At 9:30 a.m. on June 12, 2021, Employee #1 was working on an automated guided vehicle (AGV) when a second AGV approached and struck him in the leg with its forks. The employee sustained a broken leg and was hospitalized for treatment.

At 6:00 a.m. on September 2, 2020, an employee was adjusting a robot used to make molds. The robot activated and struck the employee. The employee was hospitalized to treat fractures to the ribs and back area and a punctured lung.

At 11:00 a.m. on August 28, 2020, an employee was shredding cabbage with a food processing machine (Robot Coupe CL 50). The employee was hand-feeding cabbage into the food processing machine. The employee reached too far into the machine, and the tips of her right index and middle fingers contacted the rotating blade (point of operation) of the machine, causing amputation injuries. The employee was hospitalized.

At 10:04 a.m. on August 16, 2020, an employee was unsticking a pallet and adjusting sensors on an industrial robot. The sensors were activated causing the robot to begin its cycle. The robot grabbed the employee and pulled him to the floor attempting to complete its cycle. The employee's leg was broken and required hospitalization for treatment.

At 4:30 a.m. on January 9, 2020, an employee and Coworker #1 were performing maintenance work drilling out and replacing bolts for an access panel on the pusher table of an auto depalletizing robot (Robot #2) within a robot cell. At the same time, coworker #2 was preparing to test the operational functions of the dunnage robot (Robot #1). Coworker #2 completed maintenance work on Robot #1 while the employee and Coworker #1 remained inside the robot cell. Coworker #2 exited the robot cell to reset the light curtains. The employee and Coworker #1 had entered the robot cell through the light curtains and that neither had isolated the electrical and pneumatic energy sources at the controls on Robot #2 or affixed lockout devices before performing maintenance work. Coworker #2 reset the robot cell perimeter light curtains for Robot #1 and Robot # 2 in preparation for a test run on Robot #1. The Robot #2 pusher table and robot arm turned on after the perimeter light curtains were reset and the run cycle was initiated in automatic mode on the operator control panel. The employee and Coworker #1 were both sitting on the Robot #2 pusher table while repairing damaged bolts on the table, so the pusher arm sensor for the Robot #2 pusher arm detected something on the table that needed to be pushed off. Coworker #1 managed to get off the pusher table without injury, but the employee was unable to move in time. The employee's feet had dropped down into the recessed area where they had removed an access plate from the table. His feet were repeatedly struck by the pusher arm as the robot tried to complete the normal programmed action of clearing materials from the table outgoing conveyors. His coworkers hit the emergency stop buttons on the outside of the robot cell and helped the employ

At 8:30 p.m. on November 14, 2019, an employee was working for a firm that made medical and surgical instruments. She supervised mechanics and repair technicians. She was working in the facility's HA department, where the HA1 and HA2 robotic work cells were located. She was changing out a plasma spray gun from the HA2 robot. The robot was still energized. It had not been locked out. As she was loosening a bolt to detach the plasma spray gun from the robot, the wrench she was using contacted a metal fitting on the spray gun water line. An arc flash ensued. The employee received second-degree burns on two fingers on her left hand and on her right wrist. She was treated without hospitalization. The employee had not been trained on lockout or the use of padlocks. The interlocked access doors to the cell were equipped with a limit switch that did not deenergize the robot or the spray gun. The employee entered the cell two to three times daily. A risk assessment had not been performed. The employer was not enforcing energy control procedures.

At 8:35 p.m. on October 22, 2019, an employee working for a plastics plumbing fixtures manufacturer was receiving parts from a robot press machine. The robot press struck the employee in the head. The employee lacerated his head and sustained a concussion, requiring hospitalization.

At 7:00 p.m. on March 21, 2019, an employee was realigning robot arm and ring on Press #30. The employee's hand was in the machinery when the ejector plate/ring retracted into the press which caught the employee's left hand between the mold and the ring. The employee suffered fingertip amputations to the index and middle fingers on his left-hand. Hospitalization was not required.

At 3:15 p.m. on January 30, 2019, an employee was working at a full-service restaurant. She was operating a Robot Coupe food processor. She was feeding a piece of cabbage into the chute of the food processor. As she was aligning the piece, her finger was caught and sucked into the chute. Her finger came into contact with the blade. The tip of the middle finger on her right hand was amputated. She was hospitalized.

At 11:58 p.m. on December 26, 2018, an employee noticed that a robot had a red light on and went to investigate why. The employee placed his right hand's pinky into a hole and amputated when it was caught in some gears. The employee was hospitalized.

At 12:45 p.m. on June 22, 2018, an employee was troubleshooting and performing maintenance on Robot #50. During work, the employee's right index finger became caught between the drive belt and pulley of the robot. The finger was amputated, which he was hospitalized and received treatment.

At 9:45 p.m. on December 12, 2017, an employee was working for a manufacturer of automobile chassis and body components. He leaned through a light curtain to change or clean a welding tip on a robot. Another robot unexpectedly energized. Its arm struck the employee. He sustained a fracture and dislocation of his left hip. He was hospitalized.

At 7:30 a.m. on September 18, 2017, an employee was touching up a part on a robot welder. The employee was unable to see the work area while standing on a stool. The employee shut the door to welding cage and climbed between the welding table and the robot platform. The employee was observing the welding sequence to make sure the machine was going to weld correctly. When the employee cycled the machine, the machine traveled to the home position at full speed. The employees legs were pinched between the welding table and the robot base. The employee was bruised and sustained lacerated on the back of both legs. The employee required several stiches on back of left leg. Employee was kept in the hospital for possible compartment syndrome.

At approximately 4:00 p.m. on June 23, 2017, an employee entered a robotic cell to make an adjustment to guide rails where half dive shafts were placed by a robot. The robot cycled while the employee was within the danger zone and was pinned between the robot and a conveyor, receiving a puncture wound to chest.

At approximately 7:00 a.m. on June 16, 2017, Employee #1 was watching a maintenance worker repair a sensor on an automatic robotic conveyor system located in Zone Number 2. He was in Zone Number 3 and standing in front of another robotic conveyor system when the robot struck him in his back. The robot caught and pinned him against the conveyor and fractured at least six of his ribs. Employee #1 was transported to a medical center, where he underwent treatment on the rib fractures and was then hospitalized.

At 7:45 a.m. on June 15, 2017, an employee was replacing a spring activated arm on a robot. When the employee removed the equipment's balancer, the robot's arm swung upward and struck the employee in the head. The employee lost consciousness and sustained a head contusion, which he was hospitalized and received treatment.

At 5:20 p.m. on February 16, 2017, an employee was assisting a coworker with the robot. The employee cut a piece of metal and was going to grind the edges to smooth the edge when his glove was caught and pulled his right hand/thumb into the vertical grinding wheel. The coworker disconnected the power. The employee suffered a severe laceration to his right thumb which later resulted in an amputation of the right thumb pad and nail.

At 7:20 p.m. on January 25, 2017, an employee was located inside a plastic injection molding press to adjust a gripper on the Fanuc Robot. While exiting the press, the employee slipped on a grated surface that was oily. He struck his right elbow on the grating and sustained a severe laceration. The employee was hospitalized and treated for his injury.

On December 27, 2010, an employee of the restaurant El Pollo Loco was working in its food preparation area to make a salsa. He was using a Robot Coupe, bowl cutter mixer to cut cilantro. During the cutting process, the lid was not attached. When he loaded the vegetables to the blender, both his hands were caught by the blade. The tip of the middle finger on his right hand was amputated. Emergency medical technicians were called, and he was transported to a hospital.

At approximately 1:30 p.m. on August 11, 2009, Employee #1, a 42-year-old worker employed by a vehicle parts manufacturer, was loading automobile radiators onto a fixture that was bolted to a moving table. The table, which was attached to a carousel, rotated 180 degrees, and a computerized robot spot welded the front and back of the radiators. If for any reason the machine needed to be shut down (e.g., for maintenance procedures), the person performing the maintenance was required to reset a computer pendant that hung from one side of the barrier guard. This was done by pushing station button Number 1 or Number 2, depending on which station the robot was stopped. In this instance, the maintenance person did not push or set the right button, and as a result, the table moved while Employee #1 was loading a radiator. Employee #1 was temporarily trapped between the table and the barrier guard that housed a robotic welder. She received deep bruises on her chest and back, and she was hospitalized.

On November 16, 2004, Employee #1 was assisting an electrical engineer in troubleshooting a malfunctioning robot. He was crushed between the lifting arm and the lower frame of the robot when the lifting arm dropped. Employee #1 fractured his chest and was hospitalized.

On May 7, 2002, Employee #1 was working in the refrigerator assembly line area when a piece of shipping cardboard became jammed in the transfer robot. He entered the caged area near the conveyor to clear the jam. At the same time, a coworker at the controls put the machine in manual mode and tried to release the robot arms. When the coworker did this, Employee #1's left leg became pinned between the pusher and the conveyor, and it remained caught for several minutes before coworkers were able to free him. Employee #1 suffered severe bruising to his leg but did not require hospitalization.

On January 15, 2002, Employee #1, a maintenance technician for Xilinx Corporation, was performing normal maintenance on a Seiko Epson Handler scanner. He removed a side door to improve access and finished with the adjustments. While test running the machine from in front and watching the operation, he inadvertently reached up and rested his hand on the frame of the unit. His fingers slipped into the opening, and the robot carriage head moved toward the front. The outside edge of the head became caught and pinned his right index finger between itself and the frame, amputating the finger between the first and second knuckle. The hazard was not recognizable.

Employee #1 was operating a Robot Coupe CL-50 vegetable slicing machine when his right little finger struck against the blade and was amputated. The blade cover guard was either broken or missing.

Employee #1 was using a welding/drilling robot to assemble frames for basketball backboards. In this process, the material used to make the backboards is laid out on an A-frame turning table. One side drills the holes and the other side welds the material together; when the one side has been drilled, the table rotates 180 degrees for it to be welded. Employee #1 noticed that one of the holes had not been drilled completely and he reached between the A-frame to manually set that particular drill. When he pushed the MANUAL button, the robot thought that the cycle was complete and it began turning the table for the next sequence. The rotating table and A-frame pinned Employee #1 against the wall on the welding side. He suffered chest trauma, for which he was hospitalized.

At approximately 9:45 a.m. on October 31, 1994, Employee #1, of R. Howard Strasbaugh, Inc. in San Luis Obispo, CA, was alone, testing a circular robot machine. He had done this many times before; however, this time he forgot to de-energize the machine. When he put his left hand on a wheel to adjust the belt, the machine started and caught his thumb between the wheel spoke and the hard stop for the wheel. The thumb was not amputated, but tendons were cut. Employee #1 was taken to French Hospital, where he stayed for two days. Due to lack of employer knowledge, a general citation for failing to de-energize the machine was issued instead of a serious one.

Employee #1 was working as an electrician at an auto assembly plant. He noticed that a part that had been spot welded by robots at a previous station was out of position. Employee #1 broke a light curtain, disabling another robot, and climbed up on an auto/cab shuttle transfer to hit the part into place. As the shuttle transfer device completed a cycle it caught Employee #1's right leg between the top and bottom rail. In order to extricate Employee #1, the leg had to be amputated by rescue personnel. No lockout procedures were used by Employee #1, although he had received training and was an authorized employee.

Employee #1 was operating a die casting machine that had an electrical interlock safety gate which would disengage all operations when opened. Employee #1, who is very small, was able to slide past it without disengaging the machine. She did this while cleaning the mouth of the die and was hit in the back with the robot ladle, which spilled approximately two pounds of 1,200 degree F molten aluminum on her back. Employee #1 was hospitalized with burns.

Employee #1 was manually removing plastic waste baskets from a mold. The machine normally had a robot that removes parts, but it was not functioning. The plate that forms the bottom of the wastebasket pneumatically ejects the parts from the mold, then retracts into position. Employee #1 caught her finger in the pinch point while removing the part.