The magnet holds the drill to the plate; it does not secure the plate to its supports. Plate bending or unstable support can change conditions during feed even with the magnet indicator on. Link the plate, support locations and drill position in the setup check.
This is reference content written and revised with AI. It has not been verified or approved by a professional. Review by a suitably qualified professional and site authorization are required before use.
Stop before starting
Hold unknown magnetic contact, plate thickness or secondary restraint. Stop for body lift, binding, power loss or abnormal vibration. Do not hold a moving drill by hand or remove magnetic holding before controlling the release risk.
1. Legal and technical scope
| Basis | Scope and limits |
|---|---|
| OSHA 1910.242 | Safe tool condition within scope. |
| OSHA 1910.212 | Applicable rotating-part, chip and point-of-operation safeguarding. |
| Hougen HMD906 manual OM9060619 | Manufacturer example linking magnetic holding to thickness/surface and requiring a safety chain; model-specific limits. |
For this general-industry machining setup, apply 1910.242 tool-condition requirements and 1910.212 applicable guarding. Construction use requires the relevant Part 1926 provisions. Follow the exact drill/cutter manual and specified secondary restraint; an example model is not a universal minimum plate thickness or speed. Check State Plan and actual electrical/servicing requirements.
2. Scope and required inputs
Included work
Using a portable magnetic drill and annular cutter on a securely supported horizontal ferromagnetic steel plate after the actual model material, thickness, surface, cutter and restraint conditions are verified.
Separate assessment
Vertical or overhead drilling, elevated structural work, curved pipe, nonmagnetic material, improvised stacked plates, structural hole changes and classified hazardous locations require separate plans.
| Required input | Evidence to obtain |
|---|---|
| Review plate and hole | Plate material and thickness; Hole and exit location; Approved drawing; Cutter and model limits |
| Secure plate supports | Plate fixing; Support positions; Underside clearance; Load-path acceptance |
| Set magnet and restraint | Surface and contact; Chain or strap condition; Restraint attachment; Power-loss plan |
| Fit cutter and safeguard | Cutter and fastening; Guard and clothing; Stop and restart features; Supply and cable |
No actual equipment model, SDS, site measurements, design calculations or authorization record was supplied. Product-specific limits and methods must be verified before use. Federal OSHA is a baseline within its scope; determine the applicable State Plan and local requirements. Manufacturer guidance is not government approval; an incorporated standard differs from voluntary guidance. No nationwide-compliance or expert-approval claim is made.
3. Eight-stage JSA
| Job stage | Hazards and effects | Failure factors | Technical and procedural controls | Site verification | P | S | R | A |
|---|---|---|---|---|---|---|---|---|
| 1. Review plate and hole | 1. Drill movement2. Slug strike3. Wrong hole4. Insufficient clearance | 1. Material unknown2. Exit occupied3. Drawing mismatched4. Thickness assumed | 1. Verify ferromagnetic plate2. Control exit side3. Match hole location4. Review model limits | 1. Plate material and thickness2. Hole and exit location3. Approved drawing4. Cutter and model limits | ||||
| 2. Secure plate supports | 1. Plate fall2. Support collapse3. Plate bending4. Drill displacement | 1. Plate not restrained2. Blocks unstable3. Feed load ignored4. Support moves | 1. Secure plate and supports2. Review machining load path3. Provide exit clearance4. Check setup stability | 1. Plate fixing2. Support positions3. Underside clearance4. Load-path acceptance | ||||
| 3. Set magnet and restraint | 1. Body release2. Power-loss movement3. Cutter break4. Restraint failure | 1. Paint or chips under base2. Chain absent3. Partial contact4. Attachment unsuitable | 1. Prepare permitted surface2. Use specified safety restraint3. Verify full base contact4. Inspect attachment points | 1. Surface and contact2. Chain or strap condition3. Restraint attachment4. Power-loss plan | ||||
| 4. Fit cutter and safeguard | 1. Cutter fracture2. Entanglement3. Unexpected rotation4. Electrical injury | 1. Cutter loose2. Clothing near spindle3. Live adjustment4. Supply damaged | 1. Secure body then isolate2. Fit specified cutter3. Check guards and stops4. Inspect supply protection | 1. Cutter and fastening2. Guard and clothing3. Stop and restart features4. Supply and cable | ||||
| 5. Cut controlled hole | 1. Body rotation2. Hot chip injury3. Cutter binding4. Loss of holding | 1. Feed excessive2. Hands clear chips3. Lubrication wrong4. Lift ignored | 1. Use specified feed method2. Keep clear of rotation3. Apply permitted lubrication4. Stop abnormal movement | 1. Feed and sound2. Body contact3. Chip and hand boundary4. Lubrication condition | ||||
| 6. Control breakthrough | 1. Slug burn2. Ejected-piece strike3. Coastdown contact4. Sharp hole edge | 1. Exit reopened2. Slug caught by hand3. Stop assumed instant4. Edge unmarked | 1. Maintain exit exclusion2. Wait for full stop3. Recover with suitable tools4. Mark sharp and hot areas | 1. Slug location and heat2. Cutter fully stopped3. Recovery tool4. Hole edge condition | ||||
| 7. Hold lift or outage | 1. Drill release2. Restart fracture3. Hand crush4. Repeated holding failure | 1. Body held by hand2. Power return trusted3. Restraint removed4. Cause unresolved | 1. Exclude movement path2. Secure body safely3. Prevent unexpected restart4. Reverify complete setup | 1. Outage or lift event2. Contact and restraint3. Cutter damage4. Correction and release | ||||
| 8. Remove and hand over | 1. Drill drop2. Sharp-chip cut3. Defective hole used4. Damaged tool reused | 1. Magnet released unsupported2. Chips handled blindly3. Inspection skipped4. Fault not marked | 1. Support body before release2. Collect chips safely3. Inspect hole and cutter4. Transfer defects and limits | 1. Body and power state2. Chip and slug recovery3. Hole inspection4. Tool and workpiece holds |
P = likelihood; S = severity; R = risk under the site method; A = site-defined acceptance/authorization. These actual assessment cells are blank. A low score never overrides a missing safeguard or a legal or manufacturer restriction.
4. Fictional scenario and failure mechanisms
This illustration provides educational context. It is not an actual incident photograph or evidence of equipment suitability; any AI-generated depiction is illustrative only.
The scenario and record comparisons are fictional teaching examples, not records of real incidents, measurements, inspections, signatures or approvals.
| Stage | Fictional situation |
|---|---|
| Initial situation | A fictional drill starts its first hole on a horizontal plate. |
| Changed condition | The rear of the drill body lifts slightly. |
| Failure path | The operator proposes reducing feed and continuing to the next hole. |
| Possible outcome | Lost contact could let the body rotate or damage the cutter. |
| Prevention barrier | Stop feed and rotation, exclude the movement path and safely secure the body before reviewing contact, plate support, restraint and cutter condition. |
Failure mechanisms
The magnet holds the drill to the plate; it does not secure the plate to its supports. Plate bending or unstable support can change conditions during feed even with the magnet indicator on. Link the plate, support locations and drill position in the setup check.
Loss-of-power restart prevention and continued magnetic holding are separate functions. After an outage, determine whether the body or cutter moved and recheck contact, restraint and tool condition. A chain cannot make an unsuitable magnetic surface acceptable.
The annular slug may be hot and eject at breakthrough. Keep the exit path clear throughout cutting. Hands and gloves do not belong near a rotating cutter; clear chips only after full stop and restart prevention using the approved tool and method.
Work sequence: Review plate and hole → Secure plate supports → Set magnet and restraint → Fit cutter and safeguard → Cut controlled hole → Control breakthrough → Hold lift or outage → Remove and hand over. This is a teaching flow, not a device drawing or a complete operating procedure.
5. Conditional decisions and common errors
| Situation | Required action | Evidence | Proceed when |
|---|---|---|---|
| Plate suitability unknown | Hold setup | Material, thickness and model limits | Plate accepted |
| Body lifts | Stop feed and rotation | Contact, support and cutter checks | Cause corrected |
| Power interrupted | Prevent restart | Movement, restraint and tool inspection | Setup reverified |
| Slug released | Keep exit clear | Full stop and safe recovery method | Recovery permitted |
Similar observations, different decisions
The scenario and record comparisons are fictional teaching examples, not records of real incidents, measurements, inspections, signatures or approvals.
| Observation | Insufficient conclusion | Required distinction |
|---|---|---|
| Magnet switch on | Electrical command | Holding suitability unproved |
| Chain installed | Secondary restraint present | Contact still must comply |
| Motor will not auto-restart | Restart feature | Magnetic holding separate |
6. Roles and responsibilities
| Role | Responsibility |
|---|---|
| Work supervisor | Confirm plate material and thickness and the task scope, resources, interfaces and stop authority. |
| Qualified technical reviewer | Review plate fixing, model limits, compatibility and unresolved technical conditions within assigned competence. |
| Work crew | Apply the listed controls, report changes and stop when evidence or safeguards are missing. |
| Inspector / assessor | Record actual feed and sound and other relevant checks; do not mark unverified conditions as accepted. |
| Handover authority | Reconcile body and power state, restrictions and outstanding actions before the next task. Role labels do not establish a legal credential. |
Supervision and handover focus
| Stage | Management action | Evidence |
|---|---|---|
| Review plate and hole | 1. Record plate material and thickness2. Record hole and exit location3. Record approved drawing | 1. Plate material and thickness2. Hole and exit location3. Approved drawing |
| Set magnet and restraint | 1. Record surface and contact2. Record chain or strap condition3. Record restraint attachment | 1. Surface and contact2. Chain or strap condition3. Restraint attachment |
| Fit cutter and safeguard | 1. Record cutter and fastening2. Record guard and clothing3. Record stop and restart features | 1. Cutter and fastening2. Guard and clothing3. Stop and restart features |
| Cut controlled hole | 1. Record feed and sound2. Record body contact3. Record chip and hand boundary | 1. Feed and sound2. Body contact3. Chip and hand boundary |
| Hold lift or outage | 1. Record outage or lift event2. Record contact and restraint3. Record cutter damage | 1. Outage or lift event2. Contact and restraint3. Cutter damage |
| Remove and hand over | 1. Record body and power state2. Record chip and slug recovery3. Record hole inspection | 1. Body and power state2. Chip and slug recovery3. Hole inspection |
7. Hold points and record comparison
| Hold point | Evidence before release | Actual approval |
|---|---|---|
| HP-0 Scope | Using a portable magnetic drill and annular cutter on a securely supported horizontal ferromagnetic steel plate after the actual model material, thickness, surface, cutter and restraint conditions are verified. | |
| HP-1 Set magnet and restraint | Surface and contact; Chain or strap condition; Restraint attachment; Power-loss plan | |
| HP-2 Fit cutter and safeguard | Cutter and fastening; Guard and clothing; Stop and restart features; Supply and cable | |
| HP-3 Hold lift or outage | Outage or lift event; Contact and restraint; Cutter damage; Correction and release | |
| HP-4 Remove and hand over | Body and power state; Chip and slug recovery; Hole inspection; Tool and workpiece holds |
Hold points are internal project checks. They are not universal statutory permits and do not grant work permission. Reassess after defects, changed conditions and shift changes.
Record comparison
The scenario and record comparisons are fictional teaching examples, not records of real incidents, measurements, inspections, signatures or approvals.
The boxes are static record prompts, not interactive or saved approvals. A tick does not establish suitability or permission to restart. Record the evidence, person, time and unresolved issues; retain the change history.
| Record | Insufficient record | Record checklist |
|---|---|---|
| Review plate and hole | Only marked “OK” | □ Plate material and thickness□ Hole and exit location□ Approved drawing□ Cutter and model limits |
| Fit cutter and safeguard | Only marked “OK” | □ Cutter and fastening□ Guard and clothing□ Stop and restart features□ Supply and cable |
| Hold lift or outage | Only marked “OK” | □ Outage or lift event□ Contact and restraint□ Cutter damage□ Correction and release |
| Remove and hand over | Only marked “OK” | □ Body and power state□ Chip and slug recovery□ Hole inspection□ Tool and workpiece holds |
8. Site checklist and emergency response
| Site check | Actual result | Person / action |
|---|---|---|
| Review plate and hole: Plate material and thickness; Hole and exit location; Approved drawing; Cutter and model limits | ||
| Secure plate supports: Plate fixing; Support positions; Underside clearance; Load-path acceptance | ||
| Set magnet and restraint: Surface and contact; Chain or strap condition; Restraint attachment; Power-loss plan | ||
| Fit cutter and safeguard: Cutter and fastening; Guard and clothing; Stop and restart features; Supply and cable | ||
| Cut controlled hole: Feed and sound; Body contact; Chip and hand boundary; Lubrication condition | ||
| Control breakthrough: Slug location and heat; Cutter fully stopped; Recovery tool; Hole edge condition | ||
| Hold lift or outage: Outage or lift event; Contact and restraint; Cutter damage; Correction and release | ||
| Remove and hand over: Body and power state; Chip and slug recovery; Hole inspection; Tool and workpiece holds |
Stop work
Hold unknown magnetic contact, plate thickness or secondary restraint. Stop for body lift, binding, power loss or abnormal vibration. Do not hold a moving drill by hand or remove magnetic holding before controlling the release risk.
Emergency response
Keep people clear of the body and slug movement paths, stop cutting safely and activate site first aid or emergency response. Use competent assistance to secure and isolate the drill before recovery; do not reach into a moving cutter.
9. Sources and review limits
Public-source access/review: 2026-10-14.
| Official source | Reviewed scope and limits |
|---|---|
| OSHA 1910.242 | Safe tool condition within scope. |
| OSHA 1910.212 | Applicable rotating-part, chip and point-of-operation safeguarding. |
| Hougen HMD906 manual OM9060619 | Manufacturer example linking magnetic holding to thickness/surface and requiring a safety chain; model-specific limits. |
No actual equipment model, SDS, site measurements, design calculations or authorization record was supplied. Product-specific limits and methods must be verified before use. Federal OSHA is a baseline within its scope; determine the applicable State Plan and local requirements. Manufacturer guidance is not government approval; an incorporated standard differs from voluntary guidance. No nationwide-compliance or expert-approval claim is made.
10. PDF guidance and FAQ
PDF A covers basic task controls; B focuses on technical failures; C covers supervision, records and handover. The article has eight stages with four items per main cell; each PDF has six key stages with three items per main cell. P/S/R/A, measurements, confirmations and signatures remain blank for actual site assessment.
PDFs are complementary six-stage extracts. Apply all eight body stages and the actual equipment/site procedure.
Can any thin plate be drilled if the magnet feels strong?
No. Verify the model material, thickness, full-contact and plate-support requirements.
Should the magnet be switched off first when the body lifts?
Do not remove magnetic holding before the drill movement risk is controlled. Stop cutting and use the accepted body-securing and isolation sequence.
Can chips be cleared with a gloved hand while rotating?
No. Wait for full stop, prevent restart and use suitable chip-handling tools.
Has a professional verified or approved this document?
No. Public sources and editorial, layout and consistency checks were reviewed using AI. No site inspection or professional technical approval has been performed. Obtain appropriate professional review before use.
11. Revision history and authorship
This is reference content written and revised with AI. It has not been verified or approved by a professional. Review by a suitably qualified professional and site authorization are required before use.
| Date | Version | Change | Review status |
|---|---|---|---|
| 2026-10-14 | US 1.0 | New US edition from assigned Korean source; task decisions, records and PDFs localized. | AI editorial review; no professional technical approval |
Korean edition revision history: 2026-09-26 (v1.0): initial article, sources, fictional analysis and PDF editorial checks. These are editorial records, not professional technical approval. US v1.0 adapts the earlier edition to United States requirements and terminology.
Site reviewers must add their actual qualifications, scope, date and approval only after the review occurs.