Safety First! Examples of near-misses that could happen to you!

Safety First: True Stories from the Shop Floor

We’d like to share a couple of true stories from customers who quickly learned that “Safety First” is crucial. These are examples of near-misses that could happen to anyone.

The Importance of Tool Maintenance

Tool maintenance is a critical part of working with cutting tools, yet it’s often overlooked. Though it might seem like a basic task, we hope everyone who works around cutting tools will understand its value after reading these stories. To protect their privacy, we’ll refer to them as customers “A” and “B.”

Customer “A”: A Close Call with a Flying Knife

It was a typical Friday at the shop. They had a short molding profile run to do on a 5-axis CNC with a corrugated knife head adapter. The operator grabbed the profile knives from the shelf, mounted them in the head, loaded them on the tool rack, and selected the program. On its first pass at 10,000 rpm, the tool made a loud BANG! One of the corrugated knives, thick and heavy, shot out from the cutter body like a missile!

Fortunately, the “missile” flew away from the employees. Following its path, they saw it hit the concrete floor five feet away, breaking a golf ball-sized chunk out of the cement. It ricocheted, pierced a chain-link machine fence, and finally came to a stop. If anyone had been standing on that side, the outcome could have been disastrous.

Investigation Findings
The investigation revealed that the operator hadn’t followed protocol. He mounted the knives without cleaning them or removing dust from the corrugations, and he didn’t blow out the cutter head either. This dust prevented the corrugations from locking properly, making it impossible to secure the tool safely.

Key Takeaway
The lesson here: take your time and do it right! A little prevention goes a long way.

Customer “B”: An Incident with a Damaged Cutter

Customer B’s story is another close call. Someone accidentally bumped into a setup table and knocked an insert cutter to the floor. Afraid of getting in trouble, the person picked it up, put it back on the table, and said nothing. Later, the operator returned, mounted the tool, and started the machine. Seconds later, a piece of carbide flew past him, lodging in the wall behind.

The carbide had shattered when it hit the concrete, but the operator had no idea it was damaged. After checking the security cameras, the company fired the person who had dropped the cutter—not for the accident itself, but for concealing it and putting his coworker at risk.

Final Thoughts: Safety and Maintenance Go Hand-in-Hand

These stories highlight the critical importance of proper maintenance and transparent communication in the shop. Even a small lapse can have serious consequences. In the world of cutting tools, “Safety First” is more than a motto—it’s a way of working that protects everyone.