Avoid painful machine guarding injuries
When employers receive a machine guarding citation, several OSHA standards are usually cited together. This was the case for one employer in the Midwest. A 21-year-old machine operator was fatally crushed while reaching into a machine to align automobile parts. Following an investigation into the incident, OSHA cited the facility for one willful and four serious safety violations for exposing workers to dangerous machinery and other hazards.
For incidents like this, OSHA often issues very blunt press releases. “This tragic death was preventable if [the company] ensured proper machine guarding,” said OSHA’s area director. “Failure to protect employees from dangerous machinery often leads to catastrophic injury or death. These violations are among the most frequently cited by OSHA.”
The investigation found that the sensing device to detect if someone was in the machine was improperly set, which allowed the device to cycle while the employee reached into the machine. OSHA issued a willful violation for failure to guard a sequencing machine properly. A willful violation is committed with intentional, knowing, or voluntary disregard for the law’s requirements or with plain indifference to employee safety and health.
OSHA cited the company for several serious violations, including failure to guard machines properly, conduct periodic evaluations of lockout/tagout procedures, and train workers on the procedures. An OSHA violation is serious if death or serious physical harm could result from a hazard an employer knew or should have known exists.
OSHA proposed penalties of $93,400 for the company, which employs about 106 workers. That’s enough money to buy a lot of machine guards or at least several brand-new machines.
What are the requirements for safeguards?
Ultimately, your machines need guards. Here’s a roadmap to make sure safeguards are in place:
- Make a list of all the machines in your workplace,
- Determine all the places on the machines where movement occurs,
- Identify what guards must be in place at these places of movement,
- Install the guards or ensure that the manufacturer’s pre-installed guards are still effective,
- Replace missing or defective guards, and
- Repeat the first five bullet points above at least annually or more frequently as needed.
Usually, when there are machine guarding issues, one of these six things is missing. I recommend going through this roadmap at least annually, and each time a machine is serviced or repaired. I often found that workers remove guards to perform routine maintenance on the machine or fix it and forget to put them back.
Improper machine guarding continues to be a commonly cited safety violation. “Safety Pays” isn’t just a catchy slogan. It’s a reality — the average machine guard costs under one hundred dollars. But the most common excuse for not having proper machine guards is because the employer “didn’t have the money” to buy them. I can’t stress enough, your company’s safety investments will yield returns. Millions of dollars of unused safety-related grant money are untouched every year. Find the money — your workers are worth it!