Power Press Operation SWMS (Mechanical / Hydraulic)
Mechanical and hydraulic power press operation for stamping, blanking, piercing, and forming operations. Covers die setup and removal, two-hand anti-tie-down control inspection, light curtain alignment and muting zone restrictions, die-setting LOTO procedure, flywheel/clutch brake inspection, single-stroke vs continuous-mode selection authorisation, and die-change permit requirement.
SWMS variants reference your state’s WHS legislation. Instant download after payment.
Power press operation involves cyclic application of multi-tonne closing force through mechanical flywheel-clutch or hydraulic ram systems to stamp, blank, pierce, or form sheet metal components. The die zone is one of the highest-amputation-risk locations in Australian manufacturing, with historical incident data showing that the majority of severe press injuries occur during die setting, troubleshooting jams, or when guarding has been bypassed. Under WHS Regulation 2025 Part 3.2 (Plant), the PCBU must manage risks associated with plant that can crush, cut, or trap, and presses fall squarely within the registered plant design and item registration requirements of Schedules 5 and 5A. A Safe Work Method Statement is mandatory because press operation routinely triggers Schedule 1 HRCW category 13 (powered mobile/fixed plant capable of causing crush or amputation), and because AS 4024.1601 requires documented control selection covering guarding, control reliability, and die-setting procedures before each production run.
Hazards identified
7 hazards covered, sorted by priority.
Traumatic amputation of fingers or hand, permanent disability, notifiable incident under WHS Act s37
Unexpected second stroke crushes operator hand still in die area, fatal or amputating injury
Operator reach into hazard zone undetected, ram closes on limb, severe crush amputation
One-handed initiation allows free hand entry to die zone, crushing injury, prosecution for control bypass
Uncontrolled ram descent onto setter, crushing fatality, breach of LOTO obligations under Reg 188
High-velocity projectile causes eye penetration, facial laceration, or skull fracture
Cumulative noise-induced hearing loss, tinnitus, workers compensation claim under Reg 58 exposure standard
Control measures
Hierarchy-of-controls order: elimination → substitution → isolation → engineering → administrative → PPE.
- 1Elimination — Replace manual hand-feeding with progressive die strip feed or coil-fed automation so operator hands never enter the die closing zone during normal production cycles.
- 2Elimination — Remove jammed parts only after full de-energisation and ram blocking; prohibit reach-in clearing under any powered condition without exception.
- 3Substitution — Specify hydraulic presses with controlled descent and dwell over mechanical flywheel presses for new installations where cycle time allows.
- 4Substitution — Replace open dies with fully enclosed tunnel-style or self-contained die sets that mechanically prevent finger entry to the pinch point.
- 5Engineering — Install Category 4 (AS 4024.1601) light curtains with calculated safe stopping distance, control-reliable two-hand anti-tie-down stations, and monitored guard interlocks.
- 6Engineering — Fit clutch/brake monitoring with stop-time measurement at defined intervals; press auto-disables on overrun beyond AS 4024.1601 tolerance.
- 7Administrative — Issue written die-change permit requiring authorised setter, LOTO isolation per AS 4024.1603, ram safety block in place, and supervisor sign-off before re-energising.
- 8Administrative — Restrict continuous-mode selection to keyed authorisation held by production supervisor only; log every mode change in the press operations record.
- 9Administrative — Pre-start verification of two-hand control function, light curtain alignment, and emergency stop response before first cycle each shift, recorded on the SWMS sign-on.
- 10PPE — Class 1 safety glasses or face shield for blanking work, Class 5 hearing protection where measured levels exceed 85 dB(A), and snug-fitting cuffs without loose gloves near die zone.
Applicable Codes of Practice
Mandates guarding that prevents access to moving parts, control reliability for safeguarding devices, and isolation before clearing or adjusting plant.
Specifies control category requirements for two-hand devices, light curtain stop-time calculation, and die-setting safety blocks applicable to every cycle.
Requires documented isolation, lockout, and verification of zero energy state before any die change, maintenance, or jam clearance on press plant.
Triggers noise exposure assessment, audiometric testing, and hearing protection program where press operations exceed the 85 dB(A) eight-hour standard.
High-Risk Construction Work triggered
Power press ram applies multi-tonne closing force on every stroke, creating an amputation and crushing hazard at the die zone that meets the Schedule 1 criterion for plant capable of severe injury.
PCBU must consult workers, document the SWMS before work starts, monitor compliance, and retain records for two years (or until after an incident). Penalties for breach are substantial and indexed; current maximum follows the prevailing WHS schedule.
Who this is for
- →Sheet metal stamping and pressing manufacturers
- →Automotive component and white goods fabricators
- →Tool and die setters in production engineering
- →Production supervisors authorising press mode changes
What you receive
- ✓Editable DOCX template — Microsoft Word compatible
- ✓State-specific WHS legislation schedule (NSW/VIC/QLD/SA/WA/TAS/NT/ACT)
- ✓Hazard register with risk ratings + hierarchy-of-control mapping
- ✓Worker sign-on register, pre-start checklist, and incident escalation flow
Worked example
At a suburban automotive component plant, a setter and operator are starting a 5,000-piece blanking run on a 200-tonne mechanical press. Before energising the machine, the supervisor pulls up the Power Press SWMS at the pre-start board and walks the two-person crew through it. They identify the live hazards for this job: amputation at the die zone, potential clutch-brake overrun, and slug ejection from the blanking station. Working through the control list, the setter confirms the light curtain is aligned and the muting zone is set only for the strip-feed pass-through, two-hand controls test as anti-tie-down compliant within the required response time, and the clutch stop-time monitor reading is within AS 4024.1601 tolerance. The die-change permit from the previous shift is closed out, ram safety block removed, and LOTO tags returned to the board. Both workers sign on to the SWMS, acknowledging single-stroke mode only — continuous mode is locked out because no supervisor key is issued for this job. Two hours into the run, a slug jams in the lower die. Rather than reach in, the operator stops the press, applies their personal lockout per the SWMS jam-clearance step, installs the safety block, and clears the slug. The supervisor notes the jam frequency on the SWMS review section and schedules a die inspection before the next shift.
Related legislation
- WHS Act 2011 (model)
- WHS Regulation 2025
- AS 2550 — Cranes, hoists and winches; AS 1418 series