This report selects two latest official publicly announced punch press safety accident cases in 2025, focusing on the two core high-risk scenarios of live mold debugging and unlocked blockage cleaning. Through restoring the accident process, analyzing root causes and summarizing industry professional lessons, it verifies the targeted solving ability of Qiaosen’s exclusive high-risk process safety system, providing authoritative technical reference for enterprise equipment upgrading and safety standardization construction.
Case 1: Fatal Extrusion Accident Caused by Live Mold Debugging and Unconfirmed Reset (Jiangxi Shangrao, 2025 Official Report)
1. Accident Overview
At 4:45 on November 26, 2025, a stamping production line of an auto parts manufacturing enterprise in Shangrao, Jiangxi, had a fatal mechanical injury accident. Due to material blockage of the second-sequence punch press, the maintenance worker entered the dangerous mold area for debugging and troubleshooting without power-off and LOTO lockout. The on-site line manager reset the equipment emergency stop and resumed operation without confirming the evacuation of maintenance personnel. The punch press slid down instantly, causing extrusion death of the maintenance worker, with a direct economic loss of about 1.54 million RMB. The accident was identified as a typical safety responsibility accident caused by non-standard high-risk debugging operations.
2. Professional Root Cause Analysis
From the perspective of professional equipment safety, the accident has two core defects: First, the traditional punch press has nodebugging mode isolation and operation interlock function. The equipment can be reset and started arbitrarily during manual maintenance, lacking forced equipment locking protection. Second, the equipment relies entirely on manual on-site confirmation, without equipment-level safety sensing and risk interception mechanisms. Once on-site communication and management are missing, accidents are inevitable. Third, the equipment has no power-off self-locking logic, failing to restrict live debugging violations.
3. Qiaosen Professional Targeted Solution
Qiaosen punch presses completely avoid similar accidents through three core technical protections: independent debugging mode locking, power-off self-locking mechanism, and full-time foreign object induction protection. When the equipment is in mold debugging or maintenance state, the automatic operation program is permanently locked, and the equipment cannot be reset and started forcibly. The hydraulic mold locking device locks the slide structure in real time. Even if someone mistakenly resets the program, the equipment will not act. It fundamentally eliminates operational risks caused by on-site management loopholes and unconfirmed restart, realizing absolute safety of maintenance and debugging links.
Case 2: Serious Injury Accident Caused by Shielded Protection During Blockage Cleaning (Shanghai Pudong, 2025 Official Report)
1. Accident Overview
At 8:40 on December 3, 2025, a mechanical crush injury accident occurred in a precision electrical appliance processing enterprise in Pudong, Shanghai. The operator found material accumulation and blockage during stamping production. To pursue production speed, the operator manually shielded the equipment’s photoelectric protection device and reached into the dangerous area to clean residual materials without stopping the machine completely. The punch press performed an accidental stroke, resulting in serious crush injury to the operator’s right hand. The investigation confirmed that the core cause was the enterprise’s long-term unstandardized blockage cleaning operation and the equipment’s defensible protection loopholes.
2. Professional Root Cause Analysis
This case is a typical habitual violation accident induced by equipment defects. Traditional punch press protection devices can be artificially shielded and bypassed, and there is no anti-violation operation restriction at the equipment end. In the high-frequency blockage cleaning scenario, workers often take risks to shield protection for operational efficiency. The equipment lacks active risk identification ability, which cannot restrain human irregular behaviors, eventually leading to injury accidents.
3. Qiaosen Professional Targeted Solution
Qiaosen adopts anti-bypass protection logic and integrated non-detachable safety structure. The photoelectric protection and mechanical baffles cannot be manually shielded or removed. Once the dangerous area has foreign object intrusion or abnormal operation track, the equipment will stop immediately. In view of the blockage cleaning scenario, Qiaosen sets up a mandatory stop confirmation procedure. The equipment must cut off power and lock the mold before entering the cleaning state, which completely eradicates the hidden danger of live cleaning and protection shielding, and solves the industry pain point of habitual violation accidents from the technical level.
Accident Risk Statistics & Prevention Effect Comparison Table
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Typical High-Risk Violation
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Industry Accident Proportion
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Traditional Equipment Prevention Ability
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Qiaosen Inherent Safety Prevention Effect
|
|
Live mold debugging without LOTO lockout
|
38%
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No technical restriction, rely on management
|
100% interception via mode locking + self-locking
|
|
Shield protection for blockage cleaning
|
34%
|
Protection can be bypassed artificially
|
Cannot shield protection, forced safe operation
|
|
Mistaken reset during maintenance
|
16%
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Easy to trigger accidental stroke
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Maintenance state prohibits equipment startup
|
|
Fatigue irregular operation
|
12%
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Low fault tolerance, easy to cause accidents
|
Active protection covers human negligence
|
Case Analysis Supplementary Professional Q&A
Q1: What is the essential difference between safety management and inherent equipment safety?
A1: Safety management belongs to passive prevention, which restricts behaviors through rules and training, but cannot eliminate human error and fluke mind. Inherent equipment safety represented by Qiaosen belongs to active prevention, which changes safety rules into hardware interlock and program logic. It can force standardization even if personnel operate incorrectly, which is the only fundamental way to eliminate high-risk operation accidents.
Q2: Why are debugging and cleaning the two highest-risk links in the stamping industry?
A2: These two links belong to human-machine cross-operation scenarios with frequent manual intervention. Traditional equipment has safety logic blind spots for temporary operations. Protective measures are easy to fail or be shielded, and operation steps are not fixed, resulting in far higher accident probability than standardized batch production.
Q3: What standards should high-safety punch presses meet in high-risk operation scenarios?
A3: First, independent operation mode isolation to avoid mode confusion; second, full-time protection effectiveness without shielding; third, power-off self-locking and mechanical double insurance; fourth, anti-misstart and anti-reset interlock during maintenance. Qiaosen fully meets and exceeds industry safety standards in these four core dimensions.
Professional Summary & Industry Enlightenment
Based on the analysis of the latest two official authoritative cases, all high-risk stamping accidents are caused by disordered equipment safety logic and missing technical interlock in temporary operation scenarios, rather than simple human error. Traditional punch presses have inherent safety defects in mold debugging and blockage cleaning links, which cannot be compensated by daily management and training. Qiaosen’s exclusive high-risk process safety system fills the industry’s technical loopholes in temporary operation safety, realizes full-scene and full-cycle inherent safety protection for stamping production, and provides standardized and reliable safety equipment solutions for the upgrading and transformation of global manufacturing safety production.
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