A machine guarding checklist is the record of a walk past every machine in an area, asking one question in several ways: can any part of a person reach a part of the machine that moves? It looks at the place where the machine does its work, at the belts, gears and shafts that drive it, and at the nip points where things roll together, then at whether the guards fitted are the right kind, in good order, and actually in use. This checklist gives every machine its own entry, scores each check Pass, Fail or N/A, and turns failures into findings named by machine. Fill it in here and download a PDF without creating an account, or speak while you walk, and the document writes itself.
The three places a guard has to be
Every machine has a point of operation, where it cuts, shapes, presses, punches or bends the material. That is where most amputations happen, because the operator's hands have to come close to it to feed and remove work.
Then there is the power transmission: flywheels, belts and pulleys, chains and sprockets, gears, shafts and couplings. These turn all day, often at the back or the side of the machine where nobody is looking, and they catch sleeves, gloves and hair. Last are the in-running nip points, where two parts turn toward each other or a belt runs onto a pulley, which draw a hand in faster than it can be pulled back. The checklist asks about each one separately, for every machine.
Matching the check to the guard
A fixed guard should need a tool to take off. An interlocked guard should stop the hazardous motion when it opens, and the machine should not start again until it is shut. An adjustable guard is only as good as its last setting, and a light curtain only works if it is far enough from the hazard that the machine stops before a hand arrives.
Tick the guard types a machine has and the entry asks the matching test: open the interlocked door and watch the motion stop, break the light curtain during a cycle, check the adjustable guard is set to the stock being run, or confirm a two-hand control needs both hands at once.
Bypassed guards are the finding that matters
The guard that injures people is usually not the one that was never fitted. It is the interlock taped shut to save a few seconds per cycle, the light curtain muted for a long part, or the cover left off after a repair. Each machine entry asks directly whether any guard or device has been defeated, and a Fail there is a safety finding whatever else the machine scores.
The same entry checks the things that work alongside the guards: an emergency stop the operator can reach and that works when pressed, a machine that does not restart on its own when power returns, lockout points labeled at the machine, and an operator who has been shown how this machine and its guards work.
From findings to fixes
Each machine ends with a decision on the day: safe to run, put right during the walk, or locked out until repaired. Failed checks appear in the report's summary of findings with the machine name and ID, so maintenance gets a list it can work through. Add a corrective action with an owner and a due date for anything that needs parts or a contractor, and the next inspection starts from that list.
Common questions
What does OSHA require for machine guarding?
OSHA's machine guarding rules require guards that protect operators and others from hazards such as the point of operation, nip points, rotating parts and flying chips. This checklist records what you found on each machine; whether a guard meets the rule that applies is judged against that rule by someone competent to do so.
How often should machine guards be inspected?
Operators should look over the guards on their machine at the start of each shift. A supervisor or safety person usually walks the whole area on a set schedule, often monthly, and again after a machine is installed, moved, modified or repaired.
What are the main types of machine guard?
Fixed guards that stay in place, interlocked guards that shut the machine off when opened, adjustable and self-adjusting guards that change with the stock, and safeguarding devices such as light curtains, safety mats, two-hand controls and pullback straps. Some hazards are protected by distance alone, where the moving part is out of reach.
Can a guard be removed to clear a jam or do maintenance?
Only with the machine stopped and locked out, unless the task is minor, routine and protected by other effective means the employer has set out in writing. The guard goes back on, and is tested, before the machine runs again.
Who should carry out a machine guarding inspection?
A supervisor, safety coordinator or maintenance lead who knows the machines and how their guards are meant to work. Involve the operators; they know which guards get in the way and are tempted to be left off.