This Machine Guarding Inspection & Interlock Test SOP (Safe Operating Procedure) covers scheduled inspection and function testing of fixed, interlocked and adjustable guards, interlock switches, light curtains and pressure mats on fixed machinery. It sets out isolating first, checking guards and tamper-resistant fasteners, looking for bypassed interlocks, testing stop and no-restart functions from outside the danger zone, and recording results. It's written by WHS specialists, aligned to Australian WHS legislation, and fully editable in Microsoft Word.
Who it's for
Manufacturers and factories
Maintenance and engineering teams
Food, packaging and printing businesses
Joinery and metal fabrication workshops
WHS advisors and plant inspectors
Use it to
Train and induct workers in exactly how you expect the task to be done
Keep a clear reference at the machine, in the vehicle or on site
Record competency with the built-in sign-off
Show clients, insurers and auditors your safe work methods are written down
What this SOP covers
Entanglement, crushing or amputation from missing, damaged or defeated guards
Unexpected start-up with a guard open
Ejected material, swarf or broken parts during the function test
Cuts from sharp edges, swarf or damaged guard panels
Electric shock or stored hydraulic or pneumatic energy if not isolated
Guard panels falling or swinging during removal or refitting
Bypassed or tampered interlocks going undetected
Noise during the running function test
What's included
6 pre-operational checks, from training and the test schedule to previous defects, warning other workers and the right tools
A 14-step operating procedure covering fixed, interlocked and adjustable guards, tamper checks, light curtains, pressure mats and stop and restart testing
Isolation and energy control using lockout tagout, with controlled re-energising only for the function test
6 shutdown, housekeeping and post-operation steps
Emergency actions for failed guards or interlocks, unexpected start-up and people caught or struck
PPE checklist and a list of related documents
Competency acknowledgement and worker sign-off
Space for your logo, SOP number, version and review dates
Why use this template
Saves hours compared with writing an SOP from a blank page
Written as clear, numbered steps that workers can follow on the job
Fully editable, so you can match it to your equipment, site and how your team works
The competency sign-off gives you a training record from day one
How it works
Buy online and download straight away. You'll also get an email with your link.
Add your logo, company name, SOP number and dates.
Check it suits your equipment and site, and edit anything you need to.
Train your workers and have them sign the competency acknowledgement.
Need more than one SOP?
This SOP is also included in the Ultimate Manufacturing & Industrial SOP Bundle. At $197 for the whole bundle, it works out much cheaper than buying SOPs one at a time.
Common questions
Does it cover daily start-up checks?
No. It's for periodic guard and interlock inspections. Routine start-up and shutdown, and the design or selection of guarding, are covered by other procedures.
How are interlocks tested safely?
After the visual inspection, the machine is re-energised only as far as needed for the function test, and every test is done from outside the danger zone.
What if a guard or interlock fails?
The machine is isolated, tagged Out of Service or Do Not Operate and reported, and stays out of service until it's fixed and retested.
Can I change it?
Yes. It's a Microsoft Word file, so you can add, remove or change any step, check or hazard, and add your own logo and details.
Does it suit my state?
Yes. It's written to the model WHS laws and suits all states and territories, including Victoria under the OHS Act and Regulations.
What if it doesn't suit my work?
You're covered by our 30-day money-back guarantee if it isn't fit for purpose.
