Safety Protocol 001: Machine Shop General Safety

Protocol ID: U8M1-SAFE-001

Potential Hazards

• Entanglement: Rotating chucks, spindles, and workpieces can catch loose clothing, hair, jewelry, and gloves, pulling the operator into the machine with severe or fatal consequences
• Projectile hazards: Workpieces ejected from chucks, broken cutting tools, and metal chips can fly at high velocity
• Sharp edges and chips: Machined metal produces razor-sharp burrs and hot metal chips (swarf) that cause lacerations and burns
• Crush hazards: Moving tables, carriages, and vises can crush fingers and hands
• Eye injuries: Metal chips, coolant splash, and grinding sparks are constant hazards
• Hearing damage: Machine tools produce 80-100 dB during operation
• Chemical exposure: Cutting fluids can cause skin irritation and respiratory issues with prolonged exposure
• Electrical hazards: Machines operate on 220V or 440V power

Required Precautions & Procedures

1. Dress code: Short sleeves or sleeves rolled tight above the elbow. No ties, scarves, lanyards, jewelry, watches, or loose clothing. Long hair must be secured under a cap or tied tightly.
2. NO GLOVES near rotating machinery: Gloves catch on rotating parts and pull hands into the machine. Only wear gloves when handling sharp stock or hot parts with the machine OFF.
3. Chuck key discipline: Remove the chuck key IMMEDIATELY after every use. Never leave it in the chuck for any reason. This is the #1 cause of machining injuries in educational shops.
4. Guards in place: All belt guards, gear covers, and chip shields must be in position before starting any machine.
5. Secure workholding: Verify the workpiece is securely clamped before every cut. Re-verify after any interruption.
6. Clear the machine before starting: Ensure all tools, wrenches, and indicators are removed from the work area. Verify the tool/cutter will clear the workpiece at the starting position.
7. Never reach across or over a running machine: Stop the machine to make measurements, adjustments, or chip removal.
8. Chip removal: Never use hands or compressed air (creates flying chips). Use a chip brush or hook. Never use compressed air to clean chips from clothing.
9. One operator per machine: Only one person operates a machine at a time. Observers must stand behind the operator.
10. Coolant management: Report leaks immediately. Clean up spills to prevent slip hazards. Use barrier cream on hands before working with cutting fluid.

Emergency Response

• Entanglement: Hit the emergency stop immediately. DO NOT attempt to reverse the machine or pull the person free. Call for emergency services. Administer first aid for visible injuries while waiting.
• Workpiece ejection: Stop the machine. Clear the area. Check all personnel for injuries. A thrown metal part can cause fractures, lacerations, or death.
• Severe laceration from chips/burrs: Apply direct pressure with clean cloth. Elevate if possible. Seek medical attention. Metal cuts are prone to infection.
• Eye injury: Flush with eyewash station for 15 minutes minimum. Do not rub or attempt to remove embedded objects. Seek immediate medical attention.
• Burns from hot chips: Cool under running water for 10 minutes. Apply first aid. Metal chips can be 400-800°F.
• Crush injury: Free the trapped body part if possible without causing further injury. Call emergency services. Apply first aid for fractures.

PPE Requirements

PPE Item	Required	Standard/Rating	Notes
Safety glasses	Always in shop	ANSI Z87.1+	Side shields required
Face shield	Grinding, heavy machining	ANSI Z87.1	Over safety glasses
Hearing protection	When machines are running	NRR 25+	Earplugs or muffs
Steel-toe boots	Always in shop	ASTM F2413	Closed-toe minimum
Short sleeves	Always	N/A	No loose clothing of any kind
NO GLOVES	Near running machines	N/A	Exception: handling stock/parts with machine OFF
Safety shoes (non-slip)	Always	Non-slip sole	Oil-resistant sole preferred

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Last Updated: 2026-03-19