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There are four words that could have prevented this whole thing, safety interlocks notwithstanding:

LOCK-OUT, TAG-OUT

If the machine isn't working properly, lock it out and fix it.

Still, it doesn't matter how often you communicate safety practices to your workers, some of them insist on "saving time" by sticking their hand in a moving machine to unjam something. We had an employee (who was properly trained) stick his arm in a machine while it was on. He knew he was supposed to hit the button to turn the damn thing off, but no, that meant he would have had to walk 2 feet. So he got his arm caught in a space about 2 inches wide. Luckily he didn't lose his arm. This prompted an OSHA inspection, of course, and we were not cited.

This guy may or may not have been properly trained. But don't automatically assume he wasn't. It often turns out that they are trained, they just think they can save a few seconds by sticking their hands/fingers/arms inside the machine.

This guy may or may not have been properly trained. But don't automatically assume he wasn't. It often turns out that they are trained, they just think they can save a few seconds..

You're entirely correct about lock out/tag out.. Something so simple that's constantly ignored.

I have seen situations though where the production managers (I was in Quality, so we didn't have these problems) will poo-poo the whole idea of safety. They train on it, so they can say it was done.. but in practical application they discourage even simple things like lock out.

The employee is caught in the middle. They don't want to make their boss mad by slowing his production line..

IMO, These safety procedures begin and end with the supervisors. A super or manager who reams an employee for failing to follow procedure will get his procedures followed to the letter. A manager or super who has disdain for safety, wont.

I agree with you, lock-out tag-out works. I am an instrument technician in a chemical company and use it daily at work. The plant or company worksite has a commitment to it's workers to ensure that safety happens, too many times the culture that is present at a worksite does not put safety first.