Avoiding Pinch Points on Machinery
The Problem
Pinch points are areas where a person’s body or clothing can get caught between moving parts of machinery or equipment, resulting in serious injuries such as crushed hands, broken fingers, or even amputations. These hazards are present on nearly every job site where machinery is in use, and many incidents occur because workers underestimate the risks or fail to follow proper safety precautions.
Identify the Hazards
- Rotating Parts: Gears, pulleys, belts, and rollers
- Closing Actions: Presses, doors, and clamps
- Moving Parts: Chains, conveyors, and cutting mechanisms
- Hand Tools and Equipment: Tools with moving jaws, such as shears or cutters
Safety Practices and Preventative Measures
To avoid pinch point injuries, follow these critical safety practices:
Inspect Machinery Before Use:
- Ensure all machine guards are properly installed and in good condition.
- Check for loose or damaged parts that may increase pinch point risks.
Use Machine Guards:
- Never remove or bypass safety guards—they are your first line of defence.
- Report missing or damaged guards to your supervisor immediately.
Stay Alert Around Machinery:
- Avoid distractions when working near machinery.
- Keep hands, clothing, and tools away from moving parts.
Use Personal Protective Equipment (PPE):
- Wear snug-fitting clothing to prevent loose material from getting caught.
- Use appropriate gloves when handling equipment, but do not wear gloves near rotating parts.
Follow Lockout/Tagout (LOTO) Procedures:
- Always lock out and isolate machinery before maintenance or repairs.
- Verify the equipment is completely de-energised before starting any work.
Maintain Safe Working Distance:
- Identify and stay clear of pinch point zones.
- Use tools, push sticks, or other safe alternatives rather than using hands directly.
Real-Life Case or Scenario
A worker lost two fingers while clearing a jam on a conveyor belt. The machine had not been isolated, and the worker’s hand was pulled into a pinch point when the conveyor restarted. This could have been prevented by following proper lockout/tagout procedures and using tools instead of bare hands.
Employee Responsibilities
- Recognise and avoid pinch points in your work area.
- Always inspect machinery before use and ensure guards are in place.
- Follow isolation (LOTO) procedures during maintenance or troubleshooting.
- Wear appropriate PPE and avoid loose clothing.
Employer Responsibilities
- Provide machinery with proper guarding and conduct regular inspections.
- Train workers on pinch point hazards and safe operating procedures.
- Enforce isolation procedures (lockout/tagout).
- Repair or replace defective guards and machinery promptly.
Discussion & Questions
- “What pinch point hazards have you noticed on our site?”
- “Have you ever encountered an unsafe machine or a missing guard? How did you address it?”
Encourage workers to share their experiences and discuss how site safety practices can be improved.
Commitment/Action Plan
Let’s commit to inspecting machinery daily, keeping guards in place, and reporting hazards immediately. Today, identify the pinch points in your work area and take steps to ensure they’re properly guarded and safe.
Wrap-Up
Pinch points are a serious hazard, but they’re preventable with awareness, proper equipment use, and adherence to safety procedures. Thank you for your attention and your ongoing commitment to staying safe on the job.
Standards Overview
Under the Health and Safety at Work Act 2015 (HSWA), WorkSafe New Zealand requires PCBUs (Persons Conducting a Business or Undertaking) to manage the risks of machinery hazards, including pinch points. Employers must:
- Ensure machinery is guarded where there’s a risk of injury from moving parts
- Train workers to recognise pinch point hazards
- Provide appropriate PPE and ensure isolation procedures are in place
Refer to WorkSafe NZ’s guidance documents such as “Safe use of machinery” and “Isolation of energy sources” for further best practice and regulatory requirements.
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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