ES&H Manual



6121 Machine Tools



Machine tools are inherently risky.  Jefferson Lab has determined that use of a machine tool carries an unmitigated Risk Code 3. An Operational Safety Procedure (OSP) is written for each machine tool and read by machine operators prior to use.


1.0            Purpose


Jefferson Lab requires that machine operators be adequate training and know the safety considerations involved in the operation of machine tools. Only personnel who have completed the required training can be authorized by the Machine Shop Manager to operate machine tools. This chapter provides the training and mitigation requirements to help ensure the safe operation of Jefferson Lab’s machine tools.


This program satisfies applicable federal, state, and local requirements as outlined in ES&H Manual Chapter 2410 Appendix T1 Hazard Issues List.


2.0            Scope


Jefferson Lab recognizes machine tools as:

·         Being non-portable – secured for stability.

·         Having a rotational motion, hydraulic, or leverage force.


3.0            Responsibilities


3.1              Everyone at Jefferson Lab

·         Avoid unauthorized entry into machine tool work areas. If you must enter maintain a safe distance from the tools.

·         Wear appropriate eye and hearing protection and clothing. Signs indicating the minimum level of protection and dress code are posted in the machine tool work areas.


3.2              Operators

·         Only use machine tools which you are currently trained and authorized to use, in the manner in which they were intended.

·         Use required PPE (See ES&H Manual Chapter 6620 Personal Protective Equipment Program and ES&H Manual Chapter 6640 Hearing Conservation.  Seek assistance with hazard awareness from Industrial Hygiene).


NOTE:  Wear appropriate clothing when operating machine tools.  Do not wear jewelry, neck wear, loose clothing, long hair, or other items that can get caught in the machine.


·         Ensure that the machine tool is in proper working order and guards are in place before operating. Do not make any temporary or make-shift repairs to machine tools.

·         Ensure that the proper tool, blade, or attachment is being used for both the machine tool and material being worked on.


3.3              Maintenance Personnel

·         Ensure that you are qualified and knowledgeable of the machine tool operation prior to beginning any maintenance work.

·         If it is necessary to terminate power to the machine tool use ES&H Manual Chapter 6110 Lock, Tag, Try (LTT) Program. Blocks, chocks, and other physical devices may also be required to prevent unexpected movement.

·         Refer to the Manufacturer’s Operations Manual for minimum requirements and guidance.


3.4              Machine Shop Manager or Operator’s Supervisor

·         Establish and maintain:

o   A program for qualifying operators on each machine tool under your authority.

o   An effective preventive maintenance program for each machine tool – minimal requirements are those recommended by the manufacturer.  (Ensure that machine lubricants are properly stored, handled, and disposed of in accordance with the Safety Data Sheet (SDS) (See ES&H Manual Chapter 6610 Chemical Hygiene.)

o   Equipment-specific administrative control procedures for each piece of machinery. (See ES&H Manual Chapter 6111 Administrative Control Using Locks and Tags.)

o   Adequate clearance around machine tools (See 29 CFR 1910 Subpart N).

·         Ensure that operators are authorized and appropriately trained to use machine tools.

·         Enforce the use of required personal protective equipment (PPE). (See ES&H Manual Chapter 6620 Personal Protective Equipment Program and ES&H Manual Chapter 6640 Hearing Conservation. Seek assistance with hazard awareness from Industrial Hygiene.)

·         Ensure that each machine tool has proper guards in place (See 29 CFR 1910 Subpart O).

·         Do not allow any temporary or make-shift repairs to machine tools.

·         Ensure an Operational Safety Procedure (OSP) is maintained for each machine tool in accordance with ES&H Manual Chapter 3310 Operational Safety Procedure Program.

·         Ensure that machine tools are properly maintained.

·         Ensure that safety signs are posted in the vicinity of machine tools and at shop entrances.


3.5              Associate Directors and Department Managers

·         Ensure that machine tool controls and authorization practices, under your authority, are maintained. (Refer to ES&H Manual Chapter 6121 Appendix T1 Safe Operation of Machine Tools for guidance.)


4.0            Technical Appendices


ES&H Manual Chapter 6121 Appendix T1 Safe Operation of Machine Tools provides the safety rules applicable to operating machine tools at Jefferson Lab. It is based on Occupational Safety and Health Administration (OSHA) regulations and American National Standards Institute (ANSI) standards. Operator’s Manuals also provide valuable information and are used in preparation of OSPs and training.


5.0            Revision Summary


Revision 1.3 – 04/19/16 – Periodic Review; MSDS replaced with SDS per updated OSHA regulations

Revision 1.2 – 08/19/14 – Updated TechPOC from N.Walker to B.Manzlak

Revision 1.1 – 09/28/12 – Periodic Review; clarification edits only

Revision 1.0 – 09/21/09 – Update to reflect current laboratory operations











ESH&Q Division

Bert Manzlak





This document is controlled as an on line file.  It may be printed but the print copy is not a controlled document.  It is the user’s responsibility to ensure that the document is the same revision as the current on line file.  This copy was printed on 5/26/2016.