1. Power Tools— The Case of the Kicked Back Saw
P O W E R P O I N T ® T R A I N I N G
Change notes pg #1. Handout document is not customizable word doc.
Target Audience: This session is most appropriate for workers who work with or near portable power tools either at work or at home. This session is probably not appropriate for workers who never encounter portable power tools at work or at home.
Learning Objectives: This case and its training message have to do primarily with portable power tools. This session can be used in conjunction with a full training session on tools or it can be used as refresher training.
Background for the Trainer:
This training session presents a case study of an actual accident, which was inspected and documented by the Occupational Safety and Health Administration (OSHA). The case presented in this training session is:
Accident:
Report ID:
Inspection:
You may choose to present this training information in a lecture format, or make the training presentation interactive by engaging your class in discussions that will help them identify facts of the case, potential causes of the accident, and future accident prevention measures. In either case, students will benefit by learning from a real-life scenario.
Before beginning your training session, print and make copies of the one-page Case Study Student Handout, which is provided on the disc. The Case Study Student Handout can be used as a worksheet during the training session, or as a take-away reminder once the training session is complete.
Also, print and make copies of the Case Study Quiz, which is provided on the disc as a fully customizable Word document. The students can take the quiz at the end of the training session in order to help reinforce the information presented. Note that the same quiz is included at the end of this PowerPoint presentation as actual slides to review in class.
Consider taking pictures of hand-held power tools as they are being used in your workplace. You can add these pictures to the presentation by inserting them into existing slides or creating new slides.
Make sure the trainees understand the message as you go along. Ask questions periodically to test their understanding.
Speaker’s Notes:
Welcome everyone. Today we will conduct a case study of an actual accident investigated by the Occupational Safety and Health Administration (OSHA). This is an actual tragic workplace accident that had real-life implications for the worker, the worker’s family, co-workers, and the employer. The Case Study may be disturbing and may even involve a fatality.
The purpose of this training session is to teach and reinforce the importance of power tool safety in your workplace and homes in order to prevent tragic accidents. In particular, it deals with the proper use and guarding of power tools—especially a circular saw. The intention is to learn from the accident and take steps to prevent a similar accident from changing our lives.
Power Tools—
The Case of the Kicked Back Saw
©2003

2. Let’s Look at the Hazards
Point of operation
Risk of electrical shock or fire
Dust and flying debris
Noise
Vibration
Background for the Trainer:
Bring your company’s written safe work practices plan for using portable power tools.
Speaker’s Notes:
The point of operation, or the area where the work takes place, is the primary hazard of any power tool. The powered and moving saw blade, grinding wheel, wire brush, sander, drill bit, chisel, etc., will cause a lot of damage if you make contact with them while in operation.
Electrical shock or fire is another common hazard of power tools. Never use electric power tools around water, and keep electric cords out of water. Use a ground fault circuit interrupter (GFCI) when electric tools must be used in wet or rainy conditions. The GFCI will protect the worker from shock if a short occurs in the circuit. When doing work that generates sparks, such as grinding on metal, keep combustible materials away from the work area.
Dust and flying debris generated by power tool operation can also cause injury. Grinding, cutting, chiseling, etc., all generate flying particles. Wear safety glasses at all times. Consider wearing a face shield for additional eye protection. Wear a dust mask or particulate filtering face piece to protect your respiratory system from irritating dusts.
Power tools are loud. When using them for extended periods of time, you will need to protect your ears. Wear earplugs, earmuffs, or canal caps when working with power tools.
Many power tools subject the user to vibration, which can cause nerve and tissue damage over time. If your job requires daily use of portable power tools that generate vibration, ask your supervisor for anti-vibration gloves.

3. Take a Look at the Facts
Employee prepares to cut through plywood with a circular saw
Places one end of board on ground, holds other end with hand
Tapes back the lower blade guard
Background for the Trainer:
Training Option: Pass out the Case Study Student Handout. You may have the students read the accident description to themselves before discussing it in the class, or you may use the bullet points on the slide and the speaker’s notes below to describe the accident.
Speaker’s Notes:
The employee works for a pallet company and was getting ready to cut through a 40-inch-long piece of plywood with a circular saw.
The employee places one end of the plywood on the ground.
He holds up the other end of the plywood with one hand so that he can operate the circular saw with his other hand.
The employee tapes back the self-retracting lower blade guard that automatically closes over the lower part of the blade when material is not being cut.

4. Take a Look at the Facts (cont.)
Begins cutting through the wood
Saw catches in wood and kicks back
Saw hits employee in abdomen, leaving a 10-inch laceration
Speaker’s Notes:
The employee begins cutting through the plywood.
The saw becomes caught in the wood and kicks backward.
The employee is struck in the abdomen with the unguarded circular saw.
He is hospitalized with a 10-inch laceration that requires a number of stitches.

5. What Do You Think Went Wrong?
Why did the worker tape back the lower guard?
What caused the saw to get caught in the wood and kick back?
Why did the employee cut the wood in this manner?
How could this worker have cut the board safely?
What type of PPE should be worn?
Background for the Trainer:
Use the questions on this slide to elicit discussion.
Training options: After reviewing this slide and the accident description, give the class 5 to 10 minutes to discuss the accident description in small groups, or ask the students to try to determine some of the facts, potential causes, and possible prevention measures. In either case, use the Case Study Student Handout as a way to encourage discussion as you go through this presentation.
Speaker’s Notes:
Let’s take a few minutes and, using the Case Study Student Handout, work in groups to try to determine the facts of the accident, the potential causes of the accident, and possible prevention measures. Then we will review the Case Study together in class.
Consider some of the questions on this slide when discussing the Case Study in your groups.

6. Let’s Review the Causes
Plywood not in a safe position for cutting
Lower blade guard taped back
Employee trying to hold the material while cutting
Employee not able to use both hands to hold the saw
Background for the Trainer:
Try to get the trainees to put themselves in the place of the person in the Case Study. What would they have done in this case? Point out how a near miss can turn into a catastrophe in the presence of emergencies. In this case, the worker was probably in a hurry and did not want to take the time to set up the cut so it could be done safely. Also, he had probably cut wood this way many times before and never been hurt, so he assumed it was safe.
Consider bringing a piece of plywood and a circular saw to demonstrate how difficult it would be to safely use a saw in the position that this worker is in. However, do not actually cut the wood in an attempt to reenact the accident.
Speaker’s Notes:
The sheet of plywood was not in a position that was safe for cutting. From the accident description it sounds as though the plywood was standing on one end, in a vertical position or at a steep angle. It is almost impossible to have control over a saw when cutting at such an angle. When using a circular saw, the material to be cut should be laid flat on top of sawhorses or a designated cutting table.
The employee taped back the lower retractable blade guard because he thought it might get in his way when cutting the board in this near-vertical position. In this position, the guard may not move freely out of the way as it does when cutting plywood that is laid flat in a horizontal position.
The employee was also attempting to hold the material at the same time he was cutting it. When using any type of power tool, you should avoid having to hold the material in place while working on it. Whether cutting, grinding, sanding, etc., it is almost impossible to safely hold the material in place at the same time you are using a power tool. Some workers attempt to hold material with their hands, between their knees, under their feet, etc. Instead, use a vise, clamps, or other system to hold the material in place while working on it. In this case, holding the material probably contributed to the saw getting pinched in the wood and kicking back at the employee. To hold the wood still in this upright position, he was probably pushing down, which put too much pressure on the blade and caused the saw to kick back.
Because the employee was not able to use both hands to control the saw, he was not able to control it when it kicked back. If the plywood had been in a horizontal position on a sawhorse or a designated cutting table, the employee would have been in a better position to control the saw and avoid injury, even if the saw kicked back.
Can you think of any other causes that may have contributed to this accident?

7. Power Tool Inspections
Guards in place and working properly
Blades or point of operation in good condition
Electrical cord inspected
Power switch operates correctly
Damaged tools removed from service
Background for the Trainer:
Bring in a few portable power tools from your workplace to demonstrate how to properly inspect the tools. Consider bringing in a tool that has been tagged “Do Not Use” to see if the employees can discover why it has been taken out of service until repaired.
Speaker’s Notes:
All portable power tools, including saws, grinders, etc., must be equipped with the appropriate safety guards. Never remove a guard that is installed or recommended by the tool’s manufacturer. Make sure portable circular saws are equipped with a guard that completely covers the top side of the blade. The retractable lower guard must be in place and in good working order so it retracts smoothly while cutting and automatically returns to the covering position when the saw is withdrawn from the wood or when material is not being cut.
Inspect the blade, grinding wheel, abrasive brush, sandpaper, drill bit, etc., to make sure it is in good condition before using it. Blades must be sharp and have no signs of damage. Grinding wheels must be free of any cracks or other signs of deterioration.
Inspect the electrical cord. Make sure the cord is properly connected to the power tool. Check the cord for signs of damage, such as kinks, twists, cuts, exposed wires, damaged insulation, etc. Check the plug to make sure the prongs are in good condition. If pneumatic or hydraulic powered portable tools are used, inspect the hoses and hose connections for any signs of deterioration or damage.
Before cutting, test the power switch to make sure it operates correctly. All power tools must be equipped with a switch that must be held with constant pressure in order for the tool to be in operation. Once the pressure is released from the switch, the tool should shut off automatically, although in many cases, the point of operation will continue to move for a few seconds. Some portable power tools come equipped with a switch that can be locked in the “on” position so the operator does not have to continually hold pressure on the switch. Make sure that this lock can quickly be disengaged with the same hand that is used to trigger the power switch.
If the portable power tool is damaged or unsafe to use in any way, remove it from service immediately. Red-tag the tool with a label such as “Out of service for repair” or “Do not use,” etc. The tool should be repaired or replaced. If you do not have the authority to make sure this happens, turn the tool over to someone who does, and be sure he or she knows what is wrong with the tool.

8. Keys to Safe Use of Power Tools
Unplug before adjusting or fixing power tools
Keep cords away from sharp edges, heat, water
Do not carry tools by the cord or hose
Background for the Trainer:
Bring any written procedures your company has for using portable power tools—specifically saws.
Show pictures of employees in your workplace using portable power tools correctly.
Speaker’s Notes:
Disconnect power tools when not using them. Always unplug or disconnect the power before servicing, cleaning, or changing accessories, such as blades, bits, grinding wheels, sandpaper, etc.
Keep cords and hoses away from hot machinery, oil, sharp edges, and water (for electric cords).
Never carry portable power tools by the electric cord or the pneumatic hose. Always carry the tool by designated handles.
Be sure to keep other workers at a safe distance when using portable power tools. Warn them before starting to use the tool and turn the tool off if approached by another worker.
Good housekeeping is very important for the work area when portable power tools are in use. Clean up any slip hazards, such as water or sawdust. Put away potential trip hazards, such as tools or scrap material that are on the floor. Make sure the power cord or hose is not a trip hazard while operating the tool.
Keep others at a safe distance
Maintain good housekeeping

9. Don’t Let It Happen to You
Inspect the tool
Never disable guards
Secure the material
Hold the tool with both hands
Follow safe work practices
Wear protective equipment
Speaker’s Notes:
Let’s take a look at what we can do to prevent a similar incident from happening at our facility.
Inspect portable power tools before each use. Especially make sure all guards are in place and in good working order. Be sure to take the tool out of service if it is damaged.
Never remove or disable the guard on a power tool.
Secure the material being worked on so you do not have to hold it still. Use a vise, clamps, put it on a sawhorse, or put it on a designated cutting table. Do not attempt to hold the item in place while cutting, grinding, drilling, etc.
When possible, hold the tool with both hands so you have control over the tool if it kicks back or something else unexpected happens.
Follow safe work practices, including: cut away from your body, keep electric tools away from water, keep the point of operation away from your body, put tools away properly, carry and handle tools safely, unplug tools when servicing them, etc.
Wear appropriate personal protective equipment (PPE) for the job, such as safety glasses, face shield, dust mask, ear protection, or antivibration gloves.
Be sure to have good footing before turning on the power tool, and maintain good balance when operating power tools. If you lose your balance while using a power tool, shut off the tool and reposition yourself before turning the tool back on.
Are there any questions?
Thanks for your attention.
Maintain good footing and balance

10. Quiz
1. When inspecting the electric cord on power tools, what should you look for?
2. Name two hazards associated with the use of portable power tools.
3. Name two things to inspect on portable power tools.
4. Name one way to secure the material being worked on.
Background for the Trainer:
Remind employees that the quiz is to encourage further discussion and to help you, the trainer, be sure that everyone understands what was discussed.
Print copies of the quiz for participants to take on their own, or go over the questions as part of the training session.

11. Quiz (cont.) 5. How can you have better control over your power tool?
6. What should you do if your power tool is damaged?
7. What type of PPE should be worn when cutting wood?
8. What must be done before changing a blade on a power tool?

12. Quiz Answers
1. Q. When inspecting the electric cord on power tools, what should you look for?
A. Kinks, twists, damaged insulation, damaged plugs, exposed wires, etc.
2. Q. Name two hazards associated with the use of portable power tools.
A. Point of operation, electrical shock, flying debris, noise, vibration.

13. Quiz Answers (cont.)
3. Q. Name two things to inspect on portable power tools.
A. Guards in place, electric cord, sharp blade, power switch.
4. Q. Name one way to secure the material being worked on.
A. Use a vise or clamps.

14. Quiz Answers (cont.)
5. Q. How can you have better control over your power tool?
A. When possible, hold the power tool with both hands.
6. Q. What should you do if your power tool is damaged?
A. Tag the tool “out of service.”

15. Quiz Answers (cont.)
7. Q. What type of PPE should be worn when cutting wood?
A. Safety goggles, dust mask, ear protection.
8. Q. What must be done before changing a blade on a power tool?
A. Unplug the power tool.