orker fatalitiesw from being machinery - · pdf file36 compensation and working conditions...

Compensation and Working Conditions Winter 1998 35

Worker F

atalities

Worker Fatalitiesfrom beingCaught inMachinery

Safety and Health

Fatalities resulting from workers being caught inmachinery reached a 6-year high in 1997. Halfof the workers were performing service-relatedtasks at the time.

JANICE A. WINDAU

Janice A. Windau is an epidemiologist in the Office of Safety, Health andWorking Conditions, Bureau of Labor Statistics.Telephone: (202) 606-6175E-mail: [email protected]

In 1997, the overall number of deaths from work-relatedinjuries (6,218) remained virtually the same as in 1996(6,202). In contrast, deaths caused by workers being caughtin machinery increased 29 percent, to 189. In the period1992-96, the number of work-related deaths resulting fromthe same cause averaged almost 150 a year.1 During thissame period, serious nonfatal injuries resulting from work-ers being caught in machinery totaled 34,000 and were theleading cause of amputations among private industry wageand salary workers. (See table 1.) This article profilesthese fatalities, describes related hazards, and discusses someinjury prevention methods.2

Industry and equipment involved in fatal injuries

Manufacturing is considered relatively safe in terms of fa-tal work injuries. In 1997, it accounted for 12 percent offatal work injuries, compared with its 16-percent share oftotal employment. Manufacturing is generally machine-intensive, and it accounted for the largest portion (41 per-cent) of the deaths resulting from workers being caught inoperating machinery. (See table 2.) In addition, during1996, almost 19,000 workers in manufacturing sufferedinjuries resulting in lost workdays because of such inci-dents.

In manufacturing, as well as in other industry divisions,the equipment associated with fatal injuries included mate-rial handling machinery (such as augers and other convey-ors) and forklifts, in addition to machinery designed to per-

form specific industry-related tasks. (See table 3.) Mate-rial handling equipment accounted for about one-fifth ofthe worker fatalities in the study. Workers in manufactur-ing were also fatally crushed in debarkers and chippers, aswell as in various mixers, presses, molders, and other metaland woodworking machines.

Agriculture, on the other hand, is considered relatively dan-gerous. In 1997, it accounted for 13 percent of the fatalwork injuries, but comprised only 3 percent of total em-ployment. Like manufacturing, agriculture is heavilymechanized. It accounted for one-fourth of the fatalitiesresulting from workers being caught in operating equip-ment in 1997. One-third of these fatalities involved balers,combines, and other harvesting and threshing machines.Power take-off units and driveshafts, used to transmit powerfrom tractors to other farm machinery, accounted for aboutone-sixth of the fatalities.

TABLE 1. Nonfatal injuries involving days away from workresulting from workers being caught in machinery, privateindustry, yearly average, 1992-96

Total ................................................. 34,350 100Cuts, lacerations .................................... 11,177 32Amputations .......................................... 4,832 14Fractures ............................................... 4,376 13Bruises, contusions ............................... 2,920 8Multiple injuries ...................................... 2,401 7 With fractures .................................... 1,018 3 With sprains ....................................... 191 1Sprains, strains ...................................... 1,077 3Soreness, pain ...................................... 426 1All other ................................................. 7,129 21

PercentNumberNature of injury

36 Compensation and Working Conditions Winter 1998

Mining and construction, which use some of the same typesof equipment, together accounted for one-seventh of thefatalities studied. Various earthmoving and drilling ma-chinery were primarily involved in these fatalities.

Refuse system and scrap waste material industries’ equip-ment, associated with the “caught in” fatalities, includedvarious trash compactors, balers, and shredders. These twoindustries together accounted for 7 percent of the fatalitiesin the study.

Circumstances surrounding fatal injuries 3

Workers were performing a variety of machine-related taskswhen they were fatally caught in equipment. (See table 4.)Slightly over half of the workers were reported as carryingout service- or maintenance-related tasks, that is, tasks otherthan the normal operating or feeding of the machine. One-fifth of the workers were performing general or unspecifiedrepair or maintenance. Others were reported to have beenunjamming, cleaning, adjusting, or inspecting the machine.Often these tasks were performed with the machine run-ning. In other instances, workers had turned the machineoff to work on it, but were killed when a coworker unknow-ingly turned the machine on when the workers were insideor near it. Others were killed when they bumped into orfell onto a switch or lever or activated a sensing mecha-

nism. Several other workers were fatally injured when theystepped or reached over a running machine or piece of equip-ment.

Loose or tattered clothing also presented a hazard toworkers operating or working near machines. Over one-fifth of the fatalities studied occurred after an article of cloth-ing, such as a glove, pant leg, or shirt or coat sleeve, was

TABLE 2. Worker fatalities from being caught in machinery byselected industry, 1997

Total ............................................... 189 100Agriculture, forestry, and fishing ............ 50 26 Agricultural production, crops ............ 30 16 Agricultural production, livestock ....... 12 6 Agricultural services .......................... 5 3Mining .................................................... 11 6Construction .......................................... 17 9 Heavy construction, except building .. 10 5 Special trade contractors ................... 6 3Manufacturing ........................................ 78 41 Food and kindred products ................ 11 6 Lumber and wood products ............... 11 6 Paper and allied products .................. 8 4 Chemicals and allied products ........... 4 2 Rubber and miscellaneous plastics products .......................................... 5 3 Stone, clay, and glass products ......... 9 5 Primary metal industries .................... 9 5 Fabricated metal products ................. 8 4 Industrial machinery and equipment ........................................ 7 4Transportation and public utilities ........... 11 6 Trucking and warehousing ................. 3 2 Electric, gas, and sanitary services ........................................... 5 3 Refuse systems ............................. 5 3Wholesale trade .................................... 11 6 Wholesale trade, durable goods ......... 8 4 Scrap and waste materials ............ 7 4 Wholesale trade, nondurable goods .... 3 2Services ................................................ 7 4

Industry Number Percent

TABLE 3. Selected machinery involved in fatalities resulting fromworkers being caught in machinery, 1997

Total ............................................... 189 100Agricultural and garden machinery ........ 28 15 Harvesting and threshing machinery .. 15 8 Balers ............................................ 8 4 Harvesters, reapers ....................... 4 2 Mowing machinery ............................ 4 2Construction, logging, and mining machinery ........................................... 34 18 Excavating machinery ....................... 4 2 Loaders ............................................. 4 2 Logging and wood processing machinery-specialized ..................... 7 4 Debarkers ...................................... 3 2 Mining and drilling machinery ............ 13 7 Drilling machines, drilling augers ... 7 4 Other construction, logging, and mining machinery ............................ 6 3 Agitators, mixers—earth, mineral .. 3 2 Compactors, crushers, pulverizers-earth, mineral ........... 3 2Material handling machinery .................. 34 18 Conveyors-powered .......................... 23 12 Conveyors-belt .............................. 10 5 Conveyors-live roller ...................... 3 2 Conveyors-screw, auger ................ 4 2 Cranes ............................................... 5 3 Elevators ........................................... 3 2Metal, woodworking, and special material machinery .............................. 32 17 Bending, rolling, shaping machinery .. 3 2 Extruding, injecting, forming, molding machinery ........................... 11 6 Casting machinery ......................... 5 3 Plastic injection molding machinery .................................... 4 2 Lathes ............................................... 3 2 Presses, except printing .................... 4 2 Sawing machinery-stationary ............ 6 3Special process machinery ................... 26 14 Food and beverage processing machinery-specialized .................... 4 2 Packaging, bottling, wrapping machinery ........................................ 7 4 Paper production machinery .............. 4 2 Textile, apparel, leather production machinery ........................................ 3 2 Other special process machinery ...... 7 4 Pumps ........................................... 4 2Vehicles ................................................. 18 9 Truck .................................................. 6 3 Forklift ............................................... 6 3 Tractor ............................................... 5 3Miscellaneous machinery ...................... 9 5 Trash compactors .............................. 5 3 Electronic doors, gates ...................... 3 2

PercentNumberType of machinery involved

Compensation and Working Conditions Winter 1998 37

Worker F

atalities

caught in the machine. In fact, the 11 deaths involvingpower take-off equipment or driveshafts all occurred afterthe worker’s clothing was caught in the equipment. (Work-ers’ hair being entangled in equipment is a related hazardthat can cause severe nonfatal injury, such as scalping andfacial disfigurement.4 )

Falls into machinery accounted for almost one-tenth ofthe fatalities studied. Some of the deaths resulted whenworkers fell from the driver’s seat into the working part ofthe backhoe or other earthmoving machinery after hittingrough terrain. Other deaths resulted when workers fell intothe machine while performing various work tasks near it.

Safeguarding workers from being caught inmachineryThe scenarios described above suggest that in many of theincidents proper guarding or maintenance procedures werenot in place or not followed. Guarding refers to any meansof effectively preventing personnel from coming in contactwith moving parts of machinery or equipment that couldcause physical harm. Contacting moving parts in two ma-jor areas can injure workers: the point of operation and thepower transmission apparatus.

The point of operation is the area on the machine wherework is actually performed on the material being processed,such as cutting, shaping, boring, or forming of stock. Tobe effective, point of operation guards must protect theworker against contact with dangerous moving parts whileallowing the work to continue with minimal disruption ofthe production process. Workers—both machine operatorsand service personnel—faced with machine guards that areinconvenient may be tempted to remove them, thus, expos-ing themselves to hazards.5

Power transmission apparatus, such as gears, driveshafts,pulleys, belts, cranks, and power take-off units, transmitenergy to the part of the machine performing the work.Because these parts do not have to be accessible duringnormal operation of the machine, they should be fully en-closed to prevent worker injury. Other moving parts, such

as feed mechanisms, should be safeguarded to protect work-ers.

Safeguards. Barrier guarding is the most common methodof machine safeguarding.6 These guards are physical bar-riers that are mounted on or around a machine to preventaccess to the moving parts. Today, machine manufacturersusually provide built-in guards that conform to the designand function of the machine.7 Manufacturers may also pro-vide guards for retrofitting older machinery without guardsor for machinery whose guards have proven ineffective.However, evidence confirms the fact that all machines arenot promptly retrofitted.8

Several other methods for safeguarding workers duringmachine operation exist, including devices that stop themachine if the worker’s hand is placed in the danger area;devices requiring the operator to use both hands on the con-trols, thus keeping both hands out of danger; and feedingand ejection attachments that keep the worker’s hands awayfrom the point of operation.9

Safeguarding workers during servicing or maintenanceof machinery presents employers with additional challenges.Servicing may require the worker to be near the machine’spoint of operation or power transmission without the usualguards in place. Moreover, certain machines must be run-ning to be properly lubricated or adjusted. Workers facedwith machine jams may be tempted to unjam the machinewith the power on. Even after turning the power off, work-ers may be injured or killed if a coworker turns the ma-chine on or if there is a release of residual energy.

A procedure, commonly referred to as “lockout/tagout,”was developed to protect workers from the unexpectedstartup of equipment or release of hazardous energy whileperforming servicing or maintenance. In general, this pro-cess requires that energy sources for equipment be turnedoff or disconnected and that the switch either be locked orlabeled with a warning tag, but preferably both. The per-son who applies the lock or tag should be the only one toremove it. This would ensure that a coworker does notenergize the equipment thinking that the maintenance isdone. In addition, stored or residual energy must be safelyreleased or blocked so that its unexpected release will notinjure the worker.10

Some repair and maintenance activities, such as clean-ing, lubrication, and unjamming, take place during pro-duction. Machine operators, who may have to perform thesetasks, may be unaware of the hazards involved.

Ten percent of the fatalities in the study occurred whilethe worker was unjamming a machine. Workers may betempted to unjam a machine while it is still on, resulting inthe worker being pulled in along with the jammed mate-rial. Besides turning the machine off and releasing storedenergy, special tools may be available to retrieve materialsfrom machines to avoid injury. Some machines today havereverser mechanisms to discharge clogs, thereby reducingthe need for workers to get near the machine’s point of op-

TABLE 4. Activity performed by workers fatally caught inmachinery, 1997

Total ............................................... 189 100Operating machine ................................ 85 45General (unspecified) repair or maintenance .................................... 37 20Unjamming materials ............................. 19 10Cleaning machine .................................. 14 7Adjusting machine ................................. 8 4Reaching or stepping over machine ...... 7 4Inspecting or checking machine ............ 5 3Other ..................................................... 14 7

Worker activity Number Percent

38 Compensation and Working Conditions Winter 1998

eration. Another method of avoiding injury is to preventthe jam itself. Using the machine at the correct speed, avoid-ing dust buildup, and ensuring that the machine is adjustedfor the material’s size can help forestall machine jams.11

Half of the fatalities involving machine jams occurredin agriculture. Because of this and other hazards associ-ated with tractors powering farm equipment, farmers havebeen advised to disengage the power takeoff, shut off thetractor engine, wait for all parts to stop moving, and takethe key before dismounting the tractor. This procedure pro-tects against injury from contact with the rotating powershafts and the moving parts of the attached machine. Italso prevents another person from turning the power onwhile the machine is being fixed.12

Machines with automatic or self-lubrication and adjust-ment permit these routine tasks to be performed withoutremoval of safeguards.

SummaryTo prevent further injury and death from being caught inrunning machinery, the Occupational Safety and HealthAdministration and other safety professionals recommendthat workers and their employers:

· Safeguard against contact with moving machineparts;

· Shut off power, perform lockout/tagout, and releaseresidual energy before unjamming, servicing,lubricating, or adjusting machinery (exceptionsmay apply for certain machinery);

· Avoid wearing jewelry and tattered or looseclothing around machinery, and wear hair short ortucked inside clothing;

· Avoid stepping or reaching across running equip-ment; and

· Replace guards after servicing equipment.

Because of the diversity in machinery used throughoutindustry, this discussion has been simplified. Employersand workers should follow manufacturers’ instructions,applicable regulatory standards, current industry consen-sus standards, and other safety guidelines for operating,adjusting, unjamming, and repairing equipment.13

1 Other machine hazards include being struck by moving equipment orcaught under overturning equipment, being struck by objects propelled bymachinery, coming in contact with electric current, exposure to carbon mon-oxide or other substances emitted, and exposure to noise from running equip-ment.

2 Data on nonfatal injuries are from the Bureau of Labor Statistics’ Sur-vey of Occupational Injuries and Illnesses (SOII). This program collects in-formation from a random sample of about 200,000 establishments represent-ing most private industry wage and salary workers, excluding workers onsmall farms. Worker and case characteristics are collected only for thoseworkers sustaining injuries and illnesses that require days away from work torecuperate.

Data on fatal work injuries are from the Bureau’s Census of Fatal Occu-pational Injuries (CFOI). CFOI data cover all fatal work injuries. This pro-gram, which has collected occupational fatality data nationwide since 1992,uses diverse data sources to identify, verify, and profile fatal work injuries.Information about each workplace fatality (industry and other worker char-acteristics, equipment involved, and circumstances of the event) is obtainedby cross-referencing source documents, such as death certificates, workers’compensation records, and reports to Federal and State agencies. This methodassures counts are as complete and accurate as possible. Because the scopeand methodology of CFOI and SOII are slightly different, comparisons offatal and nonfatal data are problematic. Additional information can be ob-tained from the Bureau of Labor Statistics Internet site at http://stats.bls.gov/oshhome.htm or via e-mail at [email protected] or [email protected]

3 Much of the information on the circumstances surrounding the incident

was derived from a narrative description of how the incident occurred. Insome cases, this narrative was compiled from numerous sources includinginvestigation reports. In other instances, information available to the staffperson summarizing the information was scant, particularly for fatalities thatwere unwitnessed or that were not investigated by a State or Federal agency.Although the reported data may vary from actual events, the information isstill useful for analysis.

4 “Scalping Incidents Involving Hay Balers—New York,” Morbidity andMortality Weekly Report, July 10, 1992, pp. 489-491.

5 See Concepts and Techniques of Machine Safeguarding, Occupa-tional Safety and Health Administration, OSHA 3067, Washington, DC, 1992(Revised) for a more detailed discussion.

6 Joy LePree, “Machine Guards Prevent Serious Injuries,” July 1996Staff Report, Cahners Business Information.

7 Accident Prevention Manual for Industrial Operations, 9th Edition,National Safety Council, Chicago, 1988.

8 “Scalping Incidents Involving Hay Balers—New York,” pp. 489-491.9 Concepts and Techniques of Machine Safeguarding, OSHA 3067.10 See Control of Hazardous Energy (Lockout/Tagout), OSHA 3120,

1997 (Revised) for a more detailed discussion.11 Farm and Ranch Safety Management, 4th Edition, Moline, Illinois:

Deere and Company, 1994.12 Ibid.13 For instance, see Concepts and Techniques of Machine Safeguarding,

OSHA 3067 for an explanation and list of applicable industry consensus stan-dards.

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sk wh

en

an

accid

en

t ha

pp

en

ed

to m

e. I

certa

inly w

asn

’t exp

ectin

g to

win

d

up

in th

e h

osp

ital th

at Ja

nu

ary d

ay.

I’m a

Bra

dle

y system

s ma

inta

ine

r

an

d m

ain

ten

an

ce p

lato

on

serg

ea

nt

for a

forw

ard

-sup

po

rt com

pa

ny.

We

’d ju

st com

ple

ted

the

FT

X in

pre

pa

ratio

n fo

r a d

ep

loym

en

t to th

e

Join

t Re

ad

ine

ss Train

ing

Ce

nte

r an

d,

afte

r tha

t, po

ssibly Ira

q. W

e w

ere

tired

afte

r spe

nd

ing

3 w

ee

ks in th

e

fie

ld, b

ut it w

as a

lmo

st ove

r—a

ll

we

ha

d le

ft to d

o w

as cle

an

ou

r

veh

icles. A

t ab

ou

t 17

00

, the

last

of th

e ve

hicle

s we

re sta

ge

d a

t the

wa

sh ra

ck, so

we

we

nt to

wo

rk.

Eve

rythin

g a

bo

ut th

is day w

as

rela

tively n

orm

al, w

ith o

ne

no

tab

le

exce

ptio

n: th

at m

orn

ing

, I’d ta

ken

my w

ed

din

g rin

g o

ff m

y do

g ta

gs

an

d slip

pe

d it b

ack o

n m

y left-h

an

d

ring

fin

ge

r. I fig

ure

d sin

ce o

ur

train

ing

wa

s ove

r, we

arin

g m

y ring

wa

s no

big

de

al. I say th

is is no

tab

le

be

cau

se I a

lways w

ea

r my rin

g

aro

un

d m

y do

g ta

gs w

he

n I’m

on

du

ty, esp

ecia

lly in th

e m

oto

r po

ol o

r

in th

e fi

eld

. I’d sp

en

t a ye

ar in

Iraq

du

ring

Op

era

tion

Iraq

i Free

do

m

II, an

d th

e o

nly tim

es I p

ut o

n m

y

ring

we

re w

he

n I le

ft for R

& R

leave

an

d w

he

n m

y un

it red

ep

loye

d

ho

me

. Th

at syste

m w

orke

d w

ell,

an

d th

an

kfully I ca

me

ho

me

no

t

on

ly alive

bu

t with

all 1

0 fi

ng

ers!

I ne

ed

ed

to g

et m

y we

t-we

ath

er

ge

ar, w

hich

wa

s in a

she

lter o

n th

e

ba

ck of a

n LM

TV

traile

r. I climb

ed

on

the

traile

r, go

t my th

ing

s, an

d

gra

bb

ed

the

righ

t side

rail fo

r

ba

lan

ce a

s I pre

pa

red

to clim

b

ba

ck do

wn

. Un

fortu

na

tely, m

y

foo

t slipp

ed

as I ste

pp

ed

on

the

low

er b

um

pe

r, an

d I b

eg

an

to

fall. M

y ha

nd

slid d

ow

n th

e ra

il as

I mo

ved

tow

ard

the

gro

un

d, a

nd

my rin

g ca

ug

ht in

on

e o

f the

U-

sha

pe

d g

roo

ves u

sed

for se

curin

g

can

va

s cove

rs on

the

traile

r.

I wa

s ho

rrifie

d a

s I loo

ked

at

my fi

ng

er. T

he

skin

an

d m

ost o

f

the

tissue

on

my rin

g fi

ng

er w

as

com

ple

tely g

on

e, a

nd

the

bo

ne

from

the

first jo

int ju

st ab

ove

my

fin

ge

rna

il wa

s missin

g. I ca

lled

ou

t to th

e o

the

r gu

ys an

d sa

id,

am

on

g o

the

r cho

ice w

ord

s,

“He

y, ge

t a m

ed

ic, ge

t the

aid

ba

g—

I’ve lo

st my fi

ng

er!”

Ne

ed

less to

say, I wa

s in a

lot o

f

pa

in. A

no

the

r So

ldie

r go

t a co

mb

at

lifesave

r ba

g a

nd

pu

lled

ou

t a

pre

ssure

ba

nd

ag

e, w

hich

I wra

pp

ed

aro

un

d w

ha

t wa

s left o

f my fi

ng

er.

Th

e co

mm

an

din

g o

ffice

r dia

led

91

1

an

d h

ad

a p

ickup

truck b

rou

gh

t off

the

roa

dw

ay so I co

uld

sit do

wn

an

d

take

off

my h

elm

et, w

ea

po

n, a

nd

vest. W

e w

ere

on

ly ab

ou

t 4 m

inu

tes

from

ma

in p

ost, so

the

am

bu

lan

ce

arrive

d fa

irly qu

ickly a

nd

too

k me

to th

e e

me

rge

ncy ro

om

at D

arn

ell

Arm

y Co

mm

un

ity Ho

spita

l.

Th

e d

octo

rs the

re to

ld m

e

the

da

ma

ge

to m

y fin

ge

r wa

s so

exte

nsive

the

y did

n’t k

no

w if a

ny

atte

mp

ted

rep

air w

ou

ld w

ork

. Th

e

tissue

, ne

rves, a

nd

vesse

ls we

re

torn

ho

rizon

tally, a

nd

rea

ttach

ing

my fi

ng

er w

ou

ld re

qu

ire 8

to 1

0

This

Little

Pig

gy...

SFC

DAVID

ALAN

MELAN

CO

N3rd Brigade, 1st Cavalry DivisionFort Hood, TX


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orker fatalitiesw from being machinery - · pdf file36 compensation and working conditions...

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