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Machinery is a big part of manufacturing, but if it’s not used safely, it can cause serious injuries – or worse. WorkSafe NZ has seen too many cases where unsafe machines have led to lost fingers, crushed hands, and hefty fines for businesses. The good news? Most of these incidents are preventable with the right safety measures.

Here’s the good news: most of these accidents are completely preventable with some straightforward safety measures.

The risks you need to watch out for

Let’s talk about what actually makes machines dangerous. It’s rarely the machine itself, but how we use, maintain, and protect it:

• Moving parts: rollers, blades, and presses that make production possible can grab clothing, jewelry, or worse – hands and fingers – in a split second
• Lack of proper guarding: guarding might seem like it’s slowing you down, but it’s actually a critical shield between you and serious injury, 
• Poor maintenance: Just like your car, machines need regular check-ups to prevent unexpected breakdowns that can  lead to unexpected breakdowns or failures puting operators at risk
• No lockout/tagout procedures: Imagine someone starting up a machine while a colleague is cleaning or fixing it – without proper lockout/tagout systems, this happens more often than you’d think

The cost of ignoring safety far outweighs the investment in getting it right. WorkSafe NZ provides excellent guidance to help businesses implement effective safety measures that protect both people and productivity.

5 steps to keep safe

Creating a safer workplace doesn’t require a complete factory overhaul. These five practical steps will make a real difference:

1. Do regular safety checks

Take a 15-minute walk around your site each week. Look for opportunities to improve guarding, reduce exposure to moving parts, or address signs of wear. Encourage your workers to share their insights – they often have the best suggestions for improvements.

2. Use proper guarding

Guards are as important to your machinery as any other component. Make it standard practice to keep guards in place and properly adjusted. If one needs repair, or is missing, stop using the machine until it is fixed

3. Train your team

Knowledgeable operators are your best asset when it comes to getting the most from your equipment. Take time to ensure everyone knows the basics – how to properly start up and shut down each machine, where to find emergency stops, when adjustments might be needed, and the daily best practices that keep things running smoothly. Refresher training doesn’t take long and can make a world of difference, boosting your worker’s confidence and performance on the floor. It’s a small investment in time that pays off in better quality work, and fewer disruptions and incidents.

4. Lock it out before maintenance

When equipment needs attention, a simple lockout/tagout routine keeps everyone safe and your machinery in shape. Just follow these lockout/tagout steps in order: properly shut down the machine, disconnect its power source, attach a tag with the maintenance person’s name, double-check that it won’t start unexpectedly, complete the work efficiently, and then confidently return to production. This straightforward process takes just a few minutes but prevents unexpected startups that could harm both your valuable equipment and your workers. Think of it as a quick insurance policy that protects your most important assets

5. Keep up with maintenance

Regular servicing isn’t just good for production – it’s essential for safety. Set reminders for maintenance checks and keep detailed records. Think of it as a health check-up for your machinery that helps prevent unexpected failures that could cause injuries or costly downtime.

A safe workplace is a productive one

Keeping your machinery safe isn’t just about ticking a box – it protects your team and keeps your business running smoothly. Before starting work each day, encourage operators to spend just 5 minutes getting to know their machine. Look for anything unusual, listen for different sounds, and make sure guards are properly positioned. This small investment of time helps catch minor issues before they affect production quality, create delays, or cause injuries. Unsafe machines can lead to big fines. Take the time to get it right, and you’ll create a safer, more efficient workplace for everyone.