How Do You Ensure Safety When Operators Remove Guards from Portable Hand Grinders?

In our factory, we carry out a grinding operation with the help of Portable Hand Grinders. We all know that "We should never use the Grinder without the guard." However, sometimes our operators remove the guards, saying that while grinding jobs with notches, this guard prevents the approach of the Grinder.

Till date, this practice has not caused any injury.

Now, as a Safety Professional, I always have a concern about this unsafe practice. We have given a lot of thought to this. However, we could not arrive at a practical solution.

I urge all of you to help in this regard.

Regards,
Shashikant.

Dear Shashikant,

I can't believe this as a safety professional—how can you allow your worker to perform an unsafe job? Yes, it's equivalent to putting your worker in an IDLH situation.

You should explain to your employees the direct and indirect causes of machine guarding. They are not educated; that's why our company appoints us to educate them—this is our job.

Direct Causes:

- Losing a finger; it will never grow back.
- Losing a job; one can't work without a finger.
- Increase in the company's accident rate.

Indirect Causes:

- It reflects on the employee's family.
- It affects the employee's children's studies and future.
- Insurance, compensation, etc.

I have added only a few points of direct and indirect causes.

Note for Mr. Shashikant:

If accidents happen, one day production will be lost for our company.
- Transportation charge (vehicle charge/operator charge)
- Medical charge
- Insurance
- Investigation time (During this time, you will do something for the company)
- Our HR time will be wasted (He works on employee insurance, ESI, etc.)

Mr. Shashikant, just think—it indirectly affects your company's economy. It's all controlled by 30 minutes of training; you can educate your employees within 30 minutes.

Just think, if 3 to 4 employees are injured due to inadequate machine guarding in one week, think about what's going to happen?

Kindly review the revised text and let me know if any additional changes are needed.

Regards,

Dear Raghu, What Mr. Shashikant says is a practical problem. You may not be facing the same issue in your plant. Therefore, I believe your response is not a solution to his concern. I also sometimes face this problem. The workers and the engineers themselves have explanations and reasons to justify what they are doing. Sometimes, for grinding in odd locations, they say that the grinder guard is obstructing. In practice, this is a fact. I am compelled to allow the grinder to work without the wheel guard in place when the situation demands it. I advise him to take extra precautions. That's it.

Alternative Arrangements for Safety

What alternative arrangements can we, as safety professionals, suggest to them? Please come forward with your valuable advice. @Shashikant, thanks for coming forward with this query.

Dear Dipil, I disagree with your comment, Mr. Dipil. Then, why have we created the rule? Every problem/query has a solution in the world. Everyone has reasons/explanations and tries to prove themselves right.

Example from Our Project

Last week in our project, some erectors were erecting the scaffold, almost 98% complete (I have not signed on TAG; it's still in progress). One of our GDAs visited our site; he knew me very well (as I had worked with him on a previous project). He pointed out that the scaffold bearer (scaffolding tied with the steel column of the building) was slightly bent. I quickly replied to him that our building's steel column is not straight, but the scaffolding is in PLUMB (Finally, it has been fixed). Everybody has explanations/reasons.

Suggestion Box

Write the problem/query on the DFAC (dining facilities) board with a suggestion box. Announce some good prizes/awards for the best three suggestions. You will see within a week that you will get the perfect solution. (Management should support you in this case)

(Even the workers and the engineers themselves can give some suggestions)

Mr. Dipil, just think for a minute if he loses his finger, THAT'S IT. "Follow/Obey the rule, whatever it is, NO Excuses." Rules are created for US.

Waiting for your reply, Mr. Dipil!

Dear Seniors, I am waiting for your guidance on this matter. Educate me if I am wrong.

Regards

I agree with your comments. Every problem has a solution, and we try to find the best solution for some practical problems through this forum. In our plant, we have a suggestion scheme in place where a token gift of ₹500 is given for implemented suggestions and ₹100 for each suggestion received.

Exploring Solutions for Grinding in Awkward Positions

I believe there might be small diameter grinders and wheels available in the market that could serve the purpose of grinding in awkward positions with the wheel on. I will reach out to M/s. Bosch, and if I receive any solutions from them, I will share them here on the forum.

Safety Concerns and Justifications

Raghu, the main point is that I have not delved deeply into this topic because it occurs only once in a while, perhaps 1 or 2%. However, as you mentioned, in this 2%, anything can happen. As a Safety Professional, we must prevent anything that is unsafe. But before taking action, we should have sufficient justification for why and the best way to perform the job safely.

I hope you understand the message I am trying to convey. Let's work towards reaching a common conclusion.

Regards,

Yes! I understood what you are trying to convey. I will try to provide more input practically. You and I are trying to convey the same thing in different ways. Mr. Dipil, let's wait for our members' comments. It was a really heated discussion. Keep on sharing.

Dear Mr. Raghu and Mr. Dipil, thank you for sharing your views on this topic.

Operator Awareness and Safety Measures

It's not the case at all that our operators don't want the guard in place. Most of the operators are Diploma Engineers. They are very much aware of the Safety Rules and the consequences of not following them, as we regularly educate and train them. Again, time and money are not an issue. We spend a lot of time training and discussing safety matters. Even the top management supports us a lot.

Challenges in Finding Practical Solutions

We do have a suggestion scheme, but in this issue, it has not helped. We have brainstormed a lot on this topic. However, we could not arrive at a practical solution. We have to carry out this operation once a week for 15 minutes, but as rightly said by both of you, "anything can happen during this period." Hence, we are searching for a practical solution.

Attempts to Resolve the Issue

Dear Mr. Dipil, we have tried the pencil grinder as well. However, it has not served the purpose 100%. Dear Mr. Raghu, rightly said by you – every problem has a solution, but everybody cannot have the solution for everything. As a safety professional, you have to suggest practical solutions to your employees. That is why I have started this thread.

Thank you once again for your participation. Let's hope for active participation from other members as well.

Regards,
Shashikant.

Dear Mr. Raghu & Mr. Dipil,

Thanks a lot for sharing your views on this topic.

Operator Awareness and Safety Concerns

It's not the case at all that our operators don't want the guard in place. Most of the operators are Diploma Engineers. They are very much aware of the safety rules and the consequences of not following them, as we regularly educate and train them.

Again, time and money are not an issue. We spend a lot of time in training and discussing safety matters. Even the top management supports us a lot.

Challenges in Finding a Practical Solution

We do have a suggestion scheme, but in this issue, it has not helped. We have done a lot of brainstorming on this topic. However, we could not arrive at a practical solution.

We have to carry out this operation once a week for 15 minutes, but as rightly said by both of you, "anything can happen during this period." Hence, we are searching for a practical solution.

Dear Mr. Dipil, we have tried a pencil grinder also. However, it has not served the purpose 100%.

Dear Mr. Raghu, as you rightly said, "Every problem has a solution, but everybody cannot have the solution for everything." As a safety professional, you have to suggest practical solutions to your employees.

And that is why I have started this thread.

Thanks once again for your participation. Let's hope for active participation from other members also.

Regards,

Shashikant.

Nice to hear that your management supports you. Mr. Shashikant, please upload some pictures related to your query, and we will provide a solution. Otherwise, take a video next time (15 min) and share it with us (don't capture your company logo, etc.).

I discussed the same in our 10:10 weekly meeting, and they requested the pictures. Please send them as soon as possible.

You rightly said, "But Everybody Cannot Have the Solution for Everything." As a safety professional, you have to suggest practical solutions to your employees.

Waiting for your reply.

After a long time, I have come across an 'out & out' Technical Thread in CiteHR. I am eagerly waiting for your practical solution on this issue, Raghu... seriously.

Regards,
TS

Dear Shashikant, I have discussed with my technical team and also had a conversation with the supplier who is providing us with the grinders. I received the following common comment: "We have to select the right grinder for the job; it's not that we remove the guard to suit the grinder for the job."

So, I believe you should contact suppliers like Bosch and discuss your issue. Their technical team will visit and analyze the location where you are facing this difficulty. Then, they will provide you with advice on the appropriate type of grinder. Simply make the purchase and put it to work.

Please share your thoughts.

Dear Raghu: Great job! Let's maintain the momentum.

Dear TS: Thank you for your encouraging words. Please continue to participate and motivate us for active engagement.

Regards,

I have a suggestion, Dipil Kumar. I am not sure about Shashikant's location [the visit by any technical team could take a while if it's remote—my personal experience]. But if YOU are in a town/city where you can have easy/better access to the local representatives of companies like Bosch, etc., why not talk to them and get some e-brochures or website links of their relevant products and pass them on to Shashikant? To an extent, this could help him find a solution FASTER.

Regards,
TS

Dear TS, this morning, I sent a draft to M/S Bosch for both the Technical and Design teams (India branch). Once I receive a reply from them, I will link it to Mr. Shashikant. Thank you for your contribution to this thread. Please continue to motivate our members.

Dear Dipil,

"We have to select the right grinder for the job; it's not about removing the guard to suit the grinder for the job..." - Dipil

An excellent line, Dipil. Keep up the good work.

Dear Mr. Simhan, Nice to get your reply on our thread. I am very happy with your input. Most of our seniors are watching our discussion, but they didn't get time to contribute promptly. I have already requested the picture or video from Mr. Shashikant. As soon as we receive information from him, we will have the final solution within a couple of days. We have already contacted M/S Bosch supplier, and they have assured us a reply within 24 hours. Hopefully, we can solve this problem soon. Thank you for your feedback.

Best regards

In my experience, this problem persists everywhere where grinding in corners has to be done. The guard obstructs the grinding in corner solution. Small angle grinders are available, and those can be used in such locations. Skilled grinders should be used with all PPEs.

Regards,
Pon

Yay! I got it. Just now, I spoke to M/S. Jamshedji Construction Machinery Co., which is located near your location. They are ready to send a technical team to your company. Please contact the below-mentioned person, then let me know. We hope your problem will be solved soon.

Contact Person: Dhanal
Contact Number: [Phone Number Removed For Privacy Reasons]

Note: I have not received any reply from M/S. Bosch; still waiting for them.

Have a safe day.

Regards

I am working as an HR professional in an athletics equipment manufacturing company. In my company, in the stitching department, tailors avoid using needle guards. They give the excuse that while stitching the turned corners of the fabric, the needle guard restricts the approach of their finger, which supports the fabric at the corner. Consequently, the stitching on the corners lacks a finishing touch. However, without the guard, there is a risk of injuring their fingers. A recent incident occurred, but the tailors are still continuing the same practice with the same excuse.

I need advice on how I can make them understand the importance of using the needle guard.

Regards,
Vinex