Machine Guarding Projects

Ballistic steel curtain system in Duncan, SC to reduce crush hazards in pressing applications.

Open-access telescoping guard in Benton, AR with RFID switch to reduce cut hazards.

Wire drawing enclosure in Benton, AR with zone stop control to reduce wrap hazards.

Twin-table CNC guarding in Salisbury, NC using 3D radar to reduce entanglement hazards.

Router guarding in Salisbury, NC with radar presence sensing to reduce sharp edge hazards.

Bandsaw guarding in New Philadelphia, OH with polycarbonate panels to reduce debris hazards.

Bandsaw guarding in Irvine, CA using safety laser scanner to reduce nip hazards.

Vertical guarding system in Irvine, CA with counterbalanced door to reduce pinch hazards.

Roll forming machine guarding system in Lexington, KY designed to protect operators from pinch point and entanglement hazards. Built with hood-style access doors featuring non-contact RFID safety switches and integrated safety light curtains. The system ties into an emergency stop circuit with manual reset at machine controls to ensure controlled access and safe operation during forming and adjustment processes.

Roll forming machine safety guarding system in Green Bay, WI featuring sliding access doors with trapped key safety switches for controlled entry. Built with integrated Keyence 45" safety light curtains and external rail-mounted installation, the system ties into an emergency stop circuit with manual reset at machine controls. Includes emergency rope pull systems along forming and sizing sections to help reduce pinch point and entanglement hazards during operation and adjustment.

This before photo shows a metal stamping press operating without complete machine guarding and risk reduction measures in Chicago, IL. During the machine safety assessment, PowerSafe Automation identified hazards including exposed pinch points at the ram and tooling area, rotating flywheels and belt systems, exposed electrical components, and unrestricted access to moving machine parts. To reduce risk in accordance with OSHA 1910.212 and ANSI B11 standards, engineered safeguarding solutions including interlocked machine guarding, perimeter protection, safer operator access zones, and electrical enclosure upgrades were recommended to improve worker safety and reduce operational liability.

This before photo shows an automated conveyor and transfer system operating without complete machine guarding and risk reduction measures in Shelbyville, IN. PowerSafe Automation identified exposed chains, sprockets, rollers, rotating drive components, transfer pinch points, and unrestricted access to moving machinery that increased the risk of entanglement and crushing injuries. Recommended ANSI B11 safeguarding improvements included perimeter guarding, interlocked access doors, conveyor protection, secured electrical enclosures, and safer operator access zones to improve safety and operational reliability.

This before photo shows a beverage conveyor and packaging line operating without complete machine guarding and risk reduction measures in Toledo, OH. The machine safety assessment identified exposed chains, belts, rollers, and transfer pinch points that created entanglement and contact hazards for operators. Additional concerns included exposed pneumatic and electrical components near moving machinery. Recommended safeguarding improvements included conveyor guarding, interlocked access doors, safer operator access zones, and improved electrical and pneumatic protection in accordance with OSHA 1910.212 and ANSI B11 standards.

This before photo shows a hydraulic broaching press operating without complete machine guarding and risk reduction measures in Lafayette, IN. PowerSafe Automation identified hazards including exposed ram and tooling areas, crush hazards at the point of operation, unrestricted access to moving components, hydraulic exposure risks, and exposed electrical wiring. Recommended ANSI B11 safeguarding improvements included interlocked perimeter guarding, safer operator access zones, secured electrical enclosures, hydraulic protection measures, and enhanced warning signage to improve operator safety and reduce liability exposure.

This before photo shows an automated chain assembly machine operating without complete machine guarding and risk reduction measures in Rockford, IL. The machine safety assessment identified exposed rotating shafts, chains, belts, couplings, pinch points, and unrestricted access to hazardous motion zones. Additional concerns included exposed electrical wiring and trip hazards caused by hoses and loose cables. Recommended safeguarding upgrades included interlocked machine guarding, perimeter barriers, improved hose and cable management, and safer operator access zones to support compliance with ANSI B11 machine safety standards.

This before photo shows a CNC tool changer and automated machining system operating without complete machine guarding and risk reduction measures in Pittsburgh, PA. PowerSafe Automation identified exposed chains, sprockets, rotating shafts, rollers, and moving transfer components that created entanglement and pinch point hazards for operators and maintenance personnel. Recommended ANSI B11 safeguarding improvements included fixed and interlocked machine guarding, perimeter fencing, safer maintenance access points, and improved operator protection around automated tool handling systems.

This before photo shows an industrial belt and pulley drive system operating without complete machine guarding and risk reduction measures in Lafayette, IN. The machine safety assessment identified exposed rotating belts, pulleys, and nip points that created entanglement hazards and increased the risk of contact injuries. Additional concerns included unrestricted access to moving parts, potential for thrown objects from belt failure, and elevated noise exposure. Recommended ANSI B11 safeguarding improvements included fixed and interlocked guarding, containment guarding for rotating equipment, and safer operator access zones.

This before photo shows a consumer packaging conveyor system operating without complete machine guarding and risk reduction measures in Cleveland, OH. PowerSafe Automation identified exposed conveyor belts, chains, rollers, and guide systems that created pinch point and entanglement hazards near operator workstations. Additional concerns included exposed electrical wiring, unrestricted access to moving machinery, and trip hazards caused by hoses and cable routing. Recommended safeguarding upgrades included interlocked conveyor guarding, secured electrical enclosures, improved housekeeping practices, and safer operator access zones.

This before photo shows a flame treating conveyor system operating without complete machine guarding and risk reduction measures in Atlanta, GA. The machine safety assessment identified exposed conveyor chains, sprockets, shafts, couplings, piping, hoses, and electrical wiring that increased the risk of entanglement, pinch point injuries, and operator exposure to hazardous motion. Recommended ANSI B11 safeguarding improvements included interlocked machine guarding, conveyor protection, secured electrical enclosures, and improved hose and cable management to support safer machine operation and maintenance activities.

This before photo shows a gear shaping and rotating machinery system operating without complete machine guarding and risk reduction measures in Louisville, KY. PowerSafe Automation identified exposed rotating shafts, pulleys, belts, couplings, and moving components that created entanglement and pinch point hazards for operators and maintenance personnel. Additional concerns included exposed electrical wiring, unrestricted access to hazardous motion zones, and the potential for ejected parts or debris. Recommended safeguarding upgrades included fixed and interlocked machine guarding, containment guarding, and secured electrical enclosures in accordance with ANSI B11 standards.

This before photo shows an automated labeling and conveyor system operating without complete machine guarding and risk reduction measures in Dalton, GA. The machine safety assessment identified exposed gears, shafts, chains, sprockets, reciprocating components, and conveyor pinch points that created entanglement and contact hazards for operators. Additional concerns included exposed electrical wiring, loose cables, and unrestricted access to moving machinery. Recommended ANSI B11 safeguarding improvements included fixed and interlocked guarding, conveyor protection, safer operator access zones, and improved cable management.

This before photo shows a paper converting machine operating without complete machine guarding and risk reduction measures in Decatur, IL. PowerSafe Automation identified exposed rollers, rotating shafts, and nip points that created entanglement, crush, and amputation hazards near operator and maintenance access areas. Additional concerns included unrestricted access to moving machine components and exposure to ejected debris or material during operation. Recommended safeguarding upgrades included fixed and interlocked machine guarding, safeguarded roller access points, and improved operator protection around hazardous motion zones.

This before photo shows a plate and bar straightening machine operating without complete machine guarding and risk reduction measures in Knoxville, TN. The machine safety assessment identified exposed straightening rolls, rotating shafts, pinch points, and unrestricted access to hazardous motion zones during operation and maintenance activities. Additional concerns included exposure to ejected scale or debris and increased operator interaction near moving machinery during adjustments and troubleshooting. Recommended ANSI B11 safeguarding improvements included fixed perimeter guarding, interlocked access doors, safeguarded loading zones, and enhanced operator protection around hazardous machine motion.