Proper Use and Maintenance of Die Safety Blocks for Optimal Protection

Proper use and maintenance of die safety blocks are essential for preventing injuries and ensuring the safety of workers in manufacturing environments.

• By Jane Marsh
• Jul 29, 2024

Die safety blocks may appear to be simple devices, but they are vital to protecting workers in manufacturing environments. The use of this equipment satisfies OSHA’s requirements outlined in 1910.217(d)(9)(iv), which covers machinery and machine guarding protocols. It is also crucial for meeting the tagout requirements for mechanical energy controls.

Like any other equipment, proper use and maintenance of die safety blocks are paramount. This means keeping the device in top operational condition to prevent grievous malfunctions and extend its life span.

Ensuring Safe Die Cutting and Folding Operations 

A worker’s upper limbs getting caught in a die-cutting power press is no joke. According to OSHA, 49 percent of this type of injury results in amputation, which is problematic on all fronts. On-site accidents effectively grind operations to a halt, and there is lots of paperwork involved in the compensation process. Plus, fines and other penalties for failing to meet safety guidelines are possible.

Using die safety blocks is essential to prevent these mishaps. Operators insert them between the punch and holder to support the press's dead weight in the event of a brake failure or a sudden loss of hydraulic pressure. They interlock with the machine to prevent the actuation of hazardous machine motion. The block’s electrical interlock must also interface with the machine control system. So pulling the plug automatically disconnects the power to the main drive motor and control.

Regardless of how time-consuming it is, workers must follow this procedure and other proper protection measures whenever they put their hands in the die area of a press or work on the die. Safety managers and employers are primarily responsible for enforcing this requirement in a press shop and are therefore held liable for incidents.

The manufacturing industry's rate of non-fatal injuries involving contact with objects and equipment has held steady in recent years. However, there is a bit of consolatory news, as only 2 percent of these workplace accidents between 2021 and 2022 necessitated amputation. This is a testament to the value of properly using safeguarding equipment like die safety blocks and regulatory compliance.

Maintaining Die Safety Blocks 

The maintenance procedure for safety blocks closely mirrors the standards for the die machine and is driven by the same end goal, which is to ensure proper functioning and improve service life. These include the following:

• Regular inspection. It is crucial to conduct regular visual checks of the block for any signs of wear or deformation. Inspections also encompass testing the electric component and checking to make sure the machine stops operating when the block’s plug is disconnected. Safety managers should keep detailed records of each safety block's inspections and maintenance activities.
• Cleaning. Lodged debris oil, and other contaminants could impact the safety block's load-bearing capacity. Regular cleaning is essential to keep the device in good condition and ensure smooth operation.
• Repair and replacement criteria. Companies must establish clear criteria for when to repair versus when to replace a die safety block. Facility managers may set predefined wear and tear limits or follow manufacturer recommendations. Either way, once a block meets the criteria, no further work should be carried out on that die machine until the repair or replacement has been sorted.
• Training and documentation. Regular employee training on proper maintenance procedures for die safety block usage is integral for staying up to date on the latest best practices in hydraulic press operations. User error is one of the biggest risk factors for equipment failure. This applies to both the safety block and the die machinery since they are electronically connected. Documenting each training session is also important for fostering a safety culture and educating new workers on properly handling and maintaining the device.

Best Practices for Promoting Safety Block Maintenance 

The following recommendations are essential for ensuring a more coordinated work environment and safer equipment operations:

• Stick to a schedule. Operators must perform routine maintenance activities on the safety block, die machine and other components. This approach decreases the chances of oversights and sudden malfunctions.
• Employ access control. Limiting access to potentially hazardous machinery plays a significant role in maintenance safety. Requiring specific authorization to handle die safety blocks ensures only workers with sufficient training can work with them. Additionally, if only a few people can operate or inspect the machinery, there is a lower risk of someone turning it on during maintenance checks.
• Require after-use checks. Operators should report on the equipment they use at the end of each work day. Machines are more likely to fail during operations. So the workers usually first notice issues and raise concerns.

To improve workplace safety, it’s essential to utilize the proper equipment. Die safety blocks are critical components for ensuring safe die-cutting and folding operations. Proper handling of this equipment is nonnegotiable and should be a foundational step during usage and maintenance procedures.