POWER

PRESS
OPERATOR
TRAINING
Robert N. Andres, CSP, CMfgE
OSHEX – ESA Consulting Services
© RNA, 1999
 POWER PRESSES …
 Have a flywheel
 Operate by transferring energy from a
rotating flywheel to the ram (or slide)
by means of a clutch
 May be a “full-revolution” design, with
a “trip” clutch engagement, or
 May be a “part-revolution” design,
with a friction clutch and brake
 POWER PRESSES …
 Are generally defined in “size” by the
force that they can generate – from
under 5 ton to over 300 ton capacity
 Have a variety of forms and styles. The
most common are straight-sided and
open-backed inclinable (OBI) styles.
 Are addressed in detail in ANSI B11.1
and OSHA 29 CFR 1910.217
 SAFE OPERATION OF A
POWER PRESS DEPENDS
UPON …
 The structural integrity of the machine
and it’s safeguards
 The reliability of the control system
 The condition of the tooling and feed
mechanisms, and the work area
 Your training and awareness
 Strict observance of safe work practice
 THIRTY-EIGHT
STEPS THAT CAN
SAVE YOUR
FINGERS, HANDS
OR YOUR LIFE
Safety is everyone’s
responsibility !
 THE WORK AREA

Can the metal be moved into

the work area, still leaving
enough room to get out ?
 THE WORK AREA

What is the condition of the

floor? Does it need repair?
Report it!
 PRESS INTEGRITY
 Have I checked the press
completely before beginning my
shift ?
 Use your check list! Make sure that
someone has not left something on
the press, such as a turnover bar,
blow-off hose or die block
PRESS INTEGRITY

Are all the bolts tight?

Are there any visible
cracks?
 PRESS INTEGRITY

Are all the service lines

(electrical, air, etc.) Properly
connected and free of any
damage. Report any
deficiencies to your supervisor.
 PRESS INTEGRITY

Have I tested the clutch and

brake operation before starting
the main motor? Immediately
after?
 PRESS INTEGRITY
 Does the press continue to cycle
when the footswitch or palm
buttons remain depressed? If so, it
does not have required “single-
stroke capability.”* Notify your
supervisor immediately.
* Not required on presses when used in the
continuous mode.
 PRESS INTEGRITY
 Does the press cycle with only one
palm button depressed, or with one
continuously held down and the other
depressed to start the cycle? If so, it
does not have required “anti-tie-down
circuitry.” Notify your supervisor
immediately.
 PRESS INTEGRITY
 Are the operating controls
(mode selector, palm buttons,
foot switch, top stop,
emergency stop) in good
working condition?
 Is the “ground” fault detection
lamp lit. Do not operate the
press if light is not.
 PRESS INTEGRITY

Is all of the auxiliary equipment

(roll feed, scrap chopper, blow
off, etc.) In good working
order?
PRESS ADJUSTMENTS

Have I checked all the

knockout adjustments?
 PRESS SAFEGUARDING
 POINT OF
 Does the
OPERATION
guard or GUARD OPENING
device REQUIREMENTS
positively Dist. from PO Max Open’g
prevent body 1/2” to 1-1/2” 1/4”
access into 1-1/2” to 2-1/2” 3/8”
the danger 2-1/2” to 3-1/2” 1/2”
3-1/2” to 5-1/2” 5/8”
zone?
5-1/2” to 6-1/2” 3/4”
6-1/2” to 7-1/2” 7/8”
PRESS SAFEGUARDING
 Arethe sides and back of the press
guarded or placed in such a way that
another person cannot be injured by
any part of the machine?
PRESS SAFEGUARDING

Isthe safety guard sturdy and

secure? Does the safety
device work properly?
 PRESS SAFEGUARDING

IfI have a foot pedal, is it

guarded on the top and sides?
Does it spring back when
released?
THE POINT-OF-OPERATION

Is the die area clean? Have all

slugs and debris been removed?
THE POINT-OF-OPERATION

Can the parts I feed be placed

into the die easily, without
causing damage to the parts, or
any part of my body?
UNDERSTANDING RISKS
 Do I truly understand the safe
operation of the press … or
do I need more training?
– Don’t be afraid to admit it !
– Don’t be afraid to ask
“dumb” questions !
Your life could depend on it !
UNDERSTANDING RISKS

Do I know the

“tonnage” of the press
and the requirement of
the tooling? Do I know
if the press is
overloaded?
 UNDERSTANDING RISKS

 DoI understand the

maximum thickness or
“gauge” and type of metal
which the tooling and
press can safely run?
PRESS IN OPERATION

 Does the machine operate

smoothly and sound O.K.?
 Any squealing? Shuttering?
Clicking? Clanking? Excess
vibration?
 PRESS IN OPERATION

Does the die stripper work

properly?
 PRESS IN OPERATION

Does the take-up reel work

properly?
 PRESS IN OPERATION

In operation, does the die bind

or jam? If so, notify your
supervisor. The problem may be
the tooling, the press, or the
stock/part.
 PRESS IN OPERATION

 Doesthe clutch/brake work

properly. In the case of a full
revolution press, does the drag
brake stop the press at top center?
 UNDERSTANDING RISKS

What is the expected Noise

Level? Do I need hearing
protection?
 READ AND HEED !

Never unnecessarily place your

hands or any part of your body in
the machine!
 READ AND HEED !

Never operate this machine without

proper eye, face and body
protection!
 READ AND HEED !

 Never operate this machine

without first being fully training
and instructed!
 READ AND HEED !

 Neveroperate this machine

without first reading the
manufacturer’s instruction manual!
 READ AND HEED !

 Never operate this machine if it is

not working properly! Stop
operating and advise your
supervisor immediately!
 READ AND HEED !

 Never use a foot switch to operate

this machine unless a point-of-
operation guard or device is
provided and properly maintained!
 READ AND HEED !

 Never tamper with, rewire or

bypass ANY control or component
on the machine. Interlocks are
provided for your safety. If they
prevent proper operation, consult
your supervisor immediately !
 READ AND HEED !

 Never operate this machine unless

a supplied two-hand control or
presence-sensing device is installed
at a proper safety distance. Consult
your supervisor if you have any
questions.
ANY QUESTIONS?

Talk to your plant

Safety Supervisor, call
OSHEX @ 1-888-
MORE-SAFE, or e-
mail info@oshex.com