137.229150 Osha3170

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Safeguarding Equipment and

Protecting Employees from

Amputations

www.osha.gov

Small Business Safety and

Health Management Series

OSHA 3170-02R 2007

Employers are responsible for providing a safe and

healthful workplace for their employees. OSHA’s

role is to assure the safety and health of America’s

employees by setting and enforcing standards; pro-

viding training, outreach, and education; establish-

ing partnerships; and encouraging continual im-

provement in workplace safety and health.

This publication is in the public domain and may be

reproduced, fully or partially, without permission.

Source credit is requested, but not required.

This information is available to sensory impaired

individuals upon request. Voice phone: (202) 693-

1999; teletypewriter (TTY) number: (877) 889-5627.

Edwin G. Foulke, Jr.

Assistant Secretary of Labor for

Occupational Safety and Health

Safeguarding Equipment

and Protecting Employees

from Amputations

Occupational Safety and Health Administration

U.S. Department of Labor

OSHA 3170-02R

2007

Occupational Safety and

Health Administration

This OSHA publication is not a standard or regulation, and it creates no new legal obligations. The

publication is advisory in nature, informational in content, and is intended to assist employers in

providing a safe and healthful workplace. The Occupational Safety and Health Act requires employers

to comply with hazard-specific safety and health standards. In addition, pursuant to Section 5(a)(1),

the General Duty Clause of the Act, employers must provide their employees with a workplace free

from recognized hazards likely to cause death or serious physical harm. Employers can be cited for

violating the General Duty Clause if there is a recognized hazard and they do not take reasonable

steps to prevent or abate the hazard. However, failure to implement these recommendations is not,

in itself, a violation of the General Duty Clause. Citations can only be based on standards, regula-

tions, and the General Duty Clause.

Contents

Introduction 5

OSHA Standards 5

National Consensus Standards 6

Recognizing Amputation Hazards 7

Hazardous Mechanical Components 7

Hazardous Mechanical Motions 7

Hazardous Activities 9

Hazard Analysis 9

Controlling Amputation Hazards 9

Safeguarding Machinery 9

Primary Safeguarding Methods 10

Guards 10

Safeguarding Devices 13

Secondary Safeguarding Methods 16

Probe Detection and Safety Edge Devices 16

Awareness Devices 17

Safeguarding Methods 17

Safe Work Procedures 18

Complementary Equipment 18

Administrative Issues 19

Inspection and Maintenance 19

Lockout/Tagout 20

Specific Machine Hazards and

Safeguarding Methods 20

Hazards of Mechanical Power Presses 20

Safeguarding Mechanical Power Presses 22

Other Controls for Mechanical Power Press

Servicing and Maintenance 23

Training 24

Additional Requirements 24

Power Press Brakes 25

Hazards of Power Press Brakes 25

Safeguarding Power Press Brakes 25

Other Controls for Power Press Brakes 26

Hazards of Conveyors 26

Safeguarding Conveyors 28

Other Controls for Conveyors 29

Hazards of Printing Presses 30

Safeguarding Printing Presses 31

Other Controls for Printing Presses 32

Hazards of Roll-Forming and

Roll-Bending Machines 33

Safeguarding Roll-Forming and

Roll-Bending Machines 33

Other Controls for Roll-Forming and

Roll-Bending Machines 34

Hazards of Shearing Machines 35

Safeguarding Shearing Machines 36

Other Controls for Shearing Machines 36

Hazards of Food Slicers 37

Safeguarding and Other Controls for

Food Slicers 38

Hazards of Meat Grinders 38

Safeguarding and Other Controls for

Meat Grinders 39

Hazards of Meat-Cutting Band Saws 39

Safeguarding and Other Controls for

Meat-Cutting Band Saws 40

Hazards of Drill Presses 41

Safeguarding and Other Controls for

Drill Presses 42

Hazards of Milling Machines 43

Safeguarding and Other Controls for

Milling Machines 44

Hazards of Grinding Machines 45

Safeguarding and Other Controls for

Grinding Machines 46

Hazards of Slitters 46

Safeguarding and Other Controls for

Slitters 47

OSHA Assistance 49

References 51

Appendix A.

Amputation Hazards Not Covered

in this Guide 53

Appendix B.

Amputation Hazards Associated

with Other Equipment and Activities 54

Appendix C.

OSHA Regional Offices 55

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 3

Occupational Safety and

Health Administration

List of Tables

Table 1. Commonly Used Machine Guards 12

Table 2. Types of Safeguarding Devices 13

List of Figures

Figure 1. Rotating Motion 7

Figure 2. Reciprocating Motion 7

Figure 3. Transversing Motion 7

Figure 4. Cutting Action 7

Figure 5. Punching Action 8

Figure 6. Shearing Action 8

Figure 7. Bending Action 8

Figure 8. In-Running Nip Points 8

Figure 9. Fixed Guard on a Power Press 11

Figure 10. Power Press with an Adjustable

Barrier Guard 11

Figure 11. Self-Adjusting Guard on a

Radial Saw 11

Figure 12. Interlocked Guard on a Roll

Make-up Machine 11

Figure 13. Pullback Device on a Power Press 13

Figure 14. Restraint Device on a Power Press 16

Figure 15. Presence-Sensing Device on a

Power Press 16

Figure 16. Two-Hand Control 16

Figure 17. Power Press with a Gate 16

Figure 18. Power Press with a Plunger Feed 17

Figure 19. Shuttle Ejection Mechanism 18

Figure 20. Safety Tripod on a Rubber Mill 18

Figure 21. Typical Hand-Feeding Tools 19

Figure 22. Properly Guarded Foot Control 19

Figure 23. Part Revolution Mechanical Power

Press with a Two-Hand Control 21

Figure 24. Hand-Feeding Tools Used in

Conjunction with Pullbacks

on a Power Press 23

Figure 25. Power Press Brake Bending Metal 25

Figure 26. Two-Person Power Press Brake

Operation with Pullbacks 26

Figure 27. Belt Conveyor 27

Figure 28. Screw Conveyor 27

Figure 29. Chain Driven Live Roller Conveyor 27

Figure 30. Slat Conveyor 28

Figure 31. Roll-to-Roll Offset Printing Press 31

Figure 32. Sheet-Fed Offset Printing Press 31

Figure 33. Roll-Forming Machine 33

Figure 34. In-Feed Area of a Roll-Forming

Machine 33

Figure 35. Hydraulic Alligator Shear 35

Figure 36. Power Squaring Shear 35

Figure 37. Meat Slicer 37

Figure 38. Stainless Steel Meat Grinder 38

Figure 39. Stainless Steel Meat-Cutting

Band Saw 40

Figure 40. Drill Press with a Transparent

Drill Shield 41

Figure 41. Bed Mill 43

Figure 42. Horizontal Surface Grinder 45

Figure 43. Paper Slitter 47

Introduction

Amputations are among the most severe and dis-

abling workplace injuries that often result in perma-

nent disability. They are widespread and involve

various activities and equipment. (The U.S. Bureau

of Labor Statistics 2005 annual survey data indicat-

ed that there were 8,450 non-fatal amputation cases

– involving days away from work – for all private

industry. Approximately forty-four percent (44%) of

all workplace amputations occurred in the manu-

facturing sector and the rest occurred across the

construction, agriculture, wholesale and retail trade,

and service industries.) These injuries result from

the use and care of machines such as saws, press-

es, conveyors, and bending, rolling or shaping

machines as well as from powered and non-pow-

ered hand tools, forklifts, doors, trash compactors

and during materials handling activities.

Anyone responsible for the operation, servicing,

and maintenance (also known as use and care) of

machines (which, for purposes of this publication

includes equipment) — employers, employees,

safety professionals, and industrial hygienists—

should read this publication. Primary safeguarding,

as used in this publication, includes control meth-

ods that protect (e.g., prevent employee contact

with hazardous machine areas) employees from

machine hazards through effective machine guard-

ing techniques. In addition, a hazardous energy

control (lockout/tagout) program needs to comple-

ment machine safeguarding methods in order to

protect employees during potentially hazardous

servicing and maintenance work activities.

This guide can help you, the small business

employer, identify and manage common amputa-

tion hazards associated with the operation and care

of machines. The first two sections of the document,

Recognizing Amputation Hazards and Controlling

Amputation Hazards, look at sources of amputa-

tions and how to safeguard machinery and control

employee exposure to hazardous energy (lockout/

tagout) during machine servicing and maintenance

activities. The section on Specific Machinery

Hazards and Safeguarding Methods identifies the

hazards and various control methods for machinery

associated with workplace amputations, such as:

mechanical power presses, press brakes, convey-

ors, printing presses, roll-forming and roll-bending

machines, shears, food slicers, meat grinders, meat-

cutting band saws, drill presses, milling machines,

grinding machines, and slitting machines.

The information in this booklet does not specif-

ically address amputation hazards on all types of

machinery in general industry, construction, mar-

itime and agricultural operations; however, many

of the described safeguarding techniques may be

used to prevent other amputation injuries. Ad-

ditionally, while this manual concentrates attention

on concepts and techniques for safeguarding

mechanical motion, machines obviously present a

variety of other types of energy hazards that cannot

be ignored. For example, pressure system failure

could cause fires and explosions. Machine electri-

cal sources also pose electrical hazards that are

addressed by other OSHA standards, such as the

electrical standards contained in Subpart S. Full

discussion of these matters is beyond the scope of

this publication. For compliance assistance purpos-

es, references and the appendices are provided on

applicable OSHA standards, additional information

sources, and ways you may obtain OSHA assistance.

OSHA Standards

Although this guide recommends ways to safeguard

and lockout/tagout energy sources associated with

machinery hazards, there are legal requirements in

OSHA standards that you need to know about and

comply with. The following OSHA standards are a

few of the regulations that protect employees from

amputation hazards.

Machinery and Machine Guarding:

29 CFR Part 1910, Subpart O

• 1910.211 – Definitions

• 1910.212 – General requirements for all

machines

• 1910.213 – Woodworking machinery require-

ments

• 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

Control of Hazardous Energy (Lockout/Tagout):

29 CFR 1910.147

Hand and PowerTools:

29 CFR Part 1926, Subpart I

• 1926.300 – General requirements

• 1926.303 – Abrasive wheels and tools

• 1926.307 – Mechanical power-transmission

apparatus

Conveyors:

29 CFR 1926.555

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 5

Concrete and Masonry Construction

29 CFR Part 1926, Subpart Q

• 1926.702 – Requirements for equipment and

tools

Consult these standards directly to ensure full

compliance with the provisions as this publication

is not a substitute for the standards. States with

OSHA-approved plans have at least equivalent

standards. For detailed information about machine

guarding and lockout/tagout, see the following

resources:

• Machine Guarding Safety and Health Topics

Page (http://www.osha.gov/SLTC/machine

guarding/index.html)

• Machine Guarding eTool (http://www.osha.gov/

SLTC/etools/machineguarding/index.html)

• OSHA Publication 3067, Concepts and Techniques

of Machine Safeguarding (http://www.osha.gov/

Publications/Mach_Safeguarding/toc.html)

• OSHA Directive STD 01-05-019 [STD 1-7.3],

Control of Hazardous Energy (Lockout/Tagout)—

Inspection Procedures and Interpretive Guidance

• Control of Hazardous Energy (Lockout/Tagout)

Safety and Health Topics Page (http://www.osha.

gov/SLTC/controlhazardousenergy/index.html)

• OSHA’s Lockout Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• OSHA Publication 3120, Control of Hazardous

Energy (Lockout/Tagout)

OSHA standards, directives, publications,

and other resources are available online at

www.osha.gov.

National Consensus Standards

OSHA recognizes the valuable contributions of

national consensus standards and these voluntary

standards may be used as guidance and recognition

of industry accepted practices. For example, the

American National Standards Institute (ANSI) pub-

lishes numerous voluntary national consensus stan-

dards on the safe care and use of specific machinery.

These consensus standards provide you with useful

guidance on how to protect your em-ployees from

machine amputation hazards and the control

methods described may assist you in complying

with OSHA performance-based standards.

Furthermore, OSHA encourages employers to

abide by the more current industry consensus stan-

dards since those standards are more likely to be

abreast of the state of the art than an applicable

OSHA standard may be. However, when a consen-

sus standard addresses safety considerations, OSHA

may determine that the safety practices described

by that consensus standard are less protective than

the requirement(s) set forth by the pertinent OSHA

regulations. OSHA enforcement policy regarding

the use of consensus standards is that a violation

of an OSHA standard may be deemed de minimis

in nature if the employer complies with a consen-

sus standard (that is not incorporated by reference)

rather than the OSHA standard in effect and if the

employer’s action clearly provides equal or greater

employee protection. (Such de minimis violations

require no corrective action and result in no penalty.)

For example, the OSHA point-of-operation

guarding provisions, contained in paragraph

1910.212(a)(3), require the guarding device to…be

in conformance with any appropriate standards

thereof, or in the absence of applicable specific

standards, shall be so designed and constructed as

to prevent the operator from having any part of his

body in the danger zone during the operating cycle.

The terms applicable standards or appropriate stan-

dards, as used in the context of 29 CFR 1910.212,

are references to those private consensus stan-

dards that were adopted (source standards) or

incorporated by reference in the OSHA standards.

In some instances, a specific national consensus

standard (that is not incorporated by reference or a

source standard), such as an ANSI standard for a

particular machine, may be used for guidance pur-

poses to assist employers in preventing an opera-

tor from having any body part in the machine dan-

ger zone during the operating cycle. Also, OSHA

may, in appropriate cases, use these consensus

standards as evidence that machine hazards are rec-

ognized and that there are feasible means of cor-

recting the hazard. On the other hand, some nation-

al consensus standards may sanction practices that

provide less employee protection than that provided

by compliance with the relevant OSHA provisions.

In these cases, compliance with the specific consen-

sus standard provision would not constitute compli-

ance with the relevant OSHA requirement.

Under the Fair Labor Standards Act (FLSA), the

Secretary of Labor has designated certain non-

farm jobs as particularly hazardous for employ-

ees younger than 18. Generally, these employ-

ees are prohibited from operating:

• Band saws • Circular saws • Guillotine

shears • Punching and shearing machines

• Meatpacking or meat-processing machines

• Certain power-driven machines: Paper products

machines, Woodworking machines, Metal

forming machines, and Meat slicers.

Occupational Safety and

Health Administration

Recognizing Amputation

Hazards

To prevent employee amputations, you and your

employees must first be able to recognize the con-

tributing factors, such as the hazardous energy associ-

ated with your machinery and the specific employee

activities performed with the mechanical operation.

Understanding the mechanical components of

machinery, the hazardous mechanical motion that

occurs at or near these components and specific

employee activities performed in conjunction with

machinery operation will help employees avoid injury.

Hazardous Mechanical Components

Three types of mechanical components present

amputation hazards:

Point of Operation is the area of the machine

where the machine performs work – i.e., mechani-

cal actions that occur at the point of operation,

such as cutting, shaping, boring, and forming.

Power-Transmission Apparatus is all components

of the mechanical system that transmit energy,

such as flywheels, pulleys, belts, chains, couplings,

connecting rods, spindles, cams, and gears.

Other Moving Parts are the parts of the machine

that move while the machine is operating, such

as reciprocating, rotating, and transverse mov-

ing parts as well as lead mechanisms and auxil-

iary parts of the machine.

Hazardous Mechanical Motions

A wide variety of mechanical motion is potentially

hazardous. Here are the basic types of hazardous

mechanical motions:

Rotating Motion (Figure 1) is circular motion such

as action generated by rotating collars, couplings,

cams, clutches, flywheels, shaft ends, and spin-

dles that may grip clothing or otherwise force a

body part into a dangerous location. Even smooth

surfaced rotating machine parts can be hazardous.

Projections such as screws or burrs on the rotat-

ing part increase the hazard potential.

Figure 1 Rotating Motion

Reciprocating Motion (Figure 2) is back-and-forth

or up-and-down motion that may strike or entrap

an employee 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

an employee in a pinch or shear point created by

the moving part and a fixed object.

Figure 3 Transversing Motion

Cutting Action (Figure 4) is the action that cuts

material and the associated machine motion may

be rotating, reciprocating, or transverse.

Figure 4 Cutting Action

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 7

Table

Bed (stationary)

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

employee typically inserts, holds, or withdraws

the stock by hand.

Figure 5 Punching Action

Shearing Action (Figure 6) involves applying

power to a slide or knife in order to trim or shear

metal or other materials. The hazard occurs at the

point of operation where the employee typically

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 in

a bending motion. The hazard occurs at the point

of operation where the employee typically 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 circu-

lar 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 In-Running Nip Points

Occupational Safety and

Health Administration

Blade

Stock

Punch

Stock

Die

Nip Point

Nip

Point

Typical Nip Point

Nip Point

Nip

Point

Hazardous Activities

Employees operating and caring for machinery

perform various activities that present potential

amputation hazards.

Machine set-up/threading/preparation,*

Machine inspection,*

Normal production operations,

Clearing jams,*

Machine adjustments,*

Cleaning of machine,*

Lubricating of machine parts,* and

Scheduled and unscheduled maintenance.*

* These activities are servicing and/or mainte-

nance activities.

Hazard Analysis

You can help prevent workplace amputations by

looking at your workplace operations and identify-

ing the hazards associated with the use and care of

the machine. A hazard analysis is a technique that

focuses on the relationship between the employee,

the task, the tools, and the environment. When

evaluating work activities for potential amputation

hazards, you need to consider the entire machine

operation production process, the machine modes

of operation, individual activities associated with

the operation, servicing and maintenance of the

machine, and the potential for injury to employees.

The results from the analysis may then be used

as a basis to design machine safeguarding and an

overall energy control (lockout/tagout) program.

This is likely to result in fewer employee amputa-

tions; safer, more effective work methods; reduced

workers’ compensation costs; and increased em-

ployee productivity and morale.

Controlling Amputation

Hazards

Safeguarding is essential for protecting employees

from needless and preventable injury. A good rule

to remember is:

Any machine part, function, or process that may

cause injury must be safeguarded.

In this booklet, the term primary safeguarding

methods refers to machine guarding techniques

that are intended to prevent or greatly reduce the

chance that an employee will have an amputation

injury. Refer to the OSHA general industry (e.g.,

Subpart O) and construction (e.g., Subparts I and

N) standards for specific guarding requirements.

Many of these standards address preventive meth-

ods (such as using barrier guards or two-hand trip-

ping devices) as primary control measures; while

other OSHA standards allow guarding techniques

(such as a self-adjustable table saw guard) that

reduce the likelihood of injury. Other less protective

safeguarding methods (such as safe work methods)

that do not satisfactorily protect employees from

the machine hazard areas are considered second-

ary control methods.

Machine safeguarding must be supplemented

by an effective energy control (lockout/tagout)

program that ensures that employees are protected

from hazardous energy sources during machine

servicing and maintenance work activities.

Lockout/tagout plays an essential role in the pre-

vention and control of workplace amputations. In

terms of controlling amputation hazards, employ-

ees are protected from hazardous machine work

activities either by: 1) effective machine safeguard-

ing, or 2) lockout/tagout where safeguards are ren-

dered ineffective or do not protect employees from

hazardous energy during servicing and mainte-

nance operations.

Additionally, there are some servicing activities,

such as lubricating, cleaning, releasing jams and

making machine adjustments that are minor in

nature and are performed during normal produc-

tion operations. It is not necessary to lockout/

tagout a machine if the activity is routine, repetitive

and integral to the production operation provided

that you use an alternative control method that

affords effective protection from the machine’s

hazardous energy sources.

Safeguarding Machinery

The employer is responsible for safeguarding

machines and should consider this need when pur-

chasing machinery. Almost all new machinery is

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 9

available with safeguards installed by the manufac-

turer, but used equipment may not be.

If machinery has no safeguards, you may be

able to purchase safeguards from the original

machine manufacturer or from an after-market

manufacturer. You can also build and install the

safeguards in-house. Safeguarding equipment

should be designed and installed only by technical-

ly qualified professionals. If possible, the original

equipment manufacturer should review the safe-

guard design to ensure that it will protect employ-

ees without interfering with the operation of the

machine or creating additional hazards.

Regardless of the source of safeguards, the

guards and devices used need to 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 as a guarding method that interferes with the

operation of the machine may cause employees to

override them. To ensure effective and safe operator

use, guards and devices should suit the operation.

The Performance Criteria for Safeguarding

[ANSI B11.19-2003] national consensus standard

provides valuable guidance as the standard

addresses the design, construction, installation,

operation and maintenance of the safeguarding

used to protect employees from machine hazards.

The following safeguarding method descriptions

are, in part, structured like and, in many ways are

similar to this national consensus standard.

The Performance Criteria for Safeguarding [ANSI

B11.19-2003] defines safeguarding as the protec-

tion of personnel from hazards by the use of

guards, safeguarding devices awareness devices,

safeguarding methods, or safe work procedures.

The following ANSI B11.19 definitions describe

the various types of safeguarding:

Guard: A barrier that prevents exposure to an

identified hazard.

Safeguarding device: A device that detects or

prevents inadvertent access to a hazard.

NOTE: The 1990 ANSI B11.19 term Safeguarding

device was modified to Safeguarding (Protective)

Device in the revised 2003 ANSI standard and the

new term includes a detection component. De-

vices that detect, but do not prevent employee

exposure to machine hazards are not considered

by OSHA to be primary safeguarding methods.

Awareness device: A barrier, signal or sign that

warns individuals of an impending, approaching

or present hazard.

Safeguarding method: Safeguarding implement-

ed to protect individuals from hazards by the

physical arrangement of distance, holding, open-

ings, or positioning of the machine or machine

production system to ensure that the operator

cannot reach the hazard.

Safe work procedures: Formal written instruc-

tions developed by the user which describe how

a task is to be performed.

Primary Safeguarding Methods

Two primary methods are used to safeguard

machines: guards and some types of safeguarding

devices. Guards provide physical barriers that pre-

vent access to danger areas. Safeguarding devices

either prevent or detect operator contact with the

point of operation or stop potentially hazardous

machine motion if any part of an individual’s body

is within the hazardous portion of the machine.

Both types of safeguards need to be properly

designed, constructed, installed, used and main-

tained in good operating condition to ensure

employee protection.

Criteria for Machine Safeguarding

• Prevents employee contact with the hazard

area during machine operation.

• Avoids creating additional hazards.

• Is secure, tamper-resistant, and durable.

• Avoids interfering with normal operation of

the machine.

• Allows for safe lubrication and maintenance.

Guards

Guards usually are preferable to other control

methods because they are physical barriers that

enclose dangerous machine parts and prevent

employee contact with them. To be effective,

guards must be strong and fastened by any secure

method that prevents the guard from being inad-

vertently dislodged or removed. Guards typically

are designed with screws, bolts and lock fasteners

and usually a tool is necessary to unfasten and

Occupational Safety and

Health Administration

remove them. Generally, guards are designed not

to obstruct the operator’s view or to prevent

employees from doing a job.

In some cases, guarding may be used as an

alternative to lockout/tagout because employees

can safely service or maintain machines with a

guard in place. For example, polycarbonate and

wire-mesh guards provide greater visibility and can

be used to allow maintenance employees to safely

observe system components. In other instances,

employees may safely access machine areas, with-

out locking or tagging out, to perform maintenance

work (such as machine cleaning or oiling tasks)

because the hazardous machine components

remain effectively guarded.

Guards must not create additional hazards such

as pinch points or shear points between guards

and other machine parts. Guard openings should

be small enough to prevent employees 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 an Adjustable Barrier Guard

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 11

Figure 11 Self-Adjusting Guard on a Radial Saw

Figure 12 Interlocked Guard on a Roll Make-up Machine

Transparent Insert

Entering

Stock

Exiting

Stock

Bar

Guard

Handle

Anti-

Kickback

Device

Blade

Switch Guard

Occupational Safety and

Health Administration

Type

Fixed

Adjustable

Self-

Adjusting

Interlocking

Barrier

Guards

Method of

Safeguarding

Barrier that allows for

stock feeding but does not

permit operator to reach

the danger area.

Barrier that adjusts for

a variety of production

operations.

Barrier that moves

according to the size of the

stock entering point of

operation. Guard is in place

when machine is at rest

and pushes away when

stock enters the point of

operation.

Shuts off or disengages

power and prevents

machine start-up when

guard is open. Should

allow for inching of

machine.

Advantages

• Can be constructed to suit

many applications.

• Permanently encloses

the point of operation or

hazard area.

• Provides protection

against machine repeat.

• Allows simple, in-plant

construction, with mini-

mal maintenance.

• Can be constructed to

suit many applications.

• Can be adjusted to admit

varying stock sizes.

• Off-the-shelf guards are

often commercially avail-

able.

• Allows access for some

minor servicing work, in

accordance with the lock-

out/tagout exception,

without time-consuming

removal of fixed guards.

Limitations

• Sometimes not practical

for changing production

runs involving different

size stock or feeding

methods.

• Machine adjustment and

repair often require guard

removal.

• Other means of protecting

maintenance personnel

often required

(lockout/tagout).

• May require frequent

maintenance or

adjustment.

• Operator may make

guard ineffective.

• Does not provide

maximum protection.

• May require frequent

maintenance and

adjustment.

• May require periodic

maintenance or adjust-

ment.

• Movable sections cannot

be used for manual feed-

ing.

• Some designs may be

easy to defeat.

• Interlock control circuitry

may not be used for all

maintenance and servic-

ing work.

Table 1. Commonly Used Machine Guards

Types of Machine Guards

Safeguarding Devices

Safeguarding devices are controls or attachments

that, when properly designed, applied and used,

usually prevent inadvertent access by employees to

hazardous machine areas by:

• Preventing hazardous machine component oper-

ation if your hand or body part is inadvertently

placed in the danger area;

• Restraining or withdrawing your hands from the

danger area during machine operation;

• Requiring the use of both of your hands on

machine controls (or the use of one hand if the

control is mounted at a safe distance from the

danger area) that are mounted at a predeter-

mined safety distance; or

• Providing a barrier which is synchronized with

the operating cycle in order to prevent entry to

the danger area during the hazardous part of the

cycle.

These types of engineering controls, which

either prevent the start of or stop hazardous

motion, may be used in place of guards or as

supplemental control measures when guards alone

do not adequately enclose the hazard. In order for

these safeguarding devices to accomplish this

requirement, they must be properly designed and

installed at a predetermined safe distance from the

machine’s danger area. Other safeguarding devices

(probe detection and safety edge devices) that

merely detect, instead of prevent, inadvertent

access to a hazard are not considered primary safe-

guards. (See Table 2 and Figures 13 through 17 for

the types of safeguarding devices.)

Figure 13 Pullback Device on a Power Press

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 13

Pullback

Mechanism

Pullback

Straps

Wristbands

Type

Pullback

Devices

Method of

Safeguarding

Cords connected to

operator’s wrists and

linked mechanically to

the machine automatically

withdraw the hands from

the point of operation

during the machine cycle.

Advantages

• Allows the hands to enter

the point of operation for

feeding and removal.

• Provides protection even

in the event of mechani-

cal repeat.

Limitations

• Close supervision ensures

proper use and adjust-

ment. Must be inspected

prior to each operator

change or machine set-up.

• Limits operator’s move-

ment and may obstruct

their work space.

• Operator may easily make

device ineffective by not

adjusting the device

properly.

Table 2. Types of Safeguarding Devices

Types of Machine Guards

Occupational Safety and

Health Administration

Type

Restraint

Devices

Presence-

Sensing

Devices

Presence-

Sensing

Mats

Method of

Safeguarding

Wrists are connected by

cords and secured to a

fixed anchor point which

limit operator’s hands from

reaching the point of oper-

ation at any time.

Interlock into the machine’s

control system to stop

operation when the sens-

ing field (photoelectric,

radio frequency, or electro-

magnetic) is disturbed.

Interlock into machine’s

control system to stop

operation when a predeter-

mined weight is applied to

the mat. A manual reset

switch must be located out-

side the protected zone.

Advantages

• Simple, few moving

parts; requires little

maintenance.

• Operator cannot reach

into the danger area.

• Little risk of mechanical

failure; provides protec-

tion even in the event of

mechanical repeat.

• Adjusts to fit different

stock sizes.

• Allows access to load

and unload the machine.

• Allows access to the

guarded area for main-

tenance and set-up

activities.

• Full visibility and access

to the work area.

• Install as a perimeter

guard or over an entire

area.

• Configure for many

applications.

Limitations

• Close supervision re-

quired to ensure proper

use and adjustment.

Must be inspected prior

to each operator change

or machine set-up.

• Operator must use hand

tools to enter the point of

operation.

• Limits the movement of

the operator; may

obstruct work space

around operator.

• Operator may easily make

device ineffective by dis-

connecting the device.

• Restricted to machines

that stop operating cycle

before operator can reach

into danger area (e.g.,

machines with partial

revolution clutches or

hydraulic machines).

• Must be carefully main-

tained and adjusted.

• Does not protect

operator in the event

of a mechanical failure.

• Operator may make

device ineffective.

• Restricted to machines

that stop operating cycle

before operator can reach

into danger area (e.g.,

machines with part-

revolution clutches or

hydraulic machines).

• Some chemicals can

degrade the mats.

• Does not protect

operator during

mechanical failures.

Table 2. Types of Safeguarding Devices (continued)

Types of Machine Guards

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 15

Type

Two-

Hand

Control

Two-

Hand Trip

Type “A”

Gate

(move-

able

barrier)

Type “B”

Gate

(move-

able

barrier)

Method of

Safeguarding

Requires concurrent and

continued use of both

hands, preventing them

from entering the danger

area.

Requires concurrent use of

both hands, prevents them

from being in danger area

when machine cycle starts.

Applicable to mechanical

power presses. Provides

barrier between danger

area and operator (or other

employees) until comple-

tion of machine cycle.

Applicable to mechanical

power presses and press

brakes. Provides a barrier

between danger area and

operator (or other employ-

ees) during the down-

stroke.

Advantages

• Operator’s hands are at

a predetermined safety

distance.

• Operator’s hands are free

to pick up new parts after

completion of first part of

cycle.

• Operator’s hands are at

a predetermined safety

distance.

• Can be adapted to

multiple operations.

• No obstruction to hand

feeding.

• Prevents operator from

reaching into danger area

during machine cycle.

• Provides protection from

machine repeat.

• May increase production

by allowing the operator

to remove and feed the

press on the upstroke.

Limitations

• Requires a partial cycle

machine with a brake

and anti-repeat feature.

• Operator may make

devices without anti-

tiedown ineffective.

• Protects the operator

only.

• Operator may make

devices without anti-

tiedown ineffective.

• Protects the operator

only.

• Sometimes impractical

because distance require-

ments may reduce pro-

duction below acceptable

level.

• May require adjustment

with tooling changes.

• Requires anti-repeat

feature.

• May require frequent

inspection and regular

maintenance.

• May interfere with opera-

tor’s ability to see work.

• Can only be used on

machines with a part-

revolution clutch or

hydraulic machines.

• May require frequent

inspection and regular

maintenance.

• May interfere with the

operator’s ability to see

work.

Table 2. Types of Safeguarding Devices (continued)

Types of Machine Guards

Figure 17 Power Press with a Gate

Secondary Safeguarding Methods

Other safeguarding methods, such as those described

in the Performance Criteria for Safeguarding (ANSI

B11.19-2003), may also provide employees with

some protection from machine hazards. Detection

safeguarding devices, awareness devices, safe-

guarding methods and safe work procedures are

described in this section. These methods provide a

lesser degree of employee protection than the pri-

mary safeguarding methods and they are consid-

ered secondary control measures as they do not

prevent employees from placing or having any part

of their bodies in the hazardous machine areas.

Secondary safeguarding methods are accept-

able only when guards or safeguarding devices

(that prevent you from being exposed to machine

hazards) cannot be installed due to reasons of

infeasibility. Where it is feasible to use primary

safeguarding methods, secondary safeguarding

methods may supplement these primary control

measures; however, these secondary safeguarding

methods must not be used in place of primary safe-

guarding methods.

Probe Detection and Safety Edge Devices

A probe detection device (sometimes referred to as

a ring guard) detects the presence or absence of a

person’s hand or finger by encircling all or part of

the machine hazard area. The ring guard makes

you aware of your hand’s entry into a hazardous

area and usually stops or prevents a hazardous

machine cycle or stroke, thereby reducing the likeli-

hood of injuring yourself in the point of operation.

These types of detection devices are commonly

used on spot welders, riveters, staplers and stack-

Figure 14 Restraint Device on a Power Press

Figure 15 Presence-Sensing Device on a Power Press

Figure 16 Two-Hand Control

Occupational Safety and

Health Administration

Emergency Stop

Press

Bed

Control

Box

Light

Curtain

Guarded

Foot Control

Key Selector Capable

of Being Supervised

Gate

Light Indicator

Emergency Stop

Top Stop

Safe Distance Safeguarding

Safeguarding by safe distance (by location) may

involve an operator holding and supporting a work-

piece with both hands at a predetermined mini-

mum safe distance or, if both hands cannot be used

to hold the work-piece at a distance so that the

operator cannot reach the hazard with the free

hand. For example, the feeding process itself can

create a distance safeguard if the operators main-

tain a safe distance between their hands and the

point of operation. Additionally, where material

position gauges are used, they need to be of suffi-

cient height and size to prevent slipping of the

material past the gauges.

Another example of a safe distance safeguard-

ing method is the use of gravity feed methods that

reduce or eliminate employee exposure to machine

hazards as the part slides down a chute into the

point of operation. Automatic and semiautomatic

feeding and ejection methods can also protect the

employee by minimizing or eliminating employee

exposure with potentially hazardous machinery

components. An employee places the part in a

magazine which is then fed into the point of opera-

tion. Automatic and semiautomatic ejection methods

include pneumatic (jet of air), magnetic, mechanical

(such as an arm), or vacuum. Figures 18 and 19

illustrate different types of automatic feeding and

ejecting methods.

Figure 18 Power Press with a Plunger Feed

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 17

ers because primary safeguarding methods are not

possible. However, probe detection devices do not

prevent inadvertent access to the point-of-operation

danger area; rather, they serve as a warning mech-

anism and may prevent the initiation of or stop the

machine cycle if an employee’s hand or finger(s) is

too close to the hazard area.

A safety edge device (sometimes called a bump

switch) is another type of safeguard that detects the

presence of an employee when they are in contact

with the device’s sensing edge. A safety edge

device protects employees by initiating a stop com-

mand when the sensing surface detects the pres-

ence of a person; however, they do not usually,

when used by themselves, prevent inadvertent

access to machine danger areas. Therefore, addi-

tional guarding or safeguarding devices must be

provided to prevent employee exposure to a

machine hazard.

Awareness Devices

Awareness devices warn employees of an impend-

ing, approaching or present hazard. The first type

is an awareness barrier which allows access to

machine danger areas, but it is designed to contact

the employee, creating an awareness that he or she

is close to the danger point. Awareness signals,

through the use of recognizable audible or visual

signals, are other devices that alert employees to

an approaching or present hazard. Lastly, aware-

ness signs are used to notify employees of the

nature of the hazard and to provide instructions

and training information. OSHA standard 1910.145

provides design, application, and use specifications

for accident prevention (danger, caution, safety

instruction) signs and (danger, caution, warning)

tags.

Safeguarding Methods

Safeguarding methods protect employees from

hazards by the physical arrangement of distance,

holding, openings or the positioning of the

machine components to ensure that the operator

cannot reach the hazard. Some safeguarding work

methods include safe distance safeguarding, safe

holding safeguarding and safe opening safeguard-

ing. Requirements for these secondary control

measures may be found in ANSI B11.19-2003.

Proper training and supervision are essential to

ensure that these secondary safeguarding methods

are being used properly. Safeguarding work meth-

ods may require the use of awareness devices,

including the use of accident prevention signs where

there is a need for warning or safety instruction.

Plunger Plunger

Handle

Point of

Operation

Guard

Nest

Figure 19 Shuttle Ejection Mechanism

Safe Holding Safeguarding (Safe Work-Piece

Safeguarding)

Operator’s hands are maintained away from the

hazardous portion of the machine cycle by requir-

ing that both hands are used to hold or support the

work-piece, or by requiring that one hand holds the

work-piece while the other hand operates the

machine. 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. The operator’s body

parts are out of the machine hazard area during the

hazardous portion of the machine cycle. However,

this work method only protects the operator.

Safe Opening Safeguarding

This method limits access to the machine haz-

ardous areas by the size of the opening or by clos-

ing off the danger zone access when the work-piece

is in place in the machine. Operators are prevented

from reaching the hazard area during the machine

operation; however, employee access to the danger

area is not adequately guarded when the work-

piece is not in place.

Safe Work Procedures

Safe work procedures are formal, written instruc-

tions which describe how a task is to be performed.

These procedures should incorporate appropriate

safe work practices, such as prohibiting employees

from wearing loose clothing or jewelry and requir-

ing the securing of long hair with nets or caps.

Clothing, jewelry, long hair, and even gloves can get

entangled in moving machine parts.

Complementary Equipment

Complementary equipment is used in conjunction

with selected safeguarding techniques and it is, by

itself, not a safeguarding method. Some common

complementary equipment used to augment

machine safeguarding include:

Occupational Safety and

Health Administration

Emergency Stop Devices

Emergency stop devices are designed to be used

in reaction to an incident or hazardous situation

and, as such, are not considered machine safe-

guarding. These devices, such as buttons, rope-

pulls, cable-pulls, or pressure-sensitive body bars,

neither detect nor prevent employee exposure to

machine hazards; rather they initiate an action to

stop hazardous motion when an employee recog-

nizes a hazard and activates them. (See Figure 20.)

Figure 20 Safety Tripod on a Rubber Mill

Work-Holding Equipment

Work-holding equipment is not used to feed or re-

move the work-piece, but rather to hold it in place

during the hazardous portion of the machine cycle.

Clamps, jigs, fixtures and back gauges are exam-

ples of work-holding equipment. This equipment

may be used to reduce or eliminate the need for an

employee to place their hands in the hazard area.

Feeding and Ejection Systems

A feeding and ejection system (e.g., a gravity fed

chute; semi-automatic and automatic feeding and

ejection equipment), by itself, does not constitute

secondary safeguarding. However, the use of prop-

erly designed feed and ejection mechanisms can

protect employees by minimizing or eliminating the

need for them to be in a hazard area during the

hazardous motion of the machine.

Hand-Feeding Tools

Operators can use tools to feed and remove materi-

al into and from machines so as to keep their

hands away from the point of operation. However,

this must be done only in conjunction with the

guards and safeguarding devices described previ-

ously. Hand tools are not point-of-operation guard-

Slide in

Down

Position

Slide in

Position

Point of

Operation

Guard

Completed

Part

Chute

Pan

Shuttle

Feeding

Tool

Stock

Tripod

ing or safeguarding devices and they need to be

designed to allow employees’ hands to remain out-

side of the machine danger area. Using hand tools

requires close supervision to ensure that the opera-

tor does not bypass their use to increase produc-

tion. It is recommended that these tools be stored

near the operation to promote their use.

To prevent injury and repetitive trauma disor-

ders, hand-feeding tools should be shatterproof

and ergonomically designed for the specific task

being performed. (Figure 21 shows typical hand-

feeding tools.)

Figure 21 Typical Hand-Feeding Tools

Foot Controls

Foot controls that are not securely fixed at a safe

distance do not constitute machine safeguarding

because they do not keep the operator’s hands out

of the danger area. If you use foot-actuated con-

trols that are not single-control safeguarding

devices, they will need to be used with some type

of guard or other safeguarding device.

Improperly used foot-actuated controls may

increase productivity, but the freedom of hand

movement increases the risk of a point-of-operation

injury or amputation. Foot controls must be guard-

ed to prevent accidental activation by another

employee or by falling material. Do not ride the

foot pedal. Ensure that the machine control circuit

is properly designed to prevent continuous cycling.

(See Figure 22 for an example of a properly guard-

ed foot control.)

Figure 22

Properly Guarded

Foot Control

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 19

Administrative Issues

As an employer, you need to consider housekeep-

ing practices, employee apparel, and employee

training. Implement good housekeeping practices

to promote safe working conditions around ma-

chinery 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 employee distraction.

Employees should not wear loose-fitting cloth-

ing, jewelry, or other items that could become

entangled in machinery, and long hair should be

worn under a cap or otherwise contained to pre-

vent entanglement in moving machinery.

Adequate instruction in the safe use and care of

machines and supervised on-the-job training are

essential in preventing amputation injuries. Only

trained employees should operate machinery.

Train Employees in the Following:

• All hazards in the work area, including

machine-specific hazards;

• Machine operating procedures, lockout/tagout

procedures and safe work practices;

• The purpose and proper use of machine safe-

guards; and

• All procedures for responding to safeguarding

problems such as immediately reporting un-

safe conditions such as missing or damaged

guards and violations of safe operating prac-

tices to supervisors.

In addition to employee instruction and training,

employers need to provide adequate supervision

to reinforce safe practices. Take disciplinary ac-

tion to enforce safe work practices and working

conditions.

Inspection and Maintenance

Good inspection, maintenance and repair proce-

dures contribute significantly to the safety of the

maintenance crew as well as to the operators. To

ensure the integrity of the machinery and machine

safeguards, a proactive, versus a break-down main-

Specific Machine Hazards

and Safeguarding Methods

As discussed earlier, 8,450 known non-fatal ampu-

tation cases (involving days away from work)

occurred in 2005 for all of private industry. The

most prevalent injury source was, by far, machin-

ery, which accounted for approximately 60% (5,080

instances) of the amputation cases.1The machinery

listed here cause amputation injuries, and appropri-

ate safeguarding and hazardous energy control

(lockout/tagout) methods are addressed in this sec-

tion. Employers need to consult the OSHA standard

for specific machinery to ensure compliance with

all requirements. For other types of hazardous

sources of injury, see Appendix B.

Machinery Associated with Amputations

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

Hazards of Mechanical Power Presses

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 – to punch, shear or form – the work-

piece, the desired piece is produced. Once the

downstroke is completed, the re-formed work-piece

Occupational Safety and

Health Administration

tenance program needs to be established based

upon the:

• Manufacturer’s recommendations;

• Good engineering practice; and

• Any applicable OSHA provisions (such as the

mechanical power press inspection and mainte-

nance requirements, contained in 1910.217(e)).

Lockout/Tagout

OSHA’s lockout/tagout (LOTO) standard, 29 CFR

1910.147, establishes minimum performance re-

quirements for controlling hazardous energy and it

is intended to complement and augment machine

safeguarding practices. The lockout/tagout standard

applies only if employees are exposed to hazard-

ous energy during servicing/maintenance activities.

An employer may avoid the requirements of the

LOTO standard if the safeguarding method elimi-

nates your employees’ exposure to the machine

danger area during the servicing or maintenance

work by using Machinery and Machine Guarding

methods in accordance with the requirements con-

tained in 29 CFR 1910, Subpart O.

Additionally, because some minor servicing may

have to be performed during normal production

operations, an employer may be exempt from

LOTO in some instances. Minor tool changes and

adjustments and other minor servicing operations,

which take place during normal production opera-

tions, are not covered by lockout/tagout if they are

routine, repetitive and integral to the use of the

machine for production and if work is performed

using alternative effective protective measures that

provide effective employee protection.

In short, a hazardous energy control program is

a critical part of an overall strategy to prevent

workplace amputations during machine servicing

and maintenance activities, such as during the set-

ting up of machines for production purposes, by-

passing guards to clear jams or lubricate parts, and

inspecting, adjusting, replacing, or otherwise serv-

icing machine parts. Machine amputations occur

when an employer does not have or fails to imple-

ment practices and procedures to disable and con-

trol a machine’s energy sources during machine

servicing and maintenance work.

1U.S. Department of Labor, Bureau of Labor Statistics

(BLS); Annual Survey data, Table R25. Number of non-

fatal occupational injuries or illnesses involving days

away from work by source of injury or illness and select-

ed natures of injury or illness, 2005.

is removed either automatically or manually, a new

work-piece is fed into the die, and the process is

repeated. (See Figure 23.)

Figure 23 Part Revolution Mechanical Power Press with

a Two-Hand Control

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 guard-

ing that can be used.

Full-revolution clutches, once activated, com-

plete a full cycle of the slide (lowering and rais-

ing of the slide) before stopping at dead center

and cannot be disengaged until the cycle is com-

plete. So, presence-sensing devices will not

work and operators must be protected during

the entire press operating cycle. For example,

properly applied barrier guards or two-hand

trip devices that are installed at a safe distance

from the hazard area may be used.

Machines incorporating full-revolution

clutches, such as mechanical power presses,

must also incorporate a single-stroke device and

anti-repeat feature.

The majority of part-revolution presses are

air clutch and brake. They are designed to trap

air in a chamber or tube. When the compressed

air is put into these chambers, the clutch is

engaged, the brake disengaged and the press

makes a single stroke. To stop the press, the

reverse takes place. Thus, the part-revolution

clutch can be disengaged at any time during the

cycle to stop the cycle before it completes the

downstroke.

For safeguarding purposes, part-revolution

mechanical power presses can be equipped with

presence-sensing devices, but full-revolution

mechanical power presses cannot.

NOTE: Likewise, most hydraulic power presses

and their associated control systems are similar to

part-revolution mechanical power presses in that

the slide can be stopped at any point in the cycle.

In order to ensure the integrity of the safety-related

functions, safeguarding devices (such as presence-

sensing devices) may only be used on hydraulic

power presses that are properly designed and con-

structed (in accordance with good engineering

practice) to accommodate the safeguarding system.

Refer to OSHA’s Machine Guarding eTool for addi-

tional information on hydraulic presses.

Amputations occurring from the point of opera-

tion hazards are the most common types of injuries

associated with mechanical power presses.

Improperly applied safeguarding methods (such as

using a guard with more than maximum allowable

openings or 2-hand palm buttons that are mounted

within the safety distance of the press) may allow

operators unsafe access to the press’s hazardous

area. These unsafe conditions may result in an

amputation when an operator, for example, instinc-

tively reaches into the point of operation to adjust a

misaligned part or release a jam. Also, amputations

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 usually happen while the operator is riding

the foot pedal. Additionally, some amputations are

linked to mechanical (such as the failure of a single-

stroke linkage), electrical (such as a control relay fail-

ure), or pneumatic (such as the loss of air pressure

to the clutch/brake) machine component failure.

Examples of inadequate or ineffective safe-

guarding and hazardous energy control practices

include the following:

• Guards and devices disabled to increase produc-

tion, 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 improp-

erly adjusted.

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 21

Control

Box

Control

Box

Light

Curtain

• Controls of a single-operator press bypassed by

having a coworker activate the controls while

the operator positions or aligns parts in the die,

or repairs or troubleshoots the press.

• Failure to properly disable, isolate press energy

sources, and lockout/tagout presses before an

employee performs servicing or maintenance

work.

Case History #1

While using an unguarded, foot-pedal-operated,

full-revolution mechanical power press that

made trip collars for wood stoves, an employee

used his hands to feed and remove finished parts

and scrap metal. He placed the completed part to

the left side of the press, and then turned to

place the scrap in the bin behind him. As he

turned back to face the press, he inadvertently

stepped on the foot pedal and activated the press

while his hand was in the die area. His left hand

was amputated at the wrist.

Case History #2

An employee was operating an unguarded 10-

ton, full-revolution mechanical power press to

stamp mailbox parts, and using a hand tool to

load the press, she placed her left hand in the

lower die to reposition a misaligned part. At the

same time, she inadvertently depressed the foot

pedal, activating the press and crushing her left

index finger.

Case History #3

A power press operator and helper were instruc-

ted to temporarily halt production and each

employee decided to perform servicing tasks.

The operator had a problem with a hydraulic

fluid leak and decided to deflect the liquid spray

by installing a temporary barrier while, at the

same time, the helper decided to clean up the

metal chips from the press area. The operator

then activated the press and repositioned the

press slide in order to install the cardboard barri-

er. This mechanical power press action fatally

crushed the helper’s head because his head was

between the dies while he was in the process of

cleaning up the metal chips.

Source: OSHA IMIS Accident Investigation Database.

Safeguarding Mechanical Power Presses

Mechanical power presses are extremely versatile

and selecting appropriate safeguarding methods

depends on the specific press design and use. You

should consider the press, the type of clutch used,

Occupational Safety and

Health Administration

the stock size, the length of production runs, and

the method of feeding.

You can use primary safeguarding methods,

such as guards or safeguarding devices, to prevent

injuries. For example, 29 CFR 1910.217 requires

employers to provide and ensure the use of point

of operation guards or properly installed devices on

every operation performed on a press when the die

opening is greater than 1/4inch.

In addition, guards must conform to the maxi-

mum permissible openings of Table O-10 of 29 CFR

1910.217. Guards must prevent entry of hands or

fingers into the point of operation through, over,

under, or around the guard.

Mechanical Power Press Safeguarding

Methods by Clutch Type

Full-Revolution Clutch Part-Revolution Clutch

Point of Operation Guard Point of Operation Guard

Pullback Pullback

Restraint Restraint

Type A Gate Type A Gate

Two-Hand Trip Type B Gate*

Two-Hand Control*

Presence-Sensing Device*

*”Hands-in-Die” operations require additional safe-

guarding measures: See 1910.217(c)(5).

Mechanical power press point of operation safe-

guards must accomplish the following goals:

• Prevent or stop the normal press stroke if the

operator’s hands are in the point of operation;

• 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 clos-

es; 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 dis-

tance 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 stoppage of the slide motion during the

downward stroke.

Source: 29 CFR 1910.217(c)(3)(i).

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). Em-

ployers 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.

• 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 (or a single

control mounted at a safe distance from the

machine hazards) to gradually inch the press

through a stroke when the dies are being tested

on part-revolution clutch presses.

• Observe energy control procedures and prac-

tices for press servicing and maintenance work.

For example, the changing of dies on a mechan-

ical power press requires the employer to estab-

lish a die-setting procedure that employs point-

of-operation safeguarding method(s) such as the

safe usage of an inch or jog safety device for die

set-up purposes together with LOTO. These

devices safely position the mechanical power

press slide utilizing a point-of-operation safe-

guarding technique. Thus, an energy control

procedure for these types of presses would

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 23

“No Hands-in-Die” Policy

In general, a “no-hands-in-die” policy needs to

be implemented and followed whenever possible

– that is, in the event the press is not designed

for “hands-in-die” production work. Under this

policy, operators must never place their hands in

the die area (point-of-operation) while perform-

ing normal production operations. Adherence to

this safety practice will reduce the risk of point of

operation amputations.

In terms of part-revolution mechanical power

presses that use a two-hand control, presence-

sensing device or type B gate, OSHA does allow

“hands-in-die” operation if the press control reli-

ability and brake monitoring system require-

ments are met. If these press design safety fea-

tures are not complied with, then employers

must incorporate a “no-hands-in-die” policy.

Source: 29 CFR 1910.217(c)(5).

Other Controls for Mechanical Power

Press Servicing and Maintenance

Secondary safeguarding methods may be used

alone or in combination (to achieve near equivalent

protection) only when the employer can show that

it is impossible to use any of the primary safe-

guarding methods. The following are some work

practices, complementary equipment and energy

control measures that may be used to supplement

primary safeguarding:

• If employees operate presses under a “no-

hands-in-die” policy using complementary feed-

ing methods such as hand-tool feeding, employ-

ers still must protect operators through the use

of primary safeguarding methods, such as a

properly applied two-hand control or trip safe-

guarding device. 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.)

Ram Up-Die Open

Ram Descending-Die Closing

need to integrate both point-of-operation safe-

guarding method(s) for slide positioning as well

as LOTO procedures for the die setting opera-

tion.

Additional power press energy control precau-

tions (e.g., use of safety blocks; LOTO the press dis-

connect switch if re-energization presents a hazard)

will be necessary if employees need to place their

hands/arms in a press working area (the space

between the bolster plate and the ram/slide) to

perform the servicing and/or maintenance activity

(such as adjusting, cleaning or repairing dies) be-

cause the inch or jog safety device will not protect

employees from ram movement due to potential

mechanical energy (resulting from the ram/slide

position and associated gravitational force), press

component or control system malfunction, or press

activation by others.

Minor Servicing

At times, OSHA recognizes that some minor

servicing may have to be performed during nor-

mal production operations, so a lockout/tagout

exception is allowed. See the 29 CFR 1910.147(a)

(2)(ii) Note for details. For example, a press oper-

ator may need to perform a minor die cleaning

task on a regular basis for product quality pur-

poses and the use of safety blocks – inserted

between the press dies – that are interlocked with

the press electrical controls would constitute

effective protection. Properly designed and

applied safety block interlocks may be used in

lieu of locking or tagging out the press’s electrical

energy source for purposes of the minor servic-

ing exception.

Source: 29 CFR 1910.147(a)(2)(ii) Note.

Training

Training is essential for employee protection. As an

employer, you should:

• Train operators in safe mechanical press opera-

tion and hazardous energy control (lockout/

tagout) procedures and techniques before they

begin work on the press.

• Supervise operators to ensure that correct pro-

cedures and techniques are being followed.

Additional Requirements

In addition, work practices such as regular mechan-

ical power press inspection, maintenance, and

reporting are essential.

• 29 CFR 1910.217(e)(1)(i) requires a program of

periodic and regular inspections of mechanical

power presses to ensure that all of the press

parts, auxiliary equipment and safeguards are

in safe operating condition and adjustment.

Inspection certification records must be main-

tained.

• 29 CFR 1910.217(e)(1)(ii) requires you to inspect

and test the condition of the clutch/brake mech-

anism, anti-repeat feature, and single-stroke

mechanism on at least a weekly basis for press-

es without control reliability and brake system

monitoring. Certification records must be main-

tained of these inspections and the maintenance

performed.

• 29 CFR 1910.217(g)(1) requires the reporting of

all point of operation injuries to operators or

other employees within 30 days to either the

Director of the Directorate of Standards and

Guidance, OSHA, U.S. Department of Labor,

Washington, DC 20210, or the state agency

administering a plan approved by OSHA. You

can also use the Internet to report injuries (www.

osha.gov/pls/powerpress/mechanical.html).

Applicable Standards

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout).

• 29 CFR 1910.217, Mechanical power presses.

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus.

Sources of Additional Information

• OSHA Instruction CPL 3-00-002 [CPL 2-1.35],

National Emphasis Program on Amputations

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• NIOSH CIB 49, Injuries and Amputations

Resulting From Work with Mechanical Power

Presses (May 22, 1987)

• OSHA Instruction STD 01-12-021 [STD 1-

12.21]—29 CFR 1910.217, Mechanical Power

Presses, Clarifications (10/30/78)

• ANSI B11.1-2001, Safety Requirements for

Mechanical Power Presses

Occupational Safety and

Health Administration

Power Press Brakes

Power press brakes are similar to mechanical

power presses in that they use vertical reciprocat-

ing motion and are used for repetitive tasks. Press

brake operation is either mechanical or hydraulic.

Press brakes are either general-purpose or spe-

cial-purpose brakes, according to ANSI B11.3-2002,

Safety Requirements for Power Press Brakes.

General purpose press brakes have a single opera-

tor control station. A servo-system activates the

special purpose brake, which may be equipped

with multiple operator/helper control stations. (See

Figure 25 for a power press brake operation.)

Figure 25 Power Press Brake Bending Metal

Hazards of Power Press Brakes

As with mechanical power presses, point of opera-

tion injuries are the most common type of injury

associated with power press brakes. Here are some

frequent causes of amputations from power press

brakes:

• 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 opera-

tor’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

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 25

the operator positions or aligns stock or repairs

or troubleshoots the press.

• Failure to properly lockout/tagout presses during

the necessary tasks of making adjustments,

clearing jams, performing maintenance,

installing or aligning dies, or cleaning the

machine.

Case History #4

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 opera-

tor placed his fingers close to the point of opera-

tion, but was told that nothing could be done and

that the operator should be careful.

Case History #5

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 fingertips.

Safeguarding Power Press Brakes

Primary safeguarding methods, such as physical

guards and point of operation safeguarding devices

(movable barrier devices, presence-sensing de-

vices, pull-back devices, restraint devices, single-

and two-hand devices) can be used to effectively

guard power press brakes. (Figure 26 shows a gen-

eral-purpose power press brake used in conjunc-

tion with pullbacks.) Some safeguarding methods,

such as presence-sensing devices, may require

muting or blanking to allow the bending of materi-

al. Always ensure that these safety devices are

properly installed, maintained, and used in accor-

dance with the manufacturer’s guidelines for the

specific stock and task to be performed. Failure to

do so could leave sensing field channels "blanked

out" and expose operators to point-of-operation

hazards as the safeguarding device’s safety dis-

tance increases when blanking is used.

Press Bed

Point of Operation

Figure 26 Two-Person Power Press Brake Operation

with Pullbacks

In other instances, such as with special-purpose

power press brakes, machines 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. For example, two-hand down,

foot through (actuation) methods are used to safe-

guard employees while they operate press brakes.

With this safeguarding system, an operator uses a

two-hand control to lower the press brake ram, for

example, to within 1/4inch or less of the lower die

(which is considered a safe opening). The operator

then has the ability to maneuver and align the

work-piece within this 1/4inch safe opening area

and he or she is protected from the amputation

hazard. Then the foot control is used by the opera-

tor to safely actuate the machine to produce the

desired product.

Because of constraints imposed by certain man-

ufacturing or fabricating processes, safeguarding

by maintaining a safe distance from the point of

operation may be acceptable. However, this is per-

mitted only when safeguarding by barrier guard

or safeguarding devices is not feasible (impossi-

ble) – that is, where the use of primary safeguard-

ing method (such as a restraint device) is not fea-

sible. Additional information about a safe distance

safeguarding program can be found in OSHA

Instruction 02-01-025 [CPL 2-1.25] – Guidelines for

Point of Operation Guarding of Power Press

Brakes.

Occupational Safety and

Health Administration

Other Controls for Power Press Brakes

The following are some secondary safeguarding

methods and complementary equipment that may

be used to supplement primary safeguarding or

alone or in combination when primary safeguard-

ing methods are not feasible:

• Safe distance safeguarding,

• Safe holding safeguarding,

• Safe work procedures,

• Work-holding equipment (such as back gauges),

• Properly designed and protected foot pedals,

and

• Hand-feeding tools.

Ensure that proper safeguarding and lockout/

tagout procedures are developed and implemented

for power press brakes. Train and supervise em-

ployees in these procedures and conduct periodic

inspections to ensure compliance.

Applicable Standards

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout).

• 29 CFR 1910.212, General requirements for all

machines.

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus.

Sources of Additional Information

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• OSHA Directive – CPL 02-01-025 [CPL 2-1.25],

Guidelines for Point of Operation Guarding of

Power Press Brakes

• ANSI B11.3-2002, Safety Requirements for

Power Press Brakes

Hazards of Conveyors

Conveyors are used in many industries to transport

materials horizontally, vertically, at an angle, or

around curves. Many conveyors have different and

unique features and uses, so that hazards vary due

Wristlets

Point of

Operation

Press Bed

to the material conveyed, the location of the con-

veyor, and the proximity of the conveyer to the

employees. Types include unpowered and pow-

ered, live roller, slat, chain, screw, and pneumatic.

Conveyors eliminate or reduce manual material

handling tasks, but they present amputation haz-

ards associated with mechanical motion. (See

Figures 27 through 30 for examples of common

conveyors.)

Conveyor-related injuries typically involve a

employee’s hands or fingers becoming caught in

nip points or shear points on conveyors and may

occur in these situations:

• 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 employee’s fingers or hands into the con-

veyor.

Other conveyor-related hazards include improp-

erly guarded gears, sprocket and chain drives, hori-

zontal and vertical shafting, belts and pulleys, and

power transmission couplings. Overhead convey-

ors warrant special attention because most of the

conveyor’s drive train is exposed. Employees have

also been injured or killed while working in areas

underneath conveyors and in areas around lubrica-

tion fittings, tension adjusters, and other equipment

with hazardous energy sources.

Case History #6

While removing a cleaning rag from the ingoing

nip point between the conveyor belt and its tail

pulley (the unpowered end of the conveyor), an

employee’s arm became caught in the pulley,

which amputated his arm below the elbow.

Case History #7

While servicing a chain-and-sprocket drive

assembly on a roof tile conveyor system, an

employee turned off the conveyor, removed the

guard, and began work on the drive assembly

without locking out the system. When someone

started the conveyor, the employee’s fingers

became caught in the chain-and-sprocket drive

and were amputated.

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 27

Figure 27 Belt Conveyor

Figure 28 Screw Conveyor

Figure 29 Chain Driven Live Roller Conveyor

Fixed Guard Over

Power-Transmission

Apparatus

Belt

In-Running Nip

Some guards and covers are not shown to facilitate

viewing of moving parts. Equipment must not be

operated without guards and covers in place.

Fixed Guard Over

Power-Transmission

Apparatus

In-Running

Nip Point

Fixed Guard

In-Running

Nip Point

Screw

Rotating Motion

Fixed Guard

In-Running

Nip Point

Chain

In-Running

Nip Point

Fixed Guard

Sprocket

Roller

Figure 30 Slat Conveyor

Safeguarding Conveyors

As conveyor hazards vary depending on the appli-

cation, employers need to look at each conveyor to

evaluate and determine what primary safeguarding

methods and energy control (lockout/tagout)

practices are required. Where necessary for the

protection of employees, conveyors need to have

mechanical guards that protect the employee from

nip points, shear points, and other moving parts,

including power-transmission apparatus. Guards

may include barriers, enclosures, grating, fences, or

other obstructions that prevent inadvertent physical

contact with operating machine components, such

as point of operation areas, belts, gears, sprockets,

chains, and other moving parts. A brief description

of the hazards and recognized safeguarding meth-

ods is presented for common types of conveyors.

Typical Conveyor Hazards and

Safeguarding Methods

Belt Conveyors

Hazards: Belt-conveyor drive mechanisms and

conveying mediums are hazardous as are the fol-

lowing belt-conveyor areas: 1) conveyor take-up

and discharge ends; 2) where the belt or chain

enters or exits the in-going nip point; 3) where

the belt wraps around pulleys; 4) snub rollers

where the belt changes direction, such as take-

ups; 5) where multiple conveyors are adjoined;

or 6) on transfers or deflectors used with belt

conveyors.

Controls: The hazards associated with nip and

shear points must be safeguarded. Side guards

(spill guards), if properly designed can prevent

employee contact with power-transmission com-

ponent, in-going nip points and the conveying

medium. Secondary safeguarding methods for

hazard control include the use of standard railings

or fencing, or safeguarding by distance (location),

and installing hazard awareness devices, such as

pre-start-up signals and warning signs.

Screw Conveyors

Hazards: Screw conveyors are troughs with a

revolving longitudinal shaft on which a spiral or

twisted plate is designed. In-going nip points, of

turning helical flights for the entire length of the

screw conveyor, exist between the revolving

shaft and trough. Since the trough is not usually

required to be covered for proper operation of

the conveyor and because many screw convey-

ors are located at or near the floor level, the haz-

ard of stepping into the danger area is ever pres-

ent. Once caught, the victim is pulled further into

the path of the conveying medium.

Controls: A screw conveyor housing must com-

pletely enclose the moving elements (screw

mechanism, power transmission apparatus) of

the conveyor, except for the loading and dis-

charge points. Permanently affixed grids or poly-

carbonate can be installed for visibility purposes

to allow the operator to inspect the operation.

Alternatively, the trough side walls should be

high enough to prevent employees from reach-

ing over and falling into the trough. Open

troughs can be used if covers are not feasible;

but employees need to be protected by second-

ary safeguarding methods, such as a railing or

fence.

Feed loading and discharge points can usually

be guarded by providing enclosures, screening,

grating, or some other interruption across the

openings which will allow the passage of the

material without allowing the entry of a part of

the employee’s body into the moving part(s).

Chain Conveyors

Hazards: Nip points occur when a chain contacts

a sprocket, such as when a chain runs around a

sprocket or when the chain is supported by a

sprocket or when a shoe above the chain pre-

cludes the chain from lifting off the sprocket. Nip

points also occur at drives, terminals, take-ups

(automatic take-ups may also have shear points),

and idlers. Employee clothing, jewelry, and long

hair may also get entangled and caught in the

moving chain conveyor.

Occupational Safety and

Health Administration

Fixed Guard Over

Power-Transmission

Apparatus

In-Running

Nip Point

Fixed Guard

Slats

Controls: Sometimes, moving chains cannot be

enclosed without impairing the functioning of the

conveyor. However, in some cases, barrier

guards may be installed around the moving parts

for hazard enclosure purposes or, in other in-

stances, nip and shear points may be eliminated

by placing a guard at the nip point or shear

point. Other secondary safeguarding options

include safeguarding by distance (location) and

the use of awareness devices.

Roller Conveyors

Hazards: Roller conveyors are used to move

material on a series of parallel rollers that are

either powered or gravity-fed. Powered roller

conveyors have the hazard of snagging and

pulling objects, including hands, hair, and cloth-

ing into the area between the rollers and the sta-

tionary components of the conveyor. In-going

nip points generally exist between the drive

chain and sprockets; between belt and carrier

rollers; and at terminals, drives, take-ups, idlers,

and snub rollers.

Controls: Roller conveyors need to, where feasi-

ble, have permanent barrier guards that can be

adjusted as necessary to protect the employee

from nip and shear points. For example, the

unused section of rollers closest to the employ-

ees needs to be guarded when transporting

small items on a roller conveyor that do not

require the use of the entire roller width. Also,

conveyor hazards may be reduced by eliminating

or minimizing projections from the roller and

through the use of pop-up rollers. Other second-

ary safeguarding options include safeguarding

by distance (location) and the use of awareness

devices.

Other Controls for Conveyors

The following are some secondary safeguarding

methods, work practices, and complementary

equipment that may be used to supplement pri-

mary safeguarding or alone or in combination

when primary safeguarding methods are not feasi-

ble:

• Safeguarding by safe distance (by location) —

locating moving parts away from employees to

prevent accidental contact with the hazard

point—is one option for safeguarding convey-

ors. It is particularly difficult, however, to use

this method when employees need to be at or

near unguarded moving parts.

• Use prominent awareness devices, such as

warning signs or lights, to alert employees to

the conveyor operation.

• Allow only trained individuals to operate con-

veyors and only trained, authorized staff to per-

form servicing and maintenance work.

• Visually inspect the entire conveyor and imme-

diate work area prior to start-up to determine

that the actuation will not cause an employee

hazard.

• Inspect and test conveyor safety mechanisms,

such as its alarms, emergency stops, and safe-

guarding methods.

• Do not use any conveyor which is unsafe until it

is made safe.

• Forbid employees from riding on conveyors.

• Prohibit employees working with or near con-

veyors from wearing loose clothing or jewelry,

and require them to secure long hair with a net

or cap.

• Install emergency stop devices on conveyors

where employees work when they cannot other-

wise control the movement of the conveyor.

This recognized safety feature provides employ-

ees with the means to shut off the equipment in

the event of a hazardous situation or emergency

incident.

For emergency stop devices, you will need these

engineering controls:

• Equip conveyors with interlocking devices that

shut them down during an electrical or mechani-

cal overload such as product jam or other stop-

page. Emergency devices need to be installed so

that they cannot be overridden from other loca-

tions.

• 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

employees.

• 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.

• Ensure that conveyor controls or power sources

can accept a lockout/tagout device to allow safe

maintenance practices.

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 29

Sources of Additional Information

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• ASME B20.1-2003, Safety Standard for

Conveyors and Related Equipment.

• ANSI/CEMA 350-2003, Screw Conveyors.

• ANSI/CEMA 401-2003, Unit Handling

Conveyors—Roller Conveyors—Non-powered.

• ANSI/CEMA 402-2003, Unit Handling

Conveyors—Belt Conveyors.

• ANSI/CEMA 403-2003, Unit Handling

Conveyors—Belt Driven Live Roller Conveyors.

• ANSI/CEMA 404-2003, Unit Handling

Conveyors—Chain Driven Live Roller

Conveyors.

• ANSI/CEMA 405-2003, Package Handling

Conveyors—Slat Conveyors

Hazards of Printing Presses

Printing presses vary by type and size, ranging

from relatively simple manual presses to the com-

plex 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 re-

quire rapid machine adjustments to avoid waste.

This section discusses amputation hazards asso-

ciated with two common types of printing presses:

web-fed and sheet-fed printing press systems.

Web-fed printing presses are fed by large continu-

ous 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 support-

ing 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.)

Occupational Safety and

Health Administration

• Perform servicing and maintenance under an

energy control program in accordance with the

Control of hazardous energy (lockout/tagout), 29

CFR 1910.147, standard. For example, instruct

employees to lubricate, align, service, and main-

tain conveyors when the conveyor is locked or

tagged out if the task would expose them to an

area of the conveyor (or adjacent machinery)

where hazardous energy exists.

Minor Servicing

At times, OSHA recognizes that some minor

servicing may have to be performed during nor-

mal production operations, so a lockout/tagout

exception is allowed. See the 29 CFR 1910.147(a)

(2)(ii) Note for details. An example of a common

conveyor minor servicing activity involves pack-

age jams where an employee must frequently

dislodge the jam. To prevent unexpected start-up

of the conveyor, employers may adopt alterna-

tive control measures, such as opening (placing

in the off position) local disconnects or control

switches to prevent conveyor start-up. These

properly applied devices, if used, must be

under the exclusive control of the employee per-

forming the jam release, so that no other person

can restart the conveyor without the knowledge

and consent of the person performing the servic-

ing work.

Source: 29 CFR 1910.147(a)(2)(ii) Note.

Applicable Standards

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout).

• 29 CFR 1910.212, General requirements for all

machines.

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus.

• 29 CFR 1910.269, Electric power generation,

transmission and distribution [as detailed in

section (v)(11)].

• 29 CFR 1926.555, Conveyors.

• ANSI B20.1-57, Safety Code for Conveyors,

Cableways, and Related Equipment – as incor-

porated by reference in 1910.218(j)(3),

1910.261(a)(3)(x), 1910.261(b)(1),

1910.261(c)(15)(iv), 1910.261(f)(4),

1910.261(j)(2), 1910.265(c)(18)(i)].

Figure 31 Roll-to-Roll Offset Printing Press

Figure 32 Sheet-Fed Offset Printing Press

As with other machines, printing press-related

amputations occur during servicing and mainte-

nance activities. For example, amputations occur

when employees get their fingers or hands caught

in the in-going nip points created between two

rollers while:

• Hand-feeding the leading edge of paper into the

in-running rollers during press set-up while the

machine is operating;

• Adjusting ink flow on a press;

• Cleaning ink off the press while it is operating;

• Attempting to free material from the rollers;

• Straightening misaligned sheets of paper in the

press;

• Jogging the printer and making adjustments to

the equipment (such as adjusting the nip wheel

on a sheeter);

• Using rags to clean machinery adjacent to un-

guarded rollers.

Source: OSHA IMIS Accident Investigation Database.

Case History #8

An employee was adding ink at the top of a

printing press when he spotted a small piece of

wood in the area of the moving rollers. He

caught his hand in the moving rollers as he

attempted to remove the wood and had to have

his forearm surgically amputated.

Case History #9

An offset printing press operator lost his right

hand while attempting to remove dried ink on a

moving roller using a rag. The guard covering

the lower ink train rollers had been flipped up,

exposing the rollers. The rag got caught in a

nearby roller, pulling the employee’s hand into

the in-going nip point. The employee immediate-

ly hit the press stop button, but the roller rotated

one-half turn before stopping. His hand was

crushed and had to be amputated at the hospital.

Source: OSHA IMIS Accident Investigation Database.

Safeguarding Printing Presses

As with most machinery, you can rely on primary

safeguarding methods to protect employees

against injuries when using printing presses. For

example, some primary safeguarding methods

include the following:

• Install guards on all mechanical hazard points

that are accessible during normal operation --

such as accessible in-going nip points between

rollers and power-transmission apparatus

(chains and sprockets).

• Safeguard nip point hazards with barrier guards

or nip guards. Nip guards need to be designed

and installed without creating additional haz-

ards.

• Install fixed barrier guards, with tamper-proof

fasteners, at rollers that do not require operator

access.

• Properly designed, applied, and maintained

safeguarding devices (such as presence-sensing

devices and mats) may also be used to keep

your body out of machine danger areas. How-

ever, these control circuit devices are no substi-

tute for lockout/tagout.

• Use hold-to-run controls (such as inch or re-

verse) that protect employees from machine

mechanical hazards by either: 1) requiring the

use of both hands for control initiation purpos-

es; or 2) are mounted at a safe distance so that

an employee cannot inch or reverse the press

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 31

and simultaneously access any unguarded dan-

ger area or otherwise reach into the danger zone

while the press is operating.

Other Controls for Printing Presses

The following are some secondary safeguarding

methods, work practices, and complementary

equipment that may be used to supplement primary

safeguarding or alone or in combination when pri-

mary safeguarding methods are not feasible:

• Make sure that printing presses attended by

more than one operator or ones outside of the

operator’s viewing area are equipped with visual

and audible warning devices to alert employees

regarding the press’s operational status—in

operation, safe mode, or impending operation.

• Install visual warning devices of sufficient num-

ber 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.

• Use additional secondary safeguarding methods

such as safeguarding by location and safe work

(operating) procedures for printing presses.

• Ensure that all press operators receive appropri-

ate training and supervision until they can work

safely on their own.

• Prohibit employees working with or near print-

ing presses from wearing loose clothing or jew-

elry and require them to secure long hair with a

net or cap.

• Conduct periodic inspections to ensure compli-

ance.

• Perform servicing and maintenance under an

energy control program in accordance with the

Control of hazardous energy (lockout/tagout), 29

CFR 1910.147, standard.

Minor Servicing

At times, OSHA recognizes that some minor

servicing may have to be performed during nor-

mal production operations, so a lockout/tagout

exception is allowed. See the 29 CFR 1910.147(a)

(2)(ii) Note for details. Minor servicing can

include, among other things, tasks such as clear-

ing of certain types of minor paper jams; minor

cleaning; minor lubricating and minor adjusting

operations; certain plate and blanket changing

Occupational Safety and

Health Administration

tasks; and, in some cases, paper webbing and

paper roll changing. Generally speaking, minor

servicing is considered to include those tasks

involving operations that can be safely accom-

plished by employees and where extensive dis-

assembly of equipment is not required.

One such control method that does offer effec-

tive alternative protection is the inch-safe-service

technique when it is used in conjunction with the

main drive control. This technique is specified in

the American National Standards (ANSI B65.1

and ANSI B65.2) for web- and sheet-fed printing

presses and binding and finishing equipment,

respectively.

Also, interlock guards and presence-sensing

safeguarding devices, if properly designed,

applied and maintained, would also be consid-

ered effective protection. For example, you could

simply open the barrier guard and rely on the

protection afforded by the properly designed

interlock control circuit while clearing minor

paper jams and other minor servicing functions

that occur using normal production operations

and which meet the criteria in the lockout/tagout

exception.

Source: 29 CFR 1910.147(a)(2)(ii) Note.

Applicable Standards

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout).

• 29 CFR 1910.212, General requirements for all

machines.

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus.

Sources of Additional Information

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• ANSI B65.1-2005, Safety Standard - Printing

Press Systems

Hazards of Roll-Forming and

Roll-Bending Machines

Roll-forming and roll-bending machines primarily

perform metal bending, rolling, or shaping func-

tions. Roll-forming is the process of bending a

continuous strip of metal to gradually form a pre-

determined shape using a self-contained machine.

Roll-forming machines contain a series of rolls that

may or may not have braking systems. Roll-form-

ing machines may also perform other processes

on the metal, including piercing holes, slots, or

notches; stamping; flanging; and stretch-bending.

Roll-bending machines usually have three rolls

arranged like a pyramid and they perform essential-

ly the same process as roll-forming, 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 fre-

quently are set up and operated by one person.

(Figure 33 illustrates a roll-forming machine pro-

ducing a finished product. Figure 34 illustrates the

in-feed section of a roll-forming machine.)

Figure 33 Roll-Forming Machine

Figure 34 In-Feed Area of a Roll-Forming Machine

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 33

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.

Case History #10

While feeding a metal sheet into a roller, an

employee caught his right hand in the roller and

amputated one finger.

Case History #11

An employee wearing gloves caught his left

hand in a roll-forming machine, resulting in par-

tial amputation of two fingers. The employee

was standing close to the moving rollers, feeding

flat steel sheet from behind and catching it on

the front side. There was no point of operation

guard on the front roller and the foot operating

pedal was very close to the machine.

Safeguarding Roll-Forming and Roll-

Bending Machines

Roll-forming and roll-bending machines are avail-

able in a wide variety of sizes and designs, and

safeguarding methods must be tailored for each

machine. Several factors affect the ways to safe-

guard the equipment, including whether a machine

has a brake system, its size, operating speed, thick-

ness of product, length of production runs, required

production accuracy, sheet feeding methods, and

part removal methods. Depending on the size and

type of machine, a number of different primary

safeguarding methods may be required to ade-

quately protect the operator as well as other em-

ployees nearby. For example, you can do the

following:

• Install fixed or adjustable point of operation bar-

rier guards at the in-feed and out-feed sections

of machines. If the stock or end-product does

Entering

Stock

Finished

Product

Operator

Control

Station

Guide Rollers

Power Transmission Apparatus

Entering

Stock

In-Running Nip Point

the rolls stop turning (via a brake and clutch

assembly) when you release the foot switch.

• Develop and implement safe work (operating)

procedures for roll-forming and roll-bending

machines.

• Safeguard operator control stations to prevent

inadvertent activation by unauthorized employees.

• Ensure that all operators receive appropriate on-

the-job training under the direct supervision of

experienced operators until they can work safely

on their own.

• Prohibit employees working with or near print-

ing presses from wearing loose clothing or jew-

elry and require them to secure long hair with a

net or cap.

• 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.

• Conduct periodic inspections to ensure compli-

ance.

• Perform servicing and maintenance under an

energy control program in accordance with the

Control of hazardous energy (lockout/tagout), 29

CFR 1910.147, standard.

Applicable Standards

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout).

• 29 CFR 1910.212, General requirements for all

machines.

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus.

Sources of Additional Information

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• ANSI B11.12-2005, Safety Requirements for

Roll-Forming and Roll-Bending Machines

Occupational Safety and

Health Administration

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 entry of cloth-

ing and parts of your body into the in-going nip

points of the rollers.

• Install fixed or interlocked guards to cover any

other rotating parts, such as power-transmission

apparatus.

• Install and use properly applied presence-sens-

ing safeguarding devices (light curtains, safety

mats) on roll-forming and roll-bending machines

(those equipped with brakes) to protect you

from hazardous machine areas during normal

production operations.

• Install and use properly applied two-hand con-

trol safeguarding devices to protect you from

the machine hazards during roll-bending pro-

duction operations.

• Ensure that operators use the jog mode during

feeding operations, if appropriate, and that the

control station requires the use of both hands

or is mounted at a safe distance from the ma-

chine’s danger areas.

• 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, such as

accessible in-going nip points between rollers

and power-transmission apparatus (chains and

sprockets).

Other Controls for Roll-Forming and

Roll-Bending Machines

The following are some secondary safeguarding

methods, work practices, and complementary

equipment that may be used to supplement primary

safeguarding or alone or in combination when pri-

mary safeguarding methods are not feasible:

• Use proper lighting and awareness barrier

devices (such as interlocking gates around the

perimeter of the machine to prevent unautho-

rized entry), awareness signals and signs.

• Position (safeguard by location) operating sta-

tions in a way that ensures that operators are

not exposed to the machine’s point of operation.

• Locate foot pedal controls away from the point

of operation and guard them in such a way as to

prevent inadvertent activation. Some foot con-

trols use dead-man (hold-to-run) features so that

Hazards of Shearing Machines

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 func-

tions 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 manu-

al 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 trip-

ping 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 oper-

ator uses hand-activated or foot-activated con-

trols to initiate the operation, which requires lim-

ited 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 two primary point-of-operation hazards on

shears are the shear blade and the material hold-

downs. Amputations may occur in the following

situations:

• The foot control inadvertently activates while

the operator’s hands are in the point of opera-

tion. 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 in-

crease productivity but must be used in conjunc-

tion with primary 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.

Case History #12

After breaking metal with a mechanical alliga-

tor shear, an employee turned the shear off and

was picking up debris on the ground when he

placed his left hand on the shear and amputat-

ed his fingers. The shear’s flywheel was not

equipped with a clutch or similar device. So,

when the shear was shut off, the jaw continued

to operate on stored energy.

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 35

Hold

Down

Point of

Operation Guard

Lower

Fixed

Blade

Top

Blade

Case History #13

An employee was cutting material with a 50-inch

guillotine shear equipped with two-hand trip but-

tons to prevent employees from reaching into

the blade area. He had taped up one of the but-

tons and used his knee to trip the other button.

With both hands under the blade, he inadvertent-

ly hit the free button with his knee. This activated

a stroke of the blade which amputated both of

his hands just below the wrists.

Source: OSHA IMIS Accident Investigation Database.

Safeguarding Shearing Machines

Because shears have a wide variety of applications,

safeguarding methods must be determined individ-

ually for each machine based on its use. A number

of different safeguarding methods may be neces-

sary to adequately protect the operator as well as

other employees nearby. For example, you will

need to consider the machine size, operating

speed, size and type of material, length of produc-

tion runs, required accuracy of the work, methods

for material feeding and removal, operator controls,

and clutch type.

Here are some primary safeguarding options for

protecting employees from the shear’s point of

operation during feeding activities at the front of

the machine:

• Install a properly applied 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 must prevent the employee from reach-

ing under or around it.

• Install and arrange two-hand trips and controls

so that the operator must use both hands to ini-

tiate the shear cycle. Two-hand trips and con-

trols need to be designed so that they cannot be

defeated easily. The Safety Requirements for

Shears (ANSI B11.4-2003) 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. This national consensus standard

specifies the use of guards on full-revolution

shears.

• Use a properly applied presence-sensing

device, such as a light curtain, on shears that

are hydraulically powered or equipped with a

part-revolution clutch.

Occupational Safety and

Health Administration

• Mount guarded foot-pedal controls at a safe dis-

tance (single control safeguarding devices) away

from the point of operation to protect the opera-

tor during the operating cycle.

• Use pull-backs or restraints for stand-alone

manual shears when other guarding methods

are not feasible or do not adequately protect

employees. (These devices may not be appro-

priate if the job requires employees’ mobility.)

• Use automatic-feeding devices such as convey-

ors with stand-alone manual shears when the

material is uniform in size and shape.

• Equip mechanical shears with either a part-revo-

lution or full-revolution clutch. Methods of safe-

guarding depend on the type of clutch in use.

Shears equipped with full-revolution clutches

used in single-stroke operations must be equip-

ped with an anti-repeat feature.

Other Controls for Shearing Machines

The following are some secondary safeguarding

methods, work practices, and complementary

equipment that may be used to supplement

primary safeguarding or alone or in combination

when primary safeguarding methods are not

feasible:

• Install guarded operating stations at a safe dis-

tance (safeguarding by location) from the

shear’s point of operation to prevent inadvertent

activation.

• Develop and implement safe work (operating)

procedures for shearing machines and conduct

periodic inspections to ensure compliance.

• Use proper lighting and awareness devices,

such as awareness barriers and warning signs,

to warn employees of the hazard.

• Install hold-down (work-holding) devices that

prevent the work piece from kicking up and

striking the operator. Hold-down devices may

eliminate the need for employees to hold the

material near the point of operation.

• Instruct operators to use distancing tools when

their hands might otherwise reach into the point

of operation because of the size of the material

being cut.

• Where it is possible to stop the shear during

its operating cycle, install an emergency stop

device—such as a pressure-sensitive body bar,

safety tripod, or safety tripwire cable—at the

in-feed section of the shear.

• Install an awareness barrier or a safety trip con-

trol (safety tripwire or safety tripod) on the back

side of the shear.

• Ensure that all operators receive on-the-job

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 acci-

dentally switches the slicer on.

• When the operator fails to use the sliding attach-

ment 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 push-

ing/guarding device or plunger.

Case History #14

Two employees, an operator and an assistant,

were using a meat slicer to slice turkey. The

assistant was holding a box of turkey in a tilted

position while the operator fed the turkey into

the slicer. The operator removed the guard

from the meat slicer because the turkey kept

jamming. The slicer’s knives caught the opera-

tor’s glove and pulled his hand into the knives,

amputating his finger just above the nail.

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 37

training under the direct supervision of experi-

enced operators until they can work safely on

their own.

• Instruct employees to perform routine mainte-

nance 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 oper-

ation 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 activa-

tion pedal.

• Perform servicing and maintenance under an

energy control program in accordance with the

Control of hazardous energy (lockout/tagout), 29

CFR 1910.147, standard.

Applicable Standards

• 29 CFR 1910.212, General requirements for all

machines

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout)

Sources of Additional Information

• OSHA Instruction CPL 03-00-002, National

Emphasis Program on Amputations.

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• ANSI B11.4-2003, Safety Requirements for

Shears.

Hazards of Food Slicers

Food slicers are electrically powered machines typi-

cally equipped with a rotary blade, an on/off switch,

thickness adjustment, and a food holder or chute. A

On/Off

Switch

Meat Holder

Thickness

Adjustment

Rotating

Blade

Case History #15

An employee was cleaning a meat slicer that was

turned off but was still plugged in. He inadver-

tently turned the machine on by bumping the

on/off switch, resulting in an amputation of his

right ring finger.

Safeguarding and Other Controls

for Food Slicers

Food slicers must be used with guards that cover

the unused portions of the slicer blade on both the

top and bottom of the slicer. You should buy slicers

already equipped with a feeding attachment on the

sliding mechanism of the food holder or purchase

the attachment separately and install it before use.

Instruct employees to use a pushing/guarding de-

vice with chute-fed slicers.

The following are some secondary safeguarding

methods, work practices and complementary

equipment that may be used to supplement primary

safeguarding or alone or in combination when pri-

mary safeguarding methods are not feasible:

• Develop and implement safe work (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 experi-

enced operators until they can work safely on

their own.

• Use warning signs to alert employees of the

hazard and safety instructions.

• 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.

• Instruct operators to retract the slicer blade dur-

ing cleaning operations.

• Instruct operators to turn off and unplug slicers

when not in use or when left unattended for any

period of time.

• Perform servicing and maintenance under an

energy control program in accordance with the

Control of hazardous energy (lockout/tagout), 29

CFR 1910.147, standard. You can avoid slicer

lockout/tagout if the equipment is cord-and-plug

connected equipment simply by having exclu-

sive control over the attachment plug after you

shut the slicer off and unplug it from the energy

source.

Hazards of Meat Grinders

Electric 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 can occur when the

operator accidentally switches the grinder back

on.

• The operator fails to use the attached feeding

tray and throat.

Defective meat grinders, such as ones with

holes in the throat or screw auger area, are also a

source of workplace amputations and must be

taken out of service.

Case History #16

An operator amputated his arm below the elbow

while hand-feeding potatoes into a 5-horsepower

meat grinder through a feed throat with a 4-inch-

by-6-inch opening and no point of operation

guard. This untrained employee had been work-

ing on the machine for only 15 minutes.

Case History #17

An employee amputated her hand about 4 inches

above the wrist while using an inadequately

guarded meat grinder. She had disassembled the

grinder to clean it, but did not replace the fixed

guard along with the stainless steel tray when

Occupational Safety and

Health Administration

Feeding Tray

Grinder Plate

Throat

Plunger

she reassembled it. Also, she did not use the

plunger provided for feeding the meat into the

grinder. The machine pulled her hand into the

3-inch diameter auger and amputated it above

the wrist.

Source: OSHA IMIS Accident Investigation Database.

Safeguarding and Other Controls for

Meat Grinders

Meat grinders must be retrofitted with a primary

safeguard, such as a properly designed tapered

throat or fixed guard, in cases where the machine

design is such that an employee’s hand may come

in contact with the point-of-operation (that is the

auger cutter area). You should buy meat grinders

already equipped with this primary safeguard.

The following are some other secondary safe-

guarding methods, work practices, and comple-

mentary equipment that may be used to supple-

ment primary safeguarding or alone or in combina-

tion when primary safeguarding methods are not

feasible:

• Develop and implement safe work (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 opera-

tions to ensure compliance.

• Use warning signs to alert employees of the

hazard and safety instructions.

• Ensure that all operators receive appropriate

on-the-job training under direct supervision of

experienced operators until they can work safely

on their own.

• Provide operators with properly sized plungers

to eliminate the need for their hands to enter the

feed throat during operation.

• 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 grinders only with

feeding trays and throats installed.

• Instruct operators to use the meat grinder only

for its intended purpose.

• Instruct operators to turn off and unplug grinders

when not in use or when left unattended for any

period of time.

• Perform servicing and maintenance under an

energy control program in accordance with the

Control of hazardous energy (lockout/tagout), 29

CFR 1910.147, standard. You can avoid slicer

lockout/tagout if the equipment is cord-and-plug

connected equipment simply by having exclu-

sive control over the attachment plug after you

shut the slicer off and unplug it from the energy

source.

Applicable Standards

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout).

• 29 CFR 1910.212, General requirements for all

machines.

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus.

Sources of Additional Information

• OSHA Instruction CPL 03-00-002, National

Emphasis Program on Amputations.

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

Hazards of Meat-Cutting Band Saws

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 runs on two pulleys (driver and idler) and

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.)

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 39

Figure 39 Stainless Steel Meat-Cutting Band Saw

Amputations occur most frequently when opera-

tors’ 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 feed-

ing operations. Here are some common causes of

amputations involving meat-cutting band saws:

• The operator’s hand slips off the meat or other-

wise 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.

Case History #18

While operating a band saw to cut pork loin, an

employee amputated his right index finger when

his hand slipped and contacted the moving blade.

Case History #19

An operator amputated the tip of his right ring

finger while using a band saw to cut 1/4-inch

slabs of meat from a 4-inch thick piece of beef.

As the piece of meat got smaller, his hands

moved too close to the saw blade. The employee

was not using the pusher guard provided for the

saw.

Source: OSHA IMIS Accident Investigation Database.

Safeguarding and Other Controls for

Meat-Cutting Band Saws

Primary safeguarding methods that you can use

include the following:

• Install a self-adjusting 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 com-

pletely.

The following are some secondary safeguard-

ing methods, work practices, and complementary

equipment that may be used to supplement pri-

mary safeguarding or alone or in combination

when primary safeguarding methods are not fea-

sible:

• Develop and implement safe work (operating)

procedures for meat-cutting band saws to

ensure that the guards are adequate and in

place and that operators safely perform feeding

methods.

• 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.

• Use warning signs to alert employees of the

hazard and safety instructions.

• Install a brake on one or both wheels to prevent

the saw blade from coasting after the machine is

shut off.

• Provide a pushing guard or fence to feed meat

into the saw blade.

• Instruct operators to use the pushing guard or

fence to feed the saw, especially when cutting

small pieces of meat.

• Instruct operators to adjust the point of opera-

tion guard properly to fit the thickness of the

meat.

• Instruct operators to use only sharp meat-cut-

ting blades and to tighten blades to the appro-

priate tension with the machine’s tension control

device.

Occupational Safety and

Health Administration

Fixed

Power

Transmission

Apparatus

Guard

Operator

Control

Blade

Adjustable

Point of

Operation

Guard

Pushing

Guard

Sliding

Table

• 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.

• Conduct periodic inspections of the saw opera-

tion to ensure compliance.

• Perform servicing and maintenance under an

energy control program in accordance with the

Control of hazardous energy (lockout/tagout), 29

CFR 1910.147, standard. You can avoid slicer

lockout/tagout if the equipment is cord-and-plug

connected equipment simply by having exclu-

sive control over the attachment plug after you

shut the band saw off and unplug it from the

energy source.

Applicable Standards

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout).

• 29 CFR 1910.212, General requirements for all

machines.

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus.

Sources of Additional Information

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• OSHA Publication 3157, A Guide for Protecting

Workers from Woodworking Hazards (http://

www.osha.gov/Publication/osha3157.pdf)

Hazards of Drill Presses

Electric drill presses use a rotating 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 aTransparent 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 (such as belt and pulleys)

devices;

• Removing a part from a drill press while wear-

ing gloves;

• 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;

• Changing the drill bit with the operating control

unprotected so that a falling object or otherwise

bumping the switch can accidentally start up the

press spindle and tool assembly;

• Performing servicing and maintenance activities,

such as changing pulleys and belts, without de-

energizing and locking/taging out the drill press.

Case History #20

A mechanic amputated the first joints of his left

index and middle fingers while changing the belt

position on a multi-pulley drill press. While the

mechanic was pulling the belt on, it suddenly

went around the outside pulley, pulling the

mechanic’s fingers through the nip point.

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 41

Drill Bit

Clamps to

Hold Work in

Place

Case History #21

A machinist amputated his left index finger at the

first joint while drilling holes in a machined part.

As he moved the part to begin drilling another

hole, his gloved hand got caught in the drill bit.

Source: OSHA IMIS Accident Investigation Database.

Safeguarding and Other Controls for

Drill Presses

For drill presses, you must be protected from the

rotating chuck and swarf that is produced by the

drill bit. Guarding at the point-of-operation is diffi-

cult because of the nature of the drilling press. The

following primary safeguarding methods can be

installed to guard the operator and other employ-

ees from rotating parts, flying chips, and cuttings:

• Specifically designed shields can be attached to

the quill and used to guard this area. For exam-

ple, telescopic shielding that retracts as the drill

bit contacts the piece or a more universal-type

shield can be applied.

• Automatic machines and high-production ma-

chines could have enclosures designed and

installed to guard the employee from the entire

drilling operation.

• Install guarding over the motor, belts, and pul-

leys.

• Install an adjustable guard to cover the unused

portion of the bit and chuck above the material

being worked.

The following are some secondary safeguarding

methods, work practices, and complementary

equipment that may be used to supplement pri-

mary safeguarding or alone or in combination

when primary safeguarding methods are not feasi-

ble:

• Automatic machines and high-production

machines could use barricades to separate the

employee from the entire drilling operation.

• Develop and implement safe work (operating)

practices, such as removing the chuck immedi-

ately after each use, for drill press operations

and conduct periodic inspections to ensure com-

pliance.

• Train and supervise all operators until they can

work safely on their own.

• Use the drill press only for its intended purposes.

Occupational Safety and

Health Administration

• 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 that operators secure material to the

drill press bed with clamps (work-holding equip-

ment) 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.

• 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.

• Shut off the drill press when not in use or when

left unattended for any period of time.

• Perform servicing and maintenance under an

energy control program in accordance with the

Control of hazardous energy (lockout/tagout), 29

CFR 1910.147, standard.

Minor Servicing

At times, OSHA recognizes that some minor

servicing may have to be performed during nor-

mal production operations, so a lockout/tagout

exception is allowed. See the 29 CFR

1910.147(a)(2)(ii) Note, for details. For example,

minor drill press tool changes and adjustments

may be performed without lockout/tagout if the

machine’s electrical disconnect or control (on/off)

switches control all the hazardous energy and

are: 1) properly designed and applied in accor-

dance with good engineering practice; 2) placed

in an off (open) position; and 3) under the exclu-

sive control of the employee performing the

minor servicing task.

Source: 29 CFR 1910.147(a)(2)(ii) Note.

Cord- and Plug-connected Electric Equipment

The OSHA LOTO standard would not apply when

employees are performing servicing and mainte-

nance work on a cord- and plug-connected drill

press if the press is unplugged and the plug is in

the exclusive control of the employee performing

the task. The employee would be able to control

the press from being energized by controlling the

attachment plug.

Source: 29 CFR 1910.147(a)(2)(ii)(A).

Applicable Standards

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout).

• 29 CFR 1910.212, General requirements for all

machines.

• 29 CFR 1910.213, Woodworking machinery

requirements.

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus.

Sources of Additional Information

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• OSHA Publication 3157, A Guide for Protecting

Workers from Woodworking Hazards (http://

www.osha.gov/Publication/osha3157.pdf)

• ANSI B11.8-2001, Safety Requirements for

Manual Milling, Drilling and Boring Machines

with or without Automatic Control

• ANSI O1.1-2004, Safety Requirements for

Woodworking Machinery

Hazards of Milling Machines

Electric milling machines cut metal using a rotating

cutting device called a milling cutter. These ma-

chines 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 opera-

tions.

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 cut-

ter, loading a work-piece on the milling table, con-

trolling the table movement to feed the part against

the rotating milling cutter, and callipering or meas-

uring the part. (See Figure 41.)

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 43

Figure 41 Bed Mill

Some frequent causes of amputation from

milling machines include:

• Loading or unloading parts and callipering or

measuring the milled part while the cutter is still

rotating;

• Operating milling machines with the safety door

selector switch on bypass;

• Inspecting the milling machine gearbox with the

machine still operating;

• Manually checking the machine for loose gears

(by removing the gearbox cover) while comput-

erized cutting software program was operating;

• 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

either while the milling machine is stopped but

still energized, or while the cutter is still rotating;

and

• Getting jewelry or loose-fitting clothing entan-

gled in the rotating cutter.

Case History #22

While replacing parts on a horizontal milling

machine, an employee shut off the machine,

which put the revolving cutter in a neutral posi-

tion. The employee, however, did not disengage

the clutch to stop the cutter and proceeded to

replace parts while the cutter was still moving.

He amputated three fingers.

Control

System

Milling

Bed

Milling

Cutter

Case History #23

An employee was using a milling machine to cut

metal samples to length. After a part had been

cut, the employee needed to gauge the part size.

While he was checking the edge of the sample,

the blade caught the tip of his glove, pulled his

hand into the cutting area, and amputated his

right ring finger and part of his middle finger.

Source: OSHA IMIS Accident Investigation Database.

Safeguarding and Other Controls for

Milling Machines

The following primary safeguarding methods will

help protect you from point-of-operation and other

milling machine hazard areas:

• Install guards (fixed, movable, and interlocked)

that enclose the milling cutter’s point-of-opera-

tion;

• Install properly applied safeguarding devices,

such as presence-sensing devices and two-hand

control methods;

• Install guards around the machine’s power

transmission components (such as drive mecha-

nisms).

The following are some secondary safeguarding

methods, work practices, and complementary

equipment that may be used to supplement pri-

mary safeguarding or alone or in combination

when primary safeguarding methods are not feasi-

ble:

• 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 interfer-

ing with normal production operations or creat-

ing a more hazardous situation.

• Install awareness devices, such as barriers and

warning signs, around the milling table.

• Instruct operators not to use a jig or vise (work-

holding equipment) that prevents the point of

operation guard from being adjusted appropri-

ately.

• Develop and implement safe (operating) work

procedures for machine operators, such as safe

work procedures for installing and using fixtures

and tooling.

• Instruct operators to place the jig or vise locking

arrangement so that force must be exerted away

from the cutter.

Occupational Safety and

Health Administration

• Ensure that all operators receive appropriate

safe work procedure 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 callipering or measuring

the work and not to perform these activities

while the cutter is still rotating unless the cutter

is adequately guarded.

• 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.

• Prohibit operators from reaching around the cut-

ter or hob to remove chips while the machine is

in motion or not locked or tagged out.

• Conduct periodic inspections to ensure compli-

ance.

• Perform servicing and maintenance under an

energy control program in accordance with the

Control of hazardous energy (lockout/tagout), 29

CFR 1910.147, standard.

Minor Servicing

At times, OSHA recognizes that some minor

servicing may have to be performed during nor-

mal production operations, so a lockout/tagout

exception is allowed. See the 29 CFR

1910.147(a)(2)(ii) Note, for details. For example,

minor milling machine tool changes and adjust-

ments may be performed without lockout/tagout

if the machine’s electrical disconnect or control

(on/off) switches control all the hazardous energy

and are: 1) properly designed and applied in

accordance with good engineering practice; 2)

placed in an off (open) position; and 3) under the

exclusive control of the employee performing the

minor servicing task.

Source: 29 CFR 1910.147(a)(2)(ii) Note.

Applicable Standards

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout)

• 29 CFR 1910.212, General requirements for all

machines

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus

Sources of Additional Information

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• National Safety Council, Accident Prevention

Manual for Industrial Operations: Engineering

and Technology. 10th Ed. Itasca, IL

• ANSI B11.8-2001, Safety Requirements for

Manual Milling, Drilling and Boring Machines

with or without Automatic Control

Hazards of Grinding Machines

Grinding machines primarily alter the size, shape,

and surface finish of metal by placing a work-piece

against a rotating abrasive surface or wheel. Grind-

ing machines may also be used for grinding glass,

ceramics, plastics, and rubber.

Examples of grinding machines include abrasive

belt machines, abrasive cutoff machines, cylindrical

grinders, centerless grinders, gear grinders, internal

grinders, lapping machines, off-hand grinders, sur-

face grinders, swing frame grinders, and thread

grinders. (See Figure 42.)

Figure 42 Horizontal Surface Grinder

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 45

Amputation injuries can occur when the opera-

tor’s hands enter the point of operation during the

following activities:

• Bypassing the grinding machine safety switch

feature in order to clean the machine while it is

running;

• Wearing gloves while grinding, where it is possi-

ble to have the glove get caught between the

revolving disc and the table;

• Fixing a jammed grinder machine by turning

the machine off, removing the blade guard and

reaching into the danger area before the blades

stop turning;

• Operating a grinding machine with non-func-

tional interlocks and without the guard in place;

• Using an incorrectly adjusted or missing work

rest or a poorly maintained or unbalanced abra-

sive wheel;

• Adjusting the work rest, balancing the wheel,

cleaning the area around the abrasive wheel and

loading and unloading parts or measuring parts

while the abrasive wheel is still rotating;

• Attempting to stop a rotating abrasive wheel by

hand.

Case History #24

After grinding a piece of steel on an off-hand

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 abra-

sive wheel, amputating the tip of his left middle

finger.

Case History #25

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.

Fixed

Guard

Grinding

Bed

Grinding

Wheel

Fixed

Guard

Safeguarding and Other Controls for

Grinding Machines

You can help prevent employee accidents and

injuries by using primary safeguarding methods.

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 off-

hand grinding machines; and

• Install guards over power belts and drives.

The following are some secondary safeguarding

methods, work practices, and complementary

equipment that may be used to supplement primary

safeguarding or alone or in combination when

primary safeguarding methods are not feasible:

• Develop and implement safe work procedures

for grinding machine operations.

• Install warning and safety instruction signs.

• Ensure that all operators receive appropriate on-

the-job training and supervision until they can

work safely on their own.

• Use abrasive discs and wheels that are correctly

rated for the grinder’s maximum operating spin-

dle speed. The disc or wheel rating is marked on

the disc or wheel in surface feet per minute.

• Inspect and sound test the grinding wheel to

ensure that it is not defective, unbalanced,

loose, or too small.

• Adjust the work rest to within 1/8inch of the

wheel.

• Do not wear gloves, jewelry, or loose-fitting

clothing while operating grinding machines and

secure long hair in a net or cap.

• Do not adjust the guard or clean the grinding

machine while the abrasive wheel is still rotating.

• Conduct periodic inspections to ensure compli-

ance.

• Perform servicing and maintenance under an

energy control program in accordance with the

Control of hazardous energy (lockout/tagout), 29

CFR 1910.147, standard.

Cord- and Plug-connected Electric Equipment

The OSHA LOTO standard would not apply when

employees are performing servicing and mainte-

nance work on a cord- and plug-connected grind-

ing machine if the grinder is unplugged and the

plug is in the exclusive control of the employee

performing the task. The employee would be

able to control the grinder from being energized

by controlling the attachment plug.

Applicable Standards

• ANSI B7.1-1970, Safety Code for the Use, Care

and Protection of Abrasive Wheels [incorporat-

ed by reference in 1910.94(b)(5)(i)(a),

1910.215(b)(12) and 1910.218(j)(5)].

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout).

• 29 CFR 1910.215, Abrasive wheel machinery.

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus.

• 29 CFR 1926.303, Abrasive wheels and tools.

Sources of Additional Information

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• ANSI B7.1—2000, Use, Care, and Protection of

Abrasive Wheels.

• ANSI B11.9—1975 (R2005), Safety Require-

ments for the Construction, Care, and Use of

Grinding Machines.

Hazards of Slitters

Slitters use rotary knives to slit flat rolled metal,

plastic film, paper, plastic, foam, and rubber as well

as other coiled or sheet-fed materials. Slitters range

from small hand-fed paper slitters to large-scale

automated metal slitters, complete with metal pro-

cessing and handling units such as unwinders and

rewinders. Both light and heavy gauge slitters are

available. (See Figure 43.)

Occupational Safety and

Health Administration

Figure 43 Paper Slitter

Amputations often occur when clothing or body

parts come in contact with slitter blades or get

caught in the movement of coils and rolls. Here are

some examples:

• Employees can inadvertently get their fingers

and hands caught in the in-going nip points of

the slitter or associated machinery such as re-

winders.

• Gloves, jewelry, long hair and loose clothing

can get entangled in in-going nip points or in

the rotary knives of the slitter.

• Employees 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).

Case History #26

An employee was operating a precision slitting

machine to slit a roll of aluminum. As the em-

ployee 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 #27

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.

Source: OSHA IMIS Accident Investigation Database.

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 47

Safeguarding and Other Controls for

Slitters

The following primary safeguards may be used to

protect employees from the hazardous portions of

the slitter and auxiliary equipment:

• Install a fixed or adjustable point-of-operation

guard to prevent inadvertent entry of body parts

into a hazardous area of the slitter system.

• Install a fixed point of operation guard to cover

the sides of the unwinder or rewinder to prevent

an employee’s hands or clothing from entering

into the rollers.

• Properly applied presence-sensing devices (such

as light curtains, radio-frequency devices, safety

mats) may be used to control employee exposure

to certain types of hazards (such as the slitter

knives’ point-of-operation hazard) by stopping

or preventing machine system operation in the

event any part of an employee’s body is detect-

ed in a sensing field.

• Install fixed or interlocked guards to cover other

moving parts of the machine such as the power-

transmission apparatus.

The following are some secondary safeguarding

methods, work practices, and complementary

equipment that may be used to supplement primary

safeguarding or alone or in combination when

primary safeguarding methods are not feasible:

• Use awareness devices, such as an awareness

barrier or fence (with an interlocking gate) and

hazard warning/safety instruction signs around

the perimeter of the machine to alert people of

the hazard and prevent unauthorized entry.

• Awareness signals may also be used to alert

you of an existing or approaching hazard as

these devices issue a warning sound or provide

a visible warning light.

• Restrict employee access to hazardous areas

through the application of safeguarding by loca-

tion techniques – such as utilizing the facility lay-

out (walls) and equipment location (elevation)

for isolation purposes.

• Develop and implement safe work procedures

for machine operators and conduct periodic

inspections to ensure compliance.

• Develop an operator training program to ensure

that all operators are knowledgeable and profi-

cient in the safeguarding methods and work

procedures. Employees need to be supervised

on a regular basis to ensure that they are follow-

ing the safety program requirements.

Sources of Additional Information

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Machine Guarding eTool (http://www.

osha.gov/SLTC/etools/machineguarding/index.

html)

• OSHA Lockout/Tagout Interactive Training

Program (http://www.osha.gov/dts/osta/

lototraining/index.htm)

• ANSI B11.14—1996, Coil Slitting Machines

Safety Requirements for Construction, Care

and Use

Occupational Safety and

Health Administration

• Perform servicing and maintenance under an

energy control program in accordance with the

Control of hazardous energy (lockout/tagout), 29

CFR 1910.147, standard.

Applicable Standards

• 29 CFR 1910.147, Control of hazardous energy

(lockout/tagout)

• 29 CFR 1910.212, General requirements for all

machines

• 29 CFR 1910.219, Mechanical power-transmis-

sion apparatus

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 49

OSHA Assistance

OSHA can provide extensive help through a variety of

programs, including technical assistance about effec-

tive safety and health programs, state plans, work-

place consultations, voluntary protection programs,

strategic partnerships, training and education, and

more. An overall commitment to workplace safety and

health can add value to your business, to your work-

place, and to your life.

Safety and Health Program Management Guidelines

Effective management of employee safety and health

protection is a decisive factor in reducing the extent

and severity of work-related injuries and illnesses and

their related costs. In fact, an effective safety and

health program forms the basis of good employee

protection and can save time and money (about $4

for every dollar spent) and increase productivity and

reduce employee injuries, illnesses, and related work-

ers’ compensation costs.

To assist employers and employees in developing

effective safety and health programs, OSHA pub-

lished recommended Safety and Health Program

Management Guidelines (54 Federal Register (16):

3904-3916, January 26, 1989). These voluntary guide-

lines can be applied to all places of employment cov-

ered by OSHA.

The guidelines identify four general elements criti-

cal to the development of a successful safety and

health management system:

• Management leadership and employee involvement,

• Worksite analysis,

• Hazard prevention and control, and

• Safety and health training.

The guidelines recommend specific actions, under

each of these general elements, to achieve an effec-

tive safety and health program. The Federal Register

notice is available online at www.osha.gov.

State Programs

The Occupational Safety and Health Act of 1970 (OSH

Act) encourages states to develop and operate their

own job safety and health plans. OSHA approves and

monitors these plans. Twenty-four states, Puerto Rico

and the Virgin Islands currently operate approved

state plans: 22 cover both private and public (state

and local government) employment; Connecticut,

New Jersey, New York and the Virgin Islands cover

the public sector only. States and territories with their

own OSHA-approved occupational safety and health

plans must adopt standards identical to, or at least as

effective as, the Federal OSHA standards.

Consultation Services

Consultation assistance is available on request to

employers who want help in establishing and main-

taining a safe and healthful workplace. Largely funded

by OSHA, the service is provided at no cost to the

employer. Primarily developed for smaller employers

with more hazardous operations, the consultation

service is delivered by state governments employing

professional safety and health consultants. Compre-

hensive assistance includes an appraisal of all mech-

anical systems, work practices, and occupational safe-

ty and health hazards of the workplace and all aspects

of the employer’s present job safety and health pro-

gram. In addition, the service offers assistance to

employers in developing and implementing an effec-

tive safety and health program. No penalties are pro-

posed or citations issued for hazards identified by the

consultant. OSHA provides consultation assistance to

the employer with the assurance that his or her name

and firm and any information about the workplace will

not be routinely reported to OSHA enforcement staff.

Under the consultation program, certain exemplary

employers may request participation in OSHA’s Safety

and Health Achievement Recognition Program

(SHARP). Eligibility for participation in SHARP in-

cludes receiving a comprehensive consultation visit,

demonstrating exemplary achievements in workplace

safety and health by abating all identified hazards, and

developing an excellent safety and health program.

Employers accepted into SHARP may receive an

exemption from programmed inspections (not com-

plaint or accident investigation inspections) for a peri-

od of 1 year. For more information concerning consul-

tation assistance, see OSHA’s website at

www.osha.gov.

Voluntary Protection Programs (VPP)

Voluntary Protection Programs and on-site consulta-

tion services, when coupled with an effective en-

forcement program, expand employee protection to

help meet the goals of the OSH Act. The VPPs moti-

vate others to achieve excellent safety and health

results in the same outstanding way as they estab-

lish a cooperative relationship between employers,

employees, and OSHA.

For additional information on VPP and how to

apply, contact the OSHA regional offices listed at the

end of this publication.

Strategic Partnership Program

OSHA’s Strategic Partnership Program, the newest

member of OSHA’s cooperative programs, helps

encourage, assist, and recognize the efforts of part-

ners to eliminate serious workplace hazards and

achieve a high level of employee safety and health.

Whereas OSHA’s Consultation Program and VPP entail

Occupational Safety and

Health Administration

one-on-one relationships between OSHA and individ-

ual worksites, most strategic partnerships seek to

have a broader impact by building cooperative rela-

tionships with groups of employers and employees.

These partnerships are voluntary, cooperative relation-

ships between OSHA, employers, employee represen-

tatives, and others (e.g., trade unions, trade and pro-

fessional associations, universities, and other govern-

ment agencies).

For more information on this and other coopera-

tive programs, contact your nearest OSHA office, or

visit OSHA’s website at www.osha.gov.

Alliance Program

The Alliance Program enables organizations commit-

ted to workplace safety and health to collaborate with

OSHA to prevent injuries and illnesses in the work-

place. OSHA and the Alliance participants work

together to reach out to, educate, and lead the

nation’s employers and their employees in improving

and advancing workplace safety and health.

Groups that can form an Alliance with OSHA

include employers, labor unions, trade or professional

groups, educational institutions and government

agencies. In some cases, organizations may be build-

ing on existing relationships with OSHA that were

developed through other cooperative programs.

There are few formal program requirements for

Alliances and the agreements do not include an

enforcement component. However, OSHA and the

participating organizations must define, implement,

and meet a set of short- and long-term goals that fall

into three categories: training and education; outreach

and communication; and promotion of the national

dialogue on workplace safety and health.

OSHA Training and Education

OSHA area offices offer a variety of information serv-

ices, such as compliance assistance, technical advice,

publications, audiovisual aids and speakers for special

engagements. OSHA’s Training Institute in Arlington

Heights, IL, provides basic and advanced courses in

safety and health for Federal and state compliance

officers, state consultants, Federal agency personnel,

and private sector employers, employees, and their

representatives.

The OSHA Training Institute also has established

OSHA Training Institute Education Centers to address

the increased demand for its courses from the private

sector and from other federal agencies. These centers

are nonprofit colleges, universities, and other organi-

zations that have been selected after a competition for

participation in the program.

OSHA also provides funds to nonprofit organiza-

tions, through grants, to conduct workplace training

and education in subjects where OSHA believes there

is a lack of workplace training. Grants are awarded

annually. Grant recipients are expected to contribute

20 percent of the total grant cost.

For more information on grants, training, and edu-

cation, contact the OSHA Training Institute, Office of

Training and Education, 2020 South Arlington Road,

Arlington Heights, IL 60005, (847) 297-4810, or see

Outreach on OSHA’s website at www.osha.gov. For

further information on any OSHA program, contact

your nearest OSHA regional office listed at the end of

this publication.

Information Available Electronically

OSHA has a variety of materials and tools available on

its website at www.osha.gov. These include electronic

compliance assistance tools, such as Safety and

Health Topics, eTools, Expert Advisors; regulations,

directives and publications; videos and other informa-

tion for employers and employees. OSHA’s software

programs and compliance assistance tools walk you

through challenging safety and health issues and

common problems to find the best solutions for your

workplace.

A wide variety of OSHA materials, including stan-

dards, interpretations, directives and more can be

purchased on CD-ROM from the U.S. Government

Printing Office, Superintendent of Documents, toll-free

phone (866) 512-1800.

OSHA Publications

OSHA has an extensive publications program. For a

listing of free or sales items, visit OSHA’s website at

www.osha.gov or contact the OSHA Publications

Office, U.S. Department of Labor, 200 Constitution

Avenue, NW, N-3101, Washington, DC 20210:

Telephone (202) 693-1888 or fax to (202) 693-2498.

Contacting OSHA

To report an emergency, file a complaint, or seek

OSHA advice, assistance, or products, call (800) 321-

OSHA or contact your nearest OSHA Regional or Area

office listed at the end of this publication. The tele-

typewriter (TTY) number is (877) 889-5627.

Written correspondence can be mailed to the near-

est OSHA Regional or Area Office listed at the end of

this publication or to OSHA’s national office at: U.S.

Department of Labor, Occupational Safety and Health

Administration, 200 Constitution Avenue, N.W.,

Washington, DC 20210.

By visiting OSHA’s website at www.osha.gov, you

can also:

• file a complaint online,

• submit general inquiries about workplace safety

and health electronically, and

• find more information about OSHA and occupation-

al safety and health.

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 51

References

American National Standards Institute

• 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 B11.1-2001, Safety Requirements for

Mechanical Power Presses

• ANSI B11.3-2002, Safety Requirements for the

Construction, Care, and Use of Power Press

Brakes

• ANSI B11.4-2003, Safety Requirements for

Construction, Care, and Use of Shears

• ANSI B11.8-2001, Safety Requirements for

Manual Milling, Drilling and Boring Machines

with or without Automatic Control

• ANSI B11.9—1975 (R2005), Safety Requirements

for the Construction, Care, and Use of Grinding

Machines

• ANSI B11.12-1996, Safety Requirements for

Construction, Care, and Use of Roll-Forming and

Roll-Bending Machines

• ANSI B11.14—1996, Coil Slitting Machines

Safety Requirements for Construction, Care and

Use

• ANSI B11.19-2003, Performance Criteria for

Safeguarding

• ANSI B20.1-57, Safety Code for Conveyors,

Cableways, and Related Equipment [incorporat-

ed by reference in 1926.555(a)(8)]

• ANSI B65.1-2005, Safety Standard—Printing

Press Systems

• ANSI B65.2-2005, Binding and Finishing

Systems

• ANSI O1.1-2004, Safety Requirements for

Woodworking Machinery

American National Standards Institute/

Conveyor Equipment Manufacturers

Association

• ANSI/CEMA 350-2003, Screw Conveyors for Bulk

Material

• ANSI/CEMA 401-2003, Unit Handling

Conveyors—Roller Conveyors—Non-powered

• ANSI/CEMA 402-2003, Unit Handling

Conveyors—Belt Conveyors

• ANSI/CEMA 403-2003, Unit Handling

Conveyors—Belt Driven Live Roller Conveyors

• ANSI/CEMA 404-2003, Unit Handling

Conveyors—Chain Driven Live Roller Conveyors

• ANSI/CEMA 405-2003, Unit Handling

Conveyors—Slat Conveyors

• ANSI/CEMA 406-2003, Unit Handling

Conveyors—Line-shaft Driven Live Roller

Conveyors

American National Standards Institute/

American Society of Mechanical

Engineers

• ANSI/ASME B20.1-2003, Safety Standard for

Conveyors and Related Equipment

National Institute for Occupational

Safety and Health

• NIOSH Current Intelligence Bulletin (CIB) 49,

Injuries and Amputations Resulting from Work

with Mechanical Power Presses (May 22, 1987)

National Safety Council

• 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

Occupational Safety and

Health Administration

Occupational Safety and Health

Administration Standards

• 29 CFR 1910.147—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-transmis-

sion 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-transmis-

sion apparatus.

• 29 CFR 1926.555—Conveyors.

Occupational Safety and Health

Administration Instructions

• OSHA Instruction CPL 03-00-003, National

Emphasis Program on Amputations

• OSHA Instruction STD 01-12-021—29 CFR

1910.217, Mechanical Power Presses,

Clarifications (10/30/78)

• OSHA Instruction CPL 02-01-025, Guidelines for

Point of Operation Guarding of Power Press

Brakes

• OSHA Instruction STD 01-05-019, Control of

Hazardous Energy (Lockout/Tagout)—Inspection

Procedures and Interpretive Guidance

Occupational Safety and Health

Administration Training Programs

• OSHA’s Lockout Tagout Interactive Training

Program (http://www.osha-slc.gov/dts/osta/loto-

training/index.htm)

Occupational Safety and Health

Administration Publications

• OSHA Publication 3067, Concepts and

Techniques of Machine Safeguarding

(http://www.osha.gov/Publications/Mach_

Safeguard/toc.html)

• OSHA Publication 3120 - Control of Hazardous

Energy (Lockout/Tagout)

• OSHA Publication 3157 - A Guide for Protecting

Workers from Woodworking Hazards

(http://www.osha.gov/Publication/osha3157.pdf)

Occupational Safety and Health

Administration Topic Pages

• Safety and Health Topics – Control of Hazardous

Energy – Lockout/Tagout (http://www.osha.gov/

SLTC/controlhazardousenergy/index.html)

• Safety and Health Topics – Machine Guarding

(http://www.osha.gov/SLTC/machineguarding/

index.html)

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 53

Appendix A.

Amputation Hazards Not

Covered in this Guide

The following amputation hazards and related

activities are not specifically covered in detail in this

document. They are either covered in other OSHA

publications or specific OSHA standards. While

you may find the general hazard recognition and

machine guarding concepts presented in the

Recognizing Amputations Hazards and Controlling

Amputation Hazards sections of this document

helpful, please refer to the applicable topic-specific

resources and standards listed in the reference sec-

tion of this publication for a complete discussion of

these hazards.

Amputation Hazards Associated

with Saws

Saws are the top source of amputations in whole-

sale and retail trade and in the construction indus-

try. Stationary saws, such as band, radial arm and

table saws, account for a substantial number of

amputations in the workplace. Sawing machinery

used for woodworking applications is not specifical-

ly addressed in this guide.

You can find specific guidance on these saws in

OSHA Publication 3157, A Guide for Protecting

Workers from Woodworking Hazards; 29 CFR

1910.213, Woodworking machinery requirements;

29 CFR 1910.243, Guarding of portable powered

tools; and 29 CFR 1926.304, Woodworking tools.

For additional information on how to safeguard

saws and implement hazardous energy control

practices, you can find guidance at OSHA’s

Machine Guarding eTool section for Saws (http://

www.osha.gov/SLTC/etools/machineguarding/saws.

html) Also, the national consensus standard, ANSI

O1.1-2004, Safety Requirements for Woodworking

Machinery, may provide you with valuable infor-

mation on how to prevent amputations.

Amputation Hazards Associated with

Plastics Machinery

Plastics processing machines are complex pieces

of equipment that require safeguarding and a haz-

ardous energy control program. Serious injuries,

including fatalities, amputations, avulsions, burns

and cuts can occur, especially during servicing and

maintenance work. You can find specific guidance

at OSHA’s “Machine Guarding” eTool section for

“Plastics Machinery” (http://www.osha.gov/SLTC/

etools/machineguarding/plastics/h_injectmold.html).

Amputation Hazards in Agriculture and

Maritime Operations

Requirements for machine guarding in agriculture

operations are contained in the Standards for

Agriculture, 29 CFR Part 1928 Subpart D—Safety for

Agricultural Equipment, and requirements for

machine guarding in maritime operations can be

found in the Shipyard Employment Standards, 29

CFR Part 1915 Subpart H—Tools and Related

Equipment, the Marine Terminals Standard, 29 CFR

Part 1917 Subpart G—Machine Guarding, and the

Longshoring Standard, 29 CFR Part 1918 Subpart

I—General Working Conditions.

Additional Health and Safety Hazards

Other health and safety hazards associated with

using stationary machines, but not addressed in

this guide, include noise, vibration, ergonomic

stresses, exposure to hazardous chemicals (e.g.,

metalworking fluids) and dust, electric hazards, and

flying objects.

Please visit the OSHA website at www.osha.gov

for more information on how to recognize and con-

trol these hazards.

Occupational Safety and

Health Administration

Appendix B.

Amputation Hazards

Associated with Other

Equipment and Activities

Although machinery is associated with amputations

more frequently than any other source, amputa-

tions can result from other sources. This appendix

briefly identifies other equipment and activities

associated with amputations:

• Powered and Non-Powered Hand Tools.

Portable hand tools, such as saws, grinders,

shears, and bolt cutters are associated with

amputations in the construction, retail trade,

and services industries.

• Material Handling. Amputations related to

manual material handling tasks often result

when heavy or sharp objects fall from an elevat-

ed 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 ampu-

tate fingers. These injuries typically result when

a door closes while a person’s hands are in the

doorjamb. 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 com-

pactors are not properly guarded and employ-

ees 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 de-energize and lock out the machine.

Appendix C.

OSHA Regional Offices

Region I

(CT,* ME, MA, NH, RI, VT*)

JFK Federal Building, Room E340

Boston, MA 02203

(617) 565-9860

Region II

(NJ,* NY,* PR,* VI*)

201 Varick Street, Room 670

New York, NY 10014

(212) 337-2378

Region III

(DE, DC, MD,* PA, VA,* WV)

The Curtis Center

170 S. Independence Mall West

Suite 740 West

Philadelphia, PA 19106-3309

(215) 861-4900

Region IV

(AL, FL, GA, KY,* MS, NC,* SC,* TN*)

61 Forsyth Street, SW

Atlanta, GA 30303

(404) 562-2300

Region V

(IL, IN,* MI,* MN,* OH, WI)

230 South Dearborn Street

Room 3244

Chicago, IL 60604

(312) 353-2220

Region VI

(AR, LA, NM,* OK, TX)

525 Griffin Street, Room 602

Dallas, TX 75202

(214) 767-4731 or 4736 x224

Region VII

(IA,* KS, MO, NE)

City Center Square

1100 Main Street, Suite 800

Kansas City, MO 64105

(816) 426-5861

Region VIII

(CO, MT, ND, SD, UT,* WY*)

1999 Broadway, Suite 1690

PO Box 46550

Denver, CO 80202-5716

(720) 264-6550

Region IX

(American Samoa, AZ,* CA,* HI,* NV,*

Northern Mariana Islands)

71 Stevenson Street, Room 420

San Francisco, CA 94105

(415) 975-4310

Region X

(AK,* ID, OR,* WA*)

1111 Third Avenue, Suite 715

Seattle, WA 98101-3212

(206) 553-5930

*These states and territories operate their own

OSHA-approved job safety and health programs

and cover state and local government employees

as well as private sector employees. The

Connecticut, New Jersey, New York and Virgin

Islands plans cover public employees only. States

with approved programs must have standards that

are identical to, or at least as effective as, the

Federal standards.

Note: To get contact information for OSHA Area

Offices, OSHA-approved State Plans and OSHA

Consultation Projects, please visit us online at

www.osha.gov or call us at 1-800-321-OSHA.

SAFEGUARDING EQUIPMENT AND PROTECTING EMPLOYEES FROM AMPUTATIONS 55

Occupational Safety and

Health Administration

137.229150 Osha3170

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