Machine Guarding Inspection SWMS

Machine guarding is the primary engineering control that prevents worker contact with dangerous parts of machinery. The WHS Regulation 2025 requires that guards and safety devices are maintained in effective working order, are not bypassed or defeated, and are replaced immediately when damaged or removed for maintenance. Machine guarding failures are the leading cause of serious injury prosecutions in Australian manufacturing. Guards are removed for cleaning, maintenance, or troubleshooting and not replaced. Interlocks are bypassed to increase production speed. Safety devices are defeated because they slow operations. This template provides a systematic approach to machine guarding inspection and compliance verification.

Legal Requirements

regulation

WHS Regulation 2025 Part 4.7 — Plant

hrcw category

Plant with entrapment risk

code of practice

Managing Risks of Plant in the Workplace (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Worker contact with unguarded moving parts	Amputation, crushing, entanglement, death	Possible
Interlock bypass allowing access to danger zone during operation	Entrapment, amputation, crush injuries	Possible
Guard removal for maintenance not replaced before restart	Unguarded exposure, serious injury	Possible
Projectile ejection through inadequate or damaged guards	Eye injuries, lacerations, fractures	Unlikely
Noise exposure through missing or damaged acoustic guards	Noise-induced hearing loss	Likely
Reach-through access gaps exceeding safe distances	Hand and finger entrapment, amputation	Possible

Controls (Hierarchy of Controls)

Conduct formal machine guarding inspections at defined intervals covering every machine on the factory floor

Verify that all interlocked guards function correctly by testing the interlock cycle during each inspection

Check that all fixed guards are securely fastened and cannot be removed without tools

Measure access gaps against AS 4024 safe distance tables to verify that no reach-through access to danger zones exists

Implement a guard removal permit system requiring authorisation and replacement verification before machine restart

Report and correct interlock bypasses as a critical non-conformance requiring immediate investigation

Maintain a machine guarding register listing every machine, guard type, interlock configuration, and inspection schedule

Train production and maintenance workers in guard importance, bypass prohibition, and reporting obligations

Recent Prosecutions

SafeWork SA prosecution$840,000

Apprentice killed during manufacturing operations where machine guarding was inadequate and supervision insufficient.

2024 — SafeWork SA Manufacturing Prosecution [2024]

Orica Australia Pty Ltd$1,200,000

Workers exposed to hazardous conditions due to inadequate engineering controls and maintenance procedures.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

What Your SWMS Must Include

✓Machine guarding register listing all machines and guard configurations

✓Inspection schedule with defined frequency for each machine category

✓Interlock functional testing procedure and pass/fail criteria

✓Guard removal permit system with replacement verification

✓Corrective action procedure for guarding non-conformances

Need a Machine Guarding Compliance Program?

Our WHS consultants build comprehensive guarding inspection programs that identify gaps, verify interlocks, and maintain compliance across your factory floor.