Why machinery safety is important

New machinery placed on the market in Great Britain (England, Scotland and Wales) must be UKCA marked, supplied with a declaration of conformity, and have instructions in English.

Why machinery safety is important

As an employer, you must consider how your workers will use machinery. You should also have adequate maintenance arrangements in place to ensure it remains safe to use.

Moving machinery can cause injuries when:

• people can be struck by moving parts or ejected material
• body parts can be drawn in or trapped between rollers, belts and pulley drives
• sharp edges can cause cuts and severing injuries, sharp-pointed parts can cause stabbing or puncture the skin.
• rough surface parts can cause friction or abrasion
• people can be crushed, between parts moving together or towards a fixed part of a machine, wall or other object, or 2 parts moving past one another can cause shearing
• parts, materials and emissions (such as steam or water) can be hot or cold enough to cause burns or scalds
• electricity can cause electrical shock and burns.

Injuries may be more likely to occur when:

• machinery becomes unreliable and develops faults
• machines are used improperly through inexperience or lack of training

Assessing the Risk

Before you or your employees use any machinery, you must consider what risks may occur and how these risks can be managed. Check that the machine has all the correct guarding and safeguards fitted, and is free from defects. 

The term ‘safeguarding’ includes guards, interlocks, two-hand controls, light guards and, pressure-sensitive mats.

By law, the supplier must provide the right safeguards and inform buyers of any residual risks (risks that could not be designed out). 

You should develop a safe system of work for using and maintaining the machine. Maintenance may require the inspection of critical features where deterioration would cause a risk.

You should consider any residual risks listed in the information provided with the machine. Make sure they are included in the safe system of work.

Ensure every static machine has been installed properly and is stable (usually fixed down).

All significant risks associated with machinery, including the use of and maintenance of should be subjected to a suitable and sufficient risk assessment completed by a competent person.

Failure to adequately manage your risk assessments can significantly expose your business. It’s morally unacceptable to put your staff at risk, and of course a breach of legislation. If an accident does happen it can incur financial loss including expensive fines, loss of production and damaged reputation. It is vital to continually audit your system to keep it relevant and adequate.

Control Measures

Preventing access to dangerous parts of machinery

You must consider how you can make a machine safe, it may be necessary to use a combination of control measures.

The measures you use to prevent access to dangerous parts should be in the following order:

1. Use fixed guards (for example secured with screws or nuts and bolts) to enclose the dangerous parts, whenever practical.
2. Use the best material for these guards – plastic may be easy to see through but can be damaged easily. Where you use wire mesh or similar materials, make sure the holes are not large enough to allow access to moving parts.
3. If fixed guards are not practical, use other methods, like interlocking the guard so the machine cannot start before the guard is closed and it cannot be opened while the machine is still moving.
4. In some cases, trip systems such as photoelectric devices, pressure-sensitive mats or automatic guards may be used if other guards are not practical.
5. Where guards cannot give full protection, use jigs, holders or push sticks if it is practical to do so.
6. Control any remaining risk by providing the operator with the necessary information, instruction, training, supervision and appropriate safety equipment.

Additional control measures

• If machines are controlled by programmable electronic systems, changes to any programmes should be carried out by a competent person (someone who has the necessary skills, knowledge and experience to carry out the work safely). Keep a record of such changes and check they have been implemented properly.
• Ensure control switches are clearly marked to show what operations they control.
• Have emergency stop controls where necessary, for example mushroom-head push buttons, within easy reach.
• Make sure operating controls are designed and placed to avoid accidental operation and injury, for example by using two-hand controls where necessary and shrouding start buttons and pedals.
• You must not allow unauthorised, unqualified or untrained people use or operate machinery – never allow children to operate or assist at machines. Some vulnerable workers, such as new starters, young people or those with disabilities, may be particularly at risk. Everyone who uses the machine requires adequate instruction, training and supervision.
• Adequate training should be provided to ensure that those who use the machine are competent to use it safely. This includes ensuring they have the correct skills, knowledge and experience. Sometimes formal qualifications are needed, for example for chainsaw operators.
• Supervisors must also be properly trained and competent to be effective. They may need extra specific training and there are recognised courses for supervisors.
• Ensure the work area around the machine is kept clean and tidy, free from obstructions or slips and trips hazards, and is well lit.

Machinery safety for operators

• To ensure machinery is safe you should check the machine is well maintained and fit to be used. 
• You should only operate the machinery if you have received the appropriate training and are competent to operate the machinery safely. 
• Make sure it is appropriate for the job, working properly and that all the safety measures are in place.
• Examples of safety measures include guards, isolators, locking mechanisms and emergency off switches.
• Use the machine properly and in accordance with the manufacturer’s instructions.
• Make sure you are wearing the appropriate protective clothing and equipment required for that machine, such as safety glasses, hearing protection and safety shoes.

The prevention of accidents and injuries

• Don’t use a machine or appliance that has a danger sign or tag attached to it. These signs should only be removed by an authorised person who is satisfied that the machine or process is now safe.
• Never wear dangling chains, loose clothing, rings or have loose, long hair that could get caught up in moving parts.
• Don’t distract people who are using machines.
• Never remove any safeguards, even if they seem to make the job more difficult.

If you require any help or advice regarding machinery safety, please contact Spectra where one of our experienced Consultants can help.