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Machine Guarding Audit Checklist


This checklist helps safety officers audit their workplace for noncompliance with OSHA’s machine guarding regulations. Help keep your worker’s life and limb intact by ensuring the following categories and related requirements are adhered to:

  • • Machine guarding
  • • Barrier guarding
  • • Emergency stops
  • • Grinders
  • • Tufting machines
  • • Woodworking
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Machine Guarding Audit Checklist

Audit

Machine Guarding

Are the required SAFE forms (i.e. SAFF068.1.0-New Equipment Checklist; SAFF068.2.0-Machine Audit Checklist) being used? **Verify that the required forms are being used to document the machine guarding assessments.**

Was the facility machine guarding assessment completed during the last 12 month period? **Unless an initial assessment wasn't completed this should be just a verification of the current status of guarding against the previously completed assessment.

Were machine audit checklists completed for all plant machines? **During the physical assessment, identify a sampling of equipment across the plant (i.e. 10 machines).

Has the installation of guarding retrofits on non-compliant machines been completed? **Interview the safety training manager to determine status. Verify by sampling (i.e. 10 machines) with guarding deficiencies identified during the plant assessments as d

Has a plan been developed to install guarding retrofits on non-compliant machines? **Interview the safety training manager (or as appropriate) to determine what plan for correcting deficiencies was developed following the assessments.**

Have risk assessments been completed for all machinery and equipment in use? **Have risk assessments been conducted using the machine guarding assessments as a baseline. Review the risk assessments.

Where significant risk has been identified by the risk assessment process have controls, including guarding, been identified and implemented?

The site has a documented preventative maintenance program to ensure guards are properly maintained to ensure their effectiveness. **Review documentation of preventative maintenance program. This will require reviewing the program in MRP II with the maintenance plan.

Were all Managers and Supervisors trained on machine guarding during the Review Period of the audit? **This training must be completed within 365 days of the last training. The review period may range from 12 to 60 months and will be defined by the Lead Auditor.

Were all Affected Employees trained on machine guarding during the Review Period of the audit? **This training must be completed within 365 days of the last training. The review period may range from 12 to 60 months and will be defined by the Lead Auditor.

Does the machine guarding training documentation for the Review Period of the audit include the date of training? (The review period may range from 12 to 60 months and will be defined by the Lead Auditor.)

Does the machine guarding training documentation for the Review Period of the audit include the signature of the trainer? (The review period may range from 12 to 60 months and will be defined by the Lead Auditor.)

Does the machine guarding training documentation for the Review Period of the audit include the signatures of trainees? (The review period may range from 12 to 60 months and will be defined by the Lead Auditor.)

Does the machine guarding training documentation for the Review Period of the audit include the topic of training? (The review period may range from 12 to 60 months and will be defined by the Lead Auditor.)

Does the machine guarding training documentation for the Review Period of the audit include the outline/description of what was covered? (The review period may range from 12 to 60 months and will be defined by the Lead Auditor.)

Is compressed air not used for cleaning purposes except where reduced to less than 30 psi. and then only with effective chip guarding and PPE? **During the physical assessment, look for usages of compressed air.

Abrasive blast cleaning nozzles are equipped with an operating valve that must be held open manually, with support provided on which the nozzle may be mounted when not in use.

Are machines designed for a fixed location securely anchored to prevent walking or moving? **Are stationary tools such as drill presses, hydraulic presses, table saws, grinders, etc. secured to either the floor or structure?

Are all portions of bandsaw blades enclosed or guarded, except for that portion between the bottom of guide rolls and the table? **During physical assessment, inspect each bandsaw for proper guarding.

Are guards affixed to the machine where possible and secured elsewhere if for any reason attachment to the machine is not possible. The guard shall be such that it does not offer an accident hazard in itself.

All guards are rigidly braced every 3 feet or fractional part of their height to some fixed part of machinery or building structure? **During physical assessment, inspect guards for secure mounting/reinforcement. Installations should be secure.

When the periphery of the blades of a fan is less than seven (7) feet above the floor or working level, the blades are guarded. The guard having openings are no larger than ½ inch.

Is the point of operation of machines whose point of operation exposes an employee to injury properly guarded? **During the physical assessment look at points where actual work is done on the product or its intermediates.

Where employees are exposed, are flywheels located within seven feet of floor level properly guarded? **During the physical assessment, look for any instances where flywheels are located within 7 feet of the floor?

Where employees are exposed, are pulleys located within seven feet of floor level properly guarded? **During the physical assessment, look for any instances where pulleys are located within 7 feet of the floor?

Mechanical power transmission pulleys are kept in proper alignment to prevent belts from running off. **During physical assessment, review any belt systems for proper alignment, for example, an imaginary line drawn through the centerline of the drive belt.

Where employees are exposed, are horizontal and vertical belt drives located within seven feet of floor level properly guarded? **During the physical assessment, look for any instances where belts drives are located within 7 feet of the floor?

On mechanical power transmission components inspections are made of belts, lacings, and fasteners and such equipment kept in good repair.

Where employees are exposed, are sprocket wheels and chains located within seven feet of floor level properly guarded. **During the physical assessment, look for any instances where sprockets wheels, and chains are located within 7 feet of the floor?

Are all gears within 7 feet of the floor are not properly guarded? **During the physical assessment, look for any instances where flywheels are located within 7 feet of the floor.

Are all vertical and/or horizontal shafting guarded? **During the physical assessment, look for any instances where shafts are located within 7 feet of the floor. Are the shafts either guarded with a fixed guard, a barrier, or with an electronic/mechanical guard?

Are all motor couplings, keyways, and set screws guarded? **During the physical assessment observe all motor coupling, keyways, and set screws. These should be guarded to prevent access.

Does the project shaft end present a smooth edge and the end does not project more than one-half the diameter of the shaft unless guarded by nonrotating caps or safety sleeves?

Are unused keyways on projecting shaft ends filled up or covered? Unfilled keyways/projecting keys on shafts require that either the shaft be trimmed flush or guarded with a cap or cover, otherwise they are non-compliant.

The regular oilers for mechanical power-transmission apparatus wear tight-fitting clothing or machinery is oiled when not in motion. **Interview the maintenance planner/scheduler to determine what equipment lubrication is scheduled during the audit.

Special hand tools for placing and removing material are provided to permit easy handling of material without the operator placing a hand in the danger zone.

Program Major Finding. There are not sufficient minor findings that there is an overall program/section failure.

Machine Guarding Barrier Guarding

On barrier guards, is the opening between the bottom of the barrier and the floor less than or equal to 6 inches. **During the physical assessment verify that the distance between the bottom of all barrier guards and the floor does not exceed 6".

On barrier guards, is the height of the barrier a minimum of 5'. **During the physical assessment verify that the minimum height of all barrier guards is 5'. Verify that the 8-foot rule condition is still being met.

On barrier guards, does the barrier guard completely enclose and prevent access to the hazards being guarded? **During the physical assessment, visually inspect the barrier guards for openings.

On barrier guards, any gated entry points are interlocked to machine power or openable only with a tool or through a keyed access lock.

On barrier guards, any non-gated entry points are interlocked to machine power using a presence sensing device(s), such as a scanning laser, light curtain, or safety mat.

On card barrier guards, do entry gates have a 2-minute timer (non-adjustable) preventing the release of trapped gate keys before the timer has elapsed.

Machine Guarding Emergency Stops

Are all machines equipped with a minimum of 1 Category 0 Emergency Stop? **Interview the plant engineer/electrical engineer to determine if provided emergency stops disconnect machine power.

Are emergency stops installed at all locations where workers interact with machinery/equipment? **Look for an emergency stop located at all operator control stations.

Are emergency stop buttons used for emergency stopping of machinery are red mushroom-shaped buttons with a yellow background?

Are the emergency stop buttons free of operating obstructions, i.e. hoods, cover, shrouds, etc.? **Full or partial cylinder button shrouds/hoods/protectors are not permitted. Recessed button installations are also not permitted.

Emergency stop (cable pull) cable switches used for emergency stopping of machinery are safety-rated emergency stop switches? **Safety rated cable pull switches will be so marked; an alternative marking is a circle containing an arrow.

Emergency stop cables are not obstructed/contacting the machine or adjacent structure/eyelets, etc. **Look for points in the emergency stop cable runs where the cable contact equipment framework/adjacent structure/vector and/or directional eyelets.

Emergency stop (cable pull) cables used for emergency stopping of machinery are red or labeled "emergency stop" in both English and Spanish? **All emergency stop switches should be red in color.

Emergency stop (cable pull) cables are properly tensioned? **On those installations with cable switches having tension windows typically arrows must be aligned with cursor marking.

Machine Guarding Grinders

Is the "ring test" conducted on all grinding wheels prior to mounting for use? **Ask this question of maintenance associates. Have them describe the test.

The spindle speed of the machine is checked before mounting the wheel? **Ask maintenance associates how they do this.

Do all grinding wheels fit freely on the spindle and remain free under all grinding conditions? **Inspect during the walkthrough.

On bench grinders do the distance between the wheel periphery and the adjustable tongue or the end of the peripheral member at the top never exceed one-fourth inch? **Inspect during the walkthrough.

Are work rests on grinding machines kept adjusted closely to the wheel with a maximum opening of one-eighth inch to prevent the work from being jammed between the wheel and the rest, which may cause wheel breakage? **Inspect during the walkthrough

On abrasive wheel machines (i.e. grinders) safety guards cover the spindle end, nut, and flange projections. **Inspect during the walkthrough.

Are grinding machines equipped with flanges that are at least one-third the diameter of the wheel and the flanges are in good condition? **Inspect during the walkthrough walkthrough.

Machine Guarding Tufting Machines

On tufting machine exit roller guards, are the guards an approved Risk Management design/installation? **Inspect the guard installation to ensure that they are in compliance with table 10.

On tufting, machine drive end guards, do the guards prevent access to all moving parts? **In the field, look at the drive end guard installations on a minimum of 5 tufting machines.

On tufting machine drive end guards, the interlock switches on the hinged door are safety-rated switches. **In the field, look at the interlock switches on the drive end guard hinged doors, are they safety-rated switches.

Machine Guarding Woodworking

On woodworking machines means are provided for rendering motor controls or devices inoperative while repairs or adjustments are being made to the machines they control. **Ask operators how they do this.

Woodworking machines are provided with mechanical or electrical power control on each machine to make it possible for the operator to cut off the power from each machine without leaving his position at the point of operation.

Are all woodworking machinery and equipment such as table saws, drill presses, joiners, etc., suitably guarded? **Observe equipment for manufacturer's guards being in place and functioning. Observe for areas that do not have guards that might be hazardous.

Is all woodworking machinery prevented from automatically restarting following a power failure? **Ask the operator what happens if the power goes off and how they restart the machine.

Do table saws have proper hood-type guards with spreaders and dogs intact? **Observe for manufacturers guards.

Do jointers have guards in place and operable? **Observe for hazardous areas and guards being in place.

Do self-feed rip saws have anti-kickback fingers? **Look for this during the walkthrough and have the operator explain how they work.

Do radial saws have a hood and adjustable lower guard in place? **Observe during the walkthrough and make sure guard retracts when lifted then recovers the blade when lowered.

Cleanliness is maintained around woodworking machinery. particularly as regards the effective functioning of guards and the prevention of fire hazards in switch enclosures, bearings, and motors. **Observe during the walkthrough.

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