Machine Shop Safety Manual

What Should a Machine Shop Safety Manual Include?

The contents of a Machine Shop Safety Manual should reflect the company’s actual operations.

A small manual machining operation may require a different combination of programs than a precision manufacturing facility operating CNC machining centers, automated loading systems, overhead cranes, welding equipment, and numerous production machines.

Depending on operations, the manual may address:

• Machine guarding.
• Lockout/Tagout.
• Lathes.
• Milling machines.
• CNC machines.
• Drill presses.
• Metal saws.
• Grinders and abrasive wheels.
• Metalworking fluids.
• Compressed air.
• Hand and power tools.
• Material handling.
• Electrical safety.
• PPE.
• Noise.
• Chemicals.
• Emergency procedures.

Programs should be selected according to the work actually performed and applicable requirements.

Machine Shop Safety Program

An effective Machine Shop Safety Program establishes responsibilities and procedures for identifying hazards, safeguarding machinery, controlling hazardous energy, maintaining equipment, training employees, and correcting unsafe conditions.

Management should provide the training, safeguards, PPE, equipment, and resources necessary for employees to perform machining operations safely.

Managers and supervisors should:

• Identify machine and process hazards.
• Ensure machinery is appropriately guarded.
• Establish hazardous-energy-control procedures where required.
• Authorize employees to operate appropriate machinery.
• Ensure employees receive necessary training.
• Maintain machinery and safeguards.
• Provide required PPE.
• Evaluate employee exposures.
• Correct unsafe conditions.
• Investigate incidents and near misses.
• Follow up on corrective actions.

Employees should follow established procedures, use required safeguards and PPE, inspect equipment before use, report defective machinery, and operate only machines for which they have appropriate training and authorization.

Machine Shop Hazard Assessments

Machine-shop operations should be evaluated to identify hazards associated with equipment, processes, materials, and employee exposures.

Assessments may consider:

• Points of operation.
• Rotating parts.
• Nip points.
• Cutting tools.
• Flying chips.
• Workholding.
• Machine setup.
• Hazardous energy.
• Metalworking fluids.
• Noise.
• Electrical hazards.
• Material handling.
• Chemicals.
• Ergonomic hazards.

Assessments should be reviewed when machinery, tooling, processes, or materials change significantly.

Machine Shop Safety Inspections

Machine shops should be periodically inspected to identify unsafe conditions and verify that established safety procedures are being followed.

Inspection topics may include:

• Machine guards.
• Interlocks.
• Emergency stops.
• Electrical components.
• Grinding wheels.
• Workholding equipment.
• LOTO devices.
• Cutting-fluid systems.
• Compressed-air equipment.
• PPE.
• Material storage.
• Housekeeping.
• Walking-working surfaces.
• Fire protection.

Deficiencies should be documented and corrected in a timely manner.

Job Safety Analysis (JSA/JHA)

A Job Safety Analysis or Job Hazard Analysis can be used to evaluate machining tasks and higher-hazard operations.

JSAs/JHAs may be appropriate for:

• Lathe operation.
• Milling.
• CNC setup.
• Drill-press operation.
• Grinding.
• Metal sawing.
• Machine setup.
• Clearing jams.
• Machine servicing.
• Handling large workpieces.
• Changing heavy fixtures or chucks.

The analysis should identify task steps, hazards, and controls necessary to perform the work safely.

Employee Authorization and Machine Training

Employees should operate machinery only when they have received appropriate instruction and authorization.

Training should reflect the particular machine and may address:

• Controls.
• Safeguards.
• Emergency stopping.
• Workholding.
• Tooling.
• Machine limitations.
• Setup.
• Operating procedures.
• PPE.
• Hazardous energy.
• Prohibited practices.

Employees should demonstrate that they understand safe operating procedures before independently operating machinery.

General Machine Shop Safety Rules

Employees should follow established machine-shop rules, including:

• Operate only authorized equipment.
• Inspect machinery before use.
• Keep guards and safeguards in place.
• Secure workpieces appropriately.
• Use tools suitable for the operation.
• Keep hands away from cutting tools and rotating parts.
• Stop machinery before performing tasks that cannot safely be performed while it is operating.
• Control loose clothing, jewelry, hair, and other entanglement hazards.
• Wear required PPE.
• Maintain orderly work areas.

Unsafe equipment should be reported and removed from service when necessary.

Clothing, Hair and Jewelry

Rotating machinery can catch loose clothing, jewelry, hair, lanyards, rags, and other materials.

Employees working around rotating machinery should:

• Secure long hair.
• Remove or secure jewelry as appropriate.
• Avoid loose clothing.
• Keep sleeves controlled.
• Remove dangling items.
• Keep rags away from rotating equipment.

Glove use should be evaluated carefully. Gloves may be appropriate for handling sharp stock, chemicals, or materials, but can create an entanglement hazard when worn near exposed rotating machinery.

Machine Guarding

Machine guarding is a fundamental component of machine-shop safety.

Machinery should be safeguarded to protect operators and other employees from hazards such as:

• Points of operation.
• Rotating parts.
• Ingoing nip points.
• Flying chips.
• Sparks.
• Power-transmission components.

Employees should not remove, defeat, bypass, or modify safeguards without authorization and appropriate hazardous-energy controls.

Point-of-Operation Guarding

The point of operation is the area where work is performed on the material.

Where operation of a machine exposes employees to injury, appropriate safeguarding should prevent employees from placing parts of their bodies in the danger zone during the operating cycle.

Special tools used to place or remove material may supplement required safeguards but should not be treated as substitutes for required guarding.

Rotating Parts and Entanglement

Rotating shafts, chucks, workpieces, spindles, tools, couplings, and other machine components can create severe entanglement hazards.

Employees should keep:

• Hands.
• Clothing.
• Hair.
• Jewelry.
• Gloves where inappropriate.
• Rags.
• Measuring tools.

away from exposed rotating equipment.

Machines should be stopped before performing tasks that would expose an employee to hazardous rotating parts.

Nip Points

Ingoing nip points may exist where rotating components contact other components, belts, pulleys, rollers, stock, or workpieces.

Employees should not place hands or tools into unguarded nip-point areas while equipment is operating.

Required guards should remain in place.

Cutting Hazards

Machining operations use sharp cutting tools capable of causing severe injuries.

Employees should avoid contact with:

• Cutting edges.
• Rotating cutters.
• Drill bits.
• Saw blades.
• Inserts.
• Sharp workpieces.

Tools should be installed and adjusted using appropriate procedures.

Flying Chips and Particles

Machining can generate hot, sharp, or high-velocity chips and particles.

Controls may include:

• Machine enclosures.
• Chip guards.
• Shields.
• Appropriate cutting conditions.
• Eye protection.
• Face protection where necessary.

Employees should avoid positioning themselves directly in predictable chip-discharge paths.

Guards and Shields

Guards and shields should be appropriate for the machine and hazard.

They should be maintained so they do not introduce additional hazards.

Damaged or ineffective safeguards should be reported and corrected.

Interlocks

Interlocked doors, guards, and enclosures should function as designed.

Employees should not defeat or bypass an interlock merely to increase production, simplify setup, observe a process, or operate machinery with an enclosure open.

Problems with interlocks should be reported.

Defeating or Bypassing Safeguards

Safeguards should not be intentionally defeated unless an authorized procedure requires temporary removal or bypass and appropriate alternative protections and hazardous-energy controls have been established.

Production convenience is not justification for bypassing a safety device.

Machine Setup and Adjustment

Machine setup can place employees close to cutting tools, workpieces, and machine danger zones.

Setup procedures should address:

• Workholding.
• Tool installation.
• Machine positioning.
• Speeds and feeds.
• Guards.
• Tool clearance.
• Manual movement.
• Test operation.

Hazardous energy should be controlled when the setup activity requires it.

Workholding and Fixturing

Workpieces should be appropriately secured before machining.

Workholding methods may include:

• Vises.
• Chucks.
• Collets.
• Clamps.
• Fixtures.
• Faceplates.

The workholding method should be suitable for the workpiece, machine, cutting forces, speed, and operation.

Employees should verify that workholding devices are properly engaged before starting the machine.

Speeds and Feeds

Machine speed, feed rate, tooling, and workpiece conditions should be appropriate for the operation.

Employees should follow machine, tooling, and process limitations.

Excessive speeds can contribute to tool failure, workpiece release, excessive heat, and flying debris.

Test Runs and Machine Startup

Before starting a machine, employees should verify that:

• The workpiece is secure.
• Tools are properly installed.
• Guards are positioned.
• Adjustment tools have been removed.
• Employees are clear of hazards.
• Machine settings are appropriate.

After setup, initial operation should be conducted cautiously so improper setup can be identified without unnecessary exposure.

Lathe Safety

Lathes present significant hazards from rotating chucks, workpieces, tooling, and projecting stock.

Employees should:

• Secure workpieces properly.
• Remove chuck keys before startup.
• Keep hands away from rotating work.
• Control clothing and hair.
• Use appropriate chip protection.
• Stop the machine before measuring or adjusting when necessary.
• Use tools rather than hands to remove chips.

Employees should never attempt to stop a rotating chuck or workpiece by hand.

Chuck and Workpiece Security

Workpieces should be properly seated and secured in the chuck, collet, faceplate, or other holding device.

Employees should consider:

• Workpiece size.
• Weight.
• Shape.
• Cutting forces.
• Machine speed.
• Required support.

Large or irregular workpieces may require additional planning and reduced operating speeds.

Chuck Keys

Chuck keys and similar adjustment tools should be removed before a lathe, drill, or other machine is started.

Employees should develop a consistent practice of removing the key immediately after tightening or loosening the chuck.

Long and Projecting Stock

Long bar stock or other material projecting from a machine can create severe struck-by and entanglement hazards.

Where applicable, projecting stock should be:

• Supported.
• Guarded.
• Controlled.
• Kept away from pedestrian areas.

Machine speed should be appropriate for the material and support arrangement.

Lathe Chip Removal

Lathe chips can be sharp, hot, and entangled.

Employees should not remove chips with bare hands.

Appropriate brushes, hooks, pliers, or other tools should be used after the machine is stopped or when the removal method can otherwise be performed safely.

Milling Machine Safety

Milling machines expose employees to rotating cutters, flying chips, moving tables, workpieces, and point-of-operation hazards.

Employees should:

• Secure workpieces.
• Use appropriate guards.
• Keep hands away from rotating cutters.
• Remove adjustment tools.
• Control chips.
• Stop the machine before unsafe adjustments or measurements.
• Follow established setup procedures.

Workpiece Clamping

Material should be securely clamped in an appropriate vise, fixture, or other workholding device.

Employees should not rely on hand pressure to restrain material subjected to machining forces.

Clamps and fixtures should be positioned to avoid interference with cutting tools and machine movement.

Milling Cutters

Cutters should be appropriate for the machine, material, speed, and operation.

Employees should inspect cutters and toolholders and properly secure them before use.

Damaged tooling should not be used.

Milling Machine Setup

Before machining begins, employees should verify:

• Workpiece security.
• Tool installation.
• Tool clearance.
• Machine travel.
• Guarding.
• Speeds and feeds.
• Coolant positioning.

The work area should be clear before startup.

CNC Machine Safety

Computer Numerical Control machines can reduce direct operator exposure during normal enclosed operation but can create serious hazards during setup, troubleshooting, maintenance, and other activities requiring closer interaction with the machine.

Employees should understand the operating modes and safeguards of the specific CNC equipment they use.

CNC Mills

CNC milling operations should be performed with required enclosures, doors, and interlocks functioning.

Employees should verify:

• Workholding.
• Tooling.
• Program selection.
• Offsets.
• Machine clearance.
• Guarding.

Employees should remain clear during automatic machine movement.

CNC Lathes and Turning Centers

CNC turning operations can involve high-speed rotating workpieces, automatic tool movement, bar stock, and chip generation.

Employees should verify proper chucking, tooling, guarding, and program setup before automatic operation.

Machine doors should remain closed during operations requiring enclosure protection.

Machine Enclosures and Interlocks

CNC machine enclosures help contain chips, broken tools, coolant, and moving-machine hazards.

Employees should not bypass enclosure interlocks to operate equipment in a manner that exposes them to hazardous motion.

Damaged interlocks should be reported and repaired.

CNC Setup and Prove-Out

Program setup and prove-out may involve unusual machine movements and increased employee interaction.

Employees should:

• Verify program selection.
• Check offsets.
• Confirm tool positions.
• Verify workholding.
• Anticipate machine travel.
• Use appropriate operating modes.
• Maintain a safe position.

Initial runs should be performed according to established procedures.

Automatic Tool Changes

Automatic tool changers can move rapidly and create pinch, crush, and struck-by hazards.

Employees should remain outside tool-change danger areas during automatic operation.

Servicing or clearing problems should be performed under appropriate hazardous-energy controls when required.

CNC Maintenance

CNC maintenance may involve electrical, hydraulic, pneumatic, mechanical, and stored-energy hazards.

Only appropriately trained and authorized employees should perform maintenance.

Required LOTO procedures should be followed.

Drill Press Safety

Drill presses expose employees to rotating spindles, drill bits, chucks, workpieces, and flying chips.

Employees should:

• Secure workpieces.
• Remove chuck keys.
• Use appropriate guards.
• Keep hands away from rotating parts.
• Control loose clothing and hair.
• Use tools for chip removal.

The machine should be stopped before adjustments that cannot safely be performed during operation.

Securing Workpieces

Workpieces should be held with an appropriate vise, clamp, fixture, or other suitable means when machining forces could cause the material to rotate or move.

Employees should not attempt to restrain hazardous workpieces by hand.

Band Saw Safety

Band saws should be operated with appropriate blade guarding and workpiece control.

Employees should:

• Keep hands away from the blade path.
• Adjust guards appropriately.
• Support material.
• Use proper feed pressure.
• Inspect blades.
• Keep the work area clear.

Damaged blades should be replaced.

Cold Saw Safety

Cold saws and other metal-cutting saws should be operated according to manufacturer instructions.

Employees should ensure:

• Guards are functional.
• Material is secured.
• Cutting speed is appropriate.
• Hands remain outside the cutting area.
• Chips are controlled.

The blade should be allowed to stop before employees enter hazardous areas.

Grinding Safety

Grinding equipment can expose employees to abrasive-wheel failure, flying particles, sparks, dust, noise, and rotating equipment.

Employees should:

• Inspect grinding equipment.
• Use required guards.
• Use appropriate abrasive wheels.
• Follow wheel-speed limitations.
• Wear appropriate eye and face protection.
• Control sparks and combustibles.

Damaged wheels should not be used.

Bench and Pedestal Grinders

Bench and pedestal grinders should be maintained with appropriate guards and properly adjusted components.

Employees should inspect:

• Wheel condition.
• Guards.
• Work rests.
• Adjustable guards where provided.
• Mounting.
• Speed ratings.

Employees should stand clear of the wheel’s plane during startup when appropriate.

Abrasive Wheels

Abrasive wheels should be selected, mounted, inspected, and used according to the machine, wheel, and applicable requirements.

The rated speed of the wheel should be compatible with the machine.

Employees should not use wheels that are damaged or otherwise unsuitable for service.

Metal Chips and Swarf

Metal chips and swarf can be sharp, hot, spring-like, and difficult to handle safely.

Employees should avoid direct hand contact whenever practical.

Suitable tools and containers should be provided for chip collection and disposal.

Chip Removal

Employees should use brushes, hooks, pliers, chip tools, or other appropriate means rather than bare hands to remove sharp chips.

Machinery should be stopped when chip removal would otherwise expose the employee to moving parts or cutting tools.

Accumulated chips should be removed before they interfere with safe machine operation.

Compressed Air Safety

Compressed air should be used only for appropriate purposes and according to applicable requirements.

Employees should not direct compressed air at themselves or another person.

When compressed air is used for cleaning equipment or parts, appropriate pressure control, chip guarding, and PPE should be provided as required.

Safer chip-removal methods should be used where practical.

Metalworking Fluids

Metalworking fluids may be used to cool, lubricate, and improve machining operations.

Depending on the fluid and process, employees may be exposed through:

• Skin contact.
• Splashing.
• Mist.
• Aerosols.
• Contaminated surfaces.

The company should evaluate the fluids and exposures associated with its machining processes.

Cutting Fluids and Coolants

Cutting fluids and coolants should be selected, used, and maintained according to manufacturer instructions and workplace requirements.

Employees should avoid unnecessary skin contact.

Containers and systems should be appropriately identified.

Metalworking Fluid Mist

Machining operations can generate airborne mist, particularly at higher machine speeds or when fluids are sprayed or atomized.

Controls may include:

• Machine enclosures.
• Splash guards.
• Local exhaust ventilation.
• Process modifications.
• Fluid-delivery adjustments.

Employees should report visible mist or recurring symptoms associated with machining operations.

Skin Exposure and Dermatitis

Repeated or prolonged contact with metalworking fluids can contribute to skin irritation or dermatitis.

Employees should:

• Avoid unnecessary skin contact.
• Use appropriate gloves when compatible with the task and machine hazards.
• Wash exposed skin.
• Avoid using contaminated rags on the skin.
• Change contaminated clothing as necessary.

Employees should report persistent skin irritation.

Fluid Maintenance

Metalworking-fluid systems should be maintained to reduce contamination and deterioration.

Maintenance may include:

• Maintaining proper concentration.
• Removing tramp oil.
• Controlling microbial growth.
• Cleaning systems.
• Monitoring fluid condition.

Chemical additives and biocides should be used only according to appropriate procedures.

Splash Control

Splash guards, machine enclosures, and appropriate fluid-delivery methods can reduce employee contact with metalworking fluids.

Employees should not remove splash controls without authorization.

Local Exhaust Ventilation

Local exhaust ventilation may be appropriate where machining operations generate significant airborne mist, dust, smoke, or other contaminants.

Ventilation systems should be maintained so they continue to provide intended control.

Employees should report damaged or ineffective ventilation.

Lockout/Tagout

Machine-shop equipment may contain electrical, mechanical, hydraulic, pneumatic, gravitational, thermal, or other hazardous energy.

Where servicing or maintenance exposes employees to unexpected energization, startup, or release of hazardous energy, required energy-control procedures should be followed.

The company’s Lockout/Tagout Program should address:

• Energy-control procedures.
• Authorized employees.
• Affected employees.
• Lockout/tagout devices.
• Stored energy.
• Verification.
• Periodic inspections.
• Training.

Machine Servicing and Maintenance

Before covered servicing or maintenance, employees should identify and control hazardous-energy sources.

Activities may include:

• Repairs.
• Maintenance.
• Guard removal.
• Cleaning.
• Clearing certain jams.
• Entering machine danger zones.
• Replacing components.

Employees should follow machine-specific procedures where required.

Normal Production Operations

Not every adjustment or production activity automatically requires lockout/tagout.

Normal production operations may be performed under effective machine guarding and other safeguards when employees are not exposed to hazardous energy or machine danger zones in a manner requiring energy control.

Employees should understand the difference between protected production activities and servicing or maintenance requiring LOTO.

Clearing Jams

Employees should not reach into machinery to clear a jam while exposed to unexpected machine movement or hazardous energy.

Where jam clearing constitutes covered servicing or maintenance, required energy-control procedures should be followed.

Employees should use appropriate tools and procedures.

Tool Changes and Adjustments

Tool changes and adjustments should be evaluated according to the hazards involved.

Machines should be stopped when required, and hazardous energy should be controlled where the employee could otherwise be exposed to unexpected activation, machine movement, or release of energy.

Employees should not bypass guards or enter danger zones without required protection.

Machine-Specific Energy Control Procedures

Where required, energy-control procedures should identify:

• Machine or equipment.
• Energy sources.
• Shutdown steps.
• Isolation devices.
• Lockout/tagout methods.
• Stored-energy controls.
• Verification.
• Return-to-service procedures.

Employees should be trained in their responsibilities under the program.

Hand and Power Tools

Hand and portable power tools should be appropriate for the work and maintained in safe condition.

Employees should inspect tools and use required guards and safety devices.

Defective tools should be removed from service.

Electrical Safety

Machine-shop electrical equipment should be maintained in safe condition.

Employees should report:

• Damaged cords.
• Missing covers.
• Exposed wiring.
• Defective switches.
• Electrical overheating.
• Other electrical hazards.

Electrical cabinets and components should be accessed only by appropriately qualified employees when required.

Pneumatic Tools

Pneumatic tools should be properly connected and operated within applicable pressure limitations.

Employees should inspect hoses, fittings, and tools.

Air supplies should be isolated before servicing equipment where necessary.

Personal Protective Equipment

PPE should be selected according to the hazards associated with the machine and task.

Depending on operations, PPE may include:

• Safety glasses.
• Goggles.
• Face shields.
• Hearing protection.
• Protective footwear.
• Gloves for appropriate non-entanglement tasks.
• Protective clothing.
• Respiratory protection.

PPE should not substitute for required machine guarding.

Eye and Face Protection

Machining operations can generate flying chips, fragments, coolant, sparks, and abrasive particles.

Appropriate eye protection should be worn where employees are exposed to eye hazards.

Face shields may supplement primary eye protection for higher-energy particle or splash hazards.

Hand Protection

Hand protection should be selected according to the task.

Gloves may be appropriate for:

• Handling sharp stock.
• Handling scrap.
• Chemical contact.
• Certain material-handling tasks.

Gloves should not be worn where they create an entanglement hazard with exposed rotating machinery.

Hearing Conservation — When Applicable

Machining, grinding, compressed air, saws, and other shop equipment can produce significant noise.

Employee exposure should be evaluated where warranted.

Where applicable, the company’s Hearing Conservation Program should address monitoring, hearing protection, training, and audiometric testing.

Respiratory Protection — When Applicable

Metalworking-fluid mist, grinding dust, welding fumes, and specialized materials may create respiratory hazards.

Engineering controls should be used where feasible.

Where respirators are required, the company should implement an applicable Respiratory Protection Program.

Material Handling

Machine shops may handle heavy, awkward, sharp, or long materials.

Material-handling procedures should address:

• Bar stock.
• Plate.
• Castings.
• Fixtures.
• Chucks.
• Vises.
• Finished components.
• Scrap.

Mechanical assistance should be used when appropriate.

Bar Stock and Long Material

Long material should be stored and handled so it does not create struck-by, trip, or collapse hazards.

Storage racks should be suitable for the material.

Projecting material should be controlled.

Employees should use assistance or material-handling equipment when necessary.

Manual Lifting

Employees should evaluate the weight, size, shape, and sharpness of materials before lifting.

Team lifting or mechanical assistance should be used for loads that cannot be safely handled by one employee.

Material Storage

Materials should be stored securely and in a manner that permits safe retrieval.

Heavy stock should be protected against rolling, sliding, or falling.

Aisles and machine-access areas should remain clear.

Overhead Cranes and Hoists — When Applicable

Machine shops using cranes or hoists should establish procedures for equipment inspection, operation, load control, and employee positioning.

Employees should not stand beneath suspended loads.

Only appropriately trained or authorized employees should operate lifting equipment.

Rigging — When Applicable

Slings, hooks, shackles, and other rigging equipment should be appropriate for the load and inspected as required.

Employees should understand:

• Load weight.
• Rigging capacity.
• Load balance.
• Hitch configuration.
• Sharp-edge protection.
• Suspended-load hazards.

Defective rigging should be removed from service.

Welding and Cutting — When Applicable

Machine shops performing welding or cutting should establish appropriate hot-work procedures.

Controls may address:

• Fire prevention.
• Welding fumes.
• Eye and face protection.
• Protective clothing.
• Compressed gases.
• Ventilation.
• Nearby combustibles.

Only appropriately trained employees should perform welding and cutting.

Hot Work — When Applicable

Hot work should be evaluated for fire and explosion hazards before work begins.

Combustible and flammable materials should be removed or protected as appropriate.

Required fire-protection equipment should be available.

Compressed Gas Cylinders — When Applicable

Compressed gas cylinders should be appropriately secured, stored, handled, and protected from damage.

Valves, regulators, hoses, and connections should be maintained in safe condition.

Automated Machine Systems — When Applicable

Automated machining systems may include multiple machines, conveyors, robotic equipment, pallet changers, and material-handling devices operating as an integrated system.

Safeguarding should address the hazards of the complete system rather than individual machines alone.

Employees should not enter safeguarded automated areas without following applicable procedures.

Robotic Loading — When Applicable

Robots used for loading or unloading machine tools can create unexpected movement, crush, pinch, and struck-by hazards.

Employees should remain outside safeguarded robotic work zones during automatic operation.

Entry for servicing, teaching, troubleshooting, or maintenance should be performed according to appropriate procedures and hazardous-energy controls.

Hazard Communication

Machine shops using hazardous chemicals should maintain an applicable Hazard Communication Program.

Potential chemicals may include:

• Metalworking fluids.
• Solvents.
• Degreasers.
• Lubricants.
• Hydraulic fluids.
• Cleaning chemicals.
• Welding products.

Employees should have access to labels and Safety Data Sheets and receive required information and training.

Chemical Safety

Chemicals should be used, stored, and handled according to their hazards.

Employees should:

• Review Safety Data Sheets.
• Maintain labels.
• Use appropriate PPE.
• Control spills.
• Avoid incompatible storage.
• Follow manufacturer instructions.

Unapproved containers should not be used for hazardous chemicals.

Shop Housekeeping

Good housekeeping is particularly important in machine shops because chips, fluids, stock, tooling, cords, and scrap can create hazards.

Employees should control accumulation of:

• Metal chips.
• Swarf.
• Cutting fluids.
• Oil.
• Scrap.
• Tools.
• Hoses.
• Cords.

Aisles, machine access, electrical equipment, and emergency equipment should remain accessible.

Walking-Working Surfaces

Floors should be maintained to reduce hazards from:

• Cutting fluids.
• Oil.
• Water.
• Metal chips.
• Tools.
• Cords.
• Hoses.
• Scrap.

Spills and other hazards should be corrected promptly.

Slips, Trips and Falls

Employees should maintain clear travel paths and avoid allowing stock, scrap, tooling, cords, or hoses to obstruct aisles.

Leaks and spills should be cleaned promptly.

Temporary hazards should be appropriately controlled until eliminated.

Fire Prevention

Machine shops should establish procedures for controlling foreseeable fire hazards.

Potential sources include:

• Hot work.
• Sparks.
• Flammable liquids.
• Oily materials.
• Electrical equipment.
• Combustible waste.

Employees should understand emergency procedures and maintain access to fire-protection equipment and exits.

Emergency Action Plan

Machine shops should establish procedures for foreseeable emergencies, including:

• Fire.
• Serious injury.
• Chemical release.
• Electrical emergencies.
• Equipment incidents.
• Severe weather.

Employees should understand alarm systems, evacuation procedures, emergency contacts, and assembly locations.

First Aid

First-aid supplies should be readily available according to workplace hazards and applicable requirements.

Employees should know how to obtain emergency medical assistance.

Machine-shop injuries involving severe cuts, amputations, crushing, eye injuries, or injection-type injuries require prompt medical attention.

Machine Shop Safety Training

Employees should receive training appropriate to their assigned machinery, tasks, and exposures.

Training may include:

• Machine guarding.
• Lathe safety.
• Milling-machine safety.
• CNC safety.
• Drill-press safety.
• Saw safety.
• Grinding.
• Lockout/Tagout.
• Metalworking fluids.
• Compressed air.
• PPE.
• Material handling.
• Emergency procedures.

Training should occur before employees independently perform work requiring specific knowledge or authorization.

New and Short-Service Employees

New and inexperienced employees may be unfamiliar with machine controls, cutting forces, tooling, hazardous energy, and shop procedures.

Orientation should address applicable hazards before employees begin work.

New employees should not independently operate lathes, mills, CNC machines, grinders, saws, cranes, or other specialized equipment until appropriate training and authorization have been completed.

Supervision should reflect the employee’s experience and familiarity with the equipment.

Machine Shop JSA/JHA

JSAs/JHAs can be developed for recurring or higher-hazard machining activities.

Useful topics may include:

• Lathe operation.
• Milling-machine operation.
• CNC machining.
• CNC setup.
• Drill-press operation.
• Band-saw operation.
• Grinding.
• Machine setup.
• Clearing machine jams.
• Handling large workpieces.
• Crane and hoist use.

The JSA/JHA should reflect the actual machine, tooling, material, task, and work conditions.

Machine Shop Toolbox Talks

Short safety meetings can reinforce hazards associated with current machining operations.

Useful topics may include:

• Machine guarding.
• Rotating machinery.
• Lathe safety.
• CNC interlocks.
• Chuck keys.
• Chip removal.
• Metalworking fluids.
• Compressed air.
• Grinding wheels.
• Lockout/Tagout.
• Eye protection.
• Housekeeping.

Toolbox talks supplement formal training but should not replace required machine-specific or regulatory training.

Additional Machine Shop Safety Programs

Depending on the machinery, processes, materials, and employee exposures involved, additional programs may include:

• Abrasive Wheel Safety.
• Chemical Safety.
• Compressed Air Safety.
• Compressed Gas Cylinders.
• Electrical Safety.
• Emergency Action Plan.
• Ergonomics.
• Fire Prevention.
• First Aid.
• Grinding Safety.
• Hand and Power Tools.
• Hazard Communication.
• Hazardous Waste Management.
• Hearing Conservation.
• Lockout/Tagout.
• Machine Guarding.
• Manual Lifting and Material Handling.
• Metalworking Fluids.
• Overhead Crane Safety.
• Personal Protective Equipment.
• Pneumatic Tools.
• Respiratory Protection.
• Rigging and Material Handling.
• Slips, Trips and Falls.
• Spill Prevention and Response.
• Walking-Working Surfaces.
• Welding, Cutting and Hot Work.

Programs should be selected according to actual operations rather than automatically included simply because a company operates a machine shop.

Building a Machine Shop Safety Manual

The most useful Machine Shop Safety Manual is based on the machinery and processes employees actually use.

Consider whether employees:

• Operate manual lathes.
• Operate milling machines.
• Operate CNC machining centers.
• Operate CNC turning centers.
• Use drill presses.
• Operate metal saws.
• Use bench or pedestal grinders.
• Work with metalworking fluids.
• Perform machine setup.
• Clear machine jams.
• Service or maintain equipment.
• Handle heavy or long stock.
• Use overhead cranes or hoists.
• Weld or cut metal.
• Work with automated or robotic equipment.

These activities help determine which individual safety programs should be included.

A small manual machine shop should not receive a safety manual filled with programs for robotic cells, overhead cranes, or automated CNC systems it does not have. Likewise, a large precision machining facility may require extensive programs addressing machine guarding, LOTO, CNC equipment, metalworking fluids, lifting equipment, noise, respiratory exposures, automation, and other specialized hazards.

Customized Machine Shop Safety Manuals

Companies can request a customized Machine Shop Safety Manual containing programs selected according to the machinery, machining processes, materials, chemicals, equipment, and employee exposures present.

Manuals can be developed for machine shops, CNC machining companies, precision machining facilities, tool and die shops, manufacturing machine shops, fabrication and machining companies, and other metalworking businesses.

Applicable programs can be selected for machine guarding, Lockout/Tagout, lathes, mills, CNC machines, grinders, metalworking fluids, compressed air, PPE, electrical safety, material handling, cranes, rigging, welding, chemicals, and other machine-shop hazards.

Individual safety programs can also be selected when a company needs to add or update a particular program within an existing safety manual.