Ensuring machine safety is essential for maintaining a safe and productive workplace, says Suresh Tanwar, Head of Audit and Consultancy, British Safety Council, India.

Moving machine parts poses significant risks in any workplace. The risks may include severe injuries such as crushed fingers or hands as well as burns or even blindness. An International Labour Organization (ILO) study has revealed that nearly three million workers worldwide lose their lives annually due to work-related accidents. India saw as many as 1,109 deaths and more than 4,000 injuries in registered factories, on average, each year between 2017 and 2020.

Machine-related injuries not only incur high costs but also have the potential to raise workers’ compensation premiums. Amputation, in particular, is among the most severe and disabling injuries, sometimes leading to permanent disability, too. Therefore, machine safety training and operational precautions are essential for safely using machinery.

Machine Safety: An Overview

Organisations must approach machine safety as a must-have in industrial operations. As automation and robotics become more prevalent in manufacturing, safeguarding workers and equipment is increasingly important.

Machinery can cause injuries in various ways:

Impact and Ejection: Moving parts or ejected materials can strike and injure people.

Entanglement: Body parts can be drawn or trapped between rollers, belts, and pulley drives.

Sharp Objects: Sharp edges and pointed parts can cause cuts, stab wounds, or abrasions.

Crushing: People can be crushed between moving parts or between moving and fixed parts.

Shearing: Parts moving past each other can cause shearing injuries.

Temperature Hazards: Hot or cold machine parts, materials, or emissions can cause burns or scalds. Electrical components can lead to electrical shocks and burns.

Machine safety includes the steps and precautions companies must take to shield workers and individuals from all the hazards caused by machines and equipment.

Why Machine Safety is Important

Ensuring machine safety is crucial for several reasons:

Protecting Workers

Machine safety measures must prioritise shielding employees from potential injuries and fatalities. Implementing robust safety protocols reduces the risk of accidents and leads to a safer working environment.

Preventing Damage to Equipment

Beyond protecting workers, machine safety measures also safeguard expensive equipment from damage. Industrial machinery is often costly to repair or replace,and any downtime due to equipment damage can lead to severelosses in productivity. By adhering to stringent safety standards, companies can reduce the likelihood of equipment failures and associated financial setbacks.

Maintaining Compliance

Compliance with safety regulations is imperative in industrial settings. Many countries enforce strict safety guidelines to protect workers and ensure operational integrity. Non-compliance with these regulations can result in severe penalties, finesand even temporary shutdowns of operations. Implementing comprehensive safety measures ensures compliance and mitigates the risks associated with regulatory violations.

All in all, however, machine safety isn’t just about protecting workers and equipment. It is about building a mission-critical culture of safety and responsibility to enhance overall workplace efficiency and employee well-being.

Machine Safety Rules for Employers and Employees

Before operating any machine, it is necessary to assess potential risks and plan how to mitigate them. Basic safety rules and measures are crucial for employers and employees to prevent accidents and maintain a safe workplace environment.

Rules for Employers

Comprehensive Training Programs: Ensure all employees receive thorough training in machinery operations, safety protocols, and emergency procedures.

Scheduled Maintenance Routines: Establish and follow regular maintenance schedules to keep machinery safe and operational.

Installation of Safety Guards: Equip machines with appropriate guards to protect employees from moving parts and hazards.

LockoutSystems: Implement procedures to prevent accidental machine startup during maintenance or repair.

Clear Safety Signage: Display prominent signs and instructions near machines to remind employees of hazards and procedures.

Provision of Personal Protective Equipment (PPE): Supply necessary PPE like safety glasses, gloves, and earplugs and ensure compliance with usage.

Risk Assessments: Regularly evaluate machinery-associated workplace risks and take proactive steps to mitigate them.

Organised Workspaces: Maintain machine areas tidy to reduce the risk of accidents.

Emergency Response Protocol: Establish clear guidelines for handling machine-related accidents and emergencies.

Cultivate Reporting Culture: Encourage employees to report potential hazards or equipment malfunctions without hesitation promptly.

Rules for Employees

Adhere to Procedures: Follow provided training and operational procedures specific to each machine.

Wear PPE: Always wear the provided personal protective equipment consistently.

Safely Operate Machines: Use machines strictly according to their intended purpose and do not bypass safety features like guards or interlocks.

Report Hazards: Immediately notify a supervisor of any unsafe conditions or malfunctions observed.

Engage in Safety Training: Participate in safety training sessions to stay informed about current safety practices.

Maintain Housekeeping: Keep the work area clean and organised to prevent accidents such as trips, falls, or interference with machinery.

Remain Alert: Stay vigilant and focused while operating machinery, avoiding distractions that could compromise safety.

Use Lockout Systems: Respect and utilise lockout/tagout systems during maintenance or when machines are not used.

Follow Safety Instructions: Pay attention to and comply with safety signs and instructions posted near machinery.

Avoid Taking Shortcuts: Never compromise safety by taking shortcuts in operating procedures.

Put back the guards: After the machine maintenance has been done, the guards should be put back in original condition. Many times it has been observed that the guards are not put back, or installed back inadequately,resulting in the unguarded rotating or moving partof the machine exposingthe person in close proximity to a potential accident.

Making Machine Safety an Integral Part of Overall Safety

Integrating machine safety into an organisation’s overall safety management system is crucial if you want a comprehensive approach to workplace safety. By embedding machine safety practices within broader safety protocols, companies can ensure that safety considerations are standardised and systematically addressed across all operations.

A cornerstone of this integrated approach is cultivating a strong safety culture where safety is a priority and a core value every employee embraces. This involves leadership commitment, transparent communication channels and a continuous drive for improvement. Holistic safety policies and procedures play a considerable role, encompassing machine safety, workplace ergonomics, and emergency response protocols.

Importance of Safety Audits

Regular audits and reviews of safety performance play a crucial role in identifying areas for improvement and maintaining the effectiveness of safety measures in any organisation. These audits, generally conducted by third-party organisations, cover all aspects of the safety management system, including machine safety.

Generally, a safety audit focuses on assessing situations with significant risks of injury or harm to individuals and assets within an organisation. It meticulously evaluates high-risk tasks such as working at heights, using machines and equipment, confined space entry, lifting operations, electrical and fire safety, excavation andcontractor safety. Additionally, it scrutinises leadership commitment, accountability, risk assessment, management practices, and permit-to-work procedures.

Conducting a safety audit involves thoroughly examining safety controls related to risk-based activities, including using machines. It evaluates the effectiveness of existing safety measures aimed at preventing severe injuries. The audit employs a tailored approach to assess an organisation’s safety performance, comparing it against global best practices. The findings are consolidated into a customised report that addresses the organisation’s specific needs, offering insights into its current statusrelated to safety and identifying areas for improvement.

Parting Thoughts

Ensuring machine safety is essential for maintaining a safe and productive workplace. Industrial safety begins with secure machinery and a robust safety management system. Effective steps to machine safety include conducting regular safety audits and risk assessments and applying effective safety protocols within the organisation. 

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