Power press accidents
Power press operations remain a significant source of severe workplace injuries, necessitating a rigorous approach to machine safeguarding and operator training. By prioritizing proactive hazard identification and robust engineering controls, safety managers can effectively mitigate the risks inherent in high-force metal forming processes.
About 95% of related real accidents concentrate in these types.
Key prevention
- Implement comprehensive point-of-operation guarding systems that physically prevent operator access to the danger zone during the press cycle.
- Establish a mandatory, documented lockout/tagout procedure to ensure all energy sources are fully isolated during maintenance or tool changes.
- Utilize dual-hand control devices that require both hands to be occupied away from the press bed simultaneously to initiate the stroke.
- Conduct frequent, systematic inspections of mechanical and electrical safety components to identify and replace worn parts before they fail.
- Provide ongoing, role-specific safety training that emphasizes the importance of following established protocols rather than relying on shortcuts.
Related accident cases
During a press forming operation, an employee was pushing a steel plate from the top of a 100-ton press's beams when their finger became caught between the plate and a beam. The employee sustained an injury.
While loading molds into a press, the mold lid slipped, and the employee placed their hand into the activated press, resulting in the tips of three fingers being caught.
During a press forming operation, the worker's right index finger was caught between the press arm and the press cap.
While moving components of a vulcanizing press, the employee's right middle and index fingers were caught between the press plate and table, resulting in fractures and requiring nine stitches. This incident was determined to be a time-loss injury.
During press forming operations, an employee suffered a finger injury when a filter press plate became trapped after a grip was lost while handling it.
During a tire press unloading operation, a worker's right pinky finger was caught between the press and a bracket. This task involved using powered machinery in the press forming process.
During press forming operations, a worker's left hand became caught between a torque wrench and the roll press. This incident resulted in a caught-in hazard.
While pushing a pin from a drill roller frame during press forming operations, the worker's left pinky finger became caught between the press and the press pin.