PowerSafe partners with factories in the metal forming industry, understanding their unique challenges. Their daily processes can involve high-force operations, moving parts, and extreme temperatures, making effective safeguarding more complex. That's why it's important to partner with a machine safety solutions provider that can custom build machine guarding to your needs.
Common Hazards in the Metal Forming Industry
A shop floor filled with machines and production equipment presents numerous hazards, especially with constantly moving parts. In the metal forming industry, operators work around powerful, unforgiving machines where even a moment of distraction can lead to serious injury. Some of the most common hazards include:
- Shear points
- Crush points
- Wrap points
- Cut points
- Trapped points
Common Machinery in the Metal Forming Industry
Some equipment in the metal forming industry dates back as far as the Industrial Revolution. These aging machines often lack modern OSHA safety standards, posing significant risks to operators. Having the proper machine safety guards installed is essential and can't be replaced by simply instructing workers to "just pay attention." Common machines requiring safety equipment include:
- Die cast machines
- Stamping or forming presses
- Sand mixers
- Robot packaging cells
- Molding equipment
- Conveyor systems
- Smelters
Guarding Solutions for Metal Forming Machines
A wide range of machine guards can be designed through collaboration between PowerSafe's machine safety specialists and those responsible for operating and maintaining the machine. These include:
Machine Guarding Solutions
- Point of Operation Guards – Polycarbonate plastic panels for visibility and protection.
- Perimeter Safety Guarding – Black wire mesh with opening sizes determined by safety distance.
- Safety Switch Integration – Evaluating non-locking RFID vs. locking solenoid types based on each machine's stop behavior.
Presence-Sensing Safety Devices
- Safety laser scanners
- Safety light curtains
- Safety mats or bump strips
- 3D safety radar sensors
Integrated Safety Controls for Legacy Machines
- Grip enabling switches (dead man switches) with emergency stop functionality
- Two-hand controls with anti-tie-down protection
- Pneumatic safety valves and controls
- Emergency stop buttons or emergency rope pulls
Machine Upgrades for Safety & Efficiency
- Location sensors and limit switches
- Adjustment knobs extended straight out or at 90-degree angles via gearboxes
- Encoders and drive upgrades for offline control
- Non-safety-rated cameras for internal monitoring of hazardous areas
Our machine guarding designs are built to custom fit your specific machine, application, and operational needs while remaining user-friendly to create a safer work environment. Any impact on production will depend on necessary machine upgrades or process changes, which should be evaluated internally. Machine guards and perimeter fencing are essential for employee protection, and should be a top priority at your facility.
