Emergency Stop Procedures Toolbox Talk

Emergency stops are used when a machine, tool, conveyor, lift, or piece of equipment creates an immediate danger. When something jams, grabs material, pulls in clothing, malfunctions, or puts a worker at risk, everyone needs to know how to stop the equipment fast.

This talk focuses on knowing where emergency stop controls are, when to use them, and what to do after the equipment stops. Stopping the machine is only the first step—safe communication, lockout, inspection, and restart are just as important.

Why This Matters

• A quick emergency stop can prevent crushing injuries, amputations, caught-in incidents, and struck-by hazards.
• Workers may panic if they do not know where the stop button, pull cord, disconnect, or shutoff is located.
• Equipment can restart unexpectedly if the hazard is not controlled after the stop is used.
• Clear communication helps keep other workers from entering the danger zone during a shutdown.
• Safe restart prevents the same problem from happening again after a jam, fault, or malfunction.

Common Hazards

• Emergency stop buttons, pull cords, or disconnects blocked by materials, carts, cords, ladders, or debris.
• Workers operating equipment without knowing the nearest shutdown method.
• Reaching into a machine after an emergency stop without locking out or verifying zero energy.
• Resetting equipment before confirming everyone is clear of pinch points, blades, rollers, belts, or moving parts.
• Ignoring repeated trips, jams, alarms, vibration, overheating, or unusual machine behavior.
• Using rented, older, or temporary equipment where emergency stops are hard to find, unlabeled, or not tested before use.

Safety Checklist

Before Work Begins

• Locate all emergency stop buttons, pull cords, disconnects, shutoff valves, and control stations before operating equipment.
• Make sure emergency stops are visible, labeled, accessible, and not blocked.
• Check that operators and nearby workers understand when and how to stop the equipment.
• Review the communication signal for stopping work, clearing the area, and calling for help.
• Confirm guards, interlocks, warning lights, alarms, and control panels are in working condition.
• Know who is authorized to inspect, reset, and restart the machine after an emergency stop.

During Work

• Use the emergency stop immediately if a worker is caught, pulled toward moving parts, struck, trapped, or in danger.
• Stop equipment if guards fail, material jams, the machine malfunctions, or the work area becomes unsafe.
• Alert nearby workers and keep everyone clear of the machine after it stops.
• Do not reach into equipment, clear jams, or remove material until the energy source is controlled.
• Lock out or tag out equipment when required before inspection, cleaning, adjustment, or repair.
• Do not reset or restart until the hazard is fixed, all workers are clear, and the authorized person gives approval.

Crew Talking Points

• Where are the emergency stops or shutoffs for the equipment we are using today?
• Are any stop buttons, pull cords, disconnects, or panels blocked or hard to reach?
• What situations require using the emergency stop without hesitation?
• Who is allowed to reset and restart the machine after an emergency stop?
• How will we communicate that equipment has stopped and must not be restarted?
• Ask questions now if you are unsure where a shutoff is or what to do after using it.

Stop Work If

• Emergency stop controls are missing, damaged, blocked, unlabeled, or not working.
• Workers do not know how to stop the equipment quickly in an emergency.
• A machine continues moving, coasts too long, or does not shut down as expected.
• Someone tries to clear a jam, reach into equipment, or make repairs without controlling hazardous energy.
• The equipment has repeated alarms, faults, jams, overheating, vibration, or unusual noise.
• There is confusion about who can reset, inspect, or restart the equipment.

Final Reminder

Know how to stop the machine before you start it. Use the emergency stop when someone is in danger, then keep the equipment shut down until the hazard is controlled.