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 provided with instructions in English.

Machinery safety is a critical aspect of workplace health and safety. As an employer, you must consider how workers will use machinery and ensure adequate maintenance arrangements are in place to keep equipment safe to use.

Moving machinery can cause serious injuries when:

• People are struck by moving parts or ejected material.
• Body parts are drawn in or trapped between rollers, belts and pulley drives.
• Sharp edges cause cuts and severing injuries, while sharp-pointed parts can stab or puncture the skin.
• Rough surface parts cause friction or abrasion injuries.
• People are crushed between parts moving together or towards a fixed part of a machine, wall or other object.
• Two parts moving past one another can also cause shearing injuries.
• Parts, materials and emissions (such as steam or water) are hot or cold enough to cause burns or scalds.
• Electricity causes electric shock and burns.

When Machinery Injuries Are More Likely to Occur

The risk of injury increases when:

• Machinery becomes unreliable and develops faults.
• Machines are used improperly due to inexperience or lack of training.

Machinery Risk Assessment: Assessing the Risks

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.
• 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 correct safeguards and inform buyers of any residual risks (risks that could not be designed out).

You should develop a safe system of work for operating and maintaining the machine. Maintenance may require the inspection of critical features where deterioration could create a risk.

Consider any residual risks listed in the information supplied with the machine and ensure they are included within the safe system of work.

Every static machine should be installed correctly and be stable, usually by being fixed down.

Suitable and Sufficient Machinery Risk Assessments

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

Failure to adequately manage risk assessments can significantly expose your business. It is morally unacceptable to put staff at risk and is also a breach of legislation. If an accident occurs, it can result in financial losses, including expensive fines, loss of production and reputational damage.

It is vital to continually audit your machinery safety systems to ensure they remain relevant and effective.

Machinery Safety Control Measures

Preventing Access to Dangerous Parts of Machinery

When considering machinery safety, it may be necessary to use a combination of control measures.

The measures used to prevent access to dangerous machinery parts should follow this order:

1. Use fixed guards (secured with screws, nuts or bolts) to enclose dangerous parts whenever practical.
2. Use the most suitable material for guards. Plastic guards may be easy to see through but can be damaged easily. When using wire mesh or similar materials, ensure openings are not large enough to allow access to moving parts.
3. If fixed guards are not practical, use alternative methods such as interlocking guards so the machine cannot start before the guard is closed and cannot be opened while the machine is moving.
4. Where other guards are not practical, use trip systems such as photoelectric devices, pressure-sensitive mats or automatic guards.
5. Where guards cannot provide full protection, use jigs, holders or push sticks where practical.
6. Control any remaining risks by providing operators with the necessary information, instruction, training, supervision and appropriate safety equipment.

Additional Machinery Safety Measures

• Where machines are controlled by programmable electronic systems, any programme changes should only be carried out by a competent person with the necessary skills, knowledge and experience. Records of changes should be maintained and implementation checked.
• Ensure control switches are clearly marked to indicate the operations they control.
• Provide emergency stop controls where necessary, such as mushroom-head push buttons, and ensure they are within easy reach.
• Ensure operating controls are designed and positioned to prevent accidental operation and injury. This may include using two-hand controls and shrouded start buttons or pedals.
• Never allow unauthorised, unqualified or untrained individuals to operate machinery. Children should never operate or assist with machines.
• Vulnerable workers, including new starters, young people and those with disabilities, may be at greater risk and require appropriate instruction, training and supervision.
• Provide adequate training to ensure machinery operators are competent and possess the necessary skills, knowledge and experience. In some cases, formal qualifications may be required, such as for chainsaw operators.
• Supervisors should also be trained and competent, with additional specialist training where appropriate.
• Keep work areas around machinery clean, tidy, well-lit and free from obstructions, slips and trip hazards.

Machinery Safety for Operators

To ensure machinery remains safe:

• Check that machinery is properly maintained and fit for use.
• Only operate machinery if you have received appropriate training and are competent to do so safely.
• Confirm the machine is suitable for the task, functioning correctly and equipped with all required safety measures.
• Safety measures may include guards, isolators, locking mechanisms and emergency stop switches.
• Operate machinery in accordance with the manufacturer’s instructions.
• Wear the correct personal protective equipment (PPE), including safety glasses, hearing protection and safety footwear where required.

Preventing Machinery Accidents and Injuries

Following safe working practices can significantly reduce the risk of machinery-related accidents and injuries.

• Never use a machine or appliance displaying a danger sign or tag. These should only be removed by an authorised person who is satisfied that the machine or process is safe.
• Do not wear loose clothing, dangling chains, rings or allow long hair to remain unsecured, as these can become caught in moving parts.
• Avoid distracting people while they are operating machinery.
• Never remove safety guards or safeguards, even if they appear to make the task more difficult.

To discuss how Spectra can support your business, contact us!