Rockford Systems provides machine safeguarding solutions and services to help organizations comply with OSHA and ANSI safety standards. They offer safety assessments, engineered guards, products, installation, and ongoing support. The document notes that over 50% of metalworking machines may not be properly guarded, despite guarding being one of OSHA's top cited violations. It provides an overview of various guarding methods like barriers, light curtains, and interlocks that can be used to protect operators from different machine hazards.

1. Rockford Systems, LLC
Machine Safety Compliance 101

2. Rockford Systems, LLC Overview
Rockford Systems delivers innovative machine
safeguarding solutions for organizations working with
industrial machinery.
As a trusted adviser since 1971, Rockford Systems helps
organizations interpret and apply complex OSHA
regulations and ANSI machine safety standards for a broad
array of industrial applications.
In addition, Rockford Systems provides complete Machine
Safety Life-Cycle Management Solutions, including:
– safety education and training
– onsite risk assessments
– onsite machine surveys
– customized engineered design solutions
– safeguarding products
– installation and integration services
– 24-7 technical and in-field support
– ongoing compliance validation

3. Pervasive Lack of Machine Safeguarding
Machine Guarding = OSHA’s Top 10 Most Cited Violations
– According to OSHA, workers
who operate and maintain
machinery suffer approximately
18,000 amputations,
lacerations, crushing injuries,
abrasions and more than 800
deaths per year.
– In 2016 alone, 88% of the total
number of OSHA Machine
Guarding violations were
classified as “Serious.”

4. Pervasive Lack of Machine Safeguarding
Majority of Metal Fabrication Machines Not Guarded
• Rockford Systems estimates that an alarming 50 percent or more of metal
fabricating machinery in the United States do not comply with the critical
safety requirements for guarding outlined by OSHA and the American
National Standards Institute (ANSI).

5. Even NEW Machines Need Safeguarding

6. Covered Topics
• OSHA 1910.212
• ANSI B11.19
• Awareness Barriers
• Point-of-Operation Guards
• Guard Opening Scales
• Interlock Switches
• Function Testing
• Safety Distances
• Drop Out Protection
• Perimeter Guards
• Conveyors
• Disconnect Switches
• Safety Blocks
• Active Opto-Electronic Protection
Devices
• Safety Mats
• Two Hand Controls
• Presence Sensing Devices
• Drop-Probe Devices
• Electrical Control Boxes
• Universal Ball & Socket Shields
• Safeguarding Automation Cels
• NFPA 70E & 79 Electrical Standards
Questions & Answers

7. rockfordsystems.com
OSHA Occupational Safety Health Administration
(since 1971) About half State and half Federal
ANSI American National Standards Institute
(B11 Series on metalworking since 1923)
NFPA National Fire Protection Association
(Electrical Standards NFPA 79 and NFPA 70E)
CSA Canadian Standards Association
(2003 Industrial Robots) very similar to
European MSG Standards and Regulations

8. OSHA 1910.212 General requirements (a) (1)
protect operator & other employees
in the machine area from hazards
• point of operation
• ingoing nip points
• rotating parts
• flying chips & sparks
examples of safeguarding methods: barrier guards,
two-hand actuators, electronic safety devices, etc.
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9. 5 Safeguarding Methods in ANSI B11.19
Location:
(Safe Position
of Controls)
Operator not required to be in the
in Point of Operation hazard area
Distance: Large piecepart size/shape prevents
Operator from reaching the P.O.O.(Safe Holding)
Guards: Prevent access to Point of Operation
Devices: Control access to Point of Operation
Safe Opening: ¼” or less opening at P.O.O.
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10. 1 2
4
Frequency of Exposure
Seldom Occasional Frequent
1 2
4
6
Unlikely CertainPossible Probable
Probability of Injury
1 3
6
10
Minor FatalSerious Major
Severity of Injury
4
6
1
Medium
11
10
9
8
7
6
5
4
3
2
1
12
13
14
15
High
Low
Seldom
Probable
Major
ANSI B11.0 - 2015 Safety of Machinery (Risk Assessment)10
Severity + Probability + Frequency
= Level of Exposure to Hazards
+Avoidance
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11. Rotating Motion
Rotating Motion
Rotating Motion Rotating/Reciprocating Motion
Nip Point
Nip Point
Nip Point
Nip Point
Nip Point
Nip Point
Nip Point
Nip Point
7-footcoversmeetOSHA
8-footcoversmeetANSI
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12. Tail-out
Barrier
Awareness Barriers for lower level EXPOSURES
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13. Over, Under, Through, Around
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ANSI B11.19 - 2010 Annex E “Considerations for Transparent Guards”
Point of
Operation
Guard
Reach
Through?

14. Point of Operation Guard Requirements
OSHA 1910.217(c)(2) and ANSI B11.1-2009(8)(5)
• can’t reach over, under, through, around O.U.T.A.
• OSHA Table 0-10 for openings and distances
• no pinch points between guard & moving parts
• good visibility into the point of operation
• fasteners not readily removable (tool required)
• *materials strong enough to protect people
• *free from sharp edges that could injure people
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15. OSHA Guard Opening Scale – 1971
Liberty Mutual and ANSI Standard writing committee
ANSI Guard Opening Scale – 1996
Liberty Mutual and ANSI Standard writing committee
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Both GOS are available for purchase on our website

16. OSHA
OSHA
ANSI
ANSI
Guard
Opening
Scale
Comparison
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17. Latching Interlock
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Unique Shape of Key

18. Function Testing
Point of operation Guard
2 Reasons to “Function-test” Guard Interlocks
before starting each new operating shift:
1) to make sure the interlock WORKS
2) to make sure it has NOT been CHEATED
OTHER FTC’s: Light Curtains, 2-Hand Controls, Perimeter Guards, etc.
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19. Two-hand Control rules to be a SAFEGUARDING DEVICE:
19
Protect from unintended operation,
Anti-Repeat, Concurrent ½ sec max,
Holding-time, Interrupted-stroke
Anchored at Safety Distance, etc.
rockfordsystems.com

20. Light Curtain
without damaging:
machine - tooling -
work - or creating
another hazard
Presence Sensing Devices
can only be used on
machines that can
stop consistently
and immediately
anywhere in their
stroke or cycle
PointofOperation
Perimeter(Area)
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21. LightCurtain-2HandControl-Guards
MechanicalPowerPresswith3safeguardingmethods:
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22. 2-sided Perimeter
Light Curtain 22
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23. Muting
1) parts ejection
2) circuit checking
3) material feeding
90°
180°
270°
360 °
1/4” die
opening
P.S.D. Muted
on upstroke
P.S.D. Active
on downstroke
Muting used for:
TDC
Crankshaft
Rotation
Light Curtain
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24. Light
Curtain
Blanking
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25. Amber: blanking
Red: obstructed
Green: clear
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No Protection
below this line
Indicator Lights needed for
“Function Test Procedure”

26. “Function Test
Checklist”
here is generic. Look for
make/model specific FT
procedures for your
LC OEM’s website
Function Testing
Light Curtains
before every
operating shift
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SYSTEMS.LLC

27. “Safety Distance” is required for
2-Hand Control and Light Curtain
Stopping Time in seconds at 90°crankshaft position
x 63 inches per second (hand speed constant)
.200 x 63 = 12.6” Safety Distance
= minimum OSHA safety distance
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ANSI Standard Safety Distances are
significantly further away than OSHA

28. STM FLAG NOT
interrupting
Light Curtain
STM FLAG
interrupting
Light Curtain28
rockfordsystems.comChecking Light Curtain Safety Distance on a press
STM

29. Interlocked Safety Block
ANSI B11.1-2009 - lots of new information on Safety Blocks
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MPP: required when adjusting/repairing dies in the press (OSHA)

30. Light Curtain - Press Brake bending operation
ANSI B11.3-2012 Press Brake Safeguarding
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31. LazerSafe
Safeguarding System
ONLY FOR HYDRAULIC
PRESS BRAKES
Close-proximity
Point-of-Operation
Laser AOPD Device
mounted with ZERO
Safety Distance
ANSI B11.3-2012
AOPD - Active Opto-Electronic Protection Device 31
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TM

32. Laser Device
hand-holding
small parts
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Laser Device
for parts with
tall side-legs

33. Pictograms 33
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34. 1/8” maximum opening for Work Rest
OSHA 1910.215 (a)(4)
Bench/Pedestal Grinders
1/4” maximum opening for tongue guard
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35. 1/4”
1/8”
Work Rest
Tongue
Guard
Grinder Gauge is available for
purchase on our website

36. Unused portion
of blade exposed
Unused portion
of the blade
is covered
ANSI B11.10
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37. L-shaped Mats on Horizontal Tube Bender
Two-hand
Control
on floor
pedestal
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Mats must be anchored to the floor

38. Radio Frequency
and Lexan Guards
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Capacitive
Antenna
Device

39. “Drop-Probe” Devices
Mechanically verifies the absence of
hand or fingers in Point of Operation
Riveters, Spot Welders, Staplers, Stakers
Eyeletters, Terminators, Dinkers, Clickers
“Ring-drop” Devices
“Halo” Devices
ANSI B11.19 - 2010 8.7
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40. Riveter with a Drop-Probe
Drop-ProbeDeviceonaSpot-Welder
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“Detect-a-Finger” Drop Probe DeviceTM

41. #1 Hazard - starting lathe with key in chuck
to prevent wrench from being left in chuck
Spring Loaded
Chuck-Wrench
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ANSI B11.6

42. HingedChuckShields
allintheopenposition
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43. Chip/Coolant Shield
with built-in Interlock
Hinged Chuck Shield
with built-in Interlock
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44. Telescopic stainless-steel
sleeves cover horizontal
rotating components44
www.centryco.com
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45. Universal
Ball & Socket
Shields
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ANSI B11.8

46. Upposition
One section locked up
Releasing and Lifting
Downposition
Telescopic
ChuckShield
ANSIB11.8
8.2.3MovableGuards
shallprovideaccessto
hazardareaswithout
theuseoftools
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47. Area Guarding:
1 Safety and 1 Warning
Zone, horizontal mounting
Access Guarding:
1 Safety Zone, vertical mounting,
using contour-as-reference
Access Guarding:
2 Safety Zones, vertical mounting,
using contour-as-reference
1
2
Area Guarding:
2 Safety and 2 Warning Zones,
horizontal mounting
SICKIncorporated
Area Laser Scanners
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48. reprinted with permission
Scientific Technologies Inc.
Safeguarding an Automation Cell
Rotary Interlock
Point of Operation
Light Curtain
Pressure
sensitive mat
Actuator
operated
interlock
Solenoid
locking
interlock
Point of Operation
Light Curtain
Grab-wire
E-stop cable
Actuator
operated
interlock
Magnetic
interlock
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49. 12 inch sweep and 60 inch height (ANSI/RIA) R15.06-1999
6 inch (.15m) sweep, 72 inch (1.8m) height (CSA) 2003
Perimeter Guards for
Robot Automation
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ANSI/RIA R15.06-2012 is the most recent U.S. Standard on Industrial Robots

50. These and others are free downloads; cemanet.org
Conveyor Equipment Manufacturers Association50
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51. Belt Conveyor
Conveyors that start up
automatically require an
Audible or Visual Warning
Device that can be clearly
seen or heard at all points
that people may be present
Reset
ANSI B20.1-2012 5.11.2 (1)
Manual reset or start
at the location where
the Emergency Stop
was initiated required
to resume operation
ANSI B20.1-2012 5.11.4
Reset
Red E-Stop Cables
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52. Engaged
Disengaged
This meets NFPA 79
Electrical Standard for Industrial Machinery
• Red Button
• Manual Latch
• Yellow Background
• Readily Accessible
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53. Article 119.7 Electrical Safety Program
(A) General.
Source: Littlefuse
The employer shall
implement and
document an overall
electrical safety
program that directs
activity appropriate
for the voltage, energy
level, and circuit
conditions.
53
2015
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54. Main Power Disconnects - Motor Starters
Voltages - Grounds - E-stops - and more
Category 1 Stop Controls
Category 2 Stop Controls
Category 3 Stop Controls
2015 Edition
NFPA 79
Electrical Standard
for Industrial Machinery
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55. These Disconnects are Lockable OFF only
Spring-loaded push-button on a magnetic
motor-starter indicates drop-out protection

56. rockfordsystems.com
1) For a Mechanical Power Press run in single-cycle,
are both guards and light curtains required?
Answer: No in the U.S. - Yes in Western Europe
2) What is the most common PPE used on Grinders?
Answer: A full face shield
3) Is a line marking the “Dead Zone” near the bottom
of a light curtain, required by OSHA or ANSI?
Answer: No, but it is “Best Safety Practice”
4) Do all industrial machines require “Drop out protection”
with a magnetic motor starter like you described?
Answer: Yes, per “Best Safety Practice” NFPA 79

57. Questions & Answers
• Type your question into the chat box
• Email your question to Roger.Harrison@rockfordsystems.com

58. Thank You!
Mr. Roger Harrison
Director of Training
815-874-3604
Roger.Harrison@rockfordsystems.com
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