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Reinforce safety practices and ensure machine guards are in top condition with easy-to-use machine guarding checklists
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Machine guarding is a safety practice that functions as a barrier between the dangerous or moving parts of the equipment and the workers who operate the machines. It is implemented to prevent machine-related injuries ranging from minor ones, such as burns, cuts, and minor abrasions, and severe ones, like fractures, lacerations, crushing injuries, and even amputation. Machine guarding requirements are provided by health and safety authorities like OSHA and EHS to guide industries in the selection and procurement, safe work practices, inspection, and recordkeeping of machine guarding equipment and devices.
A machine guarding checklist is a structured tool used by safety officers and operations supervisors when inspecting the condition and correct use of machine guards in the workplace. A type of machine safety checklist, machine guarding checklists help ensure that machine guards are in good working condition and that workers are protected and aware of safe practices when operating equipment that requires machine guards.
According to the US Occupational Safety and Health Administration (OSHA), workers who operate and maintain machinery suffer approximately 18,000 amputations, lacerations, crushing injuries, abrasions, and over 800 deaths per year. These incidents can be minimized or eliminated through machine guarding and the use of a dedicated machine guarding checklist.
Installation and regular maintenance of machine guards can prevent worker’s body parts from making contact with hazardous machine equipment and flying debris. Using a checklist for machine guarding will further enhance workplace safety and maintain your asset integrity. Additional defenses such as Personal Protective Equipment (PPE) and proper training are key to ensuring safety when operating machinery in your workplace.
An effective machine guarding checklist begins with identifying hazardous areas and assessing the adequacy of guarding mechanisms. The following elements collectively contribute to a robust machine guarding system, safeguarding against potential accidents:
Begin the checklist by listing the machinery that requires guarding. Include details such as machine names, serial numbers, and locations to create a clear reference point. Document the date when the checklist is created. Regularly updating this information ensures that the checklist is current and reflective of the latest safety standards.
Before operating machinery, conduct a thorough examination of all guards. Ensure that they are securely in place and free from damage. Any issues should be addressed promptly. Check that emergency stop buttons or mechanisms are easily accessible and functioning correctly. This is crucial for swiftly halting operations in case of an emergency.
Maintain records of employee training on machinery operation and safety protocols. Regular training sessions should be conducted to keep employees informed about the latest safety practices. Implement periodic refresher courses to reinforce safety procedures. This helps in preventing complacency and ensures that employees remain vigilant in adhering to safety guidelines.
Specify who is authorized to operate the machinery and inspect their PPE. Restrict access to trained and qualified individuals to minimize the risk of accidents caused by inexperienced operators. Outline any supervision requirements during machine operation. Depending on the complexity of the machinery, having a supervisor present may be necessary to ensure safe practices.
After the machinery has been used, conduct a post-operation inspection. Check for any wear and tear on guards or other safety features and address issues promptly. Include a maintenance schedule for regular checks and servicing of machinery. Well-maintained equipment is less likely to malfunction, reducing the risk of accidents.
End the checklist with a summary of the key findings. Highlight any areas that require attention or improvements, and document the actions taken to address them. Include a field for the inspector’s name and signature, as this can help with accountability and authority.
Here’s a set of questions that you can include in a machine guarding checklist:
Machine Guards | Yes | No |
Are all machine guards in good condition? | ||
Do machine guards prevent workers hands, arms, and other body parts from making contact with dangerous moving parts of machine? | ||
Are all machine guards firmly secured and not easily removed? | ||
Do machine guards ensure that no objects fall into the moving parts? | ||
Do machine guards permit safe, comfortable, and relatively easy operation of the machine? | ||
Training | Yes | No |
Are all operators trained on how machine guards work? | ||
Do operators have the necessary education and training in how to use the guards? | ||
Do operators know the procedure when guards are damaged, missing or inadequate? | ||
Are all operators trained on how and under what circumstances guards can be removed? | ||
People | Yes | No |
Are all employees wearing appropriate PPE? | ||
Do employees follow safe handling instruction using machineries? | ||
Are all employees aware of emergency procedures in case of an accident involving machinery? | ||
Is adequate supervision provided to ensure that employees are following safe machine operating procedures? | ||
Post-Operation | Yes | No |
Are all machine guards in good condition? | ||
Is lock-out tag placed when removing machine guard? | ||
Are all machine updates were escalated to a supervisor? |
Below is a sample completed inspection report for machine guarding, available in PDF format.
Machine Guarding Checklist Sample Report | Mitti (by SafetyCulture)
Employers should strive to keep their workplace and workers safe particularly when working with machinery. Here are some safety reminders when working with machine guards:
Always check if guards are properly installed before commencing work.
Machine guards must be placed in proper position and prevent physical contact with the operator.
Ensure machine guards are secure and strong.
Ensure workers cannot bypass, remove, or tamper machine guards.
When installing machine guarding ensure that no objects can fall into moving parts of the machine.
Ensure employees are trained on a specific machine guard.
Machine guards should not obstruct the operator’s view.
If possible, the machine should be lubricated without removing machine guards.
A competent person must correct the machine guard immediately if defects were detected.
Machine operators should be trained on the hazards associated with particular machines.
Reinforce employee awareness of emergency protocols around machine guarding through toolbox talks.
Lockout the machine before removing guard when performing maintenance.
Conduct regular safety checks using a machine guarding checklist to reinforce safe practices around equipment.
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This OSHA machine guarding checklist is used for evaluating the preparedness of operators when handling machines. It also covers the inspection of the machine guards to ensure that it is securely placed and anchored. Use Mitti (by SafetyCulture) to take photos of identified issues and immediately generate a report for review and corrective action.
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Perform LOTO checks before performing any maintenance work, repairs or installation of guarding on machinery. Record the nature of work, hazardous energy sources and the employees involved in the procedure. Evaluate if the step-by-step LOTO procedures are followed when applying and removing devices.
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In compliance with PUWER 1998, this checklist is designed to evaluate work equipment and/or machineries to ensure machine safety. Download this checklist to conduct regular safety checks on work equipment.
