Machine safety matters

By Staff Report October 28, 2024 6:01 pm IST

Manufacturing units are established with machinery; thus, machine safety has to be in place to prevent injuries and protect equipment. This article covers machinery, safety protocols for employers and employees, and the importance of audits to create a safe, productive workplace with strong safety management systems.

Moving machine parts in any workplace is a risky affair, leading to severe injuries such as crushed fingers or hands as well as burns and blindness. An International Labour Organisation (ILO) study has revealed that nearly three million workers worldwide lose their lives annually due to work-related accidents. India saw as many as 1,109 deaths and more than 4,000 injuries in registered factories, on average, each year between 2017 and 2020.

Machine-related injuries incur high costs, raising the potential of increased compensation premiums for workers. Amputation is the most severe and disabling injury, sometimes leading to permanent disability.

Overview of machine safety

Organisations must approach machine safety as a must-have in industrial operations. With automation and robotics prevailing in manufacturing, safeguarding workers and equipment is important. Machinery can cause injuries in various ways:

Impact and ejection: Moving parts or ejected materials can strike and injure people.

Entanglement: Body parts can be drawn or trapped between rollers, belts, and pulley drives.

Sharp objects: Sharp edges and pointed parts can cause cuts, stab wounds, or abrasions.

Crushing: People can be crushed between moving parts or between moving and fixed parts.

Shearing: Parts moving past each other can cause shearing injuries.

Temperature hazards: Hot or cold machine parts, materials, or emissions can cause burns or scalds, and electrical components can lead to electrical shocks and burns.

Why is machine safety important? 

Machine safety measures shield employees from potential injuries and fatalities. Safety protocols reduce the risk of accidents and create a safer working environment.

Machine safety measures also safeguard expensive equipment from damage. Industrial machinery is costly to repair or replace, and any downtime due to equipment damage can lead to severe productivity losses.

Compliance with safety regulations is imperative in industrial settings. Many countries enforce strict safety guidelines to protect workers and operational integrity. Non-compliance with these regulations can result in severe penalties, fines and even temporary shutdowns of operations.

Machine safety rules for employers and employees 

Potential risks must be assessed and mitigation plans developed before any machine is operated. Basic safety rules and measures are crucial for employers and employees to prevent accidents.

Rules for Employers

Comprehensive Training Programs: All employees should receive thorough training in machinery operations, safety protocols, and emergency procedures.

Scheduled Maintenance Routines: Establish and follow regular maintenance schedules to keep machinery safe and operational.

Installation of Safety Guards: Equip machines with appropriate guards to protect employees from moving parts and hazards.

Lockout Systems: Implement procedures to prevent accidental machine startup during maintenance or repair.

Clear Safety Signage: Display prominent signs and instructions near machines to remind employees of hazards and procedures.

Provision of Personal Protective Equipment (PPE): Supply necessary PPE like safety glasses, gloves, and earplugs and ensure compliance with usage.

Risk Assessments: Regularly evaluate machinery-associated workplace risks.

Organised Workspaces: Maintain machine areas tidy to reduce the risk of accidents.

Emergency Response Protocol: Establish clear guidelines for handling machine-related accidents and emergencies.

Cultivate Reporting Culture: Encourage employees to report potential hazards or equipment malfunctions without hesitation.

Rules for Employees

Adhere to Procedures: Follow provided training and operational procedures specific to each machine.

Wear PPE: Always wear the provided PPE consistently.

Safely Operate Machines: Use machines strictly according to their intended purpose and do not bypass safety features like guards or interlocks.

Report Hazards: Immediately notify a supervisor of any unsafe conditions or malfunctions observed.

Engage in Safety Training: Participate in safety training sessions to stay informed about current safety practices.

Maintain Housekeeping: Keep the work area clean and organised to prevent accidents such as trips, falls, or interference with machinery.

Remain Alert: Stay vigilant and focused while operating machinery, avoiding distractions that could compromise safety.

Use Lockout Systems: Respect and utilise lockout/tagout systems during maintenance or when machines are not used.

Follow Safety Instructions: Pay attention to and comply with safety signs and instructions posted near machinery.

Avoid Taking Shortcuts: Never compromise safety by taking shortcuts in operating procedures.

Put back the guards: After the machine maintenance, the guards should be returned to their original condition. It has often been observed that the guards are not put back or installed inadequately. This results in the unguarded rotating or moving machine part exposing the person to a potential accident.

Making machine safety an integral of overall safety 

The presence of machine safety in the overall safety of the management system of an organisation is crucial if you want a comprehensive approach to workplace safety. Safety considerations have to be standardised and systematically addressed across all operations.

A cornerstone of this integrated approach is cultivating a strong safety culture where safety is a priority and a core value every employee embraces. This involves leadership commitment, transparent communication channels and a continuous drive for improvement. Holistic safety policies and procedures play a considerable role, encompassing machine safety, workplace ergonomics, and emergency response protocols.

Importance of safety audits

Regular audits and reviews of safety performance identify areas for improvement and maintain the effectiveness of safety measures. These audits are generally conducted by third-party organisations and cover all aspects of the safety management system, including machine safety.

A safety audit assesses situations that could result in injury or harm to individuals and assets. It evaluates high-risk tasks such as working at heights, using machines and equipment, confined space entry, lifting operations, electrical and fire safety, excavation, and contractor safety. It scrutinises leadership commitment, accountability, risk assessment, management practices, and permit-to-work procedures.

Conducting a safety audit involves examining safety controls related to risk-based activities, including using machines. It evaluates the effectiveness of existing safety measures aimed at preventing severe injuries. The audit employs a tailored approach to assess an organisation’s safety performance, comparing it against global best practices. The findings are consolidated into a customised report that addresses the organisation’s specific needs, offering insights into its current status related to safety and identifying areas for improvement.

Machine safety maintains a safe and productive workplace. Industrial safety begins with secure machinery and a safety management system. Effective steps to machine safety include conducting regular safety audits and risk assessments and applying effective safety protocols within the organisation.