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Avoiding Pinch Points on Machinery

Caught In Between | OSHA Fatal Four

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

Common pinch point hazards include:

  1. Rotating Parts: Gears, pulleys, belts, and rollers.
  2. Closing Actions: Presses, doors, and clamps.
  3. Moving Parts: Chains, conveyors, and cutting mechanisms.
  4. Hand Tools and Equipment: Tools with moving jaws, such as shears or cutters.

Even brief contact with these hazards can cause severe injuries.

Safety Practices and Preventative Measures

To avoid pinch point injuries, follow these critical safety practices:

  1. 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.
  2. Use Machine Guards:

    • Never remove or disable safety guards—they are your first line of defense.
    • Report missing or damaged guards to your supervisor immediately.
  3. Stay Alert Around Machinery:

    • Avoid distractions when working near machinery.
    • Keep hands, clothing, and tools clear of moving parts.
  4. Use Personal Protective Equipment (PPE):

    • Wear snug-fitting clothing to prevent loose material from getting caught.
    • Use appropriate gloves when handling equipment, but ensure they are not worn near rotating parts.
  5. Follow Lockout/Tagout (LOTO) Procedures:

    • Always lock out machinery before maintenance or repairs.
    • Verify that the machine is de-energized before beginning work.
  6. Maintain Safe Working Distance:

    • Identify and stay clear of pinch point zones.
    • Use tools or push sticks instead of hands when possible.

Real-Life Case or Scenario

Where possible, use an actual incident that you have experienced or been involved in.

E.g. In one incident, a worker lost two fingers while clearing a jam on a conveyor belt. The machine was not locked out, and the worker’s hand was pulled into a pinch point when the conveyor restarted. This tragedy could have been prevented by following proper lockout/tagout procedures and using tools instead of bare hands.

Employee Responsibilities

  • Recognize and avoid pinch points in your work area.
  • Always inspect machinery before use and ensure guards are in place.
  • Follow lockout/tagout procedures during maintenance or troubleshooting.
  • Wear appropriate PPE and avoid loose clothing.

Employer Responsibilities

  • Provide machinery with proper guarding and conduct regular inspections.
  • Train employees on pinch point hazards and safety practices.
  • Enforce lockout/tagout procedures.
  • Replace or repair 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 employees to share their experiences and discuss potential improvements.)

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 guarded and safe.

Wrap-Up

Pinch points are a serious hazard, but they’re preventable with awareness, proper equipment use, and adherence to safety protocols. Thank you for your attention and commitment to staying safe on the job.

Standards Overview

  • OSHA defines pinch points as hazardous areas where a person or body part can get caught between moving parts, stationary objects, or both.
  • OSHA Standard 1910.212 requires that machinery be equipped with guards to protect employees from pinch points and other moving parts.
  • Employers are also required to train employees on recognizing and avoiding these hazards.
OSHA Occupational Safety and Health Administration

Legal Disclaimer

This toolbox talk is provided for informational and educational purposes only. It is not intended to be a substitute for professional legal, safety, or regulatory advice. The information presented is based on best practices and general industry standards but may not apply to all workplace situations.
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It is the responsibility of the employer, supervisors, and workers to ensure compliance with applicable federal, state, and local laws, regulations, and standards. The authors, presenters, and distributors of this toolbox talk assume no liability for the use or application of the information provided.
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Participants are encouraged to consult appropriate legal, safety, or regulatory professionals to address specific concerns or questions. Always follow your organization's policies and procedures for workplace safety and hazard mitigation.

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