(OSHA 29 CFR 1910 Compliant)
Provider: OpsIntegrity^TM

Purpose:
The purpose of this training is to provide workers with a clear understanding of OSHA’s machine guarding requirements under 29 CFR 1910 Subpart O. It ensures that all employees working with or around machinery know how to recognize machine hazards, properly use guards, and follow safety procedures that prevent amputations, lacerations, and crushing injuries.

Introduction

Machinery can be incredibly powerful and efficient, but also dangerous when not properly safeguarded. According to OSHA, hundreds of workers lose body parts or suffer serious injuries each year because proper guarding was not in place. Many of these accidents are preventable.

Machine guards are physical barriers that prevent hands, arms, and other body parts from coming into contact with moving parts. They also shield workers from flying chips, sparks, and other dangers.

This training covers OSHA’s standards for machine guarding and explains your responsibilities as an operator, maintenance personnel, or affected employee. Whether you're using a bench grinder, power press, conveyor, or other mechanical equipment, this module is your guide to safe operations.

Our Most Important Objective: A Safe and Healthful Workplace

At OpsIntegrity, we believe that maintaining a safe and healthful workplace is the highest priority for every employer and employee. This principle forms the foundation of all training modules and safety resources provided through the OpsIntegrity system.

Employers are responsible for:

• Providing a workplace free from recognized hazards.
• Complying with OSHA standards and other applicable safety regulations.
• Promoting continuous improvement in safety practices.
• Empowering workers to report safety concerns without fear of retaliation.

Employees are responsible for:

• Following safety procedures and practices at all times.
• Reporting safety concerns, hazards, or near misses.
• Actively supporting the safety culture of their workplace.

Through OpsIntegrity’s shared resources, training, and compliance tools, employers and employees work together to identify risks, prevent injuries, and maintain a strong commitment to safety excellence.

Safety is not just a policy. It is a shared responsibility and a daily practice.

What is Machine Guarding?

Machine guarding is the placement of barriers to protect workers from injuries caused by hazardous machine parts. Moving parts that can cause injury must be physically guarded to prevent access.

Common types of hazardous machine actions include:

• Rotating (shafts, pulleys, gears)
• Reciprocating (presses or rams)
• Transversing (moving belts or conveyors)
• Cutting (saws, shears)
• Punching, shearing, and bending

Machine guarding refers to the use of safety barriers or devices designed to protect workers from injury by isolating or controlling access to dangerous machine parts. It is one of the most basic and critical components of workplace safety.

• Guards not only prevent contact but also control the flow of work, protect coworkers nearby, and help maintain a clear line between operational and maintenance procedures.
• Think of a guard as a “seatbelt” for machinery; It doesn’t stop you from driving, but it protects you in case something goes wrong.
• Guards must be used even if the machine seems “safe” after repeated use. Many accidents occur when workers become overconfident or complacent.

OSHA Standard – 29 CFR 1910 Subpart O

OSHA’s machine guarding regulations are found in Subpart O and are legally enforceable. These rules exist because real people have been hurt or killed due to unguarded machines.

Key standards include:

• 1910.212 – General requirements for all machines
• 1910.213 – Woodworking machinery
• 1910.215 – Abrasive wheel machinery
• 1910.217 – Mechanical power presses
• 1910.219 – Mechanical power-transmission apparatus

Additional Guidance:

• If you can see a moving part that can grab, pinch, crush, or cut—you need to STOP and report it before operating.
• OSHA requires that any machine with moving parts that could cause injury must be safeguarded.
• Failure to follow these standards not only puts lives at risk—it can lead to citations, fines, or work stoppages.

Types of Machine Guards

• Fixed Guards: Permanent parts of the machine; simple and reliable. Common on saws, presses, and conveyors.
• Interlocked Guards: Connected to machine controls; stop the machine if opened or removed.
• Adjustable Guards: Can be repositioned for different material sizes. Must be reset properly each time.
• Self-Adjusting Guards: Automatically move based on the stock being fed. Often used in woodworking.
• Presence-Sensing Devices: Sensors (light curtains, pressure mats) that stop the machine when motion is detected in a danger zone.

Additional Guidance:

• No matter the type, the guard must serve its primary purpose: protecting you.
• Many serious injuries happen when guards are disabled “just for a second.” That second could cost a limb—or your life.
• If you're unsure what kind of guard is on your machine, ask a supervisor or consult your OpsIntegrity safety portal.

Machine Guarding Requirements

Guards must:

• Prevent contact with dangerous moving parts.
• Be securely attached and durable.
• Protect against falling objects.
• Not create new hazards (e.g., jagged edges).
• Not interfere unnecessarily with machine operations.

Additional Guidance:

• If a guard slows you down, talk to your supervisor—don’t remove it.
• OSHA fines and injuries often result from makeshift, DIY guards. If it’s not built and approved for that machine, don’t trust it.
• Report loose, damaged, or missing guards immediately. It’s not “complaining”—it’s professional responsibility.

Employee Responsibilities

Every employee working near or with machinery plays a critical role in machine safety. Your vigilance, discipline, and awareness are essential not just for your own protection, but for the safety of everyone around you. OSHA holds both employers and employees accountable for maintaining a safe work environment.

Here is what is expected of you:

Never operate a machine without all guards in place.

If a machine appears to be missing a guard, do not start or use it, even if it looks operational or someone tells you it's fine. Operating unguarded machinery is a violation of both safety policy and OSHA law, and it can result in serious injury or death.

Never bypass or disable a guard.

Even temporary bypasses, such as propping open a cover or taping down an interlock switch, can lead to devastating consequences. Guards are there for a reason. Bypassing them not only puts you at risk but may also endanger nearby workers. If you're tempted to bypass a guard because of a production issue, stop and report it instead.

Inspect guards daily for damage or displacement.

Before using any equipment, check the guard’s position and condition:

• Is it loose?
• Is it cracked, dented, or partially removed?
• Is it functioning properly, especially for interlocked or sensor-based guards?

If anything looks off, tag out the machine and notify your supervisor immediately.

Use Personal Protective Equipment (PPE) where required.

Machine guards protect you from moving parts, but you must still wear appropriate PPE such as:

• Face shields for grinding or cutting
• Cut-resistant gloves when allowed
• Safety glasses or goggles
• Hearing protection if required by noise levels

PPE is a backup layer of protection and must always be worn properly.

Report unsafe conditions immediately.

If you see a missing guard, damaged machine, exposed hazard, or coworker acting unsafely, report it without delay. Use your company's reporting procedure or submit a hazard report through the OpsIntegrity portal. Reporting is not tattling, it is how we protect lives.

Participate in all required training.

Attend all required safety orientations, refresher courses, and toolbox talks. Ask questions if something isn’t clear. Your understanding directly affects your ability to stay safe. Review OpsIntegrity training materials when prompted and stay current on safety updates.

Additional Worker Guidance

You are the final barrier between danger and disaster. Even if everything else fails, your decision to stop and check something could prevent a serious incident. If you witness someone bypassing a guard, do not ignore it. Either confront the person respectfully or escalate it to your supervisor or safety team. A few seconds of courage can prevent a lifetime of regret.

Employer Responsibilities (Expanded)

Employers must create and maintain a workplace that complies with OSHA machine guarding standards. Whether you are a small business owner, supervisor, or corporate safety manager, these responsibilities are mandatory under 29 CFR 1910 Subpart O.

Ensure machines have proper guards installed.

Machines must be equipped with appropriate guarding for:

• Point of operation
• Power transmission apparatus such as belts, pulleys, and shafts
• Other moving parts such as flywheels, gears, and chains

Homemade or makeshift guards should never be used unless specifically evaluated and approved.

Provide training to all affected employees.

Training must include:

• Machine-specific hazards
• Guarding types and functions
• Safe work practices
• Lockout and tagout requirements when guards are removed

New employees must receive training before operating any equipment.

Inspect and maintain guards regularly.

Supervisors or maintenance personnel should routinely check guards for proper attachment, damage, or signs of tampering. Any deficiencies should be corrected before the machine is returned to service.

Respond promptly to hazard reports.

All reports of unsafe conditions must be taken seriously, whether submitted in person, by form, or through the OpsIntegrity system. Investigate promptly and document corrective actions. Encourage employees to report issues without fear of retaliation.

Maintain written procedures and updates.

Employers must keep written safety policies, inspection checklists, and hazard correction records. These procedures should be reviewed annually or whenever a machine, task, or regulation changes. This information should be made available to employees through the OpsIntegrity portal.

Additional Employer Guidance

If you are in a leadership position, understand that your team follows your lead. If you ignore guard inspections or overlook hazards, others will do the same. Consistency matters. OSHA standards apply to all workplaces regardless of size. A single injury or violation can have serious financial and human consequences. Prevention is always more effective than reaction. Your minimum expectations will become your workforce's maximum level of participation.

Common Violations and Hazards

Machine guarding violations remain one of OSHA’s most frequently cited issues. These violations are not just technical errors, they represent real, immediate dangers that can cause severe injuries or fatalities.

Missing point-of-operation guards

This is one of the most dangerous and most common violations. The point of operation is where the machine performs work: cutting, drilling, grinding, punching, or shearing. If this area is unguarded, workers are directly exposed to moving blades, dies, or bits.
Employees must never operate a machine if the point of operation is not properly guarded. If a task requires access to this area for setup or adjustment, Lockout/Tagout procedures must be followed.

Exposed belts, pulleys, or rotating parts

Rotating components are particularly dangerous because they can catch clothing, gloves, long hair, or even body parts with incredible speed and force. Belts and pulleys are common on conveyors, fans, and motors and must always be covered.
Never assume that a smaller or slower-moving machine is less dangerous. Even low-speed rotating equipment can cause entanglement injuries.

Disabled interlocks or safety devices

Interlocks and sensors are designed to stop the machine if a guard is opened or removed. When employees disable these systems to "speed up" production or "make things easier," they are eliminating the very protection that keeps them alive.
Disabling safety devices is a serious violation and grounds for disciplinary action in most workplaces. It puts not only the operator at risk but also coworkers nearby.

Untrained workers using dangerous equipment

Allowing someone to operate machinery without proper training is a critical failure in safety management. Even simple-looking machines can have hidden hazards, including pinch points, stored energy, or startup sequences that are not obvious.
Employees must never operate machines they have not been trained on. Supervisors are responsible for ensuring no one is assigned to equipment they do not understand.

Complacency toward damaged or ineffective guards

Over time, employees may become “used to” a loose or broken guard and assume it’s harmless. This mindset is extremely dangerous.
Just because an issue hasn’t caused harm yet does not mean it won’t. Safety should never depend on luck or habit. If you notice damage to a guard or safety device, take immediate action by reporting it and tagging the machine out if needed.

Additional Guidance

Do not normalize shortcuts. When one person removes or ignores a guard without consequences, others may follow. Before long, unsafe behavior becomes routine, and the risk of serious injury increases exponentially.
Always treat guards like you would your seatbelt, not as an inconvenience, but as a non-negotiable part of staying alive at work.

venience.

Lockout/Tagout During Maintenance

Machine guards protect workers during normal operation, but they are not designed to protect you when the machine is being maintained or repaired. That’s where Lockout/Tagout (LOTO) procedures come in. These procedures ensure that machinery is completely powered down and cannot start unexpectedly while work is being performed.

When must LOTO be used?

• Any time a guard must be removed for maintenance, cleaning, or adjustment
• When clearing jams or replacing parts inside the point of operation
• During any task where a body part enters the machine’s danger zone
• When multiple workers are involved in servicing the same machine

What does Lockout/Tagout involve?

• Physically locking energy sources in the OFF position using a lockout device
• Attaching a tag with the worker’s name and contact info
• Verifying that energy has been released (including stored energy like compressed air or hydraulic pressure)
• Testing the machine to ensure it cannot start
• Never removing another worker’s lock unless following a written emergency removal procedure

Who is allowed to perform LOTO?

Only trained and authorized employees may perform Lockout/Tagout procedures. If you are not authorized, you must stay clear of the equipment and never attempt to remove a lock or tag.

Additional Guidance

Machine guards protect against contact. LOTO protects against motion. You need both for full protection.
Never assume a machine is safe just because it looks off. Always confirm that it has been properly locked out and tested before putting hands near any moving parts.
If you are ever unsure whether a piece of equipment has been properly locked out, stop and ask. Your life is worth the extra time.

Additional Safety Tips

Machine guarding and safe operation are not just about physical equipment—they rely heavily on personal behavior, awareness, and preparation. These additional tips can prevent injuries and reinforce a culture of safety.

Keep hands, fingers, and clothing clear of all moving parts

Even with guards in place, some moving parts may still be partially exposed, especially during tool changes or material handling. Always maintain a safe distance and avoid reaching over or near running machinery.

Use push sticks, guides, or other tools for feeding material

Never use your hands to push material into a blade, press, or grinder. Use the proper tools to keep your hands safely out of the danger zone.

Avoid wearing loose clothing, jewelry, or anything that can be caught

Necklaces, long sleeves, lanyards, and untucked shirts can all become entangled in rotating machinery. Always dress appropriately for your task.

Keep long hair securely tied back

Hair that is not restrained can be pulled into equipment in a matter of seconds. Use a hair tie, cap, or appropriate headgear.

Use the OpsIntegrity portal for safety resources

Your employer provides access to the OpsIntegrity safety portal, which contains:

Lockout/Tagout procedures

• Hazard reporting tools
• Safety videos and training records
• Inspection checklists and more
• If you are unsure about a procedure, consult the portal or speak with your supervisor.

Additional Guidance

Safety is not just about following rules, it is about taking personal responsibility for your well-being and the well-being of your team. If something feels unsafe, it probably is.
Report hazards, near misses, and unsafe behaviors immediately. Waiting until after an injury helps no one. Prevention is the most powerful safety tool you have.

Multi-Employer Worksite Considerations

Many worksites involve multiple employers working together. Each employer must ensure that their employees:

• Know the designated exit routes for the worksite.
• Are familiar with the site's Emergency Action Plan (EAP).
• Participate in coordinated emergency drills when possible.

Primary contractors or host employers typically hold responsibility for coordinating emergency planning with subcontractors and other employers present on-site. All parties must communicate and ensure that emergency procedures are clear and understood by everyone.

Reporting and Resources

• Report blocked exits, damaged signs, or any emergency hazards immediately to your supervisor or designated safety contact.
• OpsIntegrity Safety Portal provides centralized access to:Emergency Action Plans
  
  • Evacuation maps
  • Emergency contacts
  • Hazard reporting tools
  • Training materials and safety procedures
• Records of reported hazards, corrective actions, and training are maintained for compliance and continuous safety improvement.

Summary and Key Takeaways

Machine guarding is a critical component of workplace safety. OSHA’s 1910 Subpart O regulations exist to protect workers from the severe hazards associated with operating or working near machinery. Moving parts, sharp blades, rotating shafts, and other mechanical actions can cause serious injuries or fatalities when not properly guarded.

This training has provided a comprehensive overview of machine guarding requirements, common violations, and the roles and responsibilities of both employees and employers. It also emphasized the importance of Lockout/Tagout (LOTO) procedures during maintenance and offered practical tips to promote safe practices.

Whether you are operating equipment directly or working nearby, understanding how machine guards function and how to respond to hazards is essential for your safety and the safety of your team.

Key Takeaways

• Machine guards must be in place and in good condition before any equipment is operated.
• Guards are designed to prevent contact with moving parts and must never be removed, bypassed, or disabled.
• There are several types of guards, including fixed, interlocked, adjustable, and presence-sensing devices. Each is designed for a specific use.
• Daily visual inspections are essential to detect damaged or missing guards.
• Employees are responsible for reporting hazards, using proper PPE, and participating in all required safety training.
• Employers must ensure proper guarding is installed, maintained, and supported with clear procedures and training.
• Common violations include missing guards, exposed belts or pulleys, disabled safety devices, and untrained workers using machinery.
• Lockout/Tagout (LOTO) procedures must be followed whenever a guard is removed or a machine is serviced to prevent unexpected startup.
• Safe practices such as using push sticks, tying back long hair, and wearing appropriate clothing reduce the risk of entanglement.
• Access your company’s OpsIntegrity portal regularly for updated safety procedures, training resources, and reporting tools.

Acknowledgment of Completion

By completing this training module on Walking-Working Surfaces (1910 Subpart D), I acknowledge that:

• I have received training in accordance with OSHA’s General Industry standards.
• I understand the hazards associated with walking-working surfaces and how to recognize and prevent them.
• I understand both my employer’s responsibilities and my own responsibilities for maintaining safe walking-working surfaces.
• I am aware of the requirement to report unsafe conditions immediately.
• I know how to access safety procedures, training, and resources through the OpsIntegrity Safety Portal.
• I understand that this training is part of a broader safety program and that additional training may be provided by my employer.

I commit to using the knowledge gained in this training to help maintain a safe and compliant workplace.