Write a safety checklist for Machine guarding inspection

A comprehensive machine guarding inspection checklist should verify that safeguarding meets OSHA requirements, prevents contact with hazardous motion, is secure, does not create new hazards, and still allows safe operation, inspection, lubrication, and maintenance. Inspectors should confirm guards have not been removed, bypassed, modified, or left unrepaired, and that removed guards are replaced before operation resumes. [3] [7] [2]

Key hazard identification points to inspect:

• Point-of-operation hazards where the machine performs work on the material
• Ingoing nip points created by rotating parts or parts rotating against fixed objects
• Rotating components such as shafts, collars, couplings, cams, clutches, flywheels, spindles, gears, chains, sprockets, belts, and pulleys
• Reciprocating, transverse, shear, pinch, entanglement, flying chip, spark, hot-surface, and sharp-edge hazards
• Exposed set screws, keyways, collars, shaft ends, and other projections that can catch clothing or body parts

[4] [5] [5] [3] For point-of-operation guarding, verify there is a safeguard at every hazardous operating point and that it keeps the operator's hands, fingers, and body out of the danger area. Barrier guards should physically restrict access and be selected or adjusted so employees cannot reach around, over, under, or through them. Where fixed guards are used, they should fully enclose the hazard whenever practical; where adjustable or self-adjusting guards are used, they must provide equivalent protection and remain properly set for the job. [3] [7] [7] [7]

Inspect all power-transmission and rotating parts carefully. Components within 7 feet of the floor or working level should be guarded, including belts, pulleys, chains, sprockets, gears, and shafting. Projecting shaft ends should be smooth, with unused keyways filled or covered, and shaft projections beyond one-half the shaft diameter should have guarding such as a nonrotating cap or safety sleeve. Fixed barrier guards are generally the preferred method for enclosing these hazards. [1] [5] [5] [5]

Emergency stop and operator control checks should confirm that each machine has a power shutoff within reach of the operator, emergency stop buttons are red, manually operated valves and switches are clearly identified and accessible, and foot-operated switches are guarded against accidental activation. Also verify machines will not automatically restart when power is restored after an outage or shutdown. [1] [1] [1] [1] [1]

Lockout/tagout inspection criteria should confirm that hazardous energy can be isolated and locked out for maintenance, repair, cleaning, unjamming, adjustment, and servicing. During servicing or maintenance, no part of an employee's body should be exposed to a hazardous area such as the point of operation or ingoing nip point while the machine is energized, unless a narrow exception applies and effective alternative protection is provided. If guards must be removed, there should be a shutdown system and documented energy-control procedures. [1] [3] [6] [11]

Interlocks should be inspected to ensure they stop hazardous motion or prevent a cycle when a guard, access cover, or loading door is opened or removed, and that the machine cannot restart until the guard is returned to its safe position. Interlocks are especially critical on equipment such as compactors and balers, where missing or bypassed guarding can expose workers to crushing hazards. [7] [6] [6]

Inspection criteria for physical condition and installation should include:

• Guards are firmly secured, not easily removable, and do not present a hazard in their own use
• No openings allow body parts to contact moving parts
• No gaps allow objects to fall into moving parts
• Guarding is compatible with safe, comfortable operation and does not encourage bypassing
• Machines are securely fastened or anchored where needed to prevent tipping or movement
• Adequate clearance exists around and between machines for operation, setup, servicing, material handling, and waste removal
• Electrical bonding and grounding are in place on noncurrent-carrying metal parts
• Fan blades within 7 feet of the floor are guarded with openings no larger than 1/2 inch where applicable

[3] [4] [1] [1] [1] [1] Maintenance and operator protection requirements should include formal machine-safety training, supervision, scheduled inspections, and preventive maintenance. Operators and maintenance personnel should use manufacturer instructions, keep hands at a safe distance, avoid loose clothing and long hair near rotating parts, use special hand tools, push sticks, jigs, or fixtures where needed, and wear appropriate eye, face, hearing, and other PPE based on the hazard assessment. Good housekeeping, ventilation, and control of sparks, dust, and noise should also be part of the inspection. [2] [4] [10] [10] [10] [8]

For OSHA and broader regulatory compliance, the inspection should reference the general machine guarding rule, hazardous energy control requirements, applicable machine-specific standards, and relevant ANSI or manufacturer guidance. At minimum, employers should evaluate compliance with machinery and machine guarding requirements, lockout/tagout, PPE, and any machine-specific provisions that apply to the equipment being inspected. [9] [5] [8]

Practical pass/fail checklist items for an inspection:

• All required guards are present, functional, and not bypassed
• Point-of-operation hazards are guarded to prevent hand, finger, and body entry
• Nip points, rotating parts, and power-transmission components are enclosed or otherwise effectively guarded
• Emergency stops and power shutoffs are accessible and clearly identifiable
• Interlocks function correctly and prevent operation when guards are open or removed
• Lockout/tagout can isolate all hazardous energy sources and is used for servicing and maintenance
• Machines do not automatically restart after power restoration
• Operators are trained, supervised, and using required PPE and safe feeding/removal tools
• Machines are clean, maintained, anchored as needed, and surrounded by adequate working clearance
• Any deficiency is documented, corrected promptly, and the machine is removed from service if employees are exposed to an unguarded hazard

[2] [3] [1] [6]