Robot-related fatality involving a U.S. manufacturing plant employee: Case report and recommendations

Sanderson, L.M., Collins, J.W. and McGlothlin, J.D., 1986. Robot-related fatality involving a U.S. manufacturing plant employee: Case report and recommendations. Journal of Occupational Accidents, 8: 13–23. This article presents the salient characteristics of the first publicly documented robot-related fatality in the United States and summarizes recommendations for both preventing similar accidents and directing future robotic safety research and practice. In July of 1984, a 34-year-old die cast operator with 15 years experience was pinned between the right rear end of a hydraulic robot and a “safety pole”. This operator was one of approximately 66 operators employed by the die cast company and was considered by many to be among the most adept at working with the plant's two robots. The major factor contributing to the death of this worker may have been his own behavior; he had been formally trained and instructed not to enter the envelope while the robot was operational. This American fatality has several characteristics in common with reported Japanese robot fatalities. These characteristics include: experience, entering the robot range of motion with power on, overriding existing safety systems, being struck from behind, and being pinned or crushed at a pinch point between the robot and stationary equipment. Recommendations for prevention of such injuries are made according to broad categories pertaining to ergonomics, training, and supervision. Specific recommendations for future robotic safety research and practice include improving information dissemination and consultation, addressing psychological factors of workers interacting with robots, assessing the effectiveness and limitations of safeguarding, establishing uniform and objective criteria for training and possibly certification, and expanding scientific research to include better surveillance and epidemiologic and ergonomic studies.