Presented by: Tony Catterson, Pilz NZ at OHSIG 2014, Wednesday 10/9/14, NZI Room 4, 2.45pm

1. Machinery guarding What do I
need to know to get it right ?

2. Training Bio
Tony Catterson
• Manager Pilz NZ
• CMSE---- (Certified Machinery
Safety Expert Tuv Nord).
• Electronics technician
Pilz
• German based world leader in
Machinery safety.
• Offering training in machine
guarding standards in New zealand
for 12 years
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3. 3

4. 4

5.  Worksafe Actual findings--- inspections
Generally, new machinery was guarded whilst old machinery
typically lacked guarding and interlocks. There is an issue with
employers purchasing machinery marked CE from Europe
believing it to comply with AS/4024, when this is not always
the case. AS/4024 became a joint NZ Australian Standard
(AS/NZS4024 2014) on 30 June.
There was clear message from Inspectors that many employers
did not understand their responsibilities under the Health and
Safety in Employment Act (1992) and did not understand the
hazard identification and hazard management process. This is
truer of small-medium sized enterprises than of large
businesses.
On a positive note, Inspectors reported businesses are thirsty
for knowledge, are trying to do their best, and don’t have an
issue with making improvements.
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6.  Worksafe inspection ‘blitz’
Overall Inspectors made 62 workplace assessments during the
two week testing period. Resulting from the 62 assessments
114 notices were issued, which comprised:
90 improvement notices
19 prohibition notices
5 written warnings.
Metal manufacturing made up 37% of visits and 45% of notices.
It had the highest number of notices issued per visit at 2.3 per
assessment. Wood manufacturing made up 25% of visits and
20% of notices whilst Food and Beverage manufacturing
made up 24% of visits and 21 % of notices issued.
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7.  Machine guarding
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8.  Sources of Health & Safety Information
8
Must
Do
Should
Do

9.  Standards Introduction
What are Standards?
Standards are published
documents setting out
specifications and procedures
designed to ensure products,
services and systems are safe,
reliable and consistently perform
the way they were intended to.
They establish a common
language which defines quality and
safety criteria.
9

10.  Standards Introduction
Standards & Law
Standards Australia and Standards New Zealand are not part of
government, they do not make laws or regulations.
Australian and New Zealand Standards are not legal documents
but many, because of their rigour, are called up into legislation
(Acts and Regulations) by government and become mandatory
(e.g. AS/NZS 3000).
Standards are also often incorporated into legal contracts. In these
circumstances compliance with standards is necessary to comply
with contract law.
Codes of Practice in many cases make reference to standards.
This however does not make them law or mandatory to follow.
Technical Standards should only be used if it provides an
equivalent or higher standard of work health and safety than the
Codes of Practice.
10

11.  Standards Introduction
AS 4024.1 in New Zealand
“AS4024 (2014) Safety of Machinery represents the current state of
knowledge in relation to equipment safeguarding and duty holders should
refer to it as the primary standard against which to benchmark. Employers,
suppliers, manufacturers and designers remain free to work to other
Standards but will need to demonstrate that they are capable of achieving
an equivalent level of safety in the circumstances in which they are used.
The Ministry will use AS4024 as its principal guide for determining practical
steps for machine guarding, along with any New Zealand or Australian
recognised standards for specific machines.”
(Source: MBIE Position Paper for the Safe Use of Machinery)
11

12.  Standards Introduction
AS 4024 Series – Safety of Machinery Standards
AS 4024 is divided into three different categories – the text below is taken from
ISO Standard Introduction
Part 1 Standards: Basic standards
 Part 1 Standards: Generic Safety Standards giving basic concepts, principles
for design and general aspects that can be applied to machinery
Part 2 Standards: Group standards
 Part 2 standards are generic safety standards dealing with one safety aspect or
one type of safeguard that can be used across a wide range of machinery e.g.
Standards on safeguards, for example two hand controls, safety distances and
safety gaps
Part 3 Standards: Machinery Safety Standards
 Part 3 standards deal with detailed safety requirements for a particular machine
or group of machines
 When a Part 3 standard deviates from one or more technical provisions dealt
with by a Part 1 or 2 standards, the Part 3 standard takes precedence.
12

13.  Standards Introduction
Subdivision of Machinery Standards
Part 1 Standards
Part 2 Standards
Part 3 Standards
13
26 International Standards
Safety Principles
Design Parameters
Ergonomics
Technical Support
Standards
AS 4024.2601 Two hand Controls
AS 4024.2801 Approach Speeds
Machine Specific Standards
AS 4024.3001 Mechanical Power Presses
AS 4024.3002 Hydraulic Power Presses
AS 4024.3101 Milling Machines
AS 4024.3301 Industrial Robots
AS 1755 – Conveyors (to become an AS4024.3600 series standard in future)

14.  Relevant Machinery Standards
AS 4024.1201, 1202 & 1301 – Risk Assessment
AS 4024.1201, 1202 & 1301: Safety
of Machinery - General principles
for design – Risk assessment and
risk reduction
 These standards provides
guidance on the risk
assessment process and
provides general principles
intended to be used to meet the
risk reduction objectives
14

15.  Risk Estimation methods – 5X5
Example. A matrix for determining the level of risk.
Likelihood
Consequence
1 insignificant 2 minor 3 moderate 4 major 5 catastrophic
A v.likely Medium High High Extreme Extreme
B likely Medium Medium High High Extreme
C moderate Low Medium High High High
D unlikely Low Low Medium Medium High
E rare Low Low Medium Medium High
(Source. AS/NZ 4360-2004 Risk Management)
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16.  Risk Estimation
Example. Risk ranking.
Risk Level Required action
Low
Presenting very little risk.
Continuously review existing measures.
Medium
Containing hazards that require control measures.
Specify management responsibility and action dates.
High
Containing hazards that require control measures to be implemented urgently.
Should be reduced as soon as possible.
Extreme Continued operation is unacceptable.
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17.  Risk Estimation Methods - Nomogram
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Residual Risk
by admin &
ppe
Reduce probability by design

18.  Relevant Machinery Standards
AS 4024.1601 - General Requirements for Guards
AS 4024.1601 – Safety of Machinery –
Guards – General Requirements for
the Design and Construction of fixed
and moveable guards
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19.  Relevant Machinery Standards
AS 4024.1801 & 1802 - Safety Distances
AS 4024.1801 & 1802
Safety of Machinery - Safety distances to prevent hazard zones being
reached by the upper and lower limbs.
 These standards are used to establish adequate safety distances to be
determined to prevent danger zones being reached based on the upper
limbs
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20.  AS 4024.1801 Safety distances to prevent upper
limbs access
Reaching upwards
Potential consequence INSIGNIFICANT or MINOR
• Height of the danger zone 2500 mm or more
Potential consequence DISASTROUS, MAJOR or
MODERATE
“Significant hazard”
• Height of the danger zone 2700 mm or more
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Danger Zone
Height of
danger
zone
Note: If the height of the danger zone can not be achieved then
guarding shall be put in place.

21.  AS 4024.1801 Safety distances to prevent upper
limbs access
(a) Height of the danger zone.
(b) Height of the protective structure
(c) Horizontal distance to the danger zone
The gap under the distance guard (e) should be a
maximum of 180 mm to prevent access
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Danger
Zone (a)
(b)
(c)
(e)
Reaching over protective structure
Note: If the danger zone can be reached from the gap under the
protective structure (e), then the size of the opening needs to be
reduced according to the severity of the risk .

22.  AS 4024.1801 Safety distances to prevent upper
limbs access
Potential consequence MODERATE, MAJOR & DISASTROUS (High risk)
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Height of protective structure (b)
1,000 1,200 1,400 1,600 1,800 2,000 2,200 2,400 2,500
Height of danger zone (a)
2,600 900 800 700 600 600 500 400 300 100
2,400 1,100 1,000 900 800 700 600 400 300 100
2,200 1,300 1,200 1,000 900 800 600 400 300
-
2,000 1,400 1,300 1,100 900 800 600 400
- -
1,800 1,500 1,400 1,000 900 800 800
- - -
1,600 1,500 1,400 1,000 900 800 500
- - -
1,400 1,500 1,400 1,000 900 800
- - - -
1,200 1,500 1,400 1,000 900 700
- - - -
1,000 1,500 1,400 1,000 800
- - - - -
800 1,500 1,300 900 600
-
Horizontal distance
to danger zone (c )
-
600 1,400 1,300 800
- - -
400 1,400 1,200 400
- - -
200 1,200 900
- - - - - - -
-
1,100 500
- - - - - - -
Danger
Zone (a)
(b)
(c)

23.  AS 4024.1801 Safety distances to prevent upper
limbs access
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Examples of safe mesh guarding
Mesh
guard
30 mm Hazard
120 mm (Minimum)
50 mm
Hazard
Mesh
guard
850 mm (Minimum)
Reaching through protective structure

24.  AS 4024.1802 Safety distances to prevent lower
limbs access
Maximum size of gap to prevent whole body access
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240 mm
(Max)
Square
240 mm
(Max)
180 mm
(Max)
Round Slot
240 mm
(Max)

25.  Relevant Machinery Standards
AS 4024.1501 & 1502
Safety Related Parts of Control Systems
AS/NZ 4024.1501 - Safety related parts of control systems: General
Principles for Design
AS/NZ 4024.1502– Safety related parts of control systems: Validation
AS/NZ 4024. 1503 : Current Alternative Standard for safety related control
systems which incorporates Performance levels.(IEC 13849-1)
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26.  Relevant Machinery Standards
AS 4024.1-1501 - Safety Related Parts of Control Systems
 Identify the hazards on the
respective machine
 Assess risk parameters S, F, P in
accordance with Appendix C
 Determine the required performance
Category
 Confirm the category architecture is
achieved
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27.  Specifications of categories
27
Assessment guidance
Possible categories which
may require additional
measures
Preferred categories for
reference points
Measures which can be
over-dimensioned for the
relevant risk
CATEGORY of control system
S
1
S
2
F1
F2
B 1 2 3 4
P
1
P
2
P
1
P
2
STEP 1: Assess the potential SEVERITY of Injury
The potential severity of an injury is evaluated by considering the extent of injuries that a
person may suffer due to the control system fault(s).
Potential severity
factor
Assessment guidance
S1
Slight injuries may result with consequences that are normally reversible (e.g. The
person fully recovers after a period of time and/or medical treatment)
S2
Serious injuries that are normally not revisable (e.g. Loss of body function,
amputation, permanent disability and fatality).

28.  Specifications of categories
28
Assessment guidance
Possible categories which
may require additional
measures
Preferred categories for
reference points
Measures which can be
over-dimensioned for the
relevant risk
CATEGORY of control system
S
1
S
2
F1
F2
B 1 2 3 4
P
1
P
2
P
1
P
2
STEP 2: Assess the FREQUENCY and/or duration of exposure to the hazard
The frequency and/or duration of exposure to the hazard is evaluated by considering the period of time that
a person is exposed to a hazard in relation to the total period of time in which the equipment is in use.
Factor Assessment guidance
F1
A person is seldom to quite often, and/or short exposure time.
E.g. A person operating the machine is only exposed to the hazard when machine
is blocked or when a tool change is required.
F2
A person is frequently or continuously exposed to the hazard.
E.g. A machine operator is exposed to the hazard when ever the machine is in
operation.

29.  Specifications of categories
29
29
Assessment guidance
Possible categories which
may require additional
measures
Preferred categories for
reference points
Measures which can be
over-dimensioned for the
relevant risk
CATEGORY of control system
S
1
S
2
F1
F2
B 1 2 3 4
P
1
P
2
P
1
P
2
Step 3: Possibility of avoiding the hazard
Whether the hazard can be recognised by physical characteristics or only be technical means such as
indicators;
Operation with or without supervision;
Operation by experts or non-professionals;
The speed with which the hazard arises;
Possibilities for hazard avoidance, and
Practical safety experience relating to the process.
Potential severity
factor
Assessment guidance
P1 Possible under specific conditions
P2 Nearly impossible

30.  EN ISO 13849
Procedure
Risk
Assessment
Design SRP/CS
Machine Limits
Hazard Identification
Assess Risk, Plr
SRS, PLr definition
System Architecture
Detail Design
Design Evaluation
System Implementation
Principles, Fault List
Planning
Validation
Information
Analysis
Testing
Determine the required performance level PLr using
the risk parameters
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31.  Relevant Machinery Standards
AS 4024.1602 - Interlocking Devices
AS 4024.1602 - Safety of machinery - Interlocking devices associated with
guards - Principles for design and selection
 Gives principles for the design and selection of interlocking devices
associated with guards
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32.  Safety Devices
The main types of input devices are:
• Emergency stops –
buttons and lanyards
• Interlocking Devices
• Light Curtains
• Safety Mats
• Two Hand Control
Devices
• Safety Scanners
• Mechanical Trips
• Hold to Run Devices
• Key Exchange Systems
• Camera Systems
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33.  Safety switches
 Mechanical safety switches
 Prevent premature operator access via increased extraction
force
 Used to interlock the safety gate until hazardous production
processes are complete
 Magnetic safety switches
 Non-contact
 Economic ,hard to defeat
 For a high safety category, where there is heavy soiling and
where strict hygiene regulations are in place
 Coded safety switches
 5 directions of activation
 Long switching distance
 Can be series wired and still meet Cat 4

34.  Relevant Machinery Standards
AS 4024.1803 & AS 4024.1604
AS 4024.1803 - Safety of
machinery - Minimum gaps to
avoid crushing parts of the
human body
Gives data for calculation of
safe gaps between moving
parts etc
AS 4024.1604 - Safety of
machinery - Emergency Stop -
Principles for design
34

35.  Relevant Machinery Standards
Part 3 Standards
Product Specific Part 3
“Product Standards”
AS 4024.3001- Mechanical
power presses
AS 4024.3002- Hydraulic
power presses
AS 4024.3101- Milling
machines
AS 4024.3301- Industrial
robots
AS 1755 – Conveyor safety
requirements (Soon to be
replaced with AS 4024.3600
series) 35

36.  What does “All Practical Steps” mean?
“All practicable steps” is defined in the Health
and Safety in Employment Act 1992.
Briefly, it means doing what is reasonably able
to be done in the circumstances, taking into
account:
• The severity of any injury or harm to health
which may occur;
• The degree of risk or probability of that injury
or harm occurring;
• How much is known about the hazard and the
ways of eliminating, reducing or controlling it;
and
• The availability, effectiveness and cost of the
possible safeguards.
Risk
Assessment
Codes of Practice,
Standards,
Guidance Notes,
Latest Industry
Practice etc.
Cost

37.  Standards and Legislation
 The Department of Labour
consider compliance with AS/NZ
4024.1-2014 as meeting all
practicable steps.
 Non compliance with a relevant
standard will very likely be used
as evidence that a product
contravenes the legal obligation to
make a product safe.
 Standards are typically not
mandatory, but system standards
are used to demonstrate
conformance with legislation.
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38.  New Guidance on Machinery Safety
The Best Practice Guidelines for the Safe Use of
Machinery outlines the hazards associated with
machinery use in the workplace, potential injuries, and
how best to control these hazards. It gives guidance
to duty holders on how to safely use machinery to
comply with their duties and obligations under the
Health and Safety in Employment Act 1992 (HSE Act)
and the Health and Safety in Employment Regulations
1995 (HSE Regulations).
It provides guidance on:
•Designing out hazards
•Identify, assess and control hazards
•Hazard and risk assessment
•Hierarchy of controls
•Machinery hazard controls
•Machinery guarding for specific plant
•Design and construction of machinery and guards
•Responsibilities and duties for machinery
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39. Thank you for your attention.
Questions ?
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