Avoiding Caught-in Hazards with Rotating Machinery
The Problem
Caught-in hazards are a leading cause of serious injuries and fatalities on the job. Rotating machinery, such as drills, lathes, and conveyors, presents significant risks if proper precautions aren’t taken. Workers can be pulled into equipment, resulting in severe injury or death. Today, we’ll discuss how to identify these hazards and take steps to prevent incidents involving rotating machinery.
Identify the Hazards
- Unguarded Moving Parts: Exposed belts, pulleys, or gears can catch clothing, hair, or limbs.
- Loose Clothing or Accessories: Items like long sleeves, jewellery, or unsecured hair can get caught.
- Improper Maintenance: Working on machinery without isolating energy sources can result in sudden movement.
- Operating While Distracted: Lack of focus around rotating equipment increases the risk of injury.
Safety Practices and Preventative Measures
Inspect Equipment Before Use:
- Ensure all machine guards are in place and securely fastened.
- Report any missing or damaged guards to your supervisor immediately.
Wear Proper Personal Protective Equipment (PPE):
- Do not wear loose clothing, ties, or jewellery when working near rotating machinery.
- Tie back long hair and secure it under a hat or hairnet if necessary.
- Wear snug-fitting clothing and only wear gloves if the task requires them and it is safe to do so.
Follow Lockout/Tagout (LOTO) Procedures:
- Always re-energise and isolate equipment before maintenance or cleaning.
- Ensure that all stored energy (e.g. hydraulic, pneumatic, or electrical) is safely released.
Maintain a Safe Distance:
- Keep hands, tools, and clothing well clear of rotating components during operation.
- Use tools designed for working near moving parts to avoid direct contact.
Stay Focused:
- Avoid distractions while operating or working around rotating machinery.
- Be aware of your surroundings and communicate clearly with others working nearby.
Real-Life Case or Scenario
In one incident, a worker’s loose sleeve was caught in an unguarded lathe, pulling their arm into the machine. The injuries were severe and required multiple surgeries. This could have been avoided through proper guarding and attention to safe clothing requirements. Real-life events like this underscore why vigilance is essential.
Employee Responsibilities
- Inspect machinery before use and ensure guards are in place.
- Avoid loose clothing, jewellery, or unsecured long hair.
- Always follow isolation (LOTO) procedures when servicing equipment.
- Stay alert and focused when working near rotating parts.
Employer Responsibilities
- Provide properly guarded equipment and maintain it regularly.
- Train workers on the safe operation of rotating machinery and LOTO procedures.
- Ensure PPE policies are clearly communicated and enforced.
- Respond quickly to reports of missing guards or unsafe equipment.
Discussion & Questions
- “What types of rotating machinery do we commonly use on-site, and what hazards have you noticed?”
- “Has anyone experienced or witnessed a caught-in hazard? How was it resolved?”
Encourage workers to share examples, concerns, or suggestions for improvement.
Commitment/Action Plan
Let’s commit today to inspecting equipment, following safety protocols, and reporting hazards promptly. Starting now, make it a habit to double-check guards and ensure your clothing and hair are secure before approaching any rotating machinery.
Wrap-Up
Caught-in hazards can lead to life-changing injuries—but they are entirely preventable. By following simple precautions, staying alert, and adhering to WorkSafe NZ regulations, we can ensure a safer work environment for everyone. Thank you for your attention and your commitment to safety.
Standards Overview
Under the Health and Safety at Work Act 2015 (HSWA), PCBUs (Persons Conducting a Business or Undertaking) are required to eliminate or minimise the risk of harm from machinery. WorkSafe NZ expects employers to:
- Install appropriate guarding on all moving machinery
- Train workers on safe work practices, including how to avoid entanglement and caught-in injuries
- Implement isolation and lockout/tagout procedures during servicing and maintenance
- Provide and maintain PPE suited for tasks near machinery
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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