Guidelines for the Comprehensive Safety Standards of Machinery (2007)
Up Date : 2008.03.26
Attached Table 3 Method of safeguarding
- Safeguarding shall be conducted by providing the hazard zone with a fixed guard, interlocking movable guard or other guard, or active opto-electronic protective device (AOPD), tow-hand controldevice, or other protective device.
- Determine the hazard zone in consideration of the following zone:
- (1) The maximum zone (hereinafter referred to as the "maximum operating zone") where moving parts that may cause mechanical hazards
- (2) If a part of a worker's body enters the maximum operating zone regarding the mechanical hazards, the zone for ensuring the necessary space to prevent the body from getting caught or undergoing other danger depending on the zone of the body entering
- (3) The zone for ensuring the necessary distance for a guard or protection installed to function effectively according to the shape of the guard or to the type of the protective device
- (4) Any other zone around the machinery which may be exposed to hazards.
- Install the guard or protective device as follows according to the task where workers interact with machinery:
- (1) In providing the motive force transmission part with safeguarding, install a fixed guard or interlocking movable guard.
- (2) In providing any moving part other than the motive force transmission parts with safeguarding, do as follows:
- a) If a normal run of machinery entails no need for entering the hazard zone, surround the entire circumference of the said hazard zone with a fixed guard, interlocking movable guard or other guard, AOPD, pressure sensitive mat, or other protective device that stops the machinery by detecting entry of a part of a worker's body.
- b) If a normal run of machinery entails any need of entering the hazard zone, and if safeguarding is conducted by stopping a hazardous moving part, do as follows:
- (a) For the surroundings of the hazard zone other than the necessary opening through which a worker can enter a part of their body, equip the said areas with a protective device designed to stop the machinery by detecting entry of a part of the worker's body into a fixed guard, interlocking movable guard or other guard, or AOPD, pressure sensitive mat, etc.
- (b) Equip the opening with an interlocking movable guard, self-closing guard or other guard, or AOPD, tow-hand control device, etc.
- (c) If a worker can enter their whole body into the hazard zone through the opening, install a device, etc. for detecting any worker in that hazard zone.
- c) If, in a normal run of machinery, a worker needs to enter the hazard zone, and if it is not appropriate in performing the task to perform safeguarding by stopping any hazardous moving part, then provide an adjustable guard (which refers to a guard which is either adjustable in its entirety or incorporates an adjustable part) or other means that minimizes exposure of that moving part.
- (3) If oil, air, or other fluid is used, and if there is a possibility of harm due to jet, etc. of a high-pressure fluid from the hose, install a guard on the part of the hose which may be damaged.
- (4) If there is a possibility of an electric shock, equip the charging parts with an enclosure or insulated covering.
- The enclosure shall be unable to be opened without a key or tool or without disconnecting the charging part.
- (5) If there is a possibility of harm due to contact with a hot or cold part of machinery, install a guard on that hot or cold part.
- (6) If there is a possibility of harm due to noise or vibration, reduce noise or vibration generated by the use, etc. of an acoustic shield, noise eliminator, elastic sheet, etc.
- (7) If there is a possibility of harm due to radiation, etc., then take such measures as shielding the zone susceptible to radiation, etc. and reducing the level of radiation, etc. leaking outside.
- (8) If there is a possibility of harm due to hazardous substances and dust (hereinafter referred to as "hazardous substances, etc."), seal the sources of hazardous substances, etc., discharge the emissions of hazardous substances, etc., or take a similar measure to reduce exposure to that hazardous substances, etc.
- (9) If there is a possibility of any fabricated product, etc. which may be dropped or ejected by the machinery, take a measure to contain or capture that fabricated product, etc.
- Guards shall be as follows:
- (1) Guards shall be as set forth below.
- a) All parts that a worker may touch shall be avoided sharp edges and corners, protruding, etc.
- b) Use a material which will have sufficient strength and will not readily corrode, deteriorate, etc.
- c) To withstand repeated opening and closing, etc., the hinges, slides, and other movable parts and their mounts shall be have sufficient strength and equipped with a measure to keep them tight or prevent them from coming off.
- d) Install the said parts by welding, etc. or fix them with bolts, etc. to make them impossible to remove without using a tool.
- (2) To equip a guard with an opening for passing products through, etc., conform to the following:
- a) Make the opening the smallest possible size.
- b) If there is a possibility that a part of a worker's body will pass through the opening and reach the maximum operating zone, install a tunnel guard or other structure to prevent any part of that worker from reaching the maximum operating zone or conform to 3 (2) b) (b) or (c).
- (3) Movable guards shall be as follows:
- a) When the movable guard is not completely closed, the hazardous moving parts can not start up.
- b) Only when the movable guard is closed, the hazardous moving parts can not start up by automatically.
- c) For movable guards without a locking mechanism (which refers to a mechanism for fixing any hazardous moving parts while in operation to prevent their guards from opening. The same shall apply hereinafter), the hazardous moving parts shall stop operating the moment any such movable guard is opened.
- d) Movable guards with a locking mechanism shall be disabled from being opened unless after the hazardous moving parts are completely stopped.
- e) For movable guards so designed that they cannot be opened unless after a certain period after an operation is performed to stop the hazardous moving parts, the said certain time shall be set to a period longer than the time required for that moving parts stop.
- f) The locking mechanism, etc. shall be disabled from being easily defeated.
- (4) The adjustable guards shall be adjustable without using a special tool, etc. and shall, during certain runs, be able to cover the hazard zone or surround as much of the relevant hazard zone as possible.
- (1) Guards shall be as set forth below.
- Protective devices shall be as set forth below.
- (1) They shall have strength and endurance enough to meet the operating conditions.
- (2) They shall have high reliability.
- (3) They shall be impossible to be easily defeated.
- (4) They shall be so installed as to allow tool replacement, cleaning, lubrication, adjustment, etc. without being removed.
- If there is a possibility that risks will rise unless the moving parts of the machinery cannot remain stopped due to energy accumulated in the machinery, potential energy, machinery breakdown or malfunction, or erroneous operation, etc., then install a mechanical restraint device that can securely keep that moving part stopped.
- The control system for guards other than fixed guards and protective devices shall be as set forth below.
- (1) They shall be as set forth in 12 and 13 of Attached Table 2.
- (2) The machinery shall be operable only when worker safety is confirmed.
- (3) Appropriate design measures and components shall be used according to the effects of risk reductions required of the relevant control system based on the risk assessment of hazards.
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