11 Aug Power Press Safety – The Mighty Power Press

Power Press Safety – The Mighty Power Press

Power press safety is critical because mechanical power presses are powerful metalworking machines used for punching, blanking, forming, and stamping operations. A press can punch through sheet metal in a fraction of a second—and that same force can cause severe crushing injuries or amputations if a hand or other body part enters the point of operation.

Because of these hazards, power presses are equipped with safeguards such as fixed or interlocked guards, barrier guards, two-hand controls or trips, pullbacks, restraints, and presence-sensing devices. These safeguards are not optional conveniences. They are critical protections and must never be removed, bypassed, defeated, or altered without authorization.

Guide for Discussion

Know the Hazards

Power press hazards may exist at the point of operation as well as around other moving components. Employees must recognize hazards including:

• Point-of-operation crushing and amputation hazards.
• Pinch points between dies, slides, stock, and machine components.
• Unexpected cycling or movement of the press.
• Flying or ejected metal, scrap, or broken tooling.
• Improperly secured or aligned dies.
• Material-handling hazards from sharp-edged stock.
• Exposure to moving belts, gears, flywheels, shafts, and other power-transmission components.
• Unexpected startup during adjustment, cleaning, maintenance, or jam clearing.

Never place any part of your body into the point of operation or other danger zone unless the machine has been properly shut down and hazardous energy controlled.

Training and Authorization

Only employees who have been properly trained and authorized may operate a power press. Operators must understand:

• The press controls and their functions.
• Normal startup, operating, and shutdown procedures.
• The capabilities and limitations of the machine.
• Point-of-operation and other machine hazards.
• Required guards and safeguarding devices.
• Proper feeding and material-handling procedures.
• Procedures for reporting malfunctions or damaged safeguards.
• Emergency stopping procedures.
• Applicable lockout/tagout requirements.

Never operate equipment that you have not been trained and authorized to use.

Machine Guards and Safeguarding Devices

Before operating a press, verify that all required guards and safeguarding devices are properly installed and functioning.

Depending on the machine and operation, protection may include:

• Barrier or enclosure guards.
• Two-hand controls or two-hand trips.
• Presence-sensing devices.
• Pullback or restraint devices.
• Gates or movable barriers.
• Properly designed feeding and ejection methods.

Never bypass, block, disconnect, remove, or defeat a machine guard or safety device to increase production or make the job easier.

If a safeguard is damaged, improperly adjusted, or not functioning correctly, stop the machine and notify your supervisor.

Before Starting the Press

Before beginning production:

• Inspect the machine and work area.
• Verify that required guards and safety devices are in place.
• Make sure dies and tooling are properly installed and secured.
• Remove unnecessary tools, materials, and scrap from the work area.
• Ensure no one is within the machine’s danger zone.
• Verify that controls and emergency stops operate correctly.
• Perform required safety checks before beginning production.

Never assume a press is safe simply because it operated correctly during the previous shift.

Safe Operating Practices

While operating a power press:

• Keep hands and fingers away from the point of operation.
• Never reach through, around, under, or over a guard.
• Use approved hand tools, feeding devices, or other methods provided for handling material.
• Maintain a stable working position and remain focused on the operation.
• Do not wear loose clothing, jewelry, or other items that could become caught in machinery.
• Keep long hair secured.
• Wear required eye, foot, hearing, and other personal protective equipment.
• Never distract or interfere with another press operator.
• Do not operate a press when fatigued or unable to concentrate safely.

Jams, Adjustments, and Maintenance

Never reach into a press to remove jammed material, scrap, or a stuck part while hazardous machine movement is possible.

When servicing or maintenance requires an employee to enter a danger zone or when unexpected startup could cause injury:

1. Stop the machine.
2. Disconnect or isolate applicable energy sources.
3. Apply required lockout/tagout devices.
4. Release, block, restrain, or otherwise control stored energy.
5. Verify that hazardous energy has been effectively controlled before beginning work.

Use appropriate tools for removing scrap or jammed material when provided. Brushes, swabs, or other approved devices should be used where necessary to lubricate dies or remove material without placing hands in hazardous areas.

Housekeeping

Good housekeeping is especially important around power presses.

• • Keep floors free of oil, grease, scrap, and other slip or trip hazards.
  • Keep aisles and access to emergency controls clear.
  • Store dies, tools, stock, and finished parts safely.
  • Remove sharp-edged scrap promptly using appropriate tools and PPE.

Supervisor Responsibilities

Supervisors must ensure that employees are properly trained and that power presses are operated with required safeguards in place. Supervisors should also verify that:

• Guards and safety devices are properly selected, installed, and maintained.
• Operators follow established safe-work procedures.
• Required inspections are performed.
• Unsafe equipment is removed from service until corrected.
• Maintenance and die-setting activities are performed by authorized personnel.
• Lockout/tagout procedures are followed when applicable.

Remember

A power press does not know the difference between sheet metal and your hand. Never become comfortable enough with the machine to ignore its hazards.

Never remove or defeat a safeguard, never reach into an operating press, and never take a shortcut around an established safety procedure.