Name(Required)

First Last

Department(Required)

JSA by Job(Required)

CNC Machines(Required)

Doosan 4500S

Doosan Puma 2600SY

Doosan Puma DTN 2600

Multus B250II

CNC Shavings Removal

Nakamura

DMU 50

Job Safety Analysis (JSA) Doosan / DN Solutions DNM 4500S

Task: Setting up, operating, and maintaining a Doosan DNM 4500S VMC (Manual Enclosure Door Configuration).
Required PPE: Safety glasses with side shields, snug-fitting apparel (no loose sleeves). Strictly no gloves during setup or operation around the main spindle or moving worktable.

Pre-Operational Inspection & Workspace Setup

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Inspect workspace and manual door track	• Slips and falls from leaked fluids. • Finger pinching in heavy door handles. • Blunted sightlines leading to delayed emergency reaction.	• Verify the floor area is dry and clear of oil, coolant spray, or slick metal chips. • Slide the manual door fully back to ensure the track slides freely without catching. • Clean the viewing window. Never operate if the safety glass is cracked or heavily pitted. • Ensure all emergency stop (E-stop) buttons are unobstructed and responsive.
Check lubrication and TSC systems	• Machine seizure at high RPM. • Aerosolized coolant mist tracking.	• Confirm grease reservoirs (roller guideways) and spindle oil-jacket coolers are full. • Verify through-spindle coolant (TSC) filtration levels to avoid high-pressure nozzle blockages.

Machine Power-Up & Axis Initialization

Sequence of Basic Job Steps [1, 2]	Potential Hazards	Recommended Safe Job Procedures
Power on the Fanuc i-Series control panel	• Unexpected axis creep.	• Ensure the work envelope is free of loose hand tools before flipping the main breaker. • Keep your body outside the door threshold while booting up the machine.
Home and clear the X, Y, and Z axes	• Rapid physical crash between spindle nose and vices/fixtures.	• Close the manual door completely before zeroing or homing the axes. • Keep a hand floating over the Feed Hold button while the machine moves Z-axis up to its home location.

Tooling and Workholding Installation (Manual Access)

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Load CAT40 tool holders into the 30/40-station ATC	• Severe hand cuts from sharp carbide inserts. • Crush injury from automated tool-changer arm.	• Handle tool shanks carefully, using a protective cloth over cutting edges (remove before inserting). • Never reach into the tool changer matrix or arm pocket while the machine is in memory or tape mode.
Mount fixtures and secure workpieces manually	• Hand/finger crush between vise jaws or clamping blocks. • Back/shoulder strain from awkward center-table reaching.	• Push the manual door completely open until it hits its mechanical stop to prevent unintended sliding. • Clean the T-slots on the 1000x450mm table thoroughly before anchoring vices. • Use team lifting or manual hoists for workpieces or fixtures approaching 40+ lbs to prevent strains.

Work Coordinate Setup & Program Simulation

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Set Work Coordinates (WCS) and offset tools	• Catastrophic high-speed tool crash from data entry errors.	• Utilize a calibrated edge finder or Renishaw touch probe to establish part zero. • Cross-reference tool geometry offset numbers with the active G-code program lines.
Run G-code simulation check	• Program syntax errors causing rapid un-commanded movement.	• Run the program validation check via the Fanuc control screen graphic trace before initializing physical movement.

First-Article Validation & Live Production

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Secure manual door and execute dry run	• Severe impact/flying projectiles from immediate crash. • Bypassing interlocks.	• Slide the manual door completely shut. Safety switches must be naturally engaged—never cheat, defeat, or tape down door interlocks. • Mandatory Step: Run the program first with No Raw Material loaded, using Dry Run mode. • Turn down Rapid Traverse to 25% or lower and Feed Override to 0% for the first tool approach. Keep your finger physically pressed against the Feed Hold bar.
Execute live machining cycle & clear parts	• Shattered tools at 15,000 RPM throwing heavy fragments. • Lacerations from hot, sharp stringer chips. • Coolant mist inhalation.	• Monitor the cutting cycle through the safety window. Keep your hand on Feed Hold during the first active part cut. • Wait for the spindle to drop to 0 RPM and axes to stop before unlatching the door. • Open the manual door slowly (2-3 inches initially) to allow the mist collector to clear chemical aerosol before leaning in. • Never clear chips with bare hands. Always utilize brass chip hooks, specialized t-bars, or pliers.

Post-Operation & Housekeeping

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Clean enclosure and clear chip conveyor	• Deep puncture wounds from small, razor-sharp aluminum/steel needles. • Contact dermatitis from synthetic coolants.	• Engage the E-stop before full-body leaning into the VMC enclosure for sweeping or washing. • Wash down the table walls, flushing heavy chip packs directly into the internal chip conveyor. • Clean out the chip conveyor discharge bin regularly to avoid backups. • Wash hands and forearms immediately with soap and water after handling coolant-soaked parts.

Job Safety Analysis (JSA) Doosan Puma 2600SY II

Task: Setting up, operating, and maintaining a Doosan Puma 2600SYII (Manual Enclosure Door, Hand-Loading Billets & Hand-Unloading Parts).
Required PPE: Safety glasses with side shields, snug-fitting apparel (no loose sleeves or loose aprons). Strictly no gloves during setup, raw billet loading, or part unloading inside the machine.

Pre-Operational Inspection & Workspace Setup

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Inspect workspace and manual door assembly	• Slips and falls from leaked fluids. • Crushing/Pinching fingers in heavy door track. • Blunted vision leading to delayed reaction.	• Verify the floor is dry and clear of way lube oil, coolant overspray, or slick chips. • Slide the manual enclosure door open and closed completely to check for smooth track alignment. • Ensure the safety glass window has no cracks or heavy scratching that could obscure vision. • Confirm all emergency stop (E-stop) buttons are unblocked and fully functional.
Check lubrication and high-pressure systems	• Spindle seizure at high RPM. • High-pressure spray injuries.	• Confirm grease/hydraulic oil reservoirs and way lube levels are filled before power-up. • Verify the high-pressure coolant system filters are clear to prevent pressure blockages.

Machine Power-Up & Axis Initialization

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Power on the Fanuc i-Series control panel	• Unexpected axis creep or movement.	• Ensure the turning envelope is completely free of loose tools or manual gauges before powering on. • Keep your body completely outside the door threshold while the system boots.
Home and clear all axes (X, Y, Z, W, C1, C2)	• Rapid physical crash between live turret, sub-spindle, and main chuck.	• Close the manual door completely before initializing the zero-return or homing routines. • Keep one hand resting on the Feed Hold button or E-stop while the Z and W (sub-spindle) axes homing occurs.

Tooling and Workholding Installation (Manual Access)

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Load turning and live tools into the 12-station turret	• Severe hand cuts from sharp inserts/drills. • Indexing crush hazards during manual indexing.	• Handle live tool holders and turning blocks carefully, using a protective cloth over cutting edges (remove before inserting). • Use the jog panel to index the turret manually; keep hands completely clear of the turret rotational path while indexing.
Mount chuck jaws and prepare for manual loading	• Hand/finger crush between hydraulic chuck jaws. • Projectile hazard from incorrect jaw pressure.	• Push the manual door completely open until it hits its mechanical stop to prevent unintended sliding. • Clean the main and sub-spindle chuck faces thoroughly before tightening jaw mounting bolts. • Set initial hydraulic chuck clamping pressures matching the raw billet material specifications to prevent part distortion or ejection.

Work Coordinate Setup & Program Simulation

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Set Work Coordinates (WCS) and offset tools	• Catastrophic crash from data entry errors.	• Use the tool setter (Q-Setter) arm carefully to probe tools. Do not slam tool tips against the sensor. • Double-check active tool geometry offset numbers and tool direction. • Pay extreme attention to the sub-spindle part transfer (W-axis hand-off) coordinates.
Run G-code simulation check	• Program syntax errors causing rapid un-commanded movement.	• Run the program validation check via the Fanuc control screen graphic trace or Doosan’s visual guidance software prior to running a live cycle.

Production Operation, Hand-Loading & Hand-Unloading

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Manually load a raw billet into the main chuck	• Severe hand crushing from accidental foot pedal activation. • Lacerations from raw material burrs. • Entanglement from unexpected spindle rotation.	• Wait for all spindles and axes to come to a 100% complete stop before opening the manual door. • Ensure the foot pedal shroud/guard is intact so you cannot accidentally step on it while reaching into the machine. • Insert the billet firmly against the jaw steps. Keep fingers on the external face of the billet—never put fingers inside the chuck bore or behind the jaws. • Depress the foot pedal to clamp. Visually confirm the chuck clamping stroke indicator is in the safe zone before releasing your grip.
Secure manual door and execute machining cycle	• Severe impact/flying projectiles from immediate crash. • Bypassing interlocks.	• Slide the manual door completely shut. Safety switches must be naturally engaged—never cheat, defeat, or tape down door interlocks. • Turn down Rapid Traverse to 25% or lower and Feed Override to 0% for the first tool approach on a new batch of billets. Keep your finger physically pressed against the Feed Hold bar.
Manually unload the finished part from the sub-spindle	• Hand/finger crush between sub-spindle chuck jaws. • Puncture wounds or cuts from razor-sharp turning burrs. • Heavy dropped part hazard causing foot/hand injury.	• Wait for the machine to finish the cycle and the spindle to drop to 0 RPM before sliding the door open. • Pull the door open slowly to let the mist collector extract chemical aerosol. • Use a brass chip hook to clear stringy chips away from the part before touching it. • Support the weight of the finished part securely with one hand while depressing the sub-spindle foot pedal with your foot. Never allow the part to drop free into the chip pan.

Post-Operation & Housekeeping

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Clean enclosure and clear chip conveyor	• Deep puncture wounds from small, razor-sharp needles. • Contact dermatitis from synthetic coolants.	• Engage the E-stop before full-body leaning into the Puma 2600 enclosure for sweeping or washing. • Wash down both spindle faces and guiding way covers, flushing heavy chip packs directly into the internal chip conveyor. • Wash hands and forearms immediately with soap and water after handling coolant-soaked parts.

Job Safety Analysis (JSA) Multus B250II

Task: Setting up, operating, and maintaining a Multus B250II CNC Machine.
Required PPE: Safety glasses with side shields, snug-fitting apparel (no loose sleeves). Strictly no gloves during setup or operation around the main spindle or moving worktable.

Pre-Operational Inspection & Housekeeping

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Inspect workspace and machine exterior	• Slips, trips, falls from leaked fluids. • Electrical shock. • Entanglement.	• Verify the floor is dry and clear of oil, coolant, or metal chips. • Check that all safety doors, enclosures, and interlocks are intact and undamaged. • Ensure all emergency stop (E-stop) buttons are unblocked and fully functional.
Check fluid levels and air supply	• Machine malfunction. • Premature tool wear or friction fire.	• Verify coolant, hydraulic oil, and way lube levels before power-up. • Ensure main air regulator matches the manufacturer’s specification.

Machine Power-Up & Home Positioning

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Turn on main breaker and control panel	• Unexpected axis movement. • Kinetic impact.	• Clear the work envelope of any loose tools or items before powering on. • Keep hands away from the control panel buttons while the system boots up to avoid accidental cycle starts.
Home all axes (X, Y, Z, B, C, W)	• Collision between the B-axis spindle and sub-spindle or chuck.	• Visually verify that the work area is clear before initializing the zero-return sequence. • Keep one hand near the E-stop during homing cycles.

Tooling and Workholding Setup

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Load tools into the ATC (Automatic Tool Changer) magazine	• Lacerations from sharp inserts. • Crushing from ATC arm movement.	• Always handle tools using protective rags or heavy cloth (remove before operating machine). • Never reach into the ATC magazine while the system is enabled or in automatic mode.
Mount chuck jaws and load raw stock	• Crushing hands in hydraulic chucks. • Heavy lifting strain. • Projectile hazard from unsecured material.	• Use a crane or proper lifting technique for heavy raw material or sub-spindle attachments. • Ensure hydraulic chuck pressure is dialed in precisely for the material type to avoid deformation or part ejection. • Keep hands completely clear of the chuck clamping area when activating the foot pedal.

Program Loading and Dry Run Verification

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Upload G-code program and set offsets	• Data entry error leading to catastrophic machine crash.	• Double-check all tool geometry, wear offsets, and work coordinate systems (G54, etc.). • Verify the program graphic simulation on the Okuma OSP control panel before running the machine.
Execute Dry Run (Air Cut)	• High-speed crash from incorrect programming or offset errors.	• Mandatory Step: Run the program first with No Material loaded, Dry Run active, and Feed Hold / Rapid Traverse turned down to 0%–10%. • Keep your hand physically resting on the Feed Hold button or E-stop throughout the entire first-article dry run.

Production Operation

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Execute live machining cycle	• Flying chips or shattered tools. • Projectile part ejection. • High-volume noise.	• Ensure the enclosure door is completely closed. Never bypass door interlocks. • Monitor the first live cut with a hand on the Feed Hold button, watching through the safety glass. • Listen for abnormal chatter, screeching, or vibration indicating tool breakage.
Part inspection and chip clearing	• Severe lacerations from sharp stringer chips. • Entanglement in a rotating spindle.	• Wait for the spindle to come to a complete stop before opening the safety doors. • Never use your bare hands to clear chips. Always use a chip hook, pliers, or t-bar. • Do not use compressed air to blast chips off the part while it is still inside the machine; this creates airborne projectiles and forces fine dust into the machine slides.

Post-Operation Shutdown

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Power down machine and clean up	• Skin irritation from chemical coolant. • Accumulated slip hazards.	• Depress the E-stop, power down the OSP control panel, and turn off the main breaker. • Clean out the chip conveyor and wipe down the exterior of the machine. • Wash skin thoroughly if exposed to cutting fluids.

Job Safety Analysis (JSA) CNC Shavings Removal

Task: CNC Shavings Removal (Conveyor Shutdown, Hopper Transport, and Forklift Dumping).
Job Title: CNC Shavings Removal
Required PPE: Safety glasses, protective gloves (cut and chemical resistant), chemical-resistant apron, and a rake/pole tool for remote dumping.

Conveyor Shutdown and Hopper Preparation

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Shut down the chip conveyor	• Entanglement in moving conveyor parts. • Flying metal slivers.	• Ensure the conveyor system is completely powered down before working near the discharge chute.
Verify dump lock, clear drip pans, and position hopper	• Physical injury from moving heavy objects. • Slips and falls from slick surfaces. • Abrasions/cuts from metal shavings. • Chemical exposure to Sterling Cool 55 fluid.	• Mandatory: Utilize 2 people to manually push and roll the hopper to the forklift-accessible area. • Visually confirm the hopper’s manual dump lock is fully engaged before moving it. • Wear protective cut-resistant gloves and a chemical-resistant apron when handling the hopper or clearing the area. • Ensure the floor is cleaned, mopped, and completely dry immediately after removing the fluid drip pan from beneath the hopper.

Forklift Rigging and Transport

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Secure the hopper to the forklift	• Hopper slipping off forks. • Crushing/Pinch points between forklift rack and hopper.	• Only trained and authorized personnel are permitted to operate the forklift. • Drive forks fully into the hopper pockets. • Mandatory: Securely chain the hopper frame directly to the forklift carriage/rack before lifting or driving.
Transport hopper to the recycling yard	• Forklift tip-over. • Pedestrian striking hazards. • Lost load due to rough terrain.	• Keep the hopper low to the ground (4–6 inches) during transit. • Drive at safe speeds from the North Side of Mfg to the Southside shipping yard recycling dumpster, keeping a sharp lookout for foot traffic.

Dumping Operations

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Position and elevate the hopper	• Overhead powerline or structure contact. • Dumpster structural damage.	• Bring the forklift to a complete stop in front of the recycling dumpster. • Smoothly raise the hopper until it clearly clears the top edge of the recycling dumpster wall.
Actuate the dump arm and empty contents	• Severe pinch points and crushing from the swinging hopper. • Impact/cutting injuries from falling metal chunks. • Splash hazards from residual Sterling Cool 55.	• Never actuate the dump arm with your hands. • Stand completely clear and to the side of the forklift mast and recycling dumpster. • Mandatory: Use a long-handled rake, pole, or specialized tool to physically trip the hopper’s dump arm from a safe distance.

Resetting and Post-Operation

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Reset the hopper position	• Crush hazards from an unlatched hopper swinging back.	• Tilt the forklift mast backward smoothly to gravity-reset the hopper into its upright vertical orientation. • Visually confirm that the mechanical dump lock has automatically re-engaged and latched before moving the forklift.
Return hopper and conduct housekeeping	• Unsecured load movement. • Leftover chemical tracking.	• Lower the hopper back to transit height and drive it back to its designated production location. • Disconnect the safety chain, back out the forks, and return the rake/pole to its proper storage rack. • Wash gloves and apron if heavily soiled with cutting fluid to prevent secondary chemical exposure.

Job Safety Analysis (JSA) Nakamura-Tome MX-100

Task: Setting up, operating, and maintaining a Nakamura-Tome MX-100 (Manual Enclosure Door & Hand-Loaded Billets).
Required PPE: Safety glasses with side shields, snug-fitting apparel (no loose sleeves or hanging ties). Strictly no gloves during setup, part checking, or manual billet loading.

Pre-Operational Inspection & Workspace Setup

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Inspect workspace and manual door assembly	• Slips and falls from leaked fluids. • Crushing/Pinching fingers in door handles. • Penetration from broken glass.	• Verify the floor is dry and clear of oil, coolant spray, or metal chips. • Slide the manual enclosure door open and closed completely to check for smooth track alignment. • Ensure the safety glass window has no cracks or heavy scratching that could obscure vision. • Confirm all emergency stop (E-stop) buttons are unblocked and functional.
Check lubrication and high-pressure systems	• Machine seizure at high RPM. • Extreme pressure spray injuries.	• Confirm grease reservoirs, way lube levels, and spindle cooling units are filled. • Verify the high-pressure coolant system (often 1000 PSI on these machines) has clean filtration to avoid blockages.

Machine Power-Up & Axis Initialization

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Power on the Smart X / Fanuc control panel	• Unexpected axis creep.	• Ensure the tight work envelope is completely free of loose tools or manual gauges before powering on. • Keep your body completely outside the door threshold while the system boots.
Home and clear all axes (X1, Y1, Z1, B, X2, Z2, C1, C2)	• Rapid physical crash between upper B-axis, lower turret, and twin chucks.	• Close the manual door completely before initializing the zero-return or homing routines. • Keep your hand resting on the Feed Hold button or E-stop while the complex multi-axis homing occurs.

Tooling and Workholding Installation (Manual Access)

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Load CAPTO tools into the ATC magazine and lower turret	• Severe hand cuts from sharp milling tools/inserts. • Crush injury from automated tool-changer arm.	• Handle CAPTO tool shanks carefully, using a protective cloth over cutting edges (remove before inserting). • Never reach into the tool changer matrix, ATC arm zone, or lower turret area while the machine is in automatic mode.
Mount chuck jaws and prepare for billet loading	• Hand/finger crush between hydraulic chuck jaws. • Projectile hazard from incorrect jaw pressure.	• Push the manual door completely open until it hits its mechanical stop to prevent unintended sliding. • Clean the chuck faces and jaw serrations thoroughly before tightening mounting bolts. • Set initial hydraulic chuck clamping pressures matching the raw billet material specifications.

Work Coordinate Setup & Program Simulation

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Set Work Coordinates (WCS) and offset tools	• Catastrophic multi-axis crash from data entry errors.	• Use a calibrated touch probe or NT Nurse system to find part zero. Double-check all active tool length offsets. • Pay extreme attention to the synchronization parameters between the upper B-axis head and the lower turret.
Run G-code simulation check	• Program syntax errors causing rapid un-commanded movement.	• Mandatory: Run the program through Nakamura’s internal 3D collision check software (such as Luck-Bei or NT-Navigator) prior to running a live cycle.

Production Operation & Hand-Loading Billets

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Manually load a raw billet into the chuck	• Severe hand crushing from accidental foot pedal activation. • Lacerations from raw material burrs. • Entanglement from unexpected spindle rotation.	• Wait for all spindles and axes to come to a 100% complete stop before opening the manual door. • Ensure the foot pedal shroud/guard is intact so you cannot accidentally step on it while reaching into the machine. • Insert the billet firmly against the jaw steps. Keep fingers on the external face of the billet—never put fingers inside the chuck bore. • Depress the foot pedal to clamp. Visually confirm the chunk clamping stroke indicator is in the safe zone before releasing your grip.
Secure manual door and execute machining cycle	• Severe impact/flying projectiles from immediate crash. • Bypassing interlocks.	• Slide the manual door completely shut. Safety switches must be naturally engaged—never cheat, defeat, or tape down door interlocks. • Turn down Rapid Traverse to 25% or lower and Feed Override to 0% for the first tool approach on a new batch of billets. Keep your finger physically pressed against the Feed Hold bar.
Monitor live machining & remove finished part	• Shattered tools at high RPM throwing heavy fragments. • Lacerations from hot, sharp stringer chips. • Coolant mist inhalation.	• Monitor the cutting cycle through the safety window. Keep your hand on Feed Hold during the first active part cut. • Open the manual door slowly to allow the mist collector to clear chemical aerosol before leaning in to grab the finished part. • Use a brass chip hook to clear stringy chips away from the part before reaching in with your bare hand to unclamp.

Post-Operation & Housekeeping

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Clean enclosure and clear chip conveyor	• Deep puncture wounds from small, razor-sharp needles. • Contact dermatitis from synthetic coolants.	• Engage the E-stop before full-body leaning into the compact MX-100 enclosure for sweeping or washing. • Wash down both spindle faces and guiding way covers, flushing heavy chip packs directly into the internal chip conveyor. • Wash hands and forearms immediately with soap and water after handling coolant-soaked parts.

Job Safety Analysis (JSA) DMU-50

Task: Setting up, operating, and maintaining a DMU-50 5-Axis CNC Machine (Manual Enclosure Door Configuration).
Required PPE: Safety glasses with side shields, snug-fitting apparel (no loose sleeves or dangling jewelry). Strictly no gloves during setup or operation around rotating spindles or workholding.

Pre-Operational Inspection & Workspace Setup

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Inspect workspace and manual door assembly	• Slips and falls from pooled fluids. • Crushing/Pinching fingers in door track. • Penetration from broken glass.	• Verify the floor is clean and dry. Keep the area free of oil, coolant, or slippery chips. • Slide the manual door open and closed completely to check for smooth track alignment and handle stability. • Ensure the safety glass window has no cracks or heavy scratching that could obscure vision. • Confirm all Emergency Stop (E-stop) buttons are unblocked and functional.
Verify fluid levels and hydraulics	• System malfunction. • Thermal damage or tool failure.	• Check coolant, way lube, and pneumatic pressure gauges before starting. • Ensure the mist collector/extraction system is turned on and operating efficiently.

Machine Power-Up & Axis Initialization

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Power on control panel and home axes	• Unexpected axis creep or movement. • Fatal collision between the swivel-rotary table (B/C axes) and the main spindle head.	• Ensure the work area inside the cabin is completely clear of tools or manual gauges before powering up. • Keep the manual door fully closed during the home-positioning routine. • Use extra caution when manual jogging; remember that 5-axis tables tilt and rotate unpredictably compared to 3-axis machines. • Keep your hand on the feed hold dial during all manual jogging.

Tooling and Workholding Installation (Manual Access)

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Load tools into the chain/matrix magazine	• Severe hand cuts from sharp cutters. • Entrapment from automated tool changer (ATC) arm.	• Use protective cloths or plastic tool holders when inserting taper shanks into the tool magazine. • Never reach into the tool storage area while the machine is active or in automatic mode.
Mount fixtures and secure workpieces manually	• Crushing/pinching fingers in vises or heavy door frames. • Shoulder/back strain from awkward reaching into the enclosure.	• Slide the manual door completely open until it locks or stops securely to prevent it from sliding back onto your hands/arms. • Clean the swivel-rotary table surface thoroughly before mounting high-rise vises or zero-point clamping systems. • Use proper lifting posture or manual cranes for heavy fixtures, maintaining a stable footing outside the machine threshold. • Maintain explicit finger clearance when activating pneumatic or hydraulic clamping fixtures.

Work Coordinate Setup & Program Simulation

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Set Work Coordinate Systems (WCS) & Tool Lengths	• Catastrophic crash from incorrect 5-axis center of rotation (dynamic fixtures).	• Use a calibrated touch probe to find part zero. Double-check all active tool length offsets. • Pay extreme attention to the pivot point distance (B/C axis rotation center parameters). An error here will cause a massive collision.
Run G-code program simulation	• Undetected structural collisions.	• Mandatory: Run the program through the control panel’s internal 3D collision check software prior to running a live cycle.

First-Article Validation & Live Production

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Secure enclosure and execute dry run	• Rapid tool/spindle crash into the table or tilting trunnion. • Overriding door safety switches.	• Close the manual door completely before initiating cycle start. Never attempt to defeat, tape down, or bypass the mechanical or electronic door interlocks. • Run the program first with No Material loaded, using Dry Run mode with the Feed / Rapid overrides turned down to 0%–10%. • Keep your hand physically on the Feed Hold or E-stop button while watching the spindle approach the work zone through the viewing window.
Monitor live machining & remove parts manually	• Lacerations from sharp stringer chips. • Projectiles from broken tools. • Entanglement in a coasting spindle.	• Monitor through the safety glass for abnormal vibrations or thermal smoke. • Wait for the spindle and the rotary table to reach a complete, verified stop before sliding the door open. • Pull the manual door open slowly to allow residual coolant mist and smoke to be sucked out by the filtration unit before leaning in. • Never use bare hands to pull chips out. Always use heavy chip hooks or brass pliers.

Post-Operation & Housekeeping

Sequence of Basic Job Steps	Potential Hazards	Recommended Safe Job Procedures
Clean out the machine enclosure	• Puncture wounds from small chips. • Coolant skin rash.	• Turn off the main power and depress the E-stop button before full-body leaning into the machine for cleanup. • Clean out the integrated chip conveyor and rinse down the interior walls, guiding chips away from the door track so it continues to seal smoothly. • Use skin barrier creams or wash hands immediately to prevent dermatitis from contact with synthetic coolants.

Job Safety Analysis (JSA) Test Shooting Large-Caliber Air Rifles in an Indoor Shooting Range (HIGH PSI Air Charging System)

Required PPE

Safety glasses with side shields (ANSI Z87.1)
Hearing protection (ear plugs and/or earmuffs)
Closed-toe safety shoes
Gloves when connecting/disconnecting high-pressure air systems
Appropriate work clothing

Hazard Assessment

Job Step	Potential Hazards	Potential Consequences	Controls / Safe Work Practices
1. Prepare test area	Unauthorized personnel in range, trip hazards, poor housekeeping	Struck by projectile, slips/trips/falls	Restrict access to authorized personnel only. Inspect range before testing. Maintain clean work area. Verify backstop integrity.
2. Inspect air rifle	Damaged barrel, loose components, defective pressure vessel, worn seals	Equipment failure, projectile release, injury	Perform pre-use inspection. Remove damaged equipment from service. Follow work instructions.
3. Inspect 4500 PSI charging equipment	Damaged hoses, fittings, gauges, cylinders	Hose rupture, injection injury, high-pressure release	Inspect hoses and fittings before use. Verify pressure ratings exceed operating pressure. Remove defective components from service.
4. Secure air rifle for charging	Rifle movement during charging	Impact injury, equipment damage	Place rifle on stable bench or fixture. Maintain muzzle in safe direction.
5. Connect charging system	Pinched fingers, improper connection, sudden pressure release	Hand injury, lacerations, struck-by hazards	Verify system is depressurized before connecting. Use approved fittings. Keep hands clear of potential whip zones.
6. Charge rifle to specified pressure	High-pressure air release, hose failure, over-pressurization	Serious injury, hearing damage, equipment damage	Fill slowly. Never exceed manufacturer pressure limits. Monitor gauges continuously. Stand to side of fittings during pressurization.
7. Disconnect charging equipment	Residual pressure release	Eye injury, hose whip, noise exposure	Bleed pressure through approved bleed valve before disconnecting. Wear eye protection.
8. Load ammunition/projectile	Improper loading, accidental discharge	Injury to personnel, property damage	Keep muzzle pointed downrange. Follow loading procedures. Keep finger off trigger until ready to fire.
9. Move to firing position	Loss of muzzle control	Accidental discharge or unsafe direction	Maintain muzzle awareness at all times. Ensure range is clear.
10. Test fire rifle	Projectile impact, ricochet, noise, equipment malfunction	Serious injury, hearing damage, property damage	Confirm all personnel are behind firing line. Use proper backstop rated for projectile energy. Wear hearing and eye protection.
11. Observe results and conduct multiple shots	Repetitive exposure to noise and projectiles	Hearing damage, fatigue-related errors	Maintain PPE. Follow established firing sequence. Take breaks as needed.
12. Address malfunction or misfire	Delayed discharge, unexpected release of stored energy	Injury from accidental firing	Keep muzzle pointed downrange. Wait minimum 30 seconds before handling. Follow work instructions.
13. Depressurize rifle (if required)	High-pressure air release	Eye injury, hearing damage	Use manufacturer-approved depressurization method. Keep personnel clear.
14. Store equipment and cylinders	Cylinder damage, unauthorized use	Equipment failure, injury	Secure cylinders upright. Install valve protection caps. Store rifles unloaded and depressurized as required.

Additional High-Pressure Air Safety Requirements (4500 PSI)

Only trained personnel may charge or service high-pressure air systems.
Never exceed the rifles maximum fill pressure.
Use only hoses, fittings, gauges, and tanks rated for at least 4500 PSI service.
Never place body parts in front of pressurized fittings, hoses, or gauges.
Do not use damaged, kinked, cut, or leaking hoses.
Fill rifles slowly to minimize heat generation and stress on components.
Immediately stop charging if abnormal noises, leaks, or gauge fluctuations occur.
Follow lockout/tagout procedures when maintenance is performed on charging systems.

Required PPE

Safety glasses with side shields (required at all times)
Face shield (when necessary)
Hearing protection (where noise levels require)
Cut-resistant gloves for material handling only (not while operating rotating equipment)
Appropriate work clothing (no loose clothing, jewelry, or unsecured long hair)

Job Steps, Hazards, and Controls

Job Step	Potential Hazards	Recommended Controls
Enter work area and prepare workstation	Slips, trips, falls; poor housekeeping	Inspect work area; remove debris, oil, and obstacles; maintain clear walkways
Review work order and tooling requirements	Incorrect setup leading to injury or damaged equipment	Verify job instructions, tooling, materials, and machine capabilities before starting
Gather and transport materials	Strains, sprains, crushed fingers, dropped materials	Use proper lifting techniques; use carts, hoists, or lifting devices for heavy materials; wear safety shoes
Inspect machine before use	Mechanical failure, missing guards, electrical hazards	Conduct pre-use inspection; verify guards are in place; report defects immediately
Install tooling and workpiece	Pinch points, cuts, dropped tooling	Lock out equipment if required; use proper tools; keep hands clear of pinch points
Set machine parameters	Incorrect speeds or feeds causing tool failure	Verify settings before startup; follow manufacturer recommendations
Operate lathe, mill, drill press, or other machine tools	Entanglement, flying chips, cuts, amputations	Never wear gloves around rotating equipment; keep guards in place; maintain safe distance from moving parts
Remove chips and swarf	Cuts, punctures, eye injuries	Use chip hooks, brushes, or pliers; never use hands or compressed air directed at personnel
Measure and inspect parts	Sharp edges, pinch points	Deburr parts before handling when possible; use care when handling sharp materials
Grinding operations	Flying particles, sparks, eye injuries	Use wheel guards; inspect grinding wheels before use; wear eye protection
Use compressed air for cleaning	Flying debris, eye injuries, noise	Limit pressure according to OSHA Standards; use approved air nozzles; wear eye protection
Handle coolants and lubricants	Skin irritation, slips, chemical exposure	Review Safety Data Sheets (SDS); wear appropriate gloves when handling chemicals; clean spills immediately
Perform maintenance or adjustments	Unexpected startup, electrical hazards	Follow Lockout/Tagout (LOTO) procedures before servicing equipment
Housekeeping and end-of-shift cleanup	Slips, trips, cuts	Clean machines and floors; dispose of scrap properly; store tools correctly

General Safety Requirements

Only trained and authorized personnel may operate machinery.
Machine guards shall not be removed or bypassed.
Never reach into moving machinery.
Stop machines before measuring, adjusting, or removing material whenever possible.
Follow Lockout/Tagout procedures during maintenance and repair.
Know the location of emergency stops, fire extinguishers, first aid kits, and eyewash stations.
Report all incidents, injuries, near misses, and unsafe conditions immediately.
Maintain good housekeeping throughout the shift.

JSA Trotec Laser Engraving Machine Operation

Required PPE

Safety glasses with side shields (ANSI Z87.1)
Closed-toe safety shoes
Appropriate work clothing (no loose clothing)
Heat-resistant gloves when handling recently engraved materials (as needed)

Hazard Assessment

Job Step	Potential Hazards	Potential Consequences	Controls / Safe Work Practices
1. Prepare work area	Clutter, trip hazards, unauthorized personnel	Slips, trips, falls, injury	Maintain good housekeeping. Keep walkways clear. Restrict access to authorized personnel.
2. Review work order and material specifications	Incorrect material selection	Fire, toxic fumes, equipment damage	Verify approved materials before use. Follow manufacturer and company-approved material list.
3. Inspect laser machine	Damaged components, faulty interlocks, dirty optics	Equipment malfunction, exposure to laser energy	Conduct pre-operation inspection. Verify guards and interlocks are functional. Report defects immediately.
4. Verify exhaust/filtration system operation	Inadequate ventilation	Exposure to smoke, fumes, particulates	Ensure exhaust system is operating before engraving or cutting. Verify airflow indicators are functioning.
5. Load material into machine	Pinch points, sharp edges, improper placement	Hand injuries, material movement	Use proper lifting techniques. Secure material flat on work surface. Keep hands clear of moving components.
6. Set up engraving program	Incorrect settings, excessive power/speed settings	Fire, damaged product, machine damage	Verify job parameters before starting. Conduct test runs when required.
7. Close enclosure and start operation	Exposure to laser radiation if interlocks defeated	Eye injury, skin burns	Never bypass safety interlocks. Operate only with enclosure closed. Follow manufacturer operating procedures.
8. Monitor engraving/cutting process	Fire, smoke generation, material ignition	Burns, property damage, equipment damage	Remain in the area while machine is operating. Never leave laser unattended during operation.
9. Pause or stop machine if abnormal conditions occur	Fire, mechanical failure, excessive smoke	Injury, equipment damage	Use emergency stop if necessary. Investigate and correct issues before restarting.
10. Remove completed workpiece	Hot surfaces, sharp edges	Burns, cuts	Allow material to cool if necessary. Use gloves when handling hot materials.
11. Clean machine work area	Residual dust, debris, sharp scrap material	Respiratory irritation, cuts	Follow housekeeping procedures. Dispose of scrap properly.
12. Perform routine maintenance	Electrical hazards, moving components, laser exposure	Shock, burns, injury	Follow lockout/tagout procedures where applicable. Only trained personnel may perform maintenance.
13. Shutdown equipment	Improper shutdown	Equipment damage, fire risk	Follow manufacturer shutdown procedure. Verify laser and exhaust systems are properly shut down.

Specific Hazards and Controls

Laser Radiation

Never bypass safety interlocks or operate with access doors open.
Only trained and authorized employees may operate the laser system.
Follow all manufacturer safety requirements.
Report damaged safety devices immediately.

Fire Prevention

Keep approved fire extinguisher readily accessible.
Never process materials prohibited by Trotec or company procedures.
Continuously monitor operations for smoke, flame, or unusual odors.
Stop operation immediately if ignition occurs.

Ventilation and Fume Control

Verify exhaust system is operating before each use.
Ensure filters are maintained according to manufacturer recommendations.
Follow Safety Data Sheet (SDS) requirements for processed materials.

Electrical Safety

Do not open electrical panels unless qualified and authorized.
Disconnect power before maintenance activities.
Inspect cords and connections regularly.

Material Safety

Do Not Process Materials That May Produce Hazardous Fumes, Including:

PVC (Polyvinyl Chloride)
Vinyl materials
Unknown plastics
Materials not approved by the manufacturer

Emergency Procedures

Fire

Press Emergency Stop.
Shut down laser system if safe to do so.
Use appropriate fire extinguisher if trained and safe.
Activate emergency response procedures.

Injury

Stop machine operation.
Notify supervisor immediately.
Administer first aid as trained.
Seek medical attention if required.

Equipment Malfunction

Stop operation immediately.
Lock out equipment if necessary.
Report issue to maintenance or supervisor.
Do not restart until approved.

Training Requirements

Operators shall be trained on:

Trotec laser operation
Emergency stop procedures
Fire prevention and response
Approved material usage
Ventilation and exhaust requirements
Applicable PPE requirements
Facility emergency procedures

Job Safety Analysis (JSA)

Task: Deep Cleaning of Indoor Shooting Range
Location: Umarex Walther Fort Smith
Department: Facilities
Date: 4/15/26
Prepared By: Ezra Pitchford

Regulatory Basis

This task is governed by:

Occupational Safety and Health Administration (OSHA)
29 CFR 1910.134
29 CFR 1910.1025

Note:
Airborne lead levels in this facility are typically below the Permissible Exposure Limit (PEL) during normal operations. However, deep cleaning activities can create temporary airborne lead spikes, therefore respirator use is required during this task.

Scope of Work

Deep cleaning includes:

Floors, walls, and shooting stalls
Bullet traps/backstops
Ventilation system surfaces (accessible areas only)
Collection and disposal of lead-contaminated dust and debris

Required Training (OSHA-Aligned)

Employees performing this task must have:

Hazard Communication (29 CFR 1910.1200)
Respiratory Protection (per 1910.134)
Lead Awareness Training (per 1910.1025)
PPE Training (29 CFR 1910.132)
Task-specific JSA review

Required PPE (MANDATORY DURING TASK)

Because of potential airborne lead spikes:

NIOSH-approved respirator (minimum half-mask with P100 filters)
Disposable protective coveralls (Tyvek or equivalent)
Nitrile or chemical-resistant gloves
Eye protection
Protective footwear or boot covers

Respiratory Program Note:
Respirator use for this task is required, even though general facility use may be voluntary.

Tools & Equipment

HEPA-filtered vacuum
Wet cleaning materials (mops, wipes, lead-specific cleaners)
Plastic containment sheeting (if needed)
Labeled waste containers (hazardous if applicable)
Ladders/lifts (if required)

Job Steps, Hazards, and Controls

Step 1: Pre-Task Setup

Hazards:

Airborne lead exposure
Unauthorized personnel exposure

Controls:

Restrict access; post “Lead Work Area” signage
Conduct pre-task safety briefing
Verify respirator medical clearance and fit testing per 1910.134
Ensure ventilation system is functioning properly

Step 2: Don PPE

Hazards:

Improper respirator fit
Skin exposure

Controls:

Perform user seal check (required by OSHA)
Inspect PPE for defects
Ensure full coverage before entering range

Step 3: Initial Cleaning (HEPA Vacuum Only)

Hazards:

Lead dust inhalation
Dust dispersion

Controls:

No dry sweeping or compressed air (prohibited by OSHA)
Use HEPA vacuum only
Work slowly to minimize airborne dust

Step 4: Wet Cleaning

Hazards:

Lead residue contact
Slips and falls

Controls:

Use wet methods (required by OSHA lead standard)
Apply lead-specific cleaning agents
Maintain wet surfaces to suppress dust
Use slip-resistant footwear

Step 5: Bullet Trap / Backstop Cleaning

Hazards:

High lead concentration
Sharp metal fragments
Heavy materials

Controls:

Limit to trained personnel only
Use tools designed for trap system
Consider upgraded PPE (e.g., full-face respirator)
Avoid generating dust clouds

Step 6: Ventilation Surface Cleaning

Hazards:

Concentrated contaminants
Fall hazards

Controls:

Follow lockout/tagout if required
Use ladders/lifts safely
Clean with HEPA vacuum + wet wipe only

Step 7: Waste Handling

Hazards:

Exposure to hazardous waste
Environmental contamination

Controls:

Use sealed, labeled containers
Follow EPA/OSHA disposal requirements
Do not overfill or compress waste bags

Step 8: Doff PPE & Decontamination

Hazards:

Cross-contamination
Secondary inhalation

Controls:

Remove PPE in designated area
Follow proper doffing sequence
Wash hands and face immediately
Shower if required by company policy

Exposure Monitoring & Medical Considerations

Air monitoring may be conducted during deep cleaning
Employees may be included in lead medical surveillance if applicable
Any symptoms of lead exposure must be reported immediately

Emergency Procedures

Overexposure or Symptoms: Remove from area, report, seek medical evaluation
Spill/Release: Isolate area; clean using HEPA/wet methods only
Injury: Follow site emergency response plan

Supervisor Responsibilities

Enforce respirator use during this task
Verify training, medical clearance, and fit testing
Monitor work practices for OSHA compliance
Stop work if unsafe conditions exist

JOB SAFETY ANALYSIS (JSA)

Task: Laser Cutting Small Parts from 2’ x 4’ x 1/8” Steel Plate
Equipment: Boss Laser System
Department: Walther Manufacturing
4/9/26

Hazard Analysis & Controls

Step	Hazards	Controls / Safe Work Practices
1. Pre-Operation Setup	Incorrect settings, fire risk, fume exposure	Verify program/settings; inspect machine (lens, nozzle); ensure ventilation ON; trained operators only
2. Material Handling	Strains, pinch points, cuts from sharp edges	Use proper lifting or assistance; wear cut-resistant gloves; keep hands clear; handle edges carefully
3. Machine Setup	Unexpected movement, crashes, laser exposure	Verify origin/path; do dry run; never bypass interlocks; keep doors closed
4. Cutting Operation	Fire, fumes, laser exposure, flying debris	Monitor machine at all times; keep enclosure closed; ensure ventilation; keep flammables away; fire extinguisher nearby
5. Part Removal	Burns from hot metal, sharp edges	Allow cooling or use tools; wear heat & cut-resistant gloves; handle carefully
6. Cleanup / Shutdown	Cuts, fire risk, slips/trips	Remove scrap safely; clean area; dispose properly; follow shutdown procedure

Required PPE

Safety glasses (ANSI Z87.1)
Cut-resistant gloves
Heat-resistant gloves (as needed)
Closed Toe Shoes
Hearing protection (if required)
Respiratory protection (if ventilation inadequate)

Emergency Procedures

Fire: Stop machine, use extinguisher, notify supervisor
Injury: Provide first aid and report immediately
Fume Exposure: Move to fresh air and seek assistance

Training Requirements

Laser operation training
Hazard communication (metal fumes)
Fire extinguisher use
PPE training

Job Safety Analysis (JSA) – Test Shooting Firearms Manufacturing

Department: Manufacturing Location: Testing Room Bays 1-3 Job Task	Hazards	Recommended Controls	Required PPE
Pre-Operation Inspection and Setup	Unauthorized access, damaged firearm, incorrect ammunition, ventilation failure, obstructed bullet trap.	Restrict access, inspect firearm and ammunition, verify ventilation operation, inspect bullet trap, verify emergency equipment availability.	Safety glasses, hearing protection
Entering Test Shooting Room	Lead exposure, slips/trips/falls, noise exposure.	Wear PPE before entry, maintain housekeeping, ensure floor is dry and clear, post hearing protection requirements.	Safety glasses, hearing protection, lead-control garments
Loading and Chambering Firearm	Accidental discharge, improper muzzle direction, pinch points.	Keep muzzle downrange, finger off trigger, follow loading procedures, load only at designated firing position.	Safety glasses, hearing protection
Test Firing Proof Rounds	Noise, ricochet, firearm failure, overpressure events, lead exposure.	Use firing fixture, dual hearing protection, follow misfire/hang-fire procedures, maintain ventilation, stop testing if abnormal conditions occur.	Safety glasses, dual hearing protection
Test Firing Standard Rounds	Noise, ricochet, malfunction, combustion byproducts.	Fire only toward approved bullet trap, maintain ventilation, follow range SOPs, monitor firearm condition.	Safety glasses, dual hearing protection
Clearing and Unloading Firearm	Negligent discharge, burns from hot surfaces/casings.	Engage safety, remove magazine, lock action open, inspect chamber, allow cooling, insert chamber flag.	Safety glasses, gloves as needed
Bullet Trap Interaction	Lead exposure, cuts, sharp edges, hot fragments.	Wear gloves, use HEPA vacuum or wet cleaning methods, No dry sweeping, inspect trap before maintenance.	Gloves, safety glasses, lead-control PPE
Cleaning and Maintenance Activities	Lead dust, chemical exposure, ergonomic strain.	Review SDSs, use approved chemicals, wear respiratory protection if required, wash hands with D-Lead soap, use proper lifting techniques.	Gloves, safety glasses, respirator if required
Exiting Test Shooting Room	Tracking lead contamination outside range.	Remove disposable PPE, clean footwear, wash hands and face, follow decontamination procedures.	Lead-control PPE as required

Additional Controls

– Cease firing immediately upon ventilation failure.
– Report firearm malfunctions to supervision.
– Maintain current training and authorization for test-fire personnel.
– Keep first-aid and emergency communications available.
– No food, drink, or tobacco products in the range area.

Análisis de Seguridad en el Trabajo (JSA) – Recuperación, Envíos y Recepción

Departamento: Envíos y Recepción
Título del puesto: Recuperación

Tarea del trabajo | Peligros | Controles recomendados | EPP requerido

Empaque / Reempaque

Peligros: Posturas incómodas, movimientos repetitivos, sobreesfuerzo, cortes por plástico afilado, cartón o herramientas
Controles: Usar estaciones de trabajo de altura ajustable, mantener materiales dentro de la zona de poder, rotar tareas, aplicar técnicas correctas de levantamiento, inspeccionar herramientas de empaque antes de usarlas
EPP: Lentes de seguridad, guantes de trabajo

Apilado de producto en tarimas (skids)

Peligros: Caída de productos, cargas inestables, distensiones por levantamiento, resbalones/tropiezos al manipular materiales
Controles: Construir cargas estables, colocar los artículos más pesados en la parte inferior, inspeccionar tarimas antes de usarlas, usar levantamiento en equipo para cargas pesadas, mantener pasillos despejados
EPP: Lentes de seguridad, guantes de trabajo

Embalaje / Desembalaje / Construcción de cajas

Peligros: Cortes por cuchillas y cartón, puntos de atrapamiento, lesiones por movimientos repetitivos
Controles: Usar cuchillos de seguridad, cortar alejándose del cuerpo, mantener altura adecuada del área de trabajo, rotar tareas, desechar residuos de inmediato
EPP: Lentes de seguridad, guantes de trabajo

Movimiento de tarimas con patín hidráulico (manual o motorizado)

Peligros: Golpes (atropellos), puntos de atrapamiento, sobrecarga, colisiones, vuelco de carga
Controles: Completar capacitación en uso de patín hidráulico, inspeccionar equipo antes de usarlo, mantener rutas despejadas, no exceder límites de carga, transportar cargas estables y bajas
EPP: Guantes

Operaciones de engrapado, sellado con cinta y cerrado

Peligros: Lesiones por movimientos repetitivos, quemaduras por equipo de sellado, pinchazos
Controles: Asegurar que las protecciones e interbloqueos funcionen correctamente, rotar tareas, usar posicionamiento adecuado de las manos, inspeccionar equipo antes de usarlo
EPP: Guantes

Actividades de ensamble / desensamble

Peligros: Bordes afilados, abrasiones, partículas proyectadas, lesiones en manos por herramientas, esfuerzo ergonómico
Controles: Asegurar las piezas antes de trabajar, usar herramientas adecuadas, usar protección ocular al esmerilar o usar herramientas rotativas, mantener buena limpieza del área
EPP: Guantes

Reparación de armas neumáticas (aire comprimido)

Peligros: Exposición a aire comprimido, residuos de plomo, aceites, solventes, pintura, bordes afilados, puntos de atrapamiento
Controles: Seguir procedimientos escritos de reparación, usar guantes resistentes a químicos al manejar solventes, mantener ventilación adecuada, lavarse las manos después del manejo, inspeccionar sistemas de aire antes de usar
EPP: Guantes resistentes a químicos, guantes de trabajo según sea necesario

Controles adicionales

Manejo de materiales

Mantener las cargas cerca del cuerpo al levantar.
Usar ayudas mecánicas siempre que sea posible.
Levantar en equipo artículos que excedan la capacidad individual.
Evitar girar el cuerpo mientras se carga peso.

Orden y limpieza (Housekeeping)

Retirar residuos de empaque inmediatamente.
Mantener pasillos, salidas y áreas de almacenamiento de tarimas despejadas.
Limpiar derrames de inmediato.

Seguridad de equipos

Inspeccionar patines hidráulicos antes de cada turno.
Retirar tarimas dañadas del servicio.
Verificar que los interbloqueos del equipo de sellado funcionen correctamente.
Desconectar el suministro de aire antes de dar mantenimiento a equipos neumáticos.

Controles de exposición a químicos y plomo

Revisar las Hojas de Datos de Seguridad (SDS) antes de usar químicos.
Lavarse las manos antes de comer, beber o fumar.
Almacenar químicos según las instrucciones del fabricante.
Usar materiales de limpieza designados para superficies contaminadas con plomo.

Requisitos de EPP

Guantes de trabajo
Guantes resistentes a químicos (cuando se manipulen químicos)
Tapetes antifatiga para operaciones prolongadas de pie

Job Safety Analysis (JSA) – Recovery Shipping & Receiving

Department: Shipping & Receiving
Job Title: Recovery

Job Task	Hazards	Recommended Controls	Required PPE
Packaging / Repackaging	Awkward postures, repetitive motion, overexertion, cuts from sharp plastic, cardboard, or tools	Use adjustable-height workstations, keep materials within the power zone, rotate tasks, maintain proper lifting techniques, inspect packaging tools before use	Safety glasses, work gloves
Stacking Product on Skids	Falling products, unstable loads, strains from lifting, slips/trips while handling materials	Build stable loads, place heavier items on bottom, inspect pallets before use, use team lifting for heavy loads, maintain clear aisles	Safety glasses, work gloves
Boxing / Unboxing / Box Building	Cuts from knives and cardboard, pinch points, repetitive motion injuries	Use safety knives, cut away from body, maintain proper workstation height, rotate tasks, dispose of scrap material promptly	Safety glasses, work gloves
Moving Skids with Powered / Unpowered Pallet Jack	Struck-by hazards, pinch points, overloading, collisions, tipping loads	Complete pallet jack training, inspect equipment before use, maintain clear travel paths, do not exceed load limits, keep loads stable and low during transport	gloves
Stapling, Taping, and Sealing Operations	Repetitive motion injuries, burns from sealing equipment, puncture injuries	Ensure machine guards and interlocks function properly, rotate jobs, use proper hand positioning, inspect equipment before use	gloves
Assembly / Disassembly Activities	Sharp edges, abrasions, flying debris, hand injuries from tools, ergonomic strain	Secure workpieces before work, use proper hand tools, wear eye protection when grinding or using rotary tools, maintain good housekeeping	gloves
Repair of Air-Powered Guns	Exposure to compressed air, lead residue, oils, solvents, paint, sharp edges, pinch points	Follow written repair procedures, use chemical-resistant gloves when handling solvents, maintain ventilation, wash hands after handling products, inspect air systems before use	chemical-resistant gloves, work gloves as required

Additional Controls

Material Handling

Keep loads close to the body when lifting.
Use mechanical aids whenever possible.
Team lift items that exceed individual lifting capability.
Avoid twisting while carrying loads.

Housekeeping

Remove packaging debris immediately.
Keep walkways, exits, and pallet storage areas clear.
Clean spills promptly.

Equipment Safety

Inspect pallet jacks before each shift.
Remove damaged pallets from service.
Verify sealing equipment interlocks function properly.
Disconnect air supply before servicing pneumatic equipment.

Chemical and Lead Exposure Controls

Review SDSs before using chemicals.
Wash hands before eating, drinking, or smoking.
Store chemicals according to manufacturer requirements.
Use designated cleaning materials for lead-contaminated surfaces.

PPE Requirements

Work Gloves
Chemical-Resistant Gloves (when handling chemicals)
Fatigue Mats for prolonged standing operations

Job Safety Analysis

Job Title: Side Arm Pack Out

Step	Hazard	Recommended Controls
1. Receive sidearms…	Discharge risk	Follow protocol when receiving sidearms…
2. Pick accessories…	Picking parts above shoulder… repetitive motion injury	Alternate tasks to reduce repetition.
3. Put sidearm…	Lifting/twisting/bending	Keep work height mid-torso, alternate tasks…
4. Disassemble sidearm…	Forceful exertion… removing slides and pulling bore snake	Train on using both arms…
5. Reassemble…	Pinch points on slide	Train on technique… Consider gloves…
6. Pick magazines…	Forceful exertion… cycling sidearm	Train on using both arms…
7. Put sidearm… into box	Lifting/twisting/bending when stacking boxes approx. 40 lbs.	Train on proper lifting techniques…
8. Stack box on pallet	Prolonged standing	Utilize fatigue mats

PPE Requirements

Safety Glasses • Gloves • Other

Other PPE: Fatigue Mats

Notes: Make gloves available where applicable. Palm gloves may reduce impact on hands from cycling slides.

Job Safety Analysis

Job Title: Pack out Large Caliber Air Rifles

Step	Hazard	Recommended Controls
1. Prepare accessories for packaging by removing rust on bolt using brushes and then wash and oil	Compressed air cylinder sudden release, discharge risk	Ensure air cylinder is degassed by checking air gauge
2. Put rifle on vise and visually inspect for scratches marring etc.	Flying debris from brushing metal parts	Wear eye protection from flying debris
3. Apply stain / paint to scratches and marred areas using cotton swab	Paint, stain, solvent inhalation; Birchwood – Aluminum Black, Perma Blue	VOC/odor exposure, skin/eye irritation, flammability of coatings
4. Clean barrel using a bore snake threaded through the barrel and pulling through	hand/wrist strain from pulling bore snake	Pull rope straight in line with bore; inspect rope for wear; use only approved bore solvents; eye protection.
5. Test fit the magazine to ensure smooth operation	Pinch points on mag catch, sharp edges on mags	Wear gloves to protect from sharp edges
6. Check fasteners to ensure secure thread lock is applied	Skin/eye irritation from thread locker, fumes in poorly ventilated space, tool-related hand injuries	Wear safety glasses; nitrile gloves; Keep area well ventilated
7. Oil Barrel with cloth to prevent flash rust	Oil mist/inhalation, skin contact, flammability, drips causing slip hazard; Metal Guard 510	Wear safety glasses; nitrile gloves; Keep area well ventilated, Use small amounts of oil to avoid drips, Keep oil rags off the floor
8. Open flat pack boxes using hands and tape ends	Cardboard cuts, hand/wrist strain, box edges causing abrasions, tape-gun lacerations/pinch points, repetitive-motion injury.	Wear gloves, alternate tasks to reduce repetition.
9. Put rifle in plastic bag and place in box with accessories	Awkward lifting/twisting	Keep work height mid-torso, alternate tasks to reduce repetition.
10. Close box, tape ends, and stack on pallet.	Prolonged standing	Utilize fatigue mats in work area

PPE Requirements

Safety Glasses
Gloves
Other

Other PPE: Fatigue mats

Notes: Operator can alternate tasks within limits reducing fatigue and repetitive motion injuries.

Job Safety Analysis

Job Title: Heat Treat Barrels

Step	Hazard	Recommended Controls
1. Put part in fixture for induction heat treat and dip	Burns from hot parts	Wear gloves to protect hands from hot parts
2. Put heat treated part in tray	Chemical splash exposure Polyquench 15-XN	Wear eye protection for chemical splashing. Polyquench 15-XN mild eye irritant if splashed in eyes
3. Blow off fixture with compressed air	Compressed air usage	Utilize compressed air >30psi for cleaning
4. Put tray in washer 140°f	Burns from hot parts, Chemical splash	Wear eye protection, Chemical Gloves as necessary, High heat gloves as necessary
5. Put parts on rack to dry	Burns from hot parts	High heat gloves as necessary
6. Put rack in heat temper oven for 1 hour	Burns from hot parts	High heat gloves as necessary
7. Remove parts and allow to cool	Burns from hot parts	High heat gloves as necessary

PPE Requirements

Safety Glasses
Gloves
Other

Other PPE: Ventilation; Fatigue mat

Notes: Currently operator sits and stands at will.

Job Safety Analysis

Job Title: Grind and Polish Barrells

Step	Hazard	Recommended Controls
1. Off hand grind and polish	Abrasion from tool	Wear gloves to protect hands from abrasions and hot parts. Use finger protectors when grinding.
2. Wash barrels in solvent bath	Splashing from water 140°F, Burn hazard Chemical exposure, Multi-Kleen 1573	Wear chemical resistant gloves when handling Multi-kleen 1573 Wear eye protection to protect from flying debris or chemical splashing Ventilate area to avoid residual fumes when opening bath
3. Measure part for QC	Prolonged standing	Fatigue mat for prolonged standing

PPE Requirements

Safety Glasses
Gloves
Other

Other PPE: Ventilation; Fatigue mat

Notes: Currently operator sits and stands at will.

Job Safety Analysis

Job Title: Plasma Cutter Operation

Step	Hazard	Recommended Controls
1. Pre-Job Setup & Inspection	Electrical shock, equipment failure, air leaks	Inspect equipment, verify consumables, ensure dry air, proper grounding
2. Work Area Preparation	Fire, explosion, trip hazards	Remove flammables, secure workpiece, fire extinguisher present
3. Cutting Operation	Burns, arc flash, fumes, noise	Wear PPE, ventilation, stable stance, proper torch distance
4. Handling Cut Parts	Burns, lacerations	Allow cooling, use tools, deburr edges
5. Shutdown & Cleanup	Residual heat, electrical exposure	Power down equipment, allow cooling, clean area

PPE Requirements

Safety Glasses
Hearing Protection
Gloves
Respirator
Leather Work Boots
Other

Other PPE: Welding helmet or face shield (Shade 8-10), Flame-resistant clothing, Respirator (as required)

Notes: Respiratory protection (if required by exposure assessment)

Job Safety Analysis

Job Title: Licon Operation

Step	Hazard	Recommended Controls
1. Pre-Operation Inspection & Startup	Unexpected startup, pinch points, slips trips	Verify guards, clear area, housekeeping. Confirm robot and mill are in safe state.
2. Loading / Unloading Parts	Struck-by robot, crush points (robot picks and places parts into the mill)	Never enter cell during automatic operation. Wait for robot to complete cycle and lockout before entry
3. Manual Setup / Tool Change	Unexpected movement, sharp tools, robot motion	Setup mode, LOTO if entering cell. Ensure robot is locked out or in teach mode when required.
4. Normal Machining Operations	Flying chips, robot movement	Keep doors closed, wear safety glasses. Maintain safe distance from robot work envelope.
5. Clearing Jams or Faults	Stored energy, sharp chips, unexpected robot restart	E-Stop, LOTO, use tools. Follow robot-specific lockout procedures.
6. Maintenance & Troubleshooting	Electrical, hydraulic, stored energy, robot hazards	Authorized personnel only, full LOTO on both mill and robot.

PPE Requirements

Safety Glasses
Gloves

Notes: Wear cut resistant gloves when handling parts or other sharp objects. Do not wear gloves where rotation is present. Maintain awareness of robot’s programmed paths at all times.

Job Safety Analysis

Job Title: EDM Operation

Step	Hazard	Recommended Controls
1. Pre-Operation Inspection	Electrical shock, Slips from standing water, Equipment malfunction	Inspect machine, cables, and grounding. Verify emergency stop functionality, Ensure work area is dry and free of obstructions, Confirm proper ventilation/mist control
2. Loading Material / Workpiece Setup	Cuts from sharp edges, Pinch points	Wear cut-resistant gloves when handling parts, Keep hands clear of clamps and fixtures, Remove gloves before operating machine controls
3. Loading Wire / Electrode (if applicable)	Cuts from wire or electrodes, Eye injury from wire tension release	Wear safety glasses at all times, Follow manufacturer threading procedures, Use tools—not fingers—to guide wire when possible
4. Filling Tank / DI Water Exposure	Splash exposure to eyes/skin, Slip hazards	Wear face shield during filling or flushing, Clean spills immediately, Maintain proper DI water levels and conductivity
5. EDM Machining Operation	Electrical hazards, Unexpected machine movement	Keep enclosure doors closed during operation, Do not bypass safety interlocks, Monitor machine from control panel only
6. Part Removal & Inspection	Hot surfaces or parts, Sharp edges, Splash exposure	Allow parts to cool before handling, Wear cut-resistant gloves, Drain excess DI water before removal
7. Filter, Resin, and Sludge Maintenance	Exposure to metal sludge, Chemical exposure, Respiratory irritation	Follow Lockout/Tagout procedures, Wear chemical-resistant gloves and eye protection, Use respirator if dust or mist is present, Dispose of sludge per environmental requirements
8. Cleaning & Housekeeping	Slips and falls, Electrical hazards from wet conditions	Keep floors clean and dry, Use absorbent mats as needed, Never clean energized electrical components

PPE Requirements

Safety Glasses
Gloves
Respirator
Other

Other PPE: Face Shield, Chemical Resistant Gloves, Chemical Resistant Apron (When handling sludge)

Job Safety Analysis

Job Title: Handgun Assembly Line: 7 Operations

Equipment Used:

Hand-operated arbor/assembly presses
Hand tools
Parts bins
Work benches
PPE

Required PPE

Safety glasses with side shields
Cut-resistant gloves (as appropriate for handling parts)
Optional finger guards where practical

Step	Hazard	Recommended Controls
1. Receive components and inspect parts	Cuts from sharp edges, repetitive reaching.	Use proper lifting techniques, keep parts within ergonomic reach, wear cut-resistant gloves when appropriate, inspect work area before beginning
2. Assemble components using hand-operated press	Pinch points, crushed fingers, repetitive motion, poor posture	Keep hands outside pinch area, use fixtures or holding devices, maintain neutral wrist position, inspect press before use
3. Press-fit components	Pinch/crush injuries, defective tooling, flying fragments from damaged parts	Wear eye protection, inspect tooling each shift, replace damaged tooling immediately, keep hands clear of ram
4. Continue assembly using hand press.	Repetitive motion disorders, muscle fatigue, pinch points, housekeeping hazards	Rotate tasks when possible, stretch during scheduled breaks, maintain clean workstation, use proper body mechanics
5. Final assembly using hand-operated press	Pinch/crush injuries, handling completed firearm, repetitive motion	Follow handling procedures for completed firearms, maintain finger clearance from press, inspect tooling, keep workstation organized
6. Visual inspection and transfer to testing.	Dropping product, repetitive reaching, sharp edges	Use designated transfer containers, avoid overreaching, maintain clear walkways
7. End-of-shift housekeeping	Slips, trips, exposure to metal debris, ergonomic strain	Sweep or vacuum work area, dispose of waste properly, store tools correctly

General Hazards

Mechanical

Pinch points at hand-operated presses
Hand injuries from improper positioning
Sharp metal edges
Tool failures

Ergonomic

Repetitive hand motions
Shoulder fatigue
Wrist strain
Standing for prolonged periods
Awkward reaching

Housekeeping

Slips and trips due to parts on the floor
Cluttered workstations

Safe Work Practices

Inspect the hand press before each shift.
Never place fingers beneath the press ram during operation.
Keep workstations clean and organized.
Report damaged tools immediately.
Maintain neutral body posture.
Follow established procedures for handling completed firearms.

Job Safety Analysis

Job Title: Operation of PUMA DNT 2600 CNC Lathe

Required PPE:

Safety glasses with side shields
Close-fitting clothing
No jewelry
Long hair secured
Cut-resistant gloves for handling raw material and chips only (never while machine is operating)

Step	Hazard	Recommended Controls
1. Review work order and setup instructions	Incorrect setup, machining wrong part	Verify drawing, program number, tooling list, material, and revision before beginning.
2. Inspect machine before use	Equipment malfunction, coolant leaks, damaged guards	Verify emergency stop, door interlocks, guards, hydraulic pressure, coolant level, lubrication system, and work area cleanliness. Report deficiencies immediately.
3. Load raw material into chuck	Pinch points, crushed fingers, dropped material	Keep hands clear while clamping. Verify chuck pressure and secure workpiece. Remove chuck key if applicable.
4. Install or verify cutting tools	Cuts from sharp tools, pinch points	Wear gloves only when handling stationary tooling. Verify tool offsets, secure tooling, and remove gloves before machine operation.
5. Load CNC program	Incorrect program, machine crash	Confirm correct program, work offset, tool offsets, spindle speed, and feed rates before cycle start.
6. Perform dry run or single block verification	Collision, tool breakage	Run with door closed, reduced rapid speed, single block, and feed override until program is verified.
7. Start automatic machining cycle	Rotating chuck, flying chips, entanglement	Keep door closed. Never bypass interlocks. Stay outside machine enclosure during operation. Do not reach into machine while spindle is rotating.
8. Monitor machining process	Flying chips, coolant splash, unexpected machine movement	Observe through machine window. Stop machine before investigating unusual sounds, vibration, or alarms.
9. Measure part between cycles	Contact with rotating spindle, sharp edges	Ensure spindle is completely stopped. Use lockout if entering machine for maintenance. Handle sharp parts carefully.
10. Remove finished part	Sharp edges, hot part, pinch points	Verify chuck has released completely. Use gloves only for handling finished parts. Deburr carefully if required.
11. Remove chips	Cuts, burns, eye injuries	Never use hands. Use chip hook, brush, or pliers. Use compressed air only if permitted by company policy and OSHA requirements.
12. Shutdown machine	Unexpected startup	Return machine to home position, stop spindle, clean work area, turn machine off according to manufacturer procedures.

Primary Hazards

Rotating chuck and spindle
Rotating tooling
Flying metal chips
Sharp workpieces
Hydraulic chuck pinch points
Hot chips and hot parts
Coolant exposure
Manual material handling injuries
Machine crashes due to programming or setup errors

Required Safety Devices

Door interlocks
Emergency stop button
Fully enclosed guarding
Hydraulic pressure monitoring
Machine alarms
Workholding verification
Chip conveyor

Lockout/Tagout Required For

Maintenance
Clearing jams requiring entry into hazardous areas
Hydraulic repairs
Electrical troubleshooting
Turret repairs
Guard or interlock maintenance