How to Use a Gotcha Stick for Machine Safety Compliance

When it comes to machine safety, small details make a big difference. One of the simplest yet most powerful tools for ensuring compliance with machine safety standards is the Gotcha Stick, also known as a Guard Opening Scale. If you’re wondering how to use a Gotcha Stick and why it matters, this guide breaks it down simply. Let’s get into it. 

  Watch our Gotcha Stick Tutorial Video for a Visual Demo

What is a Gotcha Stick? 

Think of a Gotcha Stick as a safety “measuring stick” for machines. Its purpose is straightforward: it helps you test barrier guard openings near machine hazards to see if those openings are compliant with OSHA and ANSI machine safety standards.

By simulating the reach of a finger, hand, or arm, the Gotcha Stick verifies whether employees could accidentally come into contact with hazardous machine parts. If the stick can reach through the guard, the opening may not meet compliance, and that could mean risk for your workers.

Gotcha Stick History & Development

Since the early 1940s, workplace assumptions about machine safety proved dangerously incorrect.

Many employers believed that any guarding provided adequate protection. This assumption was tragically and quickly disproven when workers operating presses and lathes without proper safety guarding suffered numerous injuries, amputations, and fatalities.

Key Benefits of Using a Gotcha Stick

Machine guarding isn’t just about checking a compliance box; it’s about preventing injuries. Using a Gotcha Stick gives you confidence that:

 Life-Saving Benefits: 

• Protects workers from serious injuries and amputations caused by hazardous motion

• Prevents fatalities from machine-related accidents

• Creates safer working environments for all employees
  
  

 Machine Safety Compliance: 

• Openings meet OSHA 1910 Subpart O standards

• Barriers comply with ANSI B11.19 safety requirements
  
  

 Financial Protection: 

• Avoid OSHA Penalties: Fines range from $15,625 to $156,259 per violation (2025 rates)

• Reduce Insurance Costs: Lower worker compensation premiums

• Prevent Lawsuits: Demonstrate proactive safety measures

• Maintain Operations: Avoid costly shutdowns from safety violations

• Legal Protection: Demonstrates due diligence in safety practices
  
  

 2024 Machine Safety Statistics: 

• Over 18,000 workplace amputations occur annually in the US

• Proper machine guarding could prevent 70% of machine-related injuries

Source: Bureau of Labor Statistics, 2024

Whether you’re installing new machine guards, validating existing ones, or performing a safety audit, the Gotcha Stick is a fast, reliable way to reduce risk and keep your workplace safe.

How To Use a Gotcha Stick? 

Step 1: Prepare for Gotcha Stick Testing

• Ensure the machine is in a safe, de-energized state
• Remove any materials from guard openings
• Identify all hazard points requiring testing
• Have documentation ready to record results
  
  

Step 2: Position the Gotcha Stick

• Insert the smaller, scaled end of the gotcha stick into the guard opening
• Approach the hazard area at the most direct angle
• Maintain control of the tool throughout testing
  
  

Step 3: Perform the Compliance Test

• Attempt to touch the identified hazard with the gotcha stick
• Test from multiple angles and positions
• Document whether contact with the hazard is possible
  
  

Step 4: Evaluate and Document Results

Corrective Actions for Failed Tests

1. Increase Distance: Move the guard further away from the hazard
2. Reduce Opening Size: Make adjustable guard openings smaller
3. Combination Approach: Implement both distance and size adjustments

Best Practices for Using Gotcha Sticks Effectively

Essential Guidelines

• Test all guard openings, regardless of size
• Follow OSHA limits: max 5-inch opening at 36 inches away
• Measure guards empty, without material in place
• Test adjustable guards using the same standards as fixed ones

Advanced Testing

• Use the printed safe distance scale on the stick
• Check 3D access points, not just straight-line reaches
• Factor in different worker heights and reaches
• Calibrate regularly to maintain accuracy

Documentation

• Record dates, locations, and results
• Photograph non-compliance before fixes
• Note corrective actions taken
• Set a schedule for regular re-testing

When Should You Use a Gotcha Stick?

You’ll find it useful in several workplace scenarios:

• New installations or recently moved equipment – Confirm new or adjusted guards are compliant before machines go live.

• Routine audits – Validate ongoing compliance during scheduled safety inspections.

• Troubleshooting – Test guard openings if you suspect they may not meet current standards.
  
  

Final Thoughts: Gotcha Stick Usage for Workplace Safety

Learning how to use a gotcha stick correctly is fundamental to maintaining OSHA and ANSI-compliant machine safety programs. This essential tool helps ensure your barrier guard openings maintain proper minimum safe distances from machine hazards.

Whether you purchase a gotcha stick or receive one FREE by requesting a professional assessment, MPSA Safety provides the expertise and tools needed for comprehensive machine safety compliance.

Additional Resources & Information 

Request a Machine Hazard Assessment & Receive a FREE Gotcha Stick! 

Shop Gotcha Stick 

MPSA Safety Trainer 

Standards & Regulations 

MPSA Turnkey Machine Guarding