えい ご ばん

英語版
For technicalintern trainees
きん ぞく せい ひん せい ぞう ぎょう

金属製品製造業 における外国人技能実習生の安全と健康確保に向けてがい こく じんぎ

のう じっ しゅう せい

あん ぜん

き かい

けん こう かくあん ぜん たい さく

ほ

む

ちゅうしん

（プレス機械の安全対策を中心として）

Safety and Health for Foreign
Technical Intern Trainees
in the Metal Product
Manufacturing Industry(with a focus on safeguards forpress machines)

During your stay in Japan, please follow
the health and safety rules in order togain proﬁciency without injury or illness.

Contents
Q 1 What is press work? 

1

Q 2 What are the hazards of press machines? 2◎Hazards of Press Machines and How to Deal with Them 

Q 3 What safety devices do press machines have? ◎Main Safety Equipment 

Q 4 What should and should not be done to ensure safety? 

3
4
5
6

(Unsafe Behavior Prevention Checklist)◎Examples of Industrial Accidents Involving Interns(mostly caused by unsafe behavior) 

7Q 5 What are the basics for working safely? 

8◎Basics of Safe Work Practices 

Q 6 What inspections should be carried out before starting work? ◎Explanation of Inspection before Starting Work 

9
10
11

Q 7 How should press work be undertaken? 

12

Q 8 What should you pay attention to while working? 

13Q 9 What precautions are required for work other than pressing? 

14Q10	What precautions should be taken concerning the working 
environment? 

15

Q11 How do you deal with abnormal situations? 

16◎Reference―Explanation of Important Press-related Terms 

17

Q1

What is press work?

(1) Attach a top to the slide that moves up and down on the press machine and abottom die on to the bolster.
(2) Feed the material into the die and position it.
(3) Operate the press machine to shape the material by the die.
・The slide moves down applying strong force(4) When the slide moves up and stops, remove the shaped product.
(5) The operations from (1) to (4) above are called “press work.”(6) Shaping the material with the die using the strong force of the descending slide in(3) above is called “pressing.”(7) Press accidents may occur in the processes described above.

Rotation angle indicator

Control panel

Material to be processed
Upper dieSlide
Formed product

Lower die
Operation box

BolsterPress machine

Start button

Select the operation
with a key.

Safety one cycle

Off

One cycle

Inching

Key
Continuous stop button

Continuous

Emergency stop button
Operation box for two-handed safety device operation

Changeover key switch

1

Q2

What are the hazards of press machines?

Machine work area

Joint work area
(inside the danger zone)

Human work area

Slide Stopped at
top dead center
Unable to start

Slide operation
Guard
Exclusion

Fully open

Stroke※No hand access

Lock type※Hand accessWithout locked guard(a) Interlock guard type

Slide operation

Slide emergency stop

Danger zone

Danger zone

Descending

Approach
Approach（Detection）(b) Two-handed operation type

Safety distance(c) Light beam typeTemporal separation, safety measures for “hands in die” work2◎Hazards of Press Machines and How to Deal with Them
(1) What sort of industrial accidents occur with press machines?
・Crushing a hand between the dies is the main type of accident.
・Care is also required to avoid injuries due to fragmentation of dies and workpieces.
(2) What are crushing accidents?
・Crushing accidents occur when the operator puts their hands where the slide ismoving to feed or remove materials or products.
(3) How can crushing accidents be prevented.
・It is important to separate the movement of the moving parts of the press machine
and the movement of human hands, to ensure that they do not coincide.
・T here are two methods of achieving this: spatial separation, and temporalseparation.
(4) What is spatial separation or “no hands in die” work?
・It is to separate the human workspace from the dangerous area where the machine
operates.
◎Examples: Use safety fences, safe-type dies
(5) What is temporal separation or “hands in die” work?
・It is to prevent human hands from entering the danger zone while the slide ismoving.
・Safety can be maintained by the temporal separation of hand movement and slide
movement. The following safety devices are used individually or in combination.
◎Examples: Interlock guards, two-handed operation type, light beam type(6) What are accidents caused by die failure?
・Die failure is typically caused by improper attachment or overloading of the dies.
・Overloading occurs when two or more sheets of material are fed at the same time,or when scraps remain in the die.
・It is important to work correctly in accordance with proper work standards.

3

Q3

What safety devices do press machines have?

Guard-type safety device（Horizontal opening）

Guard plates
Foot switch
Guard control panel

Control panel

Light emitter and receiver

Light beam safety device

4◎Main Safety Equipment◎Outline(1) The main types of safety equipment used for press work are the guard type, two-handed operation type,and light beam type shown below.
(2) All the workers should understand the purpose and configuration of these safety devices and use themproperly according to proper work procedures. It will keep you safe.

◎Guard-type safety device
Outline of the device
・A safety device that makes the slide move only when the guard plates are closed.
(1) When the operation switch is turned on, the guard plates move, blocking the danger zone.
(2) After a safety check, the slide moves.

◎Two-handed operation safety device
Outline of the device
・A safety device that makes the machine operate only when both hands are put on the switching positions.
・It is necessary to install it so as to maintain a safe distance when operating the machine.
(1) To start the slide, both hands should press the pushbuttons simultaneously (no more than 0.5 seconds
differential).
(2) The distance between the inner edges of the pushbuttons must be at least 300 mm.
(3) T here are two types of safety systems―the safety one-cycle type used for friction clutch presses and otherpresses with sudden stop mechanisms, and the two-hand starting type for presses that cannot stop suddenly.
(4) When operating the machine with a pedal, it is possible to mistime hand and foot operations so that yourhand enters the danger zone when the slide is going down. Therefore, it is important to start the machinewith both hands.

◎Light beam safety device
Outline of the device
・A safety device that senses when a person interrupts a light beam and it then stops the slide.
・Typically, light beam and two-handed operation safety devices are used together.
(1) Carefully check whether the safety device is impaired or not, thus ensuring that it is effectively enabled.
(2) Sufficient protective height must be allowed.
・Ensure that when the worker is standing to work at the die press, the top of the light beam can detectmovement, and when sitting to work at the die press, the bottom of the light beam can detect movement.
(3) With straight-sided presses that have a long safety distance, the worker may end up inside the light beam
so that the safety device no longer functions. In that case, other measures are required.
(4) This safety device is not effective if the slide fails to stop at the upper dead-end due to some defect of the
clutch.

5

Q4

What should and should not be done to ensure safety?

◎Prevent unsafe behavior(1) Numerous industrial accidents, including some serious cases, are caused by unsafe behavior by technicalintern trainees (hereafter “interns”).
(2) Use the following checklist to prevent unsafe behavior yourself, and strive to ensure safety when you work.

(Unsafe Behavior Prevention Checklist)
Check here
if trueItems(1) Do you fully understand the task that you are performing?

□(2) Do you fully understand the work procedures?

□(3) Have the safety devices on the press machine, etc. not been removed or disabled?

□(4) Cleaning and inspection of the press machine, etc.
・Are you not performing these tasks without stopping the machine?
・Have you displayed a notice on the system activating device to inform others that themachine is stopped?

□□(5) Before starting the press machine, have you checked around the machine to make sure that
it is safe? Do you start the machine in response to appropriate signals?

□(6) When you work with others on a press machine, are you observing the correct signals toensure proper coordination?

□(7) Are you not getting unnecessarily close to moving machinery or hoists?

□(8) Have you not left machinery or materials in an unsafe state or place?

□(9) Are you not performing restricted work* for which you are not qualified?

□(10) Are you using protective equipment properly, as instructed?

□(11) Are you wearing safe work clothing?

□＊ Note: Examples of restricted work: Sling work for a crane with a hoist load of 1 tonne, and operating a crane witha hoist load of 5 tonnes

BAD

It’s inthe way.

Do not remove
safety devices

6

BAD◎Examples of Industrial Accidents Involving Interns (mostly caused by unsafe behavior)◎Working with the safety devices of a press machine switched off
Description(1) A worker was engaged in pressing products from material using a pedaloperated 100-tonne press machine.
(2) Since the worker was afraid of inefficiency, he switched off the safety device.
While feeding material with his left hand, he removed the products with amagnetic tool in his right hand.
(3) In the course of this work, he pressed the pedal before he could get his handout of the way, and his fingers, holding the magnetic tool, were crushed
between the top and bottom dies.

Important(1) Do not switch off the safety devices when working.
(2) Understand the importance of working with the safety devices.

◎Forgetting to turn off the press machine when inspecting and cleaning the equipment
Description(1) Before inspecting and cleaning a press machine, a worker forgot to switch itoff. He touched a button by accident, the slide moved, and his fingers werecrushed.

Important(1) Be sure to switch off the power before inspection and cleaning.
(2) Be sure to comply with the proper work procedures.

◎Getting foreign material in the eye during finishing work
Description(1) A worker engaged in finishing work experienced pain in the right eye andconsulted an optician.
(2) Although he was wearing protective glasses, it is thought that particles got inthrough a small gap.

Important(1) Other cases involving getting foreign material in the eyes have occurred
frequently―during finishing work with a grinder or air blower—so be sure towear your protective glasses properly.
(2) Even if it is a light injury, do not ignore it. Go to hospital promptly.

Use the stipulated safety
equipment correctly.

Wear protective glasses during finishing work.

7

Q5

What are the basics for working safely?

SafetyhelmetFollow the work
procedures.

Ear plugs
Button up
sleeves.

Safety shoes

Work procedures

Carry out standard operations.

Wear work clothes.

【Straighten】【Scrub】【Sort】

Metal【Standardize】【Sustain】

8OK！

◎Basics of Safe Work Practices(1) Compliance with work proceduresa) Follow the established work procedures, or work standards, stringently and do not use othermethods. Above all, understand the necessity of safety devices and do not remove or disablethem.
b) Practice and master the work procedures shown in the manual.
c) Obey the relevant laws and workplace rules concerning what you must do and must not do forsafety.
d) If you do not understand anything in the work procedures, do not remain silent. Ask thesupervisor.
e) Avoid injury from overconfidence. Do not engage in hasty or rough actions.
(2) Rigorously apply 5Sa) SortDistinguish between necessary and unnecessary items, and throw away unnecessary
thingsb) Straighten
Arrange necessary items so that they are easy to use.
c) Standardize
Remove dirt and maintain clean surroundings.
d) ScrubRemove dirt and trash from around machinery, equipment and desks.
e) Sustain
Follow established rules.
(3) Clothinga) Wear the designated safe work clothes when working.
b) Work clothes should fit closely and be comfortable.
c) Button the cuffs of long-sleeved clothing and tuck the hem of shirts into trousers.
d) Do not work with edged tools, screwdrivers, drills, etc. in your pockets.
e) Do not wear neckties, towels or scarves around your neck, or anything that could get caught inmachinery.
(4) Protective equipment
・Be sure to wear designated protective equipment, such as helmets, properly.
(5) Other
・Always keep the tools, materials and products tidy around the machinery.
・Make sure that the tools and materials are placed in a stable manner so that they do not fall or
become separated.

9

Q6

What inspections should be carried out before starting work?
Faulty attachment of the die

Do not operate a loose or
misaligned die.
CracksBolster
Bed
Cracks are dangerous.

Faulty attachment
Do not use a loose or
misaligned attachment.
Scrap
Reexamination of the inside and parts around the die(2) S lide at top deadcenter(3) S lide emergency
stop

Stopped at top
dead center(1) E ngagementof the die

Inspection before operating the machinery

10◎Explanation of Inspection before Starting Work
○Inspection of the inside and parts around the die before starting work
(1) Inspection details

Items

Check here
if truea) Are the upper and lower die mounted correctly?

□b) Are the inside of the die, the bolster and the head free of scraps or
foreign material?

□c) Is the die attached correctly?
→Are there no gaps or looseness in the mounting bolts?

□(2) Measures after inspection
・If you discover that the die is misaligned, there are cracks, it is difficult to remove foreignmaterial or there are any other problems, call the supervisor and follow the instructions
given.
○Re-inspection before operating the machinery(1) Inspection details

Items

Check here
if truea) A re the safety devices working and safety enclosures attachedproperly?

□b) Is the die attached firmly and aligned properly?
→Are there no abnormal sounds, scraping, movement, etc.?

□c) Is the slide stopping properly at top dead center?

□d) Does the slide stop immediately when you take your hands off the start
buttons?

□(2) Measures after inspection
・If you discover these kinds of problems or any other problems, call the supervisor andfollow the instructions given.
○Other inspection items(1) Protective equipment, gloves and hand tools
・Check for damage, and if you discover a problem, call the supervisor.

11

Q7

How should press work be undertaken?

(1) Position of the operator and workpieces
・It is best for the operator to stand in front of the press machine with the material on theleft and the products on the right, making the work flow from left to right.
The following points concerning this positioning are important.
a) The operator should have a relaxed posture and be calm and clear minded.
b) Place the material where it is easy to reach.
c) Ensure that the products can be taken from the die easily.
d) Make space to place the products.

(2) Processing procedure
・Use the following procedures.
a) Take a piece of material.
b) Place it carefully in the die with both hands. Ensure that the placement guideallows safe and easy placement.
c) Use both hands. Press both start buttons simultaneously.
d) Check that the slide is stopping properly.
e) Remove the product with both hands, and place it in the designated position.

Processed material

Workflow

Workflow

Processed material

Product

Operator
Working position

12

Q8

What should you pay attention to while working?

(1) Precautions when working
・Watch for the following abnormalities during press work.
Check here
if trueItemsa) Are there no abnormal sounds?

□b) Is there no unusual heat being generated?

□c) Are there no abnormal smells?

□d) Is the machinery not moving in an unusual manner?

□e) Are seizures not occurring?

□f ) Is scrap not being ejected properly?

□g) Is foreign material not entering the workflow?

□h) Are you feeding the material singly?

□i ) Are the products not misshapen?

□(2) Handling of abnormalities
・If an abnormality occurs, carry out the following procedure promptly.
a) Press the emergency stop button and stop the machine.
b) Check that the machine has stopped completely, then report immediately to thesupervisorc) The supervisor, or both you and the supervisor, will then take the necessary
measures.
d) The supervisor will restart the machine.

Slide
SeizureUpper dieDeformed product

Abnormal sound
Heat

Lower dieFeeding two sheets of material
Abnormal movement

Emergency stop button
Abnormalities during work

13

Q9

What precautions are required for work other than pressing?

(1) Product checking
・C heck whether the finished products are marketable before shipment. In
particular, check for scratches and cracks.
・If you find a defective product, stop working and report it to the supervisor.
(2) Supplementary work
・Pay attention to the following tasks that supplement press work.
a) Periodically dispose of scrap and clean the work area.
b) Wipe up any oil in the workplace immediately.
c) Periodically move materials and products.
d) Hold discussions with your partner away from the machinery.
e) When leaving the machine temporarily, be sure to stop the machine byswitching off the motor.
(3) Actions after finishing press work
・Pay attention to the following tasks when finishing press work.
a) Switch off the motor.
b) Tidy the machinery, equipment and workspace.
c) Return the materials, tools and products to their designated storage place.
d) Report the completion of the three tasks above to the supervisor.

Motor stop button
When leaving the machine,
switch off the motor.

Rules when leaving the machine or workplace

14

Q10

What precautions should be taken concerning the working environment?

○Noise and hearing loss
(1) Conditions for press work
・Manufacturing facilities with press machines are noisy.
・B eing in a noisy environment for a long time can cause noise deafness.
Measures are required to prevent this.
(2) Measures to take against noise・In places with intense noise, use protectors such as earplugs or earmuffs.
○Preventing back injury(1) Conditions for press work
・Preparation for press work involves carrying a lot of materials and products.
・Moving things by hand involves lifting, twisting the body (excessive movement),and sudden movement, which places strain on the lumbar region in particular,
leading to lumbar pain. Therefore, care is required.
(2) Measures to prevent back injury
・When lifting objects, squat down before lifting.
・Next, place yourself as closely to the center of gravity, and then lift the object.
・Maintaining good working posture is the best way to avoid back injury.

Good

Use the designated protective equipment
such as earplugs correctly.

Squat down.

BAD

How to lift heavy objects

15

Q11

How do you deal with abnormal situations?

○Action when you discover an abnormal situation(1) If you discover an abnormal situation, first confirm what is happening.
(2) Alert the nearby supervisor and your colleagues in a loud voice.
・It is important to remember what to say in Japanese in this situation.
(3) Cooperate with your colleagues to carry out corrective actions as directed by the supervisor.
・Do not act on your own.
(4) W hen the abnormal situation has returned to normal, report to the supervisor on thecircumstances leading up to the situation.
○Evacuation and disaster prevention training(1) In case of an explosion or fire, alert the people nearby and evacuate to a safe place. It is
important to ensure that there is illumination of the evacuation route and exits if there is a
blackout.
(2) Always take part in disaster prevention training, and receive expert advice on responding toabnormal situations and evacuation methods.

Alert others
If the machinery is not working normally, alert the leader and others around!
For example:
へんな においが します
There is a strange smell.
レバーが ぐらぐら します
The lever is wobbling.

へんな おとが しますIt makes a strange noise.

あかい ランプが ついて います
The red light is on.

あおい ランプが きえて います
The green light is out.

ランプが てんめつして います
The light is flashing.

さわると あついです
It is hot to touch.
○○が ありません○○ is missing.

16

◎Reference (Explanation of Important Press-related Terms)
Term◎SlideDefinition of terms
・A part that is moved up and down by a crank. The upper die is attached to thebottom of the slide.

◎Bolster・A mounting for the lower die.

◎Control panel,(1) A panel incorporating the operating power source switch, the press stroke

consolechangeover switch and selector switch, switches for operation methods such as
two-handed, one-handed, pedal, etc., the motor operation button (start-stop), andso forth, and lights indicating the status of the various switches.
(2) There is a key for the stroke changeover switch and for the operation methodchangeover switch, and it is not possible to operate either switch without the key.

◎One-handed
operation◎Pedal operation(1) A method of operation that allows starting by pressing a single button.
(2) The other hand is free, so safeguards are required.
(1) The machine starts by pressing a pedal switch with your foot.
(2) This leaves both hands free for taking out the materials and feeding work, but if
the timing of pressing the pedal is not coordinated with these movements, there isa high risk of accident, so safeguards are required.

◎Clutch(1) This moves the slide intermittently by connecting the flywheel shaft with thecrankshaft.
(2) There are two types of clutch, a friction clutch and positive clutch.
(3) With a positive clutch, the clutch is not released until one stroke is finished, so theslide cannot stop suddenly. Therefore care is required.

◎Brake(1) Stops the movement of the slide.
(2) If the function of the brake deteriorates, the slide will no longer stop at the proper
position, and it may descend to bottom dead center, which is very dangerous.

◎Emergency stop
device◎One cycle・This is a device that stops the movement of the slide if the operator detects ahazard and operates the device.
・When the slide makes one cycle, stopping at the top dead center, even though theoperator releases the start button.
・T he mechanism where the slider stops at the top dead center until the next
operation is called “one cycle, one stop.”◎Safety one cycle

・“Safety one cycle” is when the slide stops immediately if the operator releases thestart button when the slide is descending in mid-cycle.

◎Danger limit

・The range of motion of a slide or edged tool.

◎Safety distance・The distance between a two-handed push button or optical axis and the danger
limit.

◎Industrial

・A case in which a worker is injured, contracts a disease or is killed due to causes

accident

attributable to buildings, facilities, raw materials, gases, vapors, particulate matter,etc. in or with which he is employed, or as a result of his work actions or attending
to his duties.

17Commissioned by the Ministry of Health, Labour and Welfare

Created March 2014