According to OSHA, operating machinery in the workplace contributes to approximately 18,000 serious injuries (amputations, lacerations, crushing injuries, and abrasions) and 800 deaths per year. It’s no surprise given the inherent dangers of operating machinery, but an effective safety program can significantly reduce the likelihood of accidents and injuries.
There are a lot of moving parts when it comes to machine shop safety, and some may not be so obvious. OSHA’s Occupational Safety and Health Standards (29 CFR 1910) have multiple sections relevant to machine shop safety, and there are also local rules and regulations to consider.
One of the most fundamental safety controls when it comes to operating machinery is guarding. OSHA lays out general requirements for machine guarding in 29 CFR 1910.212, which requires guarding to protect workers from hazards created by point of operation, in-running nip points, rotating parts, flying chips, and sparks. The guard must be securely in place, and it should not hinder the proper operation of the machine and create additional hazards. There are also specific guarding requirements for woodworking machinery, abrasive wheels, power presses, portable power tools, and welding equipment, to name a few.
Personal protective equipment (PPE) is also top-of-mind for machine shop safety programs. Guarding is generally a more effective exposure control method than PPE, but guards cannot always eliminate hazards completely, so protective gear is still necessary. Employers are required to assess the machinery being used, the work being conducted, and the engineering controls that are in place to determine what PPE is needed. Aside from eye and face protection and hand protection, foot protection, hearing protection, and respirators may also be appropriate. Selecting the specific type of PPE is equally important. For example, protection from high temperatures, cuts and abrasions, and electric shock would require different types of gloves. The same is true for respirators, and fit testing and a medical evaluation are often needed to determine the correct respirator for an individual.
It’s important to keep in mind that an effective machine shop safety program is more than just guarding and PPE. Here are some less-common elements to consider:
- Lockout/Tagout (LO/TO) – According to OSHA’s Control of Hazardous Energy Standard (29 CFR 1910.147), employees are required to receive training if they apply LO/TO devices and/or they encounter them in their work area when they are applied by others to perform equipment servicing. LO/TO devices are safety devices often used when machinery or equipment is being serviced to physically prevent the transmission of hazardous energy.
- Hazardous Waste Disposal – Machine shops commonly generate solvent waste, used oil, contaminated rags, and empty aerosol cans, which may need to be collected as hazardous waste. In Massachusetts, oily rags need to be disposed of through a hazardous waste vendor; and in New York, solvent contaminated wipes are managed as ordinary hazardous waste. Certain aerosol cans are also collected as hazardous waste under the EPA’s Universal Waste Program which has been adopted by many states.
- Laser Safety Program – Equipment or machinery equipped with a powerful laser (e.g., laser cutter) may necessitate a Laser Safety Program. Although there is no specific OSHA standard for laser safety, OSHA cites several ANSI standards on the safe use of lasers as guidance. Some states also require a permit or registration for certain classes of lasers.
- Compressed Air – Many states regulate the use of compressed air tanks that meet certain criteria. Registration and regular inspection are required in Massachusetts and California. OSHA also limits the use of compressed air for cleaning purposes to less than 30 psi and requires appropriate chip guarding and PPE.
There are many components to machine shop safety. It’s not just nuts and bolts—it’s the whole assembly that keeps things running smoothly and injury-free. In addition to the regulations cited above, there are requirements and best practices for training programs, housekeeping, signage, maintenance, and ventilation. Whether your company has a dedicated machine shop or just a few hand tools, having a machine shop safety officer, in addition to a written safety program, can help ensure someone is responsible for safety trainings, PPE assessments, program evaluation, and overall compliance.
For more information on machine shop safety or for help implementing a well-oiled safety program at your facility, please contact us.
This blog was written by Mutya Cruz, PhD, a Quality, Research, and Training (QRT) Specialist at Safety Partners
