A Complete Guide to Machine Safety

Machine safety involves implementing practices, procedures, and technologies to shield workers from hazards posed by industrial machinery. Machines pose risks in factories and industrial settings such as sharp edges, clamps, and hot surfaces. Operational precautions, including physical guarding and warning signs, are crucial for safety. Additionally, machinery safety systems utilising switches and sensors help monitor operator-machine interactions, reducing risks when physical guarding is challenging.

Machine safety is vital to prevent injuries and accidents in industrial settings, where machinery poses diverse risks to operators and workers. Risks associated with industrial machinery include cuts, burns, crushing injuries, limb entanglement, concussions, and wounds from moving parts or ejected objects. Operating machines safely is paramount, as poorly maintained equipment is more prone to hazardous breakdowns and power failures. Regular risk assessments and proper training for machine operators are essential measures to ensure safety.

Let’s take a look at the key products that can be integrated into machinery or production lines to help ensure the health and safety of your employees:

While industrial machinery varies in function, safety principles remain consistent across lathe machines, grinding machines, presses, and packaging machines.

• It is essential to read the operating manual of any new machine carefully, even if you are already familiar with the basics. Always follow the instructions given. For more detailed guidance, refer to the handbook on guarding and operation of machinery provided by the HK Labour Department.
• Always wear machine-appropriate personal protection equipment (PPE). Closed-toe shoes protect your feet from impact and falling items and also reduce the risk of slips. Full wrap goggles shield your eyes from debris that may escape the guarding. Cut-resistant gloves can ward off injuries caused by exposure to sharp edges and blades. Read our guide to PPE here.
• Only operate machinery for which you have received full training.
• Visually assess the machinery and its fixtures and fittings before use, looking for any potential problems.
• Tie back loose clothing and hair and remove any jewellery to avoid the risk of entanglement.
• Ensure that there are no slipping or tripping hazards in the vicinity.
• Ensure you know the location of the emergency stop (e-stop) button if one is present and make sure you can access it immediately if needed.
• Establish clear lockout procedures and install barriers as appropriate, enabling the complete cessation of electrical current in emergencies or for maintenance. Presence-detecting light curtains will induce an emergency shutdown if they detect limbs in hazardous areas.
• Make sure appropriate guarding (shielding) is securely installed to protect operators and critical parts of the machinery itself from flying debris, sparks, moving parts, or entanglement hazards. Cabling should also be appropriately guarded. Only use guarding that is free from its own hazards – e.g., sharp edges. Always switch off machinery when stepping away from it.
• Fit easy-to-understand safety warning signs in visible locations for the benefit of anybody in the vicinity of the machine.
• Ensure that a well-thought-through cleaning and maintenance system is in place so that workers involved in such tasks are not exposed to unnecessary risks.
• Only fully trained technicians should conduct repairs and modifications.

Machine Guarding Safety Guidelines

• Never remove or tamper with machine guarding. If the shielding is worn or is coming loose, it should be repaired or replaced as soon as possible, not removed. Don’t run the risk of serious injury.
• Guarding repair or replacement should only take place during properly organised machinery maintenance.
• Never be tempted to bypass guarding and barriers, even to dislodge jammed items or conduct very small tasks: this is a regular cause of accidents.
• Guarding and barriers are not replacements for PPE when operating hazardous equipment.
• Proper training is vital to risk management. A machine operator who is aware of the key risks is much less likely to injure themselves.
• Always be aware of your surroundings when operating factory machinery. Notice if things don’t look or sound right. Surprises cause accidents.
• Don’t distract machine operators unless it is really necessary – a loss of attention could have serious consequences.
• Maintain regular maintenance schedules. Don’t skip scheduled checks: it’s far better to catch mechanical issues or developing faults before they cause an accident. Replace filters, sharpen blades and lubricate parts as necessary to cut the risk of breakdowns and overheating.