A Guide to the Factories (Power Presses) Regulations, 1965

Power presses are essential machines in metal-working industries, used for stamping, pressing, blanking, drawing, and similar operations. However, they pose significant hazards to workers, including crushing injuries and amputations. To address these risks in Indian factories, the Factories (Power Presses) Regulations, 1965 were introduced as a supplementary schedule under the Factories Act, 1948. These regulations establish specific safety requirements for the installation, operation, and maintenance of power presses, ensuring that workers are protected from point-of-operation hazards.

Scope and application of the Power Press Regulations 🔗

The Power Press Regulations apply to all types of power presses including press brakes used in factories for metal-working operations such as moulding, pressing, blanking, raising, and drawing. However, these provisions exclude presses used for working hot metal, focusing specifically on the hazards associated with cold metal stamping and forming.

These regulations work alongside the general safety provisions of the Factories Act, 1948. While the parent Act establishes broad safety principles for all machinery, the Power Press Regulations provide detailed, machine-specific requirements addressing the unique dangers of power presses.

Key definitions under the regulations 🔗

Understanding the terminology is crucial for compliance. A “power press” is defined as a machine used in metal or other industries for moulding, pressing, blanking, raising, drawing, and similar purposes. The term “safety device” encompasses all fencing and other safeguards provided for the tools of a power press, while “fixed fencing” refers to guards that have no moving parts associated with the press mechanism.

Guarding and protection requirements 🔗

The regulations mandate comprehensive guarding arrangements for power presses. Each press must be provided with a fixed guard enclosing the front and all sides of the tool, with a slip plate on the underside. Similarly, each disc must be provided with a fixed guard surrounding its front and sides, extending to the back in the form of a tunnel through which the pressed article falls to the rear of the press.

The design and positioning of guards must preclude the possibility of the worker’s hand or fingers reaching the danger zone. Material feeding is done through a small aperture at the bottom of the guard, though a wider aperture may be permitted for secondary operations when feeding is done through a chute.

Alternative guarding options 🔗

Automatic or interlocked guards may be used in place of fixed guards, but they must be maintained in efficient working condition. If any guard develops a defect, the power press cannot be operated until the defect is rectified. Additionally, the starting and stopping mechanism must be provided with a safety stop to prevent over-running of the press or descent of the ram during tool setting.

Appointment and training of competent persons 🔗

One of the most critical safety measures under these regulations is the strict control over who can prepare power presses for use. No person may set, re-set, adjust, or try out tools on a power press unless they have attained the age of eighteen, have been trained accordingly, and have been appointed by the occupier to carry out those duties.

The training must include suitable and sufficient practical instruction in matters relating to each type of power press and safety device that the person will work with. This is not merely theoretical knowledge but hands-on competency development.

Documentation requirements 🔗

The name of every appointed person must be entered in a Register maintained by the factory. This register serves as formal documentation of who is authorised to perform specific tasks on power presses, creating accountability and traceability.

According to OSHA’s mechanical power press regulations, employers must ensure the original and continuing competence of personnel caring for, inspecting, and maintaining power presses through initial and periodic training. This international standard reinforces the importance of ongoing competency verification.

Mandatory examination and testing of equipment 🔗

The regulations establish a comprehensive examination regime for power presses and their safety devices. No power press or safety device can be taken into use for the first time unless it has been thoroughly examined and tested-the press after installation in the factory, and the safety device when in position on the press.

Periodic examination schedule 🔗

After initial testing, the regulations prescribe ongoing examination frequencies. Power presses must be thoroughly examined and tested by a competent person within the immediately preceding period of twelve months. However, if a press uses safety devices other than fixed fencing, more frequent examinations may be required.

For safety devices specifically, every safety device other than fixed fencing must be thoroughly examined and tested within the immediately preceding six months while in position on the power press. This more frequent testing recognises that movable safety devices face greater wear and have more potential failure points.

Examination reports 🔗

The competent person conducting examinations must prepare detailed reports containing specific particulars. These reports must include the name of the occupier, factory address, identification number of the press or safety device, the date it was first taken into use, dates of periodical examinations, and particulars of any defects found along with steps taken to remedy them.

As noted by the UK Health and Safety Executive’s guidance on power presses, thorough examination should document what constitutes a proper test, with examples of maintenance log sheets and checklists for daily inspections and periodic maintenance.

Procedures for dealing with defects 🔗

The regulations establish clear protocols when examinations reveal defects. If a defect is discovered, the competent person must assess whether it poses an immediate danger or could become dangerous over time.

Immediate danger defects 🔗

Where a defect is a cause of danger to workers, the power press or safety device must not be used until the defect has been remedied. The competent person must notify the occupier in writing as soon as possible after completing the examination.

Potential future danger defects 🔗

For defects that may become dangerous over time, the notification must include the period within which the defect ought to be remedied, as determined by the competent person. The press may continue operating only until that period expires, after which it must be taken out of service unless repaired.

Notification to inspectors 🔗

In all cases where defect notification has been given, a copy of the examination report must be sent to the Inspector for the area within fourteen days of completing the examination. This ensures regulatory oversight and allows inspectors to follow up on serious safety concerns.

Recording remedial actions 🔗

As soon as practicable after any notified defect has been remedied, a record must be made stating the measures by which and the date on which the defect was corrected. This documentation links back to the original inspection report, creating a complete audit trail of the defect’s identification and resolution.

Frequent inspection of safety devices before use 🔗

Beyond the periodic examinations by competent persons, the regulations require more frequent operational checks. No power press may be used after the setting, resetting, or adjustment of tools unless a person appointed for the purpose has inspected and tested every safety device while in position on the press.

This requirement ensures that any changes to tooling don’t compromise safety device effectiveness. The appointed person must confirm that safety devices haven’t been altered or disturbed during tool changes.

Daily inspection requirements 🔗

Every power press and every safety device must be inspected and tested by a trained person every day. This daily verification creates a routine safety checkpoint that can identify developing problems before they cause injuries.

Responding to inspection findings 🔗

When inspections reveal problems, immediate action is required. If it appears that any necessary safety device is not in position, not properly positioned, or not suitable, the manager must be notified forthwith. Similarly, any defect disclosed during inspection must be immediately reported to the manager.

OSHA regulations specify that pull-out devices must be visually inspected and checked for proper adjustment at the start of each operator shift, following a new die set-up, and when operators are changed. Necessary maintenance or repair must be performed and completed before the press is operated.

Operator training requirements 🔗

Beyond those who set and maintain presses, the regulations address training for machine operators. Operators must be trained and instructed in the safe method of work before starting work on any power press.

This training requirement ensures that even workers who don’t adjust or maintain presses understand the hazards they face and the proper procedures for safe operation. An effective training programme is a vital step to prevent power press injuries, and training from a competent person is required before anyone operates a power press.

Identification and exemptions 🔗

For proper tracking and compliance, every power press and every safety device must be distinctively and plainly marked for identification purposes. This marking enables accurate record-keeping and ensures that examination and maintenance records can be matched to specific equipment.

Chief Inspector’s exemption powers 🔗

The Chief Inspector may exempt a factory from all or any provisions of the regulations if satisfied that certain circumstances make compliance unnecessary for worker protection. Such exemptions may be granted due to the infrequency of processes or other valid reasons, and may include conditions.

When exemptions are granted, a legible copy of the certificate showing any conditions must be kept posted in the factory where employees can conveniently read it. This transparency ensures workers know which protections apply to their workplace.

Integration with the Factories Act, 1948 🔗

The Power Press Regulations don’t operate in isolation. The Factories Act, 1948 governs health, safety, welfare, working hours, and employment conditions of workers in factories. It establishes broad requirements for machinery safety, inspection systems, and penalties for non-compliance.

The Factories Act makes it obligatory for employers to provide proper safety facilities, including adequate guarding of machinery and arrangements for dealing with workplace injuries. The Power Press Regulations supplement these general requirements with specific provisions tailored to the unique hazards of power press operations.

Penalties for non-compliance 🔗

The Factories Act establishes a penalty framework for violations of safety provisions, including those in the Power Press Regulations. Factory occupiers and managers who fail to comply with mandatory examination requirements, who operate defective equipment, or who employ untrained persons on power presses face legal consequences including fines and potential prosecution.

Beyond legal penalties, non-compliance creates significant risks. Power presses are responsible for a substantial proportion of workplace amputations, making adherence to these regulations a matter of worker protection, not just regulatory compliance.

Best practices for compliance 🔗

Achieving and maintaining compliance with the Power Press Regulations requires systematic approaches. Factories should maintain comprehensive registers of all power presses, their safety devices, appointed personnel, and examination schedules. Regular internal audits can help identify compliance gaps before they lead to injuries or regulatory action.

Developing written procedures for tool setting, die changes, and safety device inspection ensures consistency and provides documentation of safe work practices. These procedures should be reviewed periodically and updated based on experience and any regulatory changes.

What do you think? Are the examination intervals specified in the 1965 regulations still adequate for modern power press technology, or should they be revised to reflect advances in safety device design and monitoring capabilities?

References

1. https://www.comply4hr.com/docs/tn/tnfr/TNFR53SVIII.htm
2. https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.217
3. https://www.hse.gov.uk/pubns/books/hsg236.htm
4. https://www.safeatworkca.com/safety-articles/power-press-safety/
5. https://en.wikipedia.org/wiki/Factories_Act,_1948_(India)
6. https://nyaaya.org/guest-blog/health-and-safety-provisions-for-factory-workers-in-india/