Clearing Jams & Cleaning Machines Safely

Many of the worst machine injuries, including amputations, happen when a worker reaches in to clear a jam or clean a machine “just for a second” without shutting it down. A jammed machine can start again when the jam clears.

• Manufacturing
• Food processing
• Warehouses
• Machine operators

Why jams are so dangerous

• The machine may be stopped but still powered, waiting for the jam to clear.
• Sensors can restart the cycle as soon as the product moves.
• Stored energy (springs, air, hydraulics, gravity) can move parts after shutdown.
• Someone else may restart the machine without knowing you’re in it.

The rule: lock it out

OSHA’s lockout/tagout standard applies to servicing and maintenance, including clearing jams and cleaning, whenever you must remove or bypass a guard or put any part of your body where you could be caught by moving parts.

1. Tell affected workers you’re shutting down.
2. Shut the machine down normally.
3. Isolate all energy sources.
4. Apply your personal lock and tag.
5. Release or block stored energy.
6. Try to start it (verify) to make sure it’s dead.

See Lockout/Tagout.

The minor-servicing exception

Some minor tool changes, adjustments and servicing during normal production don’t require full lockout, but only if they’re routine, repetitive and part of normal production, and other measures give effective protection, such as specially designed tools that keep hands out of the danger zone, or guards that stay in place. If you’re not sure your task qualifies, lock out.

Safe habits

• Use jam-clearing tools, hooks and sticks so your hands stay out.
• Never reach around, over or under a guard.
• Never wear gloves, loose sleeves or jewelry near rotating parts.
• Report machines that jam often so the cause can be fixed.
• Cleaning crews, often on night shifts, must be trained in lockout too.

Last updated: October 2, 2026