Modifications to plant and equipment guards should not be made without proper assessment and approval due to several legal, safety, and compliance reasons.
Work Health and Safety (WHS) Regulations
- Under the Work Health and Safety Act 2011 and associated regulations, employers must ensure that machinery and equipment are safe for use.
- Modifying guards may create new hazards, making the equipment non-compliant with Safe Work Australia standards.
Manufacturer’s Specifications and Warranty
- Modifications may void the manufacturer’s warranty and liability coverage.
- Manufacturers design guards to meet AS/NZS safety standards, and unauthorised changes can compromise their effectiveness.
Risk of Injury and Legal Liability
- Guards are designed to prevent entanglement, crushing, cutting, and impact injuries.
- Unauthorised modifications can expose workers to serious injuries, leading to workers’ compensation claims, legal penalties, and prosecution.
Compliance with Australian Standards
- This standard governs the safety of machinery and requires guards to be designed and installed to prevent operator exposure to hazards.
- Modifying guards may render the equipment non-compliant, leading to legal consequences and enforcement actions by Safe Work regulators.
Consultation and Risk Management Requirements
- WHS laws require employers to consult with workers and safety representatives before altering plant and equipment.
- A formal risk assessment is required before making any changes to safety controls.
Potential for Increased Maintenance Costs and Downtime
- Unapproved modifications can cause equipment failure, breakdowns, or inefficiencies, increasing downtime and repair costs.
What Should Be Done Instead?
- If changes to guards are necessary, they should be:
- Assessed by a qualified engineer or safety professional.
- Approved by the manufacturer where possible.
- Tested and documented through a risk assessment process.
- Compliant with relevant Australian Standards and WHS laws.
Plant and Equipment Emergency Stops
In addition to avoiding unauthorised modifications to plant and equipment guards, it is essential to check the operation and positioning of emergency stops to ensure compliance with safety regulations.
Compliance with WHS Regulations and Australian Standards
- The Work Health and Safety (WHS) Act 2011 mandates that plant and equipment must have effective emergency stops.
- AS/NZS 4024.1604 (Emergency Stop Principles) specifies that emergency stops must be:
- Easily identifiable and accessible.
- Located in positions where operators can quickly activate them.
- Designed to override all other controls and stop the machine immediately.
Risk of Delayed Emergency Response
- Poorly positioned or non-functional emergency stops can delay critical responses, leading to serious injuries or fatalities.
- Regular checks ensure that emergency stops are operational and within easy reach of workers.
Prevention of Equipment Damage and Downtime
- A functional emergency stop prevents further mechanical damage to equipment in case of malfunction.
- Proper positioning helps reduce machine downtime and costly repairs.
Legal and Financial Consequences
- Failure to ensure emergency stops are functional and correctly positioned may result in Safe Work Australia enforcement actions, penalties, or even prosecution.
Best Practices for Emergency Stop Checks
Visual Inspection – Ensure emergency stop buttons are clearly marked (red with a yellow background) and not obstructed.
Operational Testing – Regularly test emergency stops to confirm they work as intended.
Worker Accessibility – Ensure emergency stops are within easy reach of operators and maintenance personnel.
Training and Awareness – Educate workers on proper emergency stop usage and procedures.
Sherm Software will schedule routine Workplace Inspections to ensure plant and equipment safety guards and emergency stops are regularly tested, while Sherm’s Training and Competency module will leave employers with the peace of mind that their workers have been educated on the importance of proper emergency stop usage and procedures.
