Safe Use of Metal Lathes

This resource serves as a training aid for those conducting safety meetings, toolbox talks or tailgate sessions. Presenters should review it beforehand, emphasize the most important information and tailor the discussion to site-specific conditions.

Hazard Overview

Metal lathes are machine tools used across various industries for the purpose of shaping, cutting and finishing metal workpieces that include cylindrical parts, screws and tools. Though a useful piece of equipment, lathes present hazards if not used correctly. Risks are primarily associated with the chuck and spindle, other holding fixtures, and the turning piece itself, which rotate at extremely high speeds. Contact with the rotating components of the lathe produces entanglement hazards which can result in injuries, including, but not limited to, amputations, severe lacerations, fractures, loss of consciousness and death.

An additional hazard associated with extremely fast-rotating components is the risk of projectiles from improper placement of the chuck key, as well as chips and sparks produced during metalworking. Projectiles may be ejected at a high velocity and may cause severe eye damage and bodily harm to the operator.

Lathes also have multiple locations on the machine where pinch and in-running nip points are a hazard to the operator. The chips produced by metalworking can also be hot due to the friction produced by the task and may be very sharp. Poor housekeeping and unsecured components of the machine may contribute to an injury.

Electrical and maintenance-related hazards must also be considered. Damaged cords, improper grounding or exposed electrical components can lead to shock or fires. Energy sources must be completely isolated and locked out before performing maintenance tasks such as part replacements, adjustments or repairs. Failure to isolate energy sources and lock them out may expose the maintenance employee or other affected employees to the accidental startup of the machine. Understanding these risks and following proper safety procedures is essential to preventing injuries and ensuring a safe work environment.

Safe Work Procedures

The following procedures can help keep workers safe when working with metal lathes:

Receive proper training and authorization before operating a lathe, ensuring you understand the machine’s controls, hazards and emergency shutoff procedures.
Inspect the lathe for damaged parts, loose components, missing guards or exposed wiring, and do not operate the machine if any issues are found.
Ensure all guards and shields are in place and function properly.
Wear appropriate personal protective equipment, including safety glasses or a face shield, hearing protection and appropriate footwear.
Tie back or confine long hair.
Avoid wearing loose-fitting clothing and jewelry, including neck ties, watches/bracelets, rings and necklaces.
Inspect the work area to make sure the working surface and floor are clear of debris.
Ensure that all cutting tools on the lathe are sharp.
Follow recommended settings for revolutions per minute, feed and depth of cut for the metal being turned.
Ensure that the workpiece is centered and is properly secured by the chuck.
Ensure the chuck key is removed before turning on the lathe.
Be sure to adjust the tool and the tool rest so that both are set slightly above the center of the workpiece.
Utilize a lifting device to assist if the chucks or the workpiece itself are too heavy to manually lift.
Keep hands and fingers a safe distance from the rotating bit.
Use a brush, tool, or vacuum to remove chips and shavings only after the lathe has come to a complete stop.
Turn off the machine and allow it to come to a complete stop before adjusting or taking any measurements.
Shut off and lock out the lathe before conducting any maintenance activities.
Return tools to their designated locations after completing work tasks.
Clean your workstation after all other tasks have been completed.

What Not to Do

Workers must not do the following when working with lathes:

Do not operate a lathe without proper training or authorization.
Do not wear gloves while operating the lathe. They may be caught by the rotating spindle and cause significant injury.
Do not wear loose clothing or dangling jewelry near lathes.
Do not hold the workpiece by hand while operating the lathe. Always secure it with the lathe’s chucks.
Do not leave the chuck key in the chuck. Remove it immediately after tightening, before starting the machine.
Do not bypass, disable or remove any safety guards or shields.
Do not lean on the machine; remain upright while doing work.
Do not place your hands on any moving components of the lathe.
Do not adjust the speed, table or depth stop while the machine is running.
Do not take any measurements of the workpiece while the machine is running.
Do not adjust the speed to operate faster than recommended by the manufacturer.
Do not allow chips and shavings to build up. They create slip and fire hazards.
Do not clean up chips with your hands. Chips may be sharp and hot. Instead, use a tool such as a brush or a vacuum to clean the area.
Do not leave the lathe running unattended.
Do not operate the lathe if you are distracted, and do not distract or talk to an operator while a machine is in use.
Do not continue to operate the lathe if the workpiece is vibrating or if unusual noises are produced. Turn it off and report the issue to a supervisor.
Do not make cuts on workpieces that are too long relative to the tool and require additional support.

Take Action

Complete one or more of the following activities with workers to reinforce the safety messaging. The following activities are sample activities that can be performed.

Demonstrate: Show how to properly position and secure your workpiece, and demonstrate where to place the chuck key after it has been used and prior to starting the lathe.
Demonstrate: Show employees how to perform a pre-use inspection of the machine.
Review: Look over the machine’s speed chart and what settings apply to common materials in your facility.
Group Discussion: Review common hazards associated with lathes, including entanglement, flying debris and pinch points.
Group Discussion: Explain why gloves, loose clothing, jewelry and long hair present serious entanglement risks.
Review: Discuss housekeeping expectations around the lathe work area.
Ask: What signs tell you the lathe is not operating safely?

Applicable Standards/Regulations/Policies

The following list provides notable applicable standards, regulations and guidance. Please note that additional federal and state rules may apply, as well as company safety policies.

Section 5(a)(1) of the Occupational Safety and Health Act of 1970 (General Duty Clause)
OSHA 29 CFR 1910.212 (General Requirements for All Machines)
OSHA 29 CFR 1910 Subpart O (Machinery and Machine Guarding)
OSHA 29 CFR 1910.147 (Control of Hazardous Energy [Lockout/Tagout])
OSHA 29 CFR 1910 Subpart I (Personal Protective Equipment)
ANSI B11.0 (General Safety Requirements for Machinery)
ANSI B11.6-2022 (Safety Requirements for Manual Turning Machines [Lathes] with or Without Automatic Control)