Machine guarding is consistently among OSHA's top 10 most-cited violations, underscoring how frequently employers fail to adequately protect workers from mechanical hazards. Under 29 CFR 1910.212, one or more methods of machine guarding must be provided to protect the operator and other employees from hazards created by point of operation, ingoing nip points, rotating parts, flying chips, and sparks. This guide covers the complete inspection requirements for barrier guards, safety devices, power transmission apparatus, and interlocks, with a free downloadable checklist.
Free Machine Guarding Inspection Checklist
Download our Word document checklist covering barrier guards, point of operation, power transmission, safety devices, and interlocks.
Download Checklist (.docx)Why Machine Guarding Inspections Are Required
OSHA 29 CFR 1910.212 — General Requirements for All Machines
- 1910.212(a)(1): One or more methods of machine guarding shall be provided to protect from hazards such as point of operation, ingoing nip points, rotating parts, flying chips, and sparks.
- 1910.212(a)(2): Guards shall be affixed to the machine where possible and secured elsewhere if attachment to the machine is not possible. The guard shall not be an accident hazard in itself.
- 1910.212(a)(3)(ii): Point of operation guarding devices shall prevent the operator from having any part of his body in the danger zone during the operating cycle.
- 1910.212(a)(5): Fan blades less than 7 feet above the floor shall be guarded with openings no larger than ½ inch.
OSHA 29 CFR 1910.219 — Mechanical Power Transmission Apparatus
- Requires guarding of flywheels, pulleys, belts, chains, sprockets, shafts, couplings, gears, and other power transmission components.
- Projecting keys, setscrews, and bolts on rotating parts must be made flush or guarded.
- All belts, pulleys, and shafting within 7 feet of the floor or working platform must be guarded.
Important: When guards must be removed for maintenance or servicing, lockout/tagout procedures per OSHA 1910.147 must be followed before any employee places any body part in the danger zone. Guards must be reinstalled and verified before returning equipment to production.
Barrier and Fixed Guards
| Inspection Item | What to Check |
|---|---|
| Guard integrity | No cracks, breaks, holes, dents, or deformation. Material appropriate for the hazard (metal, polycarbonate, expanded metal, wire mesh). No sharp edges on the guard itself. |
| Secure attachment | All fasteners in place and tight. Guard does not shift, wobble, or rattle during machine operation. Hinged guards close and latch properly. |
| Openings and gaps | No openings large enough to allow fingers, hands, or other body parts to reach the danger zone. Complies with OSHA Table O-10 for maximum permissible openings based on distance from the hazard. |
| Visibility | Transparent or mesh guards allow the operator to observe the operation where necessary. Guard does not obstruct safe operation or required sightlines. |
| Accessibility | Guard does not prevent proper machine operation, feeding, or material removal. Does not create pinch points or new hazards. Allows for routine lubrication and adjustment without removal where possible. |
Point of Operation Guarding
| Inspection Item | What to Check |
|---|---|
| Guard coverage | Guard fully covers the point of operation where work is performed on material. No access to nip points, shear points, or cutting edges during the operating cycle. |
| Adjustable guards | Adjustable guards properly set for the current stock size. Adjustment mechanism holds position during operation. Minimum practical opening maintained. |
| Self-adjusting guards | Guard opens only enough to admit stock and closes when stock is withdrawn. Spring tension adequate. No binding or sticking. Returns to closed position reliably. |
| Interlocked guards | Machine cannot operate when guard is open or removed. Interlock switch functional — test by opening guard while machine is running (it must stop). No bypassing or defeating of interlock. |
| Two-hand controls | Both hands required to initiate cycle. Concurrent activation required (anti-tie-down). Hands protected by distance from danger zone. Cannot be defeated by blocking one button. |
Safety Devices and Presence Sensing
| Inspection Item | What to Check |
|---|---|
| Light curtains | All beams functional — test by breaking beam (machine must stop or not cycle). Proper alignment. Minimum object sensitivity appropriate for finger/hand detection. Blanking not excessive. |
| Safety mats / edges | Pressure-sensing mat or edge activates when stepped on or contacted. Machine stops within safe stopping time. No dead spots. Edges not worn or damaged. |
| Laser scanners | Scanning area properly configured for the hazard. Warning and safety zones set correctly. Response time adequate. No obstructions in scanning field. |
| Emergency stops | E-stop buttons accessible from all operator positions. Red mushroom-head style, clearly labeled. Latching (stays engaged when pressed). Machine stops within acceptable time. Reset requires deliberate action. |
| Safety relays / controllers | Safety-rated relay or controller monitoring guard circuits. Indicator lights show normal status. No fault codes. Wiring intact and properly terminated. |
Power Transmission Guards (1910.219)
| Inspection Item | What to Check |
|---|---|
| Belts and pulleys | All belts and pulleys within 7 ft of floor guarded. Guard covers both sides and face of pulley. Belt tension does not cause guard contact. No frayed or damaged belts exposed. |
| Chains and sprockets | Drive chains fully enclosed or guarded. Sprocket teeth not accessible. Guard secure and intact. No excessive chain slack creating snag hazards. |
| Shafts and couplings | Rotating shafts within 7 ft of floor fully guarded. Coupling guards in place. No exposed keyways, setscrews, or projecting bolts on rotating parts. |
| Gears | All gears enclosed or guarded to prevent contact. Guard openings do not allow fingers to reach gear teeth. Lubrication points accessible without guard removal where possible. |
| Flywheels | Flywheels with any part within 7 ft of floor guarded with enclosure. Upper flywheel exposed above guard is acceptable if above 7 ft. Guard structural integrity adequate for flywheel failure containment. |
Lockout/tagout connection: OSHA 1910.147 requires energy control procedures whenever guards are removed for servicing or maintenance. Periodic inspections of the energy control program must be conducted at least annually. The machine guarding inspection and the LOTO periodic inspection complement each other — both are essential to a complete machine safety program.
Corrective Actions
Tag Out of Service When:
- Any guard is missing, removed, bypassed, or not functioning
- Interlocks have been defeated or are not stopping the machine when activated
- Guard openings exceed permissible limits for the distance from the hazard
- Safety devices (light curtains, E-stops, two-hand controls) fail functional testing
- Power transmission components are exposed within 7 feet of the floor
- Guards create new hazards (sharp edges, pinch points, instability)
- Any condition that allows an operator to place body parts in the danger zone
Download the Free Checklist
Get our machine guarding inspection checklist in Word format. Customize for your specific machines and operations.
Download Checklist (.docx)Go digital with Ecesis. Replace paper machine guarding inspection logs with Ecesis inspection software. Create custom checklists by machine. Track guard conditions with photos. Automatically generate corrective actions for deficiencies. Link to your LOTO program. Request a free demo.
Ecesis EHS Software
Inspections
Machine-specific digital checklists with photo documentation and corrective actions.
Safety Inspections
Workplace safety inspections with machine guarding compliance verification.
Preventive Maintenance
Schedule guard inspections, safety device testing, and machine maintenance intervals.
Training
Track machine operator training, guard awareness, and LOTO certification.
Compliance Calendar
Schedule periodic LOTO inspections, guard audits, and safety device testing.
Task Management
Assign corrective actions for missing or deficient guards and track to resolution.
