Introduction
In today’s fast-paced manufacturing environment, industrial motion machines are the workhorses of production lines delivering precision, speed, and power. But their complexity and high-speed operation also make them prime candidates for serious workplace injuries if left unguarded or inadequately protected. Companies like Regal Rexnord and Parker Hannifin, which depend on high-performance motion systems, faced significant safety risks with legacy equipment and semi-automated machines.
PowerSafe Automation stepped in to deliver tailored custom machine guarding solutions that not only brought both facilities into compliance with OSHA and ANSI standards but also boosted production efficiency and workforce morale. This case study explores how PowerSafe's engineering-led approach provided custom-fit, high-value safety outcomes across Regal Rexnord's gear-driven machines and Parker Hannifin's motion control platforms.
Client Backgrounds
Regal Rexnord is a global leader in electric motors, bearings, gearing, and power transmission components. Their production environments involve gear hobbing machines, high-torque spindles, shaft coupling systems, and legacy CNC setups.
Parker Hannifin operates as one of the world's largest motion and control technology manufacturers. Their facilities include actuator lines, pneumatic and hydraulic machining, valve body assemblies, and motion-control testing platforms.
Both companies faced similar challenges:
- Aging machines not designed with modern safety in mind.
- Manual operator interactions near nip points, rotating spindles, and moving actuators.
- Lack of reliable emergency stop circuits or interlocked guarding systems.
- Frequent maintenance requiring quick access but without compromising safety.
Challenges and Risk Factors
Unaddressed Hazards
- Entanglement and Wrap Points: Shafts, belts, and rotating elements posed risks of clothing or glove entanglement.
- Crush and Pinch Points: Actuators and guided cylinders created crush zones during cycling.
- Flying Debris: Gear hobbing and valve machining often created hazardous chip ejection.
- Accessibility Issues: Maintenance and setup required guard removal, introducing non-compliance risks.
Compliance Gaps
- Many machines lacked interlocks or emergency stop (e-stop) redundancy.
- OSHA 1910.212 and ANSI B11 standards were not fully met.
- Machines failed internal safety audits due to incomplete guarding.
These gaps placed both operators and companies at risk for injuries, fines, and unplanned downtime.
PowerSafe’s Tailored Guarding Solution
PowerSafe Automation specializes in engineering-driven safety programs that go beyond off-the-shelf guards. For Regal Rexnord and Parker Hannifin, they deployed their Tailored Custom Machine Guarding process:
Step 1: Machine Risk Assessment
- PowerSafe engineers conducted on-site TBRA (Task-Based Risk Assessments) across legacy gear systems, actuator setups, and semi-automated lines.
- Stop-Time Measurement (STM) studies helped define safe opening distances for interlocks and guards.
Step 2: Custom Design & Fabrication
- CAD-modeled T-slot aluminum framing ensured precision fit around unique machine geometries.
- Clear polycarbonate panels-maintained visibility for supervision and troubleshooting.
- Guards included ergonomic access doors, safety hinges, and gas struts for ease of use.
Step 3: Integrated Safety Controls
- Interlocked Doors: Ensured machines de-energized when opened.
- Emergency Stops: Added in reach zones per ANSI B11.19
- Spin Windows: Allowed safe visibility into gear-cutting and lathe operations.
- Two-Hand Controls: Installed on punch and press equipment.
- Presence Sensors: Light curtains and radar devices used where guarding was not feasible.
Step 4: Installation & Operator Training
- Installations occurred with minimal production interruption thanks to pre-fabrication.
- PowerSafe trained operators on safe interaction, emergency protocols, and how to test guards.
- Final inspection validated OSHA 1910.212, ANSI B11.22, and ISO 13857 compliance.
Outcomes & Measurable Benefits
1. Reduced Risk of Injury
Both clients saw a dramatic reduction in near-misses, hand placement injuries, and guard bypass behavior.
- Regal Rexnord reported a 76% decrease in safety incident reports within the first year.
- Parker Hannifin noted zero OSHA recordables related to guarded machines after install.
2. Streamlined Maintenance & Setup
- Maintenance techs had quicker, safer access via removable access panels
- Machine operators used spin-windows and lighted interior zones to inspect without disassembly.
3. Downtime Prevention
- Guard-integrated interlocks reduced unexpected shutdowns due to operator bypass.
- Emergency stops were now fully zoned and labeled, reducing confusion and response time.
4. Compliance & Audit Success
- Both facilities passed internal and third-party audits with zero non-compliance citations
- Insurance providers recognized the upgrades with lower premiums.
5. Operator Morale & Safety Culture
- Operators reported higher confidence working with high-speed systems.
- Maintenance supervisors praised the intuitive design and field-serviceability of the guards.
Sample Projects from the Field
| Machine Type | PowerSafe Guarding Solution |
| CNC Gear Hubbers (Regal) | Hinged enclosures with interlocks and polycarbonate windows |
| Lathe with Tool Changer | Sliding doors with STM-validated magnetic interlocks |
| Pneumatic Actuator Line | Aluminum-framed perimeter guards with light curtain zoning |
| Valve Body Test Rig | Radar sensors + interlocked door systems for partial access |
Why Tailored Machine Guarding Wins
Most guarding solutions on the market are built to be ‘good enough’ or generic. But generic does not work when:
- Machines are decades old.
- Operators need real-time access.
- Multiple shift teams require intuitive, visual safety.
PowerSafe’s approach centered on human interaction, regulatory science, and lean manufacturing. The result was not just a guard. It was a fully engineered risk reduction system.
This included:
- Reduced exposure time
- Safe access for tasks like tool change or part loading
- Clear lines of sight
- Robust controls integration
Strategic Benefits for Regal Rexnord & Parker Hannifin
| Strategic Objective | PowerSafe’s Contribution |
| Increase Uptime | Less unplanned downtime from safety events or e-stop gaps |
| Retain Skilled Labor | Safer, user-friendly systems reduced turnover |
| Reduce OSHA Exposure | Met all relevant standards and passed all audits |
| Improve Insurance Rating | Recognized by carriers as risk-mitigated environments |
| Support Culture of Safety | Boosted buy-in from employees and supervisors alike |
Looking Ahead
Both companies have since expanded the scope of their safety programs with PowerSafe:
- Parker Hannifin has added guarding assessments to their procurement pre-checklists.
- Regal Rexnord is working on site-wide upgrades across their Midwest facilities.
As machine technologies evolve, PowerSafe Automation continues to lead with proactive solutions that blend engineering, compliance, and practical usability.
Conclusion
The success of these projects reinforces why tailored machine guarding is a strategic investment in today’s industrial operations. For Regal Rexnord and Parker Hannifin, it was more than just meeting a safety requirement—it was about engineering peace of mind, efficiency, and a better tomorrow for every operator on the floor.
To learn how PowerSafe Automation can custom design your next guarding solution, visit: https://powersafeautomation.com/tailored-custom-machine-guarding
