The operator’s part in safety
Design, guarding and maintenance all matter, but the person running a machine makes many small decisions every shift that decide whether those protections do their job. This article lists general precautions from the operator’s point of view. It is not a substitute for the manual of the machine you use, your employer’s procedures or the rules where you work.
Be trained and authorized
Operate only equipment you have been trained and authorized to use. Training normally covers how the machine works, its hazards, the controls, normal and emergency stopping, and what to do when something goes wrong. If the machine, the material or the process changes, ask whether additional training is needed. The reasons behind this are discussed in operator training. Never assume that experience on a similar machine is the same as training on this one.
Read the manual and follow procedures
Manufacturer manuals and written site procedures set out how the machine is intended to be used, including limits such as speed, load, pressure or material type. Using a machine outside those limits is a common cause of incidents. If instructions are missing, unclear or in a language you do not read well, ask your supervisor before proceeding. Do not improvise settings or methods.
Before you start
A short pre-use routine, done the same way each time, is among the most effective habits. Typical items include:
- Look at the area. Floors and walkways clear, adequate lighting, no stray tools or material near moving parts.
- Look at the machine. Guards in place and undamaged, covers closed, no obvious leaks, loose parts or frayed cables.
- Check the controls. Know where the stop and emergency stop controls are and that nothing blocks access to them.
- Check the safety devices. Where the procedure calls for it, confirm that interlocks, sensors and warning devices work as intended.
- Check for tags or locks. If a machine has a lock or tag on it, it is out of service for a reason. Never remove or ignore one that is not yours.
- Confirm that others are clear. Make sure no one is in or near the machine before starting.
If something looks wrong, do not start the machine. Report it and wait for it to be assessed.
Wear suitable personal protective equipment
PPE is selected for the hazards of the job and the site. It commonly includes eye protection, hearing protection, gloves, safety footwear and head protection where needed, but the required items vary. Some points apply nearly everywhere:
- Use the PPE specified for the task, and check that it fits and is in good condition.
- Keep in mind that gloves can be a hazard around rotating parts on some machines, so follow the instructions for that machine.
- Avoid loose clothing, dangling jewelry and uncontained long hair near moving parts.
- Remember that PPE is a last layer, and it does not replace guards or safe procedures.
See choosing protective gear for more on how selection is approached.
While the machine is running
- Keep your attention on the task. Avoid distractions, and do not operate when overly tired or impaired.
- Keep guards in place, and never bypass, remove or tape over an interlock or sensor.
- Do not reach into or clear a jam from a running machine. Stop it and follow the isolation procedure first.
- Stay within the machine’s rated limits.
- Use the proper tools and handling methods for loading and unloading, and ask for help with loads that are heavy or awkward.
- Pay attention to unusual noises, vibrations, smells or heat, and stop and report them rather than hoping they pass.
- Keep communication clear with coworkers, especially where more than one person works on the same line.
Servicing, cleaning and clearing jams
Many injuries occur when someone enters a danger zone for adjustment, cleaning or clearing a blockage while energy is still present. The general approach is to stop the machine, isolate all energy sources, apply locks and tags according to the site procedure, release stored energy and verify that the machine cannot start. This idea is explained further in lockout tagout. Only people trained in the procedure should carry it out, and each person working on the machine usually applies their own lock.
Stopping and shutting down
Know the normal shutdown sequence and use it. Leave the machine in a safe state, with guards closed, and report any issues for the next shift. If you must use the emergency stop, report it and do not restart until the cause is understood and the machine has been checked according to procedure.
Report and speak up
Report damaged equipment, missing guards, near misses and unsafe conditions promptly. A workplace where people can raise concerns without blame tends to find problems earlier. If you are asked to do something you believe is unsafe, raising the concern with a supervisor or safety representative is reasonable and often expected under workplace rules.
Limits
Precautions reduce risk but cannot remove it. Hazards differ between machines, and this list is general. Follow the manufacturer’s manual, your site’s procedures and the local regulations, and ask a supervisor or safety professional whenever you are unsure.