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Plant and Machine Guarding Awareness

For workers who use or work near machines: how moving parts injure, how guards work, and why a guard is never removed or bypassed.

  • SeriesToolbox Talks
  • AudienceWorkers who use or work near machinery
  • Duration20–30 minutes
  • CodeHAZ-GRD
  • Version1.0 · 871 KB ZIP

About this package

Moving parts of machinery can entangle, crush, shear, cut and throw out material. Guarding is one of the most effective controls for machinery, and many serious injuries happen when a guard was missing, removed for a quick job, or bypassed to keep production going.

This talk covers the hazards of moving parts, the types of guard and what each does, pre-start checks, never removing or bypassing a guard, isolating before clearing a jam, and reporting damaged or missing guards.

Learning outcomes

After the session, participants will be able to:

  • Describe the ways moving parts injure people: entanglement, crushing, shearing, cutting, impact and ejected material
  • Identify the types of guard: fixed, interlocked, adjustable and presence-sensing systems
  • Carry out pre-start checks, including that guards are in place and working
  • Explain why a guard is never removed, defeated or bypassed while the machine can operate
  • Isolate the machine before clearing a jam, cleaning or adjusting
  • Recognise how loose clothing, hair, jewellery and gloves can be caught, and report damaged or missing guards

Training outline

MODULE 1

Moving parts

  • How machines injure
  • Danger zones
  • Common incidents
MODULE 2

Guards

  • Fixed, interlocked and adjustable guards
  • Presence-sensing devices
  • Why guards are removed, and why they must not be
MODULE 3

Your part

  • Pre-start checks
  • Isolating before you reach in
  • Clothing, hair and jewellery
  • Reporting

What is in the package

Training

  • Editable PowerPoint presentation with speaker notes, plus PDF
  • Facilitator guide with a running sheet, discussion prompts and model answers
  • Participant handout with the key points to take away

Records and assessment

  • Attendance record form, to capture who attended, when, and who facilitated
  • Excel attendance register
  • Multiple-choice theory assessment, to record understanding if your business wants to
  • Answer key for the assessment
  • Certificate template

Start here

  • Read Me First guide
  • Product overview
  • Permitted use terms
  • Version information

Practical activities

  • Danger zones: workers mark the danger zones on a photo of a machine they use
  • Production pressure: a scenario where a jam keeps happening and a guard is in the way

Delivery requirements

  • A facilitator such as a supervisor, leading hand or WHS adviser who has read the facilitator guide and knows your site's arrangements for the topic
  • A screen or projector, or printed slides or handouts: it works in a crib room, site office or on a video call
  • Your own site procedures for the topic, to point to during the session

File formats

  • PowerPoint (.pptx), editable, with speaker notes
  • Word (.docx), editable
  • Excel (.xlsx) attendance register
  • PDF copies of the slides, guide, handout and forms
  • Delivered as a single ZIP download

Questions about this package

Can we add our own site procedures and photos?

Yes. The slides, handout and guide are editable, and the facilitator guide marks the places to add your own procedures, contacts and photos of your workplace.

Do we have to use the assessment?

No. It is there if your business wants a record that each worker understood the key points. The attendance record on its own shows who attended and when.

Can we edit the documents?

Yes. Presentations, guides, workbooks and templates are supplied in editable formats so you can adapt them to your workplace. The copyright notice must stay.

Can we use the packages outside Australia?

Yes. The hazards and the controls in each toolbox talk apply in any workplace. The duties slide and the facilitator guide's "check before you deliver" table refer to Australian WHS and OHS laws, licences and standards, so a business elsewhere should swap those for its own country's rules. Everything is editable.

Do participants get a certificate?

Yes. The package includes an editable certificate template, an attendance record (Word, plus an Excel register) and an optional 10-question multiple-choice assessment with an answer key, so you can record who attended and, if you choose, that each worker understood the key points. It is a certificate of completion issued by your business, not a nationally recognised qualification.

Can we deliver it face to face and online?

Yes. The packages are designed for face-to-face sessions and work over a video meeting platform. The facilitator guide notes where an activity needs adjusting for online delivery.

Can we run it more than once?

Yes, as many times as you like, for your own organisation's workers.

What is your refund policy?

Your rights under the Australian Consumer Law are not affected. See the Refund Policy for how we handle a package that is faulty, not as described, or not what you ordered.

Do we get future updates?

You keep the version you bought for as long as you use it, and corrections to that version are made available to you. A new edition, for example following a significant change in the law, may be sold separately.

More answers on the home page, or contact us.

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