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PR-2127-055-05 - Machine Guarding


PR-2127-055-05 - Machine Guarding

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Machine Guarding

This procedure applies to all personnel of Redland City Council performing work which include
contractors, visitors and volunteers.


The purpose of this procedure is to provide guidelines for Redland City Council machinery users
on machine guarding to minimise the risk to health and safety when working with or near

Enclosure – a fixed physical barrier.

Fence – fence or rail enclosure restricting access.

Guard – prevents contact with moving parts.

Hazard - a hazard is a source of potential harm or a situation with the potential to cause loss.

In-going Nip Points - two or more mechanical components rotating in opposite directions in the
same plane and in close conjunction or interaction.

Location – physical inaccessibility under normal operating conditions - hazards within one meter
of the floor are considered accessible.

Mechanical Power – mechanical components including gears, cams, shafts, pulleys and belts etc
that transmit energy and motion from source of power to points of operation.

Point of Operation – where work is actually performed on materials.

Risk – a chance that an event will occur in a workplace which will result in personal injury or loss to
an organization.

RCC – Redland City Council.

Shear Points – a reciprocal (sliding) movement of a mechanical component past a stationary point
on a machine such as the blades of a screw conveyor.

Supervisor - a person in control of a workplace. (Example: overseer, foreman, ganger, leading
hand & team leader).

Training Officer – any person that performs or conducts training to any employee, contractor,
visitor or volunteer.

                                                  CMR Team use only
Department: CORPORATE SERVICES                                        Effective date: 08/12/2008
Group: Human Resources                                                Version: 2
Approved by: General Manager Corporate Services                       Review date: 31/12/2011
Date approved: 08/12/2008                                             Page: 1 of 4
Actions and Responsibilities

Chief Executive Officer - The Chief Executive Officer is responsible for any outcomes from hazards
or risks associated with the organisation.

Managers - Managers are responsible for ensuring the development and implementation of the
machine guarding management procedure.

Supervisors - Supervisors are responsible for ensuring staff and contractors under their control are
aware of, and comply with, machine guarding requirements.

WHS Unit – The WHS Unit are responsible for:

     •    providing assistance in machine guarding development;
     •    assisting in the selection of personal protective equipment;
     •    ensuring risk assessments are conducted for machine guarding;
     •    providing periodic audits of machine guarding;
     •    advising Managers / Supervisors on machine guarding control strategies;
     •    ensuring ongoing training and educational sessions are conducted.

Training Officer - The Training Officer in association with the Supervisor is to ensure that
employees have access to appropriate training in the area of machine guarding. Training should be
provided in the following instances:

     •    when a worker is inducted into jobs which require machinery use;
     •    when new tasks, equipment, tools or processes are introduced;
     •    refresher training at regular intervals and after returning from an extended absence.

Employees - Employees are to:

     •    comply with machine guarding requirements as detailed in this procedure;
     •    look for hazards / risks in relation to machine guarding and report them to their Supervisor
          together with any suggestions to manage / reduce the risk.

General Safety

Machines are a major cause of accidents and must be identified and controlled to avoid injury to
employees working on or near machines.

General Requirements Regarding: Service and Maintenance

Machine manufacturers consider a range of likely hazards associated with use of a machine at the
time of manufacture and accordingly install machine guards where it is considered by the
manufacturer to be appropriate. Guarding supplied by the manufacturer should therefore remain in
place on the equipment except during properly protected repair and maintenance that utilises
energy neutralisation procedures such as lock out / tag out. All guards shall be
re-installed before the equipment is returned to service.

                                                  CMR Team use only
Department: CORPORATE SERVICES                                        Effective date: 08/12/2008
Group: Human Resources                                                Version: 2
Approved by: General Manager Corporate Services                       Review date: 31/12/2011
Date approved: 08/12/2008                                             Page: 2 of 4

All personnel performing servicing and maintenance must be properly trained, qualified, and
competent to perform the task.

Only authorised employees are permitted to perform servicing and maintenance on machines and
remove guards.

Risk Assessment

Manufacturers cannot however anticipate the complete range of uses to which machines will be
applied. Accordingly, any machine motion or condition, which can cause injury, is considered
hazardous and the risks associated with this hazard should be assessed and controlled using the
Risk Assessment Process.

By performing a risk assessment, decisions related to requirements for safe handling (e.g. lock out
and tagging, guards effectiveness, maintenance and replacement) can be made.

Potential machine hazards that may require guarding controls can be identified through reviewing
manufacturer checklists, consultation with suppliers and employees, and a review of injury records.

Where Risk Assessment shows that the machinery presenting the hazard needs to continue in
use, guarding should be considered as one of the risk control measures. In considering guarding
as a control the following points, as an example, require specific consideration:

     •    points of operation;
     •    in-going nip points;
     •    rotating parts;
     •    flying chips and sparks.

Requirements of Machine Guards

Where machine safeguards are determined as an appropriate risk control measure they must:

     •    conform to or exceed the requirements of Australian Standards and workplace health and
     •    afford maximum protection;
     •    prevent access to the danger zone during operation;
     •    not weaken the structure of the machine;
     •    not interfere with the machines operation;
     •    be designed for the specific machine and job;
     •    be fire and corrosive resistant;
     •    be durable;
     •    not be a source of additional hazard.

Requirement for Subsequent Risk Assessment

Wherever the risks associated with machinery have been controlled via use of a guard (either
through modification of an existing guard or the development of a new guard) a subsequent written
risk assessment must be completed. From the findings of the risk assessment a work procedure
would need to be developed to guide operators.

                                                  CMR Team use only
Department: CORPORATE SERVICES                                        Effective date: 08/12/2008
Group: Human Resources                                                Version: 2
Approved by: General Manager Corporate Services                       Review date: 31/12/2011
Date approved: 08/12/2008                                             Page: 3 of 4

Even the most elaborate safeguarding system can not offer effective protection unless the operator
knows how to use it and why. Specific and detailed training is therefore a crucial part of any effort
to provide safeguarding against machine related hazards. Thorough operator training should
involve instruction or hands on training in the following:

     •    a description and identification of the hazards associated with particular machines;
     •    the safeguards themselves, how they provide protection and the hazards for which they
          are intended;
     •    how to use the safeguards and why;
     •    how and under what circumstances safeguards can be removed and by whom (in most
          cases, repair or maintenance personnel only);
     •    what to do (e.g. contact the supervisor) if a safeguard is damaged, missing or unable to
          provide adequate protection.

This kind of safety training is necessary for new operators and maintenance or set up personnel.
When any new or altered safeguards are put in service or when operators are assigned to a new
machine or operation.

Reference Documents
Workplace Health and Safety Act 1995;
Workplace Health and Safety Regulations 2008;
Plant Advisory Standard;
Australian Standard AS 4024.1- 1996 Safeguarding of Machinery;
Workplace Health and Safety – Guide to Practical Machine Guarding.

Associated Documents
FACT-2127-055-B   Machine Guarding Guidelines;
FACT-2127-055-C   Types of Machine Safeguarding.

Document Control

    •    Only the General Manager Corporate Services can approve amendments to this document.
         Please forward any requests to change the content of this document to the General

    •    Approved amended documents must be submitted to the Office of the Chief Executive
         Officer to place the document on the Policy, Guidelines and the Procedures Register.

                                                  CMR Team use only
Department: CORPORATE SERVICES                                        Effective date: 08/12/2008
Group: Human Resources                                                Version: 2
Approved by: General Manager Corporate Services                       Review date: 31/12/2011
Date approved: 08/12/2008                                             Page: 4 of 4

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