APPENDIX 1.

MACHINE SHOP RISK ASSESSMENT

This list is not all-inclusive. Not all hazards will apply to a particular machine. Always refer to the manufacturer’s instruction manual for specific information.
Hazard Class 1 2 3 4 5
Power Low power hand/small bench Medium power tools Powerful portable and Light industrial tools Large industrial tools
tools (2-4 amp @ 120 VAC, (1/4 to 1/2 hp; <10 amp small benchtop tools (typically benchtop; (manual and NC-
<9V cordless) @120 VAC; 14-18V (<1/2 hp; 10-15 amps >1/2 hp, pneumatics, controlled)
cordless; specialized @ 120 VAC; 24-36V hydraulics)
enclosed NC- computer portable, pneumatics,
tools) hydraulics)
Common Examples x Dremel tool x Jig Saw x Circular saw x Small bandsaw x Full sized milling
x Cordless drill under 18V x Corded devices <1/3 hp x Hand held belt x Small drill press machine
x Palm Sander x 18-24V cordless drill sander x Small/benchtop x Full sized metal lathe
x Soldering iron/gun x Laser cutter/engraver x Framing nailer milling machine x Table saw (non-
x Heat gun x Thermal foam cutter x ½ hp geared drill x Small/benchtop lathe SawStop)
x Hot melt glue gun x Reciprocating saw x Belt/disc sander x Radial arm saw
x 3D printer (closed frame) x >18V cordless tool x Horizontal saw x Large drill press
x Chop/miter saw x Scroll saw x Large band saw
x Router x Sewing machine x Surface grinder
x Mini-lathe x Planer/jointer x Large jointer/planer
x Angle grinder x Bench grinder x Shaper/moulder
x Small press x SawStop style x Power shear
tablesaw x Industrial press
Potential Injuries Cuts As for Class 1, plus: As for Class 2, plus: As for Class 3, plus: As for Class 4, plus:
Eye injuries Lacerations Severe bleeding Entanglement Immediately life
Abrasions Minor burns Punctures Minor amputations threatening injury or
Minor struck-by flying objects Minor crushing injuries Minor entanglement death
Electric shock
Potential Severity Low: Medium: First Aid or High: Immediate emergency room visit; Highest: Serious injury
First Aid minor injury; requiring Permanent disability of disfigurement or death
emergency room visit

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 Task Hazard Danger Zone Risk Reduction Methods
Workpiece clamping Crushing Between fixed and moving part including
work clamping (chuck or tailstock) and Safeguarding:
tool magazine Guards: Fixed, interlocked, adjustable,
Whipping bar stock Crushing Either end of spindle moveable
Devices: Movable barrier devices; Light
Moving axis Shearing Between tool/spindle and table
curtains/beam device; Two-hand operating
Spindle or tool running or cutting Cutting or severing At spindle or tool
lever, trip and control device; Safety mat device
Part feeding Entanglement By moving part including bar feed and
Awareness: Barriers; Signals; Safety signs
tool magazine
Other measures: Safe-distance guarding
Rapid travel of table or spindle Drawing in or trapping Envelope of movement of workpiece on Equipment:
head table axes or tool in spindle head Emergency Stop device (palm or push button)
Moving or rotating tool Impact At spindle or tool Safety blocks, locking pins or limiting pins
Stabbing or puncture At sharp tool faces Slide locks
Maintenance or repair Electrical contact Direct or indirect contact with normally Work holding equipment
(direct or indirect) live parts Process malfunction, detection & monitoring
Crushing Near moving parts equipment
Cutting Electrical noise Safety interface/relay modules
Trapping Electrostatic discharge Shields
Arc flash hazard Enabling devices
Improper wiring or grounding Hold-to-run controls
Liquid or wet locations Measures for isolation and energy dissipation
Overvoltage or overcurrent Information and Training:
Insulation failure (vibration or thermal Signage
cycling) Instruction Operating
Control system failure: Crushing Dropping or ejection of a mobile part of Manuals Safe Work
Modification of control system Shearing the machine or of a workpiece clamped Procedures Supervision
Defect or failure of one or several Cutting by the machine Permit-to-work system
components of the control system Severing Personal Protective Equipment
Failure to stop moving parts
Variation or failure in power Entanglement Machine action resulting from defeating
supply to control system Trapping or failure of safeguarding devices
Inappropriate selection, design or Impact Uncontrolled speed change
location or control devices Puncture Unintended or unexpected start-up
Electrical contact
This list is not all-inclusive. Not all hazards will apply to a particular machine. Always refer to the manufacturer’s instruction manual for specific information.
Based on Yale EH&S Student Shop Safety Policies & Procedures, ANSI B11.0 and B11.6

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