17 May Die Setting Safety

Die Setting Safety

Die setters set up, adjust, maintain, and operate presses and other machinery used to form, stamp, punch, or cut metal, plastic, and other materials. These operations can expose workers to crushing, amputation, caught-between, struck-by, electrical, noise, and material-handling hazards.

Only trained and authorized employees should perform die-setting operations.

Before Setup or Operation

Before setting or operating a die:

• Understand the manufacturer’s operating instructions and safety procedures for the specific machine.
• Inspect the press, die, and associated equipment before use.
• Verify that guards, interlocks, emergency stops, presence-sensing devices, and other safeguards are functioning properly.
• Check brakes, clutches, anti-repeat devices, and other safety-related components as applicable.
• Inspect dies for cracks, damage, loose components, or excessive wear.
• Ensure the work area is adequately illuminated and free of unnecessary materials and trip hazards.
• Remove defective equipment from service and report deficiencies to your supervisor.

Never bypass, defeat, remove, or disable a machine safeguard or safety device.

Lockout/Tagout During Die Setting

Die installation, removal, adjustment, cleaning, maintenance, and servicing can expose employees to unexpected machine movement or stored energy.

Before placing any part of the body into a hazardous area:

• Shut down the equipment using established procedures.
• Isolate hazardous energy sources.
• Apply required lockout/tagout (LOTO) devices.
• Release, restrain, or otherwise control stored energy.
• Verify that energy isolation is effective before beginning work.
• Use approved safety blocks or other required mechanical restraints when working in the die area or point of operation where hazardous movement could occur.

Never rely solely on the machine’s stop button, emergency stop, control circuitry, or interlock as protection during servicing when energy-isolation requirements apply.

Point-of-Operation and Pinch-Point Hazards

Presses can generate tremendous force. Hands and fingers must be kept away from the point of operation and other hazardous moving parts.

• Keep machine guards and point-of-operation safeguards properly installed.
• Never reach into operating machinery to position material or remove scrap.
• Use properly designed hand tools when necessary to handle material or scrap, but remember that hand tools do not replace required machine guarding or safeguarding.
• Keep hands clear while dies are being positioned, aligned, or secured.
• Stay clear of pinch points between dies, bolsters, slides, machine frames, and material-handling equipment.
• Secure loose clothing and long hair and remove jewelry that could become caught in machinery.
• Never reach around, under, or through a guard.

Handling and Positioning Dies

Dies can be extremely heavy and difficult to handle.

• Determine the weight of the die before attempting to move it.
• Use appropriate die carts, hoists, cranes, forklifts, or other mechanical handling equipment whenever necessary.
• Verify that lifting equipment and rigging have adequate capacity for the load.
• Inspect rigging before use.
• Keep hands and feet away from suspended or shifting dies.
• Never position yourself beneath a suspended die.
• Keep body parts out of pinch points while positioning and securing the die.
• Ensure the die is properly seated, aligned, and secured before operation.

Flying Material and Scrap

Press operations may eject pieces of material, broken tooling, scrap, or finished parts.

• Maintain required barriers, screens, enclosures, and guards.
• Use designated containers, trays, or chutes for finished parts and scrap.
• Do not operate equipment when required barriers or collection systems are missing.
• Use tools rather than hands to remove sharp scrap whenever practical.
• Keep scrap and waste material from accumulating around the machine.
• Stop and properly isolate equipment before clearing jams when exposure to hazardous machine movement exists.

Personal Protective Equipment

Wear PPE identified by the hazard assessment, which may include:

• Safety glasses with side shields.
• Face protection where flying-particle hazards require it.
• Hearing protection where required.
• Safety footwear appropriate for heavy-material handling.
• Appropriate gloves for handling sharp materials when they do not create an entanglement hazard around moving machinery.
• Respiratory protection when required for airborne contaminants and only in accordance with the company’s Respiratory Protection Program.

Ergonomics and Housekeeping

Die-setting work can involve prolonged standing, repetitive movements, and heavy material handling.

Use mechanical assistance and proper lifting techniques when handling heavy components. Keep frequently used tools within comfortable reach and use anti-fatigue mats where appropriate.

Maintain floors and work areas free of oil, scrap, tools, packaging, and other slip or trip hazards.

Remember

A press can move faster than you can react. Never place your hands or body into a hazardous machine area unless hazardous energy has been properly controlled. Use required guarding, follow lockout/tagout procedures, use mechanical assistance for heavy dies, and never bypass a safety device.