Machine Safety Talk | MPSA

How to Use a Gotcha Stick for Machine Safety Compliance

Written by John Guckin | Mar 31, 2022 3:30:00 PM

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

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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.

 

1948: The Birth of the Gotcha Stick

In 1948, Liberty Mutual Insurance collaborated with the ANSI B11.1 Safety Standard Writing Committee to engineer a stair-step-shaped measurement tool. This innovation determined minimum safe distances between guard openings and point-of-operation hazards.


2025 Update: For over 75 years, the gotcha stick has remained the most effective method for ensuring barrier guard openings prevent machine hazards.

 

Different Types of Gotcha Sticks for Safety Testing

When learning how to use a gotcha stick, it's crucial to understand that different standards require different tools:

1. OSHA Compliance Gotcha Stick

  • Tests conformance to OSHA regulations established in 1971

  • Based on 29 CFR 1910.217 standards

  • Required for federal compliance audits

2. ANSI Scale Gotcha Stick

  • Tests conformance to current ANSI and CSA standards

  • Updated measurements for modern safety requirements

  • Recommended for comprehensive safety programs

Important: Visit our Standards & Regulations page for the most current OSHA and ANSI safety standards and requirements.

 

 

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: 

 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.

Need Expert Help? Request a professional safety assessment and receive a FREE gotcha stick when our certified experts visit your facility.
 


How To Use a Gotcha Stick? 

Gotcha Sticks are unique because the tool mimics the human hand and forearm dimensions to ensure hazards maintain minimum safe distances from workers. So it’s important to use proper techniques to ensure accurate barrier guard measurements.

That’s where we come in. Watch our Gotcha Stick Demo and see our expert John Guckin walk through each step of this process to ensure you're using it correctly and in compliance with OSHA and ANSI B11 machine safety standards.

Watch John Guckin demonstrate proper Gotcha Stick testing in under 3 minutes.
Video not loading? Watch on YouTube.

This video is great, but here’s a comprehensive step-by-step breakdown anyway:

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

 COMPLIANT RESULT:
If the barrier guard stops the gotcha stick from touching the hazard area, your machine guarding meets safety standards.

 NON-COMPLIANT RESULT:
If the gotcha stick touches the hazard, your machine guards are too close, and someone could potentially be injured. Immediate corrective action is required.

Corrective Actions for Failed Tests

Fix non-compliant machine guarding using one or both solutions:
  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
This step-by-step process ensures your barrier guards truly protect employees, not just in theory, but in real-world conditions.
 

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.

MPSA's Portable Machine Safety Trainer:

Need comprehensive training on how to use a gotcha stick and other machine safeguarding concepts? Our portable machine safety trainer features five access points demonstrating compliant vs. non-compliant safeguarding methods.

This hands-on training tool reveals how improper safety component selection can leave you with non-compliant solutions, even when you think you're protected.

Interested in Training Equipment? Ask our experts about purchasing training solutions for your facility's needs.

 

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.

Key Takeaways:

  • Gotcha sticks test guard opening compliance with OSHA and ANSI standards

  • Proper usage requires understanding both OSHA and ANSI measurement requirements

  • Regular testing prevents injuries and costly compliance violations

  • Professional training ensures accurate and effective usage

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.

 

 

Frequently Asked Questions About How to Use a Gotcha Stick

How often should I test machine guards with a gotcha stick?

Test machine guards with a gotcha stick whenever modifications are made to equipment, during regular safety audits, and at a minimum annually as part of your safety compliance program. High-risk operations may require more frequent testing.

What happens if my machine guard fails the gotcha stick test?

If the gotcha stick can touch the hazard through the guard opening, you must immediately stop using the equipment and implement corrections. Either move the guard further from the hazard, make the guard opening smaller, or implement both solutions to achieve compliance.

Can I use the same gotcha stick for both OSHA and ANSI testing?

No, you need separate gotcha stick tools for OSHA and ANSI testing as they have different measurement standards and requirements. Using the wrong tool could result in false compliance readings.

Who should be trained on how to use a gotcha stick properly?

Safety managers, maintenance supervisors, machine operators, and anyone responsible for machine safety compliance should receive proper gotcha stick training. Consider certifying multiple team members to ensure consistent testing capabilities.

What are the penalties for non-compliant machine guarding?

OSHA fines for machine guarding violations can range from $15,625 for serious violations to $156,259+ per willful or repeat violations (2025 penalty structure). Beyond fines, non-compliance can result in work stoppages and increased liability.

 

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 

 
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