Although every machine shop is unique, they all share certain hazards and require employees to follow similar rules to prevent accidents. By covering all the bases, you can provide a strong foundation for your machine shop safety program.
A while back when OSHA inspected a woodworking shop, the compliance officer cited the company for 36 violations with a proposed penalty of $57,600. The violations ranged from unguarded woodworking machines and saws to electrical hazards. On appeal, the Review Commission upheld all of the violations.
That’s the trouble with machine shops. There are such a wide variety of potential hazards that can change almost daily. Employees may be assigned to work on all types of machines. They may be required to use different tools and perform diverse tasks. While the jobs rarely become boring, the unexpected can make safety a challenging goal.
Design It Right
If you have the luxury of designing the ideal workshop, make sure that there is adequate space between machines and materials and goods. Walkways should be clearly marked with yellow lines to separate them from the work areas. They should be wide enough (at least 3 feet) for emergency evacuations if leading directly to an exit. And use a nonslip material for your walkways.
Also make sure your shop has a good ventilation system. There should be a minimum of three fresh air exchanges per hour. If you have processes that release toxic, flammable or corrosive gases, vapors, dusts, mists, or fumes, use a local exhaust system capable of capturing contaminants at the source. The outlets for the local exhaust system should be located far away from the air intakes to avoid recontamination.
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Fires and Other Emergencies
Fires and flammable liquid spills are an ever-present danger in workshops. At the woodworking shop mentioned previously, an employee received third degree burns when he carried an open container of a flammable liquid through an area where an electric sander was being used. A spark from the sander ignited the liquid.
Avoid such incidents by making sure that flammable liquids are stored in closed containers and cabinets approved for this type of material. These liquids should be kept away from sources of heat, sparks or open flames.
Make sure to have fire extinguishers on hand that can contain the classes of fires common to machine shops:
- Class A—Combustibles (paper, wood, cardboard)
- Class B—Liquid fuels (solvents, oil-based paints, gasoline)
- Class C—Electrical fires
A combination fire extinguisher may be an appropriate choice for such a diverse work environment. Make sure the fire extinguisher is charged and ready for use.
In case of chemical splashes or spills, your shop should have emergency eyewashes and showers within reach of any workstation where toxic, corrosive, or oxidizing substances are handled. Also, make sure to have plenty of first aid kits readily accessible to all shop employees.
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Keep a Clean Shop
And don’t forget about housekeeping. A well-maintained and orderly workshop is a safe shop. Look around your facility. What do you see?
- Are floors wet or dirty?
- Are tools and equipment lying haphazardly around?
- Is there trash or debris everywhere?
- Is material stored properly as soon as it is received or is it left lying around?
- Are there sharp edges, nails or fasteners sticking out where employees can be cut?
- Are hazardous materials, compressed gas cylinders, and other flammable materials stored in their proper place?
- Are fire extinguishers blocked by materials or stored items?
- Are power cords strung in high traffic areas?
If you have answered “yes” to many of these questions, it’s time to form a housekeeping squad of employee volunteers that will perform an inspection of these items sometime during the work shift each day. Use this checklist as a starting point. You might even want to give out awards to volunteer inspectors and employees with the cleanest, safest workstations.