What are the key steps to improve workplace safety with machine guarding?

Improving workplace safety with machine guarding involves a structured approach that ensures both compliance and protection for personnel. Here are the key steps:

1. Conduct a Machine Risk Assessment
   Identify all potential hazards associated with each machine, including pinch points, rotating parts, and cutting edges. Evaluate the severity, frequency, and probability of exposure to determine the required level of safeguarding.

2. Implement the Hierarchy of Controls
   Apply engineering controls first—such as fixed guards, interlocked gates, and presence-sensing devices—before relying on administrative controls like training or PPE. This ensures hazards are eliminated or controlled at the source.

3. Select the Right Guarding Solutions
   Use appropriate guarding for the specific application:

   • Fixed guards for infrequently accessed areas

   • Interlocked guards where access is needed but must trigger machine stop

   • Light curtains, safety scanners, or 3D radars for flexible, high-traffic zones

4. Follow Applicable Standards and Regulations
   Ensure all guards meet OSHA requirements and ANSI/ISO standards such as ANSI B11.19 or ISO 13857. Understand the difference between shall (mandatory) and should (recommended) requirements.

5. Verify Safety Distances and Proper Installation
   Guards must be installed at safe distances to prevent access to hazards during machine operation. Verify dimensions using minimum opening charts and reach distance standards.

6. Integrate Safety Devices into the Control System
   Use safety relays or safety PLCs to monitor guard status, emergency stops, and energy isolation points. Ensure devices meet required Performance Levels (PLr) or Safety Integrity Levels (SIL).

7. Train Employees and Promote Safety Culture
   Ensure operators, maintenance staff, and supervisors understand the purpose and proper use of guards. Reinforce the message that safety is a shared responsibility.

8. Perform Regular Inspections and Preventive Maintenance
   Schedule routine checks to ensure guards and safety devices remain effective and functional. Damaged or bypassed guarding should be repaired or replaced immediately.

9. Partner with a Turnkey Machine Guarding Solutions Provider
   Collaborate with experts who can evaluate your facility, design custom solutions, ensure compliance, and provide full installation and support.

By following these steps, manufacturers can reduce injury risk, improve compliance, and create a safer, more productive workplace.

For help improving your facility’s machine guarding, contact PowerSafe Automation today.