Machine Safety Controls

Most serious machine injuries happen when a person and hazardous energy end up in the same place. The controls below keep them apart in normal running, during setup and during maintenance.

1. Guarding: normal operation

Guards stop contact with moving parts, flying material and pinch points while the machine runs. The best guard removes access entirely. When access is needed for the job, interlocked guards or presence-sensing devices stop the machine before a person can reach the danger. Details in types of machine guards.

2. Authorization: who may operate

Every machine should have a defined list of people allowed to run it, set it up and maintain it. Authorization follows training and a practical check, and it is recorded. Controls such as keyed switches, badge readers or password-protected panels can back this up. See who should operate a machine.

3. Lockout/tagout: service and maintenance

Before anyone works inside the danger zone, all energy sources are isolated, locked and verified dead. Each worker applies a personal lock. The machine cannot restart until the last lock comes off. Read what lockout/tagout is.

How they fail

• Guards bypassed to save time or because they make the job awkward
• Training given verbally and never checked
• Machines stopped at the control panel instead of isolated
• Stored energy such as pressure, springs or gravity overlooked
• Nobody owns the list of who is authorized

Building a simple programme

• Inventory machines and their hazards
• Check every guard works and is in place
• Write down who is authorized for which machine
• Write a lockout procedure for each machine
• Train, check, record and review regularly

This is general information, not legal or compliance advice. Rules differ by country and industry, so confirm requirements with your safety regulator or a qualified safety professional.