Module 1: Introduction to Machinery Safety

• Importance of machinery guarding in the workplace
• Common machinery-related hazards
• Regulatory standards (OSHA 29 CFR 1910 Subpart O, ISO 14120, EN standards)

Module 2: Understanding Machine Hazards

• Mechanical hazards: cutting, crushing, entanglement, shearing, impact
• Non-mechanical hazards: noise, vibration, hot surfaces, ejected materials
• Hazard recognition and risk assessment

Module 3: Principles of Machine Guarding

• Purpose and function of guards
• Hierarchy of controls for machinery hazards
• Key design principles for effective guarding

Module 4: Types of Machine Guards

• Fixed guards
• Interlocked guards
• Adjustable and self-adjusting guards
• Distance and perimeter guards

Module 5: Types of Safeguarding Devices

• Presence-sensing devices (light curtains, pressure mats)
• Two-hand controls and trip devices
• Automatic and remote controls
• Emergency stop devices

Module 6: Guard Design and Installation Requirements

• Material selection and construction standards
• Visibility, accessibility, and strength of guards
• Design considerations for maintenance and cleaning

Module 7: Inspection and Maintenance of Guards

• Routine inspection procedures
• Identifying damaged or missing guards
• Maintenance planning and recordkeeping

Module 8: Safe Work Practices Around Machines

• Pre-start checks and authorization
• Never removing or bypassing guards
• Reporting unsafe conditions or defective equipment

Module 9: Lockout/Tagout (LOTO) Integration

• Relationship between LOTO and guarding
• Isolating energy before maintenance
• Verification of zero-energy state

Module 10: Roles and Responsibilities

• Operators’ duties and accountability
• Supervisors’ and maintenance personnel’s roles
• Employer’s responsibility for compliance and enforcement

Module 11: Incident Response and Reporting

• Steps to take if a guard is missing or damaged
• Reporting and investigating machine-related injuries
• Corrective and preventive actions

Module 12: Promoting Machinery Safety Culture

• Continuous improvement in guarding programs
• Training, refresher courses, and awareness campaigns
• Case studies and lessons learned from accidents