should be securely fenced unless it is in such a position or of such construction as to be safe to every person as it would be if securely fenced. Provided that in so far as the safety of a dangerous part of any machinery cannot by reason of the operation be secured by means of a fixed guard, it will be satisfactory for a device to be provided which automatically prevents the operator from coming into contact with that part. A safety device will ensure that while the dangerous part is exposed it does not move or that the motion of a dangerous part will be stopped before any person can reach it. Any part of a stock bar which projects beyond the head stock of a lathe should be securely fenced unless it is in such a position as to be safe to every person in the place of work as it would be if securely fenced. OSH publication Dangerous Parts of Machinery and Its Guarding (to be produced) Ergonomics of Machine Guarding Legislation Transmission machinery ACT Section 6(c) applies. It is reproduced in section 1.1 of these guidelines. Regulations 66 and 67 also apply. They are reproduced in sections 2.4 and Machine guarding and ergonomics When guards and barriers are used to provide secure fencing for machinery these guards and barriers should be designed so that people cannot reach over, around or through them and come into contact with the prime movers, transmissions and other dangerous parts of machinery. GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER

13 The OSH booklet The Ergonomics of Machine Guarding, sets out some criteria to which such guards and barriers can be designed. These design criteria are based on the physical dimensions and reach capabilities of humans. There will be some people, such as the very tall or very short, whose physical dimensions are such that they will not be protected by the criteria in this booklet. It will be necessary to take the reach capabilities of these people into account when designing guards and barriers. OSH publication Ergonomics of Machine Guarding 1.6 Guarding types If after taking all practical steps to eliminate machinery hazards it is found that the hazards cannot be eliminated, then all practical steps should be taken to isolate people from those hazards. If neither elimination or isolation can be achieved, then the exposure to and the effect of the hazards on people in the place of work should be minimised. This concept is a fundamental requirement of the Health and Safety in Employment Act Legislation Guarding types ACT Section 6(c) applies, also sections They are reproduced in section 1.1 of these guidelines. To achieve isolation a number of possibilities exist, and these are set out below. When applying the appropriate control to machinery hazards the practicability of the control should be taken into consideration. The objective is to take all practicable steps. OSH publication A Guide to the Health and Safety in Employment Act 1992 The Small Business Guide to the Health and Safety in Employment Act 1992 Fixed guards These guards should be constructed and arranged so that it is impossible for any person to reach the dangerous parts. This includes access from the rear or the sides of the machine. They should be fastened securely. It is not suitable to secure fixed guards with butterfly nuts or similar arrangements that allow the guard to be removed by hand. Interlocked guards Interlocked guards may operate mechanically, hydraulically, centrifugally, pneumatically, electrically (or a combination of these ways) and make the machinery safe by ensuring that the hazard is not present when the guard is opened. This is achieved by disconnecting the machine from its power source so that it cannot be started if the guard is open. Likewise, if the machine is running and the guard is opened, the power to the machine will be disconnected. Where there is likely to be overrun on a machine then devices which do not allow the guard to be opened until the motion of the machine has stopped or devices which will stop the 13 GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER 1995I

14 motion of the machine, should be fitted. It is essential that any brakes fitted to machinery are well maintained. Interlocked rise and fall guards or machine tools which are capable of inflicting injury if they free fall under gravity should be provided with a suitable anti-free-fall device. Poweroperated guards should be operated with the minimum of force to prevent the guard from causing a trapping hazard. Where it is not possible to reduce the closing force of a guard, a safety trip device could be fitted to the leading edge of the guard which will stop and reverse the motion of the guard. Standards BS 5304: 1988: Code of Practice for the Safety of Machinery AS (Int) Safeguarding of Machinery: Part 1 General Principles OSH publication Guidance Notes for Electrical Interlocking for Safety in Industrial Processes Bulletin Hydraulic Press Safety Principles (to be produced) Safe by position This method relies on dangerous machinery parts being out of the reach of people. The deficiency with this method of making machinery safe is that often the dangerous parts do become accessible when people use ladders and other things to gain access to the dangerous parts. Safe by position is only a suitable option when policies and practices are set in place by employers to ensure that the protection provided by this method is not compromised. Trip guards Trip guards can be used where other guarding methods are not practical. They work on similar principles as that of a pressure sensitive mat or operate by limit switches. A trip guard is arranged so that if a person reaches into a dangerous part of a machine, the trip guard will be activated, which in turn will cause the hazard presented by the machine to cease. When a trip guard is depressed, an impulse from the detector or limit switch will cause, via a suitable interface, an emergency stop of the machine and shut down of its power source. If this system fails, there is no substantial physical barrier to stop people from coming into contact with the dangerous parts. All safety trip guards should be hard wired to directly activate the machine control and power brake systems. Photoelectric safety devices This method of making machinery safe is often used when other methods of guarding are not practicable. They operate on the principle that if a light beam is broken the machine ceases its hazardous operation. Likewise if the beam is being broken by the presence of a GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER

15 person the machine is prevented from starting its hazardous operation. It should be noted that if the system fails there is no physical barrier to stop people being exposed to the hazard. Single light beams will not normally provide suitable protection as it will usually be possible for a person to reach around the light beam and reach a dangerous part. A satisfactory arrangement can be provided by placing a number of light beams so that there are no gaps in the arrangement of light beams that will allow people to reach through, around, under or over the dangerous parts. It is also important to ensure that the distance a light beam curtain is placed from the dangerous part is not too close otherwise there is a possibility that even with the light-beam curtain functioning properly a person could be injured by the dangerous part because of the overrun or cyclic nature of the machine. Photoelectric safety devices can be used in conjunction with other methods of guarding, to create a safe zone in situations where loading or unloading of a machine requires frequent access by the operator. Photoelectric safety devices should comply with and be installed to high performance standards such as BS 6491: Electro-sensitive safety systems for industrial machines, Parts 1 and 2 and HSE (UK) Guidance note PM41. Standards BS 6491: Part 1: 1984 Electro-Sensitive safety systems for industrial machines, Part 1: Specification for general requirements BS 6491: Part 2: 1987 Electro-sensitive safety systems for industrial machines, Part 2 Specification for particular requirements for electro-sensitive safety systems incorporating a photoelectric sensing unit(s) Health and Safety Executive (UK) Guidance Note PM OSH publication Guidance Notes for Electrical Interlocking for Safety in Industrial Processes Automatic push away guards With this type of guarding a barrier moves towards the machine operator when the hazardous part of the machine operation occurs. This in turn requires the operator to step back out of reach of the hazard. It should be noted that if this type of guard is not carefully designed and maintained then the push-away guard can itself become a hazard and cause injury. Thorough training of operators in the safe use of machinery guarded in this way is essential. OSH publication Safety Principles for the Guarding of Heavy Power Presses (to be produced) Two-handed controls This method of isolating people from machinery hazards is only acceptable where it can be shown that it is not practical to use any other method. It is not favoured because it may be possible with some two-handed controls to tape down one control thus making one-handed operation possible. To reduce the likelihood of this occurring two-handed controls should 15 GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER 1995I

16 be designed so that both controls have to be applied simultaneously. Even when operated properly, two-handed controls do not protect people other than the machine operator. For these reasons two-handed controls are not favoured. The controls should also be a hold-to-run type so that on release of hand pressure to the control the dangerous motion of the machine will stop immediately. The controls should be spaced well apart and be shrouded. The rear and sides of the machine should be guarded by fixed guards where practical to prevent access by other people. Pressure-sensitive mats These mats should also only be used when superior guarding methods cannot be applied. They operate on the principle that to gain access to the dangerous part a person has to step on to a mat or platform which then disconnects the machine from its power source. Pressure mats may also be used in conjunction with other methods of isolating people from hazards. If used, pressure mats should be of type that will not fail to danger. Because pressure-sensitive mats do not usually show any external sign of failure, they should be used with a control system that monitors their operation which in the event of a failure shuts down the machine. OSH publication Guidance Notes for Electrical Interlocking for Safety in Industrial Processes Locked guards and gates This method should only be used where there are no practical alternatives. It relies on a responsible person (usually a responsible senior employee) having possession of the key to the guard at all times. This person is also responsible for ensuring that the gate is not opened until the machine is switched off, isolated and all motion of the machine has stopped. Isolation, hold cards and lockout devices can also be used to ensure that the machine is not accidentally restarted. The guard or gate should be locked by the responsible person and the hold cards and lockout devices removed, before the machine is restarted. Adjustable guards Adjustable guards comprise a fixed guard with adjustable elements that should be positioned to suit each operation. Where these guards are used, full training in their use and adjustment is essential. Adjustable guards can also take the form of self-adjusting guards which are forced open by the entry of work, and distance guards which are simply barriers sited at an appropriate distance from the danger zone. These guards are only effective when the operator uses them correctly. GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER

17 PART 2 Design and construction of machinery and guards

18 LEGISLATION - Construction of machinery and guards ACT. 6. Employers to ensure safety of employees Every employer shall take all practicable steps to ensure the safety of employees while at work; and in particular shall take all practicable steps to... (c) Ensure that plant used by any employee at work is so arranged, designed, made, and maintained that it is safe for the employee to use; and... Regulations 66 and 67 also apply. They are reproduced in sections 2.4 and Construction of machinery All machinery should be soundly constructed and maintained. Machinery should also be so constructed as to be free from dangerous vibration when operating, or a cutter fitted to a machine, is correctly mounted on it and it is run a full or idle speed. 2.2 Construction of machinery guards Machinery guards should be made of substantial materials such as sheet steel, wire mesh, wood or other materials of rigid nature which cannot be easily damaged. These guards shall be well secured to machinery. Standard NZS 5801: 1974 Specification for the construction and fitting of machinery guards OSH publication Dangerous Parts of Machinery and its Guarding (to be produced) Legislation Prime movers ACT Section 6(c) applies. It is reproduced in section 2.1 above. 2.3 Power controls The power control is the device on a machine which controls the flow of energy to the prime mover. This energy may be: Electrical; Hydraulic oil under pressure; or Compressed gas. The power control should be capable of interrupting the flow of all energy sources and, where there is more than one energy source, it should be made clear by the use of interlocks or labels that all sources are interrupted to stop the flow of energy to the prime movers. The power control(s) should be: Capable of opening all energy sources, for example all phases of a three-phase electrical supply; Constructed and shrouded to prevent inadvertent starting of the machine; Clearly identifiable, and with guidance provided on actuating principles through appropriate labelling; Convenient to operate and located in accordance with sound ergonomic principles; If hydraulic controls, be of the dead man or hold to run type so that if the control is GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER

19 released the motion of the machine ceases. The controls should also be positioned so that they are out of reach of the dangerous parts and can be easily operated. Fail-safe in the event of an interruption to the energy supply. Lockable in the off position when a person at the controls is likely to be unable to see maintenance staff working on the machine. (Refer also to section 3.9.) The direction of movement of controls should correspond logically to the motion of the moving parts. Unable to be locked out in the on position. Unable to indicate off if it is in fact in the on position. Emergency stop controls should be conveniently located and clearly labelled so that machinery can be quickly shut down in the event of an emergency. Some machines will need to have a number of stop controls fitted so that operators will not have to travel long distances to shut down machinery in emergency situations. When a machine energy source falls to a low level or is interrupted completely, and parts of the machine are exposed which may cause a significant hazard when the power is restored, restarting the hazardous parts of the machine should require the deliberate operation of the power control. Where the machine operator cannot see all of the machine, a warning device should be provided which either visually or by sound or by both alerts people before the machine is restarted. Trip wires and switches, if used, should be non-resetting and the machinery should only be capable of being restarted from the main starter switch. Trip wires and switches are one type of emergency control, however, they should not be used as a substitute for suitable guarding. OSH publication Guidance Notes for Electrical Interlocking for Safety in Industrial Processes 2.4 Duties of designers Designers of machinery and plant should take all practicable steps to ensure that machinery and plant they design will not become a source of harm to any person involved in its manufacture, installation, use, maintenance, and repair. Designers of machinery and plant should design in accordance with the relevant ergonomic principles so that potential hazards are either eliminated, isolated or minimised at the design stage. This will include the placing of power controls. (Refer also to sections 1.5 and Legislation Duties of designers REGULATION. 66. Duties of designers of plant (1) Every designer of plant shall take all practicable steps (a) To design any plant in accordance with applicable ergonomic principles, including (without limitation) any such principles in relation to the placement of any power control; and (b) To design any plant in such a way that, if the plant is (i) Manufactured in accordance with the design; and (ii) Used for the purpose for which it was designed; and (iii) Installed, adjusted, used, cleaned, maintained, repaired, and dismantled in accordance with the designer s instructions, there is no likelihood that the plant will be a cause or source of harm to any person, or the likelihood that the plant will be such a cause or source of harm is minimised as far as is practicable. (2) Every designer of plant shall take all practicable steps to ensure that every manufacturer of the plant receives comprehensive and comprehensible information, including, where relevant, detailed instructions, about (a) The use for which the plant has been designed; and (b) How to install, adjust, use, clean, maintain, repair, and dismantle the plant in accordance with the designer s instructions; and (c) Any other matters about which the manufacturer needs information from the designer in order to be able to carry out the manufacturer s duties under regulation 67 of these regulations. 19 GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER 1995I

20 2.3 of these guidelines.). Designers should also have regard to human physical and mental processing capabilities, in order to eliminate, isolate or minimise the risk of harm to machinery operators, users, repairers and installers, from occupational overuse syndrome and stress and manual handling injuries. All practicable steps should be taken by designers to eliminate the noise and vibration hazards produced by the machinery they design. Where it is not practical to eliminate noise, then all practical steps should be taken to isolate people from noise, and where this is not practical, then the effects of the noise should be minimised. Exposure to noise levels below 85 db(a) for no more than 8 hours a day, is not likely to cause noise-induced hearing loss in most people, however, an increase in either the noise level or duration of exposure is likely to result in noise-induced hearing loss for people not using hearing protection. To ensure that noise control measures specified by designers are effective, manufacturers should ensure that suitable materials are used when constructing noise enclosures and controls for machinery. Designers should have regard to appropriate New Zealand and International Standards when designing equipment. (Refer to appendix 2.). Designers should provide comprehensive and comprehensible information and instructions to the manufacturer about the method of manufacture necessary to comply with the design criteria. Information must also be provided on the correct operation, adjustment, installation, maintenance, repair and any other relevant matters. Designers should also have regard to the information contained in the remainder of this guideline. LEGISLATION - Duties of manufacturers and suppliers of machinery and plant REGULATION. 67. Duties of manufacturers and suppliers of plant (1) Every manufacturer and supplier of plant shall take all practicable steps to ensure that any plant manufactured by that manufacturer or supplied by that supplier is so designed that, if the plant is (a) Manufactured in accordance with the design; and OSH publications Ergonomics of Machine Guarding Manual Handling: A Workbook Manual Handling: Guidelines for the Workplace Manual Handling: In the Manufacturing Industry Noise Abatement for Circular Saws Noise Induced Hearing Loss: A Message to Employees Noise Induced Hearing Loss: A Message to Employers Reduction of Noise from Multi-head Woodworking Planers 2.5 Duties of manufacturers and suppliers of machinery and plant Manufacturers and suppliers of plant should take all practicable steps to ensure that it is designed, manufactured and tested so that its installation, use, maintenance, repair, GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER

21 dismantling and cleaning will not cause harm to any person. Manufacturers of machinery and plant should take all practicable steps to provide comprehensive and comprehensible information and instructions to any supplier, about the use for which their machinery was designed, manufactured and tested and its correct use, adjustment, installation, maintenance, dismantling, repair and any other relevant matters. To ensure that noise control measures specified by designers are effective, manufacturers should ensure that suitable materials are used when constructing noise enclosures and controls for machinery. Suppliers of machinery and plant should take all practicable steps to provide comprehensive and comprehensible information and instructions to any purchaser or hirer, about the use for which it was designed, manufactured and tested and its correct use, adjustment, installation, maintenance, dismantling, repair and any other relevant matters. Manufacturers and suppliers should also have regard to the information contained in the remainder of this guideline. OSH publications Noise Abatement for Circular Saws Reduction of Noise from Multi-head Woodworking Planers Noise Induced Hearing Loss: A Message to Employees Noise Induced Hearing Loss: A Message to Employees (b) Used for the purpose for which it was designed; and (c) Installed, adjusted, used, cleaned, maintained, repaired, and dismantled in accordance with the designer s instructions, there is no likelihood that the plant will be a cause or source of harm to any person, or the likelihood that the plant will be such a cause or source of harm is minimised as far as is practicable. (2) Every manufacturer and supplier of plant shall take all practicable steps to ensure that any plant manufactured by that manufacturer or supplied by that supplier is so manufactured and tested that, if the plant is (a) Used for the purpose for which it was designed; and (b) Installed, adjusted, used, cleaned, maintained, repaired, and dismantled in accordance with the designer s instructions, there is no likelihood that the plant will be a cause or source of harm to any person, or the likelihood that the plant will be such a cause or source of harm is minimised as far as is practicable. (3) Every manufacturer of plant shall take all practicable steps to ensure that every supplier of the plant receives comprehensive and comprehensible information, including, where relevant, detailed instructions, about (a) The use for which the plant has been designed; and (b) How to install, adjust, use, clean, maintain, repair, and dismantle the plant in accordance with the designer s instructions; and (c) Any other matters about which the supplier needs information from the manufacturer in order to be able to carry out any duty of the supplier under this regulation. (4) Every supplier of plant shall take all practicable steps to ensure that every purchaser or hirer of the plant receives comprehensive and comprehensible information, including, where relevant, detailed instructions, about (a) The use for which the plant has been designed; and (b) How to install, adjust, use, clean, maintain, repair, and dismantle the plant in accordance with the designer s instructions; and (c) Any other matters about which the purchaser or hirer needs information from the supplier in order to be able to carry out any duty of the purchaser or hirer under the Act or these regulations. 21 GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER 1995I

22

23 PART 3 Safe operation of machinery and other responsibilities

24 LEGISLATION - Restrictions relating to young people REGULATIONS. Duties of Employers to Young Persons 54. Employment of young persons (1) Subject to subclause (2) of this regulation, every employer shall take all practicable steps to ensure that no employee under the age of 15 years works in any area at a place of work under the control of that employer (a) At any time when goods are being prepared or manufactured for trade or sale in that area: (b) At any time when any construction work is being carried out in that area: (c) At any time when any logging operation or treefelling operation is being carried out in that area: (d) At any time when any work is being carried out in that area that is likely to cause harm to the health and safety of a person under the age of 15 years. (2) Subclause (1) of this regulation does not apply to any area if an employee under the age of 15 years works at all times (a) In any office in that area; or (b) In any part of that area used only for selling goods or services Machinery Every employer shall take all practicable steps to ensure that no employee under the age of 15 years, at any place of work under the control of that employer, (a) Works at or with any machinery; or (b) Assists with work at or with any machinery. LEGISLATION - Long hair, loose clothing and machinery use ACT. 6. Employers to ensure safety of employees Every employer shall take all practicable steps to ensure the safety of employees while at work; and in particular shall take all practicable steps to... (d) Ensure that while at work employees are not exposed to hazards arising out of the arrangement, disposal, manipulation, organisation, processing, storage, transport, working, or use of things (i) In their place of work; or (ii) Near their place of work and under the employer s control; and Restrictions relating to young people All practicable steps should be taken by employers to ensure that no person under the age of 15 years works at or with machinery or assists with work at or with machinery. Where goods are being prepared or manufactured for trade or sale and where construction work or forestry work is carried out, then no person under the age of 15 years should be present unless they are in a public access area, are under the direct supervision of an adult, on a guided tour of the area or in an area only used for the sale of goods or services. 3.2 Long hair, loose clothing and machinery use Where there is a risk of entanglement with machinery, people with long hair should have it securely fixed and confined close to the head. People at risk of entanglement in machinery should not wear loose clothing. 3.3 Cleaning and maintenance of machinery When cleaning and maintenance of machinery is to be carried out, employers should take all practicable steps to ensure that the hazardous motion of machinery is stopped before work is carried out. Isolation, hold cards and lockout devices should also be used as described in section 3.9. Any other hazard present should also have the appropriate control applied to prevent people being harmed. Where it is not practical for the machine to be stopped and it is essential to the process, cleaning, maintenance, or repair procedure that the machine remain in operation, then the following steps should be taken by employers: Only the part of the machine which is vital to the process or required to be in motion should be energised. Those working in this hazardous situation should be adequately trained. A safe work procedure should be established and followed. Such procedures should be regularly reviewed. GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER

25 Inching machinery by a hold-to-run control, with the machine running at the slowest practical operating speed, for the purposes of cleaning, loading, and setting up, is an acceptable practice. The inching control should be a hold-to-run type, so that on release of hand pressure to the control the dangerous motion of the machine will stop immediately. Machinery should be maintained and kept in sound operating condition at all times. Preventive maintenance schedules, regular inspections, and unsafe condition reports may be used to help manage the maintenance of machinery. 3.4 Training and supervision of machine operators The employer or person in control of the place of work should ensure that no person operates a machine unless they have been instructed in the actual and potential hazards associated with the machine, and the precautions to be taken in relation to these hazards. Unless the machine operator has the skills to operate the machine safely, then the employer or person in control of the place of work should ensure that the operator is closely supervised by a person who does have the skills. When training people to operate machinery, the following things should be explained. It should be noted that this list is not exhaustive: Actual and potential hazards and appropriate controls. Correct use and adjustment of guards. Correct work methods to be used. Emergency procedures. How the machine works. How to check and adjust the machine prior to starting it. How to recognise faults with the potential to cause harm. How to stop and start the machine. Limitations and capabilities of the machine. Location and operation of other controls. Purpose of guards and other safety devices. What the machine does. Manufacturers recommendations should be taken into consideration when developing training programmes for operators of machinery and plant. LEGISLATION - Cleaning and maintenance of machinery REGULATION. 17. Cleaning, maintenance, or repair of machinery (1) Subject to subclause (2) of this regulation, every employer shall take all practicable steps to ensure, in relation to every place of work under the control of that employer, that, where the cleaning, maintenance, or repair of any machinery while the whole or a part of the machinery is moving may cause harm to any employee, the machinery is not cleaned, maintained, or repaired (a) Until every part of the machinery, including any extension or attachment, has been secured against movement, including inadvertent movement; and (b) Until every control device has been secured in the inoperative position by the use of locks or lock-out procedures or other equally effective means. (2) Every employer shall take all practicable steps to ensure, in relation to any machinery to which subclause (1) of this regulation applies, that, where it is essential to the process that the machinery performs, or to the procedure for cleaning, maintaining, or repairing the machinery, that the whole or a part of the machinery remains in motion during cleaning, maintenance, or repair, (a) A procedure is established for the carrying out of the cleaning, maintenance, or repair in a safe manner; and (b) The procedure contains at least the following features: (i) No employee who has not been adequately trained for the purpose shall carry out the cleaning, maintenance, or repair: (ii) Where it is essential that a part of the machinery remains moving, only that part shall be set in motion; and (c) The procedure is followed on every occasion to which it applies. LEGISLATION - Training and supervision of machine operators ACT. Duties of Employers in Relation to Training and Supervision 13. Training and supervision Every employer shall take all practicable steps to ensure that every employee who does work of any kind, or uses plant of any kind, or deals with a substance of any kind, in a place of work (a) Either (i) Has; or (ii) Is so supervised, by a person who has such knowledge and experience of similar places, and work, plant, or substances of that kind, as to ensure that the employee s doing the work, using the plant, or dealing with the substance, is not likely to cause harm to the employee or other people; and REGULATION. Regulation 17, above, also contains training and supervision requirements for employees. 25 GUIDELINES FOR GUARDING PRINCIPLES AND GENERAL SAFETY FOR MACHINERY OCTOBER 1995I