What Are Common Types of Machine Hazards That Can Be Mitigated with Proper Machine Guarding?

Proper machine guarding is essential for protecting workers from a wide range of mechanical hazards found in industrial environments. These hazards can cause serious injuries such as amputations, lacerations, crushing, or entanglement if not properly controlled. Common machine hazards include:

Point of Operation Hazards

Where the machine performs work on material—such as cutting, punching, or bending. Guarding prevents contact with moving parts like blades, dies, or drills.

Rotating Parts

Includes spindles, chucks, shafts, couplings, and flywheels. Guards protect against entanglement, especially with loose clothing or hair.

In-Running Nip Points

Where two rotating parts move toward each other (e.g., rollers, gears, or pulleys). These can pull in fingers or hands if not properly guarded.

Shear Points

Created when two machine parts move across one another or a moving part passes a fixed object. Common in press brakes or robotic cells.

Impact Hazards

From moving machine components such as swinging arms, robotic arms, or parts ejected during operation.

Flying Chips or Sparks

Produced during cutting, grinding, or machining operations. Barrier guards or enclosures help contain debris and protect workers’ eyes and skin.

Stored Energy and Unexpected Startup

Hydraulic or pneumatic systems can release hazardous energy unexpectedly. Interlocks, lockout points, and pressure sensors help mitigate these risks.

Using the right machine guarding—whether fixed, interlocked, adjustable, or presence-sensing—dramatically reduces these hazards and ensures compliance with OSHA 1910 Subpart O and ANSI B11 standards.