Scaled Management Systems

Spot welder guard


Metal products are often manufactured using, amongst other things, a series of floor-mounted spot welding machines. During the welding process and while employees held small components together by hand to weld them, sparks and occasionally larger pieces of molten metal can fly toward the operators’ faces and neck. A metal guard was fitted on the top electrode, but it was found that it interfered with the operator’s view and hit the operator’s hands during welding.


The metal guard was replaced with a transparent, polycarbonate material. The new guard allows full view of the operation, does not hit the operator’s hands as the metal guard did, and protects the operator from sparks.

Hierarchy of Controls:



  • Burns to the face and neck have been eliminated.
  • Improved confidence during the work process has resulted in an improvement in quality.