FHM TRAINING TOOLS

This training presentation is part of FHM’s

commitment to creating and keeping safe
workplaces.

Be sure to check out all the training programs

that are specific to your industry.
 Power Press
Operator Training
 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
• Does the POINT OF OPERATION GUARD
guard or OPENING REQUIREMENTS

device Dist. from PO Max Opening

positively 1/2” to 1-1/2” 1/4”
prevent body 1-1/2” to 2-1/2” 3/8”
access into 2-1/2” to 3-1/2” 1/2”
3-1/2” to 5-1/2” 5/8”
the danger
5-1/2” to 6-1/2” 3/4”
zone?
6-1/2” to 7-1/2” 7/8”
 Press Safeguarding
• Are the 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
• Is the safety guard sturdy and secure?
• Does the safety device work properly?
 Press Safeguarding
• If I 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

• Do I 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
• Does the 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!
• Never operate 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.