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Power presses are powered equipment used to stamp, cut or form materials by the use of dies (or tools). They include equipment known as 'croppers' or 'metal workers'.
Did you know?
Adequate guards must be provided. Some power press injuries are caused by relying on the operator to synchronise the movement of their hand with the operation of the foot pedal. No amount of experience will prevent this type of accident.
Two-hand controls on their own are not an acceptable means of protection. They offer no protection to assistants or bystanders, and are easily defeated.
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Are the power presses in your workplace adequately guarded with the Code of practice - Managing risks of plant in the workplace? (See in particular Section 4.1 of the code) |
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To prevent fingers entering the danger zone, have one or more of the following measures (listed in priority order) been taken?
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If fixed guards are used:
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If a guard has to be opened during normal operation of the press, is it an interlocking guard? |
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If an interlocking guard is used, is it set to ensure:
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Are guards designed to ensure a good view of the tool area? Physical barrier guards should have rods that are parallel to the direction of the press stroke. |
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Is an appropriate guard nominated for every die? In some cases each die may require an adjustment to the guard. |
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Does any adjustment to the guard require a special tool? There should be no wing nuts, knurled knobs, or hexagon nuts. |
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Are other dangerous moving parts, such as the flywheel, gears or shafts, also guarded? |
Guarding by itself will not prevent injuries. Presses must be properly used and maintained for maximum safety.
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Is there a safe work procedure for how to set up and operate each power press in your workplace? |
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Do they ensure that:
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Is there a safe work procedure for die-setting?
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Are automatic or semi-automatic feed and ejection methods used where possible, avoiding the need for the operator to reach into the hazard area? |
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Are all controls fail safe? For example, some metal worker machines have two modes of operation - single and continuous stroke. Check that:
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Are all start and stop controls clearly marked? |
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Is an appropriate 'power on' indicator provided? |
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Are foot-operated controls:
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Are realistic production demands set, providing sufficient variety of work to avoid monotony and fatigue? |
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In the event of an operator being trapped in a press, are there people with sufficient knowledge and equipment available to free the operator without causing further injury? |
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Is appropriate seating provided where possible to reduce fatigue? |
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Is adequate space provided for working at the press, handling materials, and for changing and maintaining dies? |
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Have procedures been developed for the safe manual handling of dies, where unavoidable? Suitable lifting points should be provided on the die to enable mechanical handling instead. |
Lack of training is a common cause of injury to power press operators. Many have been seriously injured within the first days, or even hours, of starting work on an unfamiliar power press.
No person should be permitted to operate a power press unless properly trained.
The WHS regulations (r. 39) provide that information, training and instruction must be suitable and adequate, with considerations made to:
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Have all new operators been given induction training by a competent person? |
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Have manufacturers and suppliers provided adequate information on the safe operation and maintenance of the machinery? |
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Have all operators been provided with clear instructions on the safe operation of the power press from 'start up' to 'close down', including all possible sequences of control and operation? |
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Have operators been instructed in the hazards of the machines they operate? Make sure that each operator understands and can demonstrate the safe operation of the power press. |
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Are all operators instructed:
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Is the operator's knowledge on the use of the power press and the precautions to be taken regularly assessed? |
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Are trainee operators supervised by somebody familiar with operating power presses? |
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Particularly for metal worker machines:
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Keeping guards and press equipment well maintained is a vital safety measure. Most serious injuries with presses are due to malfunction of the press guards or other safety devices.
It is a requirement under the WHS regulations (r. 213) that persons with management or control of plant such as power presses at a workplace ensure that maintenance, inspection and, if necessary, testing is carried out by a competent person:
in accordance with the manufacturer’s recommendations if any; or
if there are no manufacturer’s recommendations, in accordance with the recommendations of a competent person; or
in relation to inspection, if the above are not reasonably practicable, annually.
Poor maintenance often results in a 'foul stroke' - when the tool descends without the machine being operated. Common problems include:
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Is there a safety inspection and maintenance program drawn up for each power press in your workplace? |
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Are written records kept of inspections and maintenance carried out? |
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Do inspection and maintenance programs include instruction on complete routines for lubrication and maintenance? |
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Have safe work procedures been developed for maintenance work that ensure the press is locked out and tagged to prevent it being accidental switched on while someone is working on it? Removable guards should be clearly labelled 'DANGER - Isolate power supply before removing guard'. |
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Particularly for metal worker machines: Is the feed table maintained to keep it level with the blade? Wear on the feed table of shearing machines has led to serious injury in the past. If the feed table is worn, it prevents material being fed under the clamp or blade, and leads to the operator reaching under the blade. |
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