Machine Shop Tool Risk Assessment

From: EH&S Machine Shop Safety policy http://www.stonybrook.edu/EHSD0411/$FILE/EHSD0411.pdf

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 Medium power tools Powerful portable and small Light industrial tools Large industrial tools
bench tools (1/4 to ½ hp; <10 amp @120 benchtop tools (typically benchtop; <1/2 hp, (manual and NC-controlled)
(2-4 amp @ 120 VAC, <9V VAC; 14-18V cordless; specialized (>1/2 hp; 10-15 amps @ 120 VAC; pneumatics, hydraulics)
cordless) enclosed NC-computer tools) 24-36V portable, pneumatics,
hydraulics)
Common  Dremel tool  Jig Saw  Circular saw  Small bandsaw  Full sized milling machine
Examples  Cordless drill under  3/8” hand drill  Belt sander  Small drill press  Full sized metal lathe
18V  Corded devices <1/3 hp  Framing nailer  Small/benchtop milling  Table saw (non-SawStop)
 Palm Sander  18-24V cordless drill  ½ hp geared drill machine  Radial arm saw
 Soldering iron/gun  Laser cutter/engraver  Reciprocating saw  Small/benchtop lathe  Large drill press
 Heat gun  Thermal foam cutter  >18V cordless tool  Belt/disc sander  Large band saw
 Hot melt glue gun  Chop/miter saw  Horizontal saw  Surface grinder
 Sewing machine  Router  Scroll saw  Large jointer/planer
 3D printer  Mini-lathe  Planer/jointer  Shaper/moulder
 Angle grinder  Bench grinder  Power shear
 Printing press  SawStop style tablesaw
Potential Cuts As for Class 1, plus: As for Class 2, plus: As for Class 3, plus: As for Class 4, plus:
Injuries Abrasions Lacerations Severe bleeding Minor entanglement Immediately life threatening
Minor burns Punctures Minor amputations injury or death
Minor struck-by flying Minor crushing injuries
objects Eye injuries
Electric shock
Potential Low: Low: Medium: High: Highest:
Severity First Aid First Aid or minor injury requiring Immediate emergency room visit Immediate emergency room visit Serious injury or death
emergency room visit Permanent disability or Permanent disability or
disfigurement disfigurement
Risk Grounded power cords or Grounded power cords or double As for Class 2, plus: As for Class 3, plus: As for Class 4
Reduction double insulated tools insulated tools Relevant tool guarding E-stops or equivalent
Mitigation Bracing/clamping of work
Method - 3D printers: Laser Cutter/engraver; thermal
Tools Enclosure interlocks foam cutter:
Lock-out unauthorized Enclosure interlocks
users Lock-out unauthorized users

EHSD0425 (03/12) Page 1 of 2 www.stonybrook.edu/ehs

 Task Hazard Danger Zone Risk Reduction Methods
Between fixed and moving part including
Workpiece clamping Crushing work clamping (chuck or tailstock) and tool
magazine
Safeguarding:
Whipping bar stock Crushing Either end of spindle Guards: Fixed, interlocked, adjustable,
Moving axis Shearing Between tool/spindle and table moveable
Spindle or tool running or cutting Cutting or severing At spindle or tool Devices: Movable barrier devices; Light
By moving part including bar feed and tool curtains/beam device; Two-hand operating
Part feeding Entanglement
magazine lever, trip and control device; Safety mat device
Envelope of movement of workpiece on Awareness: Barriers; Signals; Safety signs
Rapid travel of table or spindle head Drawing in or trapping
table axes or tool in spindle head Other measures: Safe-distance guarding
Impact At spindle or tool Equipment:
Moving or rotating tool
Stabbing or puncture At sharp tool faces Emergency Stop device (palm or push button)
Direct or indirect contact with normally live Safety blocks, locking pins or limiting pins
parts Slide locks
Electrical noise Work holding equipment
Process malfunction, detection & monitoring
Electrostatic discharge
equipment
Electrical contact (direct Arc flash hazard Safety interface/relay modules
Maintenance or repair Shields
or indirect) Improper wiring or grounding
Enabling devices
Liquid or wet locations Hold-to-run controls
Overvoltage or overcurrent Measures for isolation and energy dissipation
Insulation failure (vibration or thermal Information and Training:
cycling) Signage
Instruction
Crushing Dropping or ejection of a mobile part of the
Control system failure: Operating Manuals
Shearing machine or of a workpiece clamped by the
 Modification of control system Safe Work Procedures
Cutting machine
 Defect or failure of one or several Supervision
Severing Failure to stop moving parts
components of the control system Permit-to-work system
Entanglement Machine action resulting from defeating or
 Variation or failure in power supply to Personal Protective Equipment
Trapping failure of safeguarding devices
control system
Impact Uncontrolled speed change
 Inappropriate selection, design or Puncture Unintended or unexpected start-up
location or control devices
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

EHSD0425 (03/12) Page 2 of 2 www.stonybrook.edu/ehs