AC DataCenter
Press die change — real accidents & risk assessment
Real Press die change accident cases (AI-cleaned) plus example risk assessment, JSA and TBM. Free, no sign-up.
Real AI output
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Below are actual outputs generated by our AI engine (sample). After sign-up they are generated for your exact task.
Sample for: Press die change
7
Hazards
5
Unit tasks
6
Related laws
Criminal 4
Full risk assessment
| Unit task | Hazard / Cause | Current controls | Risk (F×S) | Controls | After | Legal |
|---|---|---|---|---|---|---|
| Machine shutdown & energy isolation (LOTO) | Press unexpectedly energises during die change — worker's hands caught Energy not fully isolated; LOTO procedure skipped Caught-in / Entrapment | Verbal reminder to turn off | 15· Critical 3×5 |
| 5· Medium | 제146조 크레인 작업 시의 조치 Criminal |
| Machine shutdown & energy isolation (LOTO) | Contact with uninsulated electrical component during maintenance Electrical supply not de-energised; insulation worn Electrical Shock | General electrical safety training | 8· Medium 4×2 |
| 4· Medium | Art. 385 Handling Heavy Loads Criminal |
| Die removal | Worker's finger crushed between die and bolster during die removal Die not supported before removing bolts; die tilts unexpectedly Caught-in / Entrapment | Manual handling | 8· Medium 2×4 |
| 4· Medium | 제146조 크레인 작업 시의 조치 Criminal |
| Die removal | Musculoskeletal injury lifting heavy die without mechanical aid Die too heavy (>25 kg) for manual lift; awkward posture in press gullet Musculoskeletal Disorder | Two-person manual lift | 6· Medium 3×2 |
| 2· Low | 제146조 크레인 작업 시의 조치 Criminal |
| Die installation | Press activates while worker is positioning die — hand crush injury Worker initiates press stroke before removing hands from die area Caught-in / Entrapment | Two-hand control button | 4· Medium 1×4 |
| 4· Medium | 제104조 금형조정작업의 위험 방지 Criminal |
| Trial press & adjustment | Hand caught during trial press when adjusting die clearance Worker reaches into die zone during trial stroke Caught-in / Entrapment | Verbal warning | 15· Critical 3×5 |
| 5· Medium | 제103조 프레스 등의 위험 방지 Criminal |
| Production restart & monitoring | Worker strikes press activation before confirming die area is clear Distraction or rush; no barrier to prevent inadvertent activation Caught-in / Entrapment | Safety checklist | 10· High 2×5 |
| 5· Medium | 제146조 크레인 작업 시의 조치 Criminal |
Legal compliance (OSH rules)
Art. 88Machine Guarding Requirements
CriminalMust-check
Art. 89LOTO (Lockout / Tagout) Procedure
CriminalMust-check
Art. 90Two-hand Control Devices
CriminalMust-check
Art. 91Die Change Safety Procedure
CriminalMust-check
Art. 93PPE Provision
Art. 38Employer Duty to Prevent Hazards
Grounding real accidents
Worker's hand was amputated when press cycled during die adjustment — LOTO was not applied.
⚠ Machine energy not isolated — LOTO violation
Die fell from handling crane and struck worker's foot; fractured metatarsals.
⚠ Dropped heavy die during handling
Operator started production press after die change without confirming all workers clear; colleague's hand was struck.
⚠ Premature machine activation after die change