Moving machinery can cause serious injuries if safety procedures are not followed. The document outlines machine guarding rules and isolation and lockout procedures to protect workers. It emphasizes that failing to follow these safety rules can lead to death or injury and will result in disciplinary action. Machine guards, such as fixed enclosures and interlocks, help prevent entanglement and access to dangerous moving parts. The isolation and lockout process identifies all energy sources, isolates and secures them with locks before work begins to prevent accidental start-up of equipment during maintenance.

1. Machine Safety
Work safely

2. Moving Machinery

4. Moving Machinery Golden Rule
• Why do we have this rule
• Failure to protect People from becoming entangled
with pieces of moving machinery is one of the biggest
killers in world wide and we don’t want you to be a
victim.
• What is the rule?
• When working near moving
machinery/equipment You must protect
yourself from injury:
• It is prohibited to remove a machine guard or access
the machine/equipment while the machine/
equipment is being operated.

5. What is Moving Machinery
• Examples of Moving Machinery are
• Rotating components, e.g., drive-shafts, flywheels, pulleys,
sprockets.
• Cutting and shearing action, e.g., saws, shears, augers,
grinders.
• Drive Gear, e.g., belts/pulleys, chain/sprockets, rollers, gears.
• Forming and bending action, e.g., press brakes, mechanical
power presses
Good Machine Guarding

6. Types of Injuries from
Moving Machines
• Pinching injuries: When two pieces of machinery move together
with at least one piece moving in a circle, Your clothing or fingers,
hands, or other body parts could be caught near a rotating part
and severed.
• Wrapping injuries: If there's a rotating shaft, your clothing or hair
could be wrapped around the shaft, trapping you and pulling You
toward the machinery.
• Cutting or shearing injuries: Machinery that contains blades or
hard edges, such as those found on rotating gears or presses, can
cut material or skin or even sever limbs.
• Thrown-object injuries: Machinery such as grinders, lathes even
mowers can throw out objects while in operation and can injure
You.
• Crushing injuries: Raised equipment may fall, roll, or be lowered,
causing serious injury or death to any person trapped beneath.

7. Protect Yourself from Moving Machinery!
• Know how to operate machines safely!
• Keep clothing, fingers, hair, and other parts
of the body away from moving machine
parts!
• Don’t load machine outside of the design
limits!
• Only sit or ride on a machine if it is designed
for this purpose and only on a properly
designed seat
• Know location and function of all stop/start
controls.
• Keep all stopping/starting control devices
free from obstructions.

8. What else do You need to do?
• Make sure all personnel are clear of
machine before starting
• Keep area around machines clear of
obstructions.
• Only service machine with authorized
maintenance personnel.
• Don’t perform service on a machine
until it is Locked Out!
• Don’t remove or alter machine guards
or other safety devices!
• Report all unsafe practices to your
supervisor!

9. Know Your Machine Guards!
Fixed Enclosure Guard
•Covers area of possible entanglement
Fixed Distance
•Eliminates ability to reach hazard
Nip Guards
•Eliminates being caught in rollers
Interlock Guards
•Stops machine when Guard opened
Trip or Pressure Guards
Stops machine if person breaks
barrier or pressure changes
Pressure mat
Light Curtain

10. What happens if I don’t follow this Rule?
• At best it is a breach of the
Golden Rules for which
you will subject to the
disciplinary process
• At worst you or one of
your work mates will die
or be seriously injured

12. MACHINE GUARDS
Method Safeguarding Action Advantages Limitations
Fixed Provides a barrier Can be constructed to suit
many specific applications
In-plant construction is often
possible
Can provide maximum
protection
Usually requires minimum
maintenance
Can be suitable to high
production, repetitive operations
May interfere with visibility
Can be limited to specific
operations
Machine adjustment and repair
often require its removal, thereby
necessitating other means of
protection for maintenance
personnel
Interlocked Shuts off or disengages
power and prevents
starting of machine when
guard is open; should
require the machine to
be stopped before the
worker can reach into the
hazardous area
Can provide maximum
protection
Allows access to machine for
removing jams without time-
consuming removal of fixed
guards
Requires careful adjustment and
maintenance
May be easy to disengage or
bypass

13. MACHINE GUARDS
Method Safeguarding Action Advantages Limitations
Adjustable Provides a barrier
which may be
adjusted to facilitate a
variety or production
operations
Can be constructed to suit
many specific applications
Can be adjusted to admit
varying sizes of stock
Hand may enter Hazardous
area – protection may not be
complete at all times
May require frequent
maintenance and/or
adjustment
The guard may be made
ineffective by the operator
May interfere with visibility
Distance
(Gate/Fence)
Provides a barrier
between hazardous
area and operator or
other personnel
Can prevent reaching into or
walking into the hazardous
area
May require frequent
inspection and regular
maintenance
May interfere with operator’s
ability to see the work
Self-adjusting Provides a barrier
which moves
according to the size
of the stock entering
hazardous area
Off-the-shelf guards are
often commercially available
Does not always provide
maximum protection
May interfere with visibility
May require frequent
maintenance and adjustment

14. Isolation and Lockout
ACCESS
EQUIPMENT
RESTORE
EQUIPMENT
1
2
3 4
5
6
7
8
9 10
11
12
Identify
Energy
Sources
Advise
Relevant
Parties
Isolate & Secure
Energy
(Master Lock)
Test
Isolation
Place Locks
or Permits
Commence
Work
Complete
Work
Check
Work
Clear
Area
Remove Personal
Locks & Then
Master Lock
Restore
Energy
Check
Operation
ACCESS
EQUIPMENT
RESTORE
EQUIPMENT
1
2
3 4
5
6
7
8
9 10
11
12
Identify
Energy
Sources
Advise
Relevant
Parties
Isolate & Secure
Energy
(Master Lock)
Test
Isolation
Place Locks
or Permits
Commence
Work
Complete
Work
Check
Work
Clear
Area
Remove Personal
Locks & Then
Master Lock
Restore
Energy
Check
Operation
PERSONAL DANGER
TAG
DO NOT OPERATE
This equipment must not be operated while
this tag is in place.
This tag must not be removed except by the
person whose name and signature is on
reverse side or as provided by the Isolation
and Lockout procedures
Violations of the Isolation and Lockout
Procedures will result in discipline and or
instant dismissal
PERSONAL DANGER
TAG
PERSONAL DANGER
TAG
DO NOT OPERATE
This equipment must not be operated while
this tag is in place.
This tag must not be removed except by the
person whose name and signature is on
reverse side or as provided by the Isolation
and Lockout procedures
Violations of the Isolation and Lockout
Procedures will result in discipline and or
instant dismissal

15. Isolation and Lockout Golden Rule
• Why do we have this rule
• Failure to make sure fixed and mobile machinery is correctly
isolated before people commence working is one of the
biggest killers world wide and we don’t want you to be a
victim.
• What is the rule?
• Isolation and Lock Out Procedures must always be followed.
Before working on machinery and equipment that can cause
injury, it must be made safe by isolating and locking out the
equipment. This means that the equipment/ machine You
are working on is to be isolated and your Personal Danger
Tag and Lock is to be attached to the isolation point

16. Isolation and Lockout is more than Electrical
• You must identify all energy sources that are capable of
causing fatality or serious injury if the energy released
• Isolation seeks to control all energy sources
• Here are some which must be isolated
Hazardous Energies
Requiring Isolation
Electrical Thermal Chemical Radiation Mechanical

17. A Systematic Process to Follow
ACCESS
EQUIPMENT
RESTORE
EQUIPMENT
1
2
3 4
5
6
7
8
9 10
11
12
Identify
Energy
Sources
Advise
Relevant
Parties
Isolate & Secure
Energy
(Master Lock)
Test
Isolation
Place Locks
or Permits
Commence
Work
Complete
Work
Check
Work
Clear
Area
Remove Personal
Locks & Then
Master Lock
Restore
Energy
Check
Operation
ACCESS
EQUIPMENT
RESTORE
EQUIPMENT
1
2
3 4
5
6
7
8
9 10
11
12
Identify
Energy
Sources
Advise
Relevant
Parties
Isolate & Secure
Energy
(Master Lock)
Test
Isolation
Place Locks
or Permits
Commence
Work
Complete
Work
Check
Work
Clear
Area
Remove Personal
Locks & Then
Master Lock
Restore
Energy
Check
Operation
Single key
PERSONAL DANGER
TAG
DO NOT OPERATE
This equipment must not be operated while
this tag is in place.
This tag must not be removed except by the
person whose name and signature is on
reverse side or as provided by the Isolation
and Lockout procedures
Violations of the Isolation and Lockout
Procedures will result in discipline and or
instant dismissal
PERSONAL DANGER
TAG
PERSONAL DANGER
TAG
DO NOT OPERATE
This equipment must not be operated while
this tag is in place.
This tag must not be removed except by the
person whose name and signature is on
reverse side or as provided by the Isolation
and Lockout procedures
Violations of the Isolation and Lockout
Procedures will result in discipline and or
instant dismissal

18. What else must you do?
• Every one working on a job must must
individually lockout.
• The isolation must be confirmed before
work is commenced
• Isolations must remain in place while work
is underway
Wheel chocks form
part of your
isolation for mobile
equipment
Isolation
points

19. Other types of Isolations
Steering wheel
Truck body
Pneumatic lines
Valves
Electrical equipment

20. Electrical isolation failure
What happens if I don’t Isolate and Lock
out?
• At best it is a breach of the
Golden Rules for which
you will subject to the
disciplinary process
• At worst you or one of
your work mates will die
or be seriously injured

21. •ELECTRICAL ENERGY IS THE MOST COMMONLY USED FORM OF ENERGY.
ONE CAN NOT IMAGINE LIFE WITHOUT ELECTRICITY IN MORDEN SOCIETY.
USING ELECTRICITY IS VERY SIMPLE, BUT, LITTLE DOES ONE KNOW ABOUT HOW ELECTRICITY REALLY
WORKS.
BECAUSE ELECTRICITY IS A GOOD SERVENT BUT A VERY BAD MASTER.
IT CAN CAUSE INSTANTANIOUS DEATH,LIFE LONG DISABILITY DUE TO SEVERE BURNS OR DEVASTATING
FIRES TURNING CRORES OF RUPEES WORTH ESATES TO ASHES.
WHAT ARE THE HAZARDS IN USING IT AND WHAT SHOULD BE DONE TO AVOID EXPOSURE TO THE
HAZARDS.
WHAT IS ELECTRIC SHOCK ?
ELECTRIC SHOCK IS THE NET EFFECT OF THE DIRECT PASSING OF THE CURRENT THROUGH A HUMAN
BODY WHEN IT ACCIDENTLAY BRIDGES THE GAP BETWEEN TWO POTENTIALLY DIFFERENT POINTS.
SHOCK IS NOT A PHENOMENON BUT IS A GENERAL TERM FOR THE EXCITATION OR DISTURBANCE OF
THE FUNCTION OF NERVES OR MUSCLES CAUSED BY THE PASSAGE OF AN ELECTRIC CURRENT.
IN COMPARISON TO ANY OTHER ACCIDENT, ELECTRICAL ACCIDENTS ARE PECULIAR. IN OTHER ACCIDENT
VICTIM HIMSELF VICTIMISE OF HIS OWN MISTAKE OR CARELESSNESS.
IN ELECTRICAL ACCIDENT THE SITUATION IS DIFFERENT
“ A CARELESS ENGINEER MAY VICTIMISE INNOCENT WORKMAN BY OVER LOOKING SOME STEPS WHILE
GIVING SHUTDOWN. WRONG OR BADLY DONE CONNECTIONS BY AN ELECTRICIAN CAN SUBJECT AN
INNOCENT OPERATOR TO THE DANGER OF ELECTROCUTION.”
THE ELECTRICAL PROFESSIONAL THEREFORE, HAS TO BE VERY VERY CAREFUL IN HIS WORK.
Electrical Safety

22. Electrical Hazards
• Primary hazards
• 1.Electric shock - electrocution.
• 2.Burns :
• Flash over burns
• Spark burns
• 3.Fire and explosions
Secondary hazards
• A. Persons falling from
height.
• B. Dropping of tools.

23. Current values affecting the human body.
• Current strength Effect
• 1 m A or less Causes no sensation.
• 1 to 8 m A Sensation of shock, not
painful
• 8 to 15 m A Painful shock, muscular
control is not lost, no
striking.
• 20 to 50 m A Painful, severe muscular
contraction, striking and
breathing difficult.
• 50 to 200 m A Painful, severe muscular
contraction, striking,
ventricular fibrillation and
possible death.
• 200 m A and above. Severe burns, severe
muscular
contraction, severe
ventricular
fibrillation and death.

24. Shock Hazards and Remedies
Sr.No Causes Remedies.
1 Crane boom touching over
head bare wires.
Avoid crane movement in that area
crane booms to be kept well clear
of overhead power lines
2 Repair work on switch gear,
control panel, switch board
etc.
Use rubber mats.
3 Leakage of current and shock
hazard from portable
electrical driven hand tools.
Proper Earthing connection.
Use proper plug.
4 Temporary or wrong wiring Avoid temporary wiring.
5 Testing of live wire or electric
supply.
Use proper tester. Use hand lamp
with proper protective shield.
6 Electric shock inside the tank
from portable hand lamp.
Good wiring. Connection to be
given from 24 volts.

25. Precaution
Use a fuse puller.
Only non-conductive ladder should be used.
Finger rings, bracelets, chains and metal wrist watch
bands should not be worn by persons.
Keep all electrical connections tight.
Keep main switch gear rooms clean, free of
combustibles and properly ventilated.
Men working on high locations and electrical pole
are required to wear safety belts properly.
Before starting the repair works, get clearance from
proper authority.
Before resuming the supply, get the clearance from
proper authority.

26. REMEMBER ELECTRICITY EXCUSES NO ONE !
YOU MAY BE THE ONLY BREAD WINNER OF A LARGE FAMILY,
AN ORDINARY WORKER OR THE GENERAL MANAGER OF A
LARGE INDUSTRIAL HOUSE.
WHEN YOU ARE IN CONTACT WITH ELECTRICITY, IT ASKS YOU
ONLY ONE .
QUESTION
“HOW MUCH IS YOUR BODY RESISTANCE” (rm) ?
•DEFECTIVE MATERIAL OR EQUIPMENTS.
•IMPROPER ILLUMINATION.
•NONSTANDARD DESIGN AND CONSTRUCTION.
•UNGUARDED EQUIPMENTS.
UNSAFE ACTS
• OPERATING OF EQUIPMENT WITHOUT AUTHORITY OR WARRANTY
 OPERATING OR WORKING WITHOUT PROPER INSTRUCTIONS.
 MAKING SAFETY DEVICE INOPERATIVE.
 USING DEFECTIVE EQUIPMENTS OR USING EQUIPMENTS IMPROPER WAY.
 WORKING NEAR BY DANGEROUS OR LIVE ELECTRICAL EQUIPMENTS.

27. Thanks
Work safely