Relied on Robot Cage Door Interlock; Operator closed the door and started the robot, killing the maintenance tech

At 10:35 a.m. on December 2, 2024, Employee #1, 18, was performing maintenance on a sensor inside a robotic enclosure. As he entered the area, the robot was stopped by the entrance sensors. While he was cleaning the sensor, a coworker reset the machine from the control panel, unaware that Employee #1 was still inside the enclosure.

The robotic arm activated and struck Employee #1, reportedly lifting and placing him onto a roller platform. He sustained multiple internal and external injuries and was killed as a result of the incident.

Violations/PenaltiesSeriousWillfulRepeatOtherUnclassTotal
Initial Violations639
Current Violations325
Initial Penalty$62,890$0$0$2,790$0$65,680
Current Penalty$34,755$0$0$5,895$0$40,650
FTA Penalty$0$0$0$0$0$0
#Citation IDCitation TypeStandard CitedIssuance DateAbatement Due DateCurrent PenaltyInitial PenaltyFTA PenaltyContestLatest EventNote
1.01001ASerious19100146 C0105/28/2025$11,585$11,585$0I – Informal Settlement 
2.01001BSerious19100146 C0405/28/2025$0$11,585$0I – Informal Settlement 
3.01001CSerious19100146 G0105/28/2025$0$11,585$0I – Informal Settlement 
4.01002Serious19100147 C0105/28/202508/22/2025$16,550$16,550$0I – Informal Settlement 
5.01003ASerious19100219 C02 I05/28/2025$6,620$6,620$0I – Informal Settlement 
6.01003BSerious19100219 E02 I05/28/2025$0$0$0I – Informal Settlement 
7.02001AOther19101200 E0105/28/2025$4,965$4,965$0I – Informal Settlement 
8.02001BOther19101200 H0105/28/2025$0$0$0I – Informal Settlement 
9.02002AOther19100134 C02 II05/28/202508/22/2025$930$930$0I – Informal Settlement 
10.02002BOther19100134 E0105/28/202508/22/2025$0$930$0I – Informal Settlement 
11.02002COther19100134 K0605/28/202508/22/2025$0$930$0I – Informal Settlement 

Source: https://www.osha.gov/ords/imis/establishment.inspection_detail?id=1790802.015

2 thoughts on “Relied on Robot Cage Door Interlock; Operator closed the door and started the robot, killing the maintenance tech”

  1. Lawrence Halprin

    The OSHA write up has too many gaps. It could be interpreted to mean there were entry sensors but no gate or means of blocking the sensors. If that was the situation, I would investigate and probably terminate the employees that developed and installed a walk in design like that. If other sensors were supposedly to pick up a person inside the cell and failed, and there was not adequate redundancy and cross monitoring again I would likely terminate the designer unless the proper design was rejected for cost reasons in which case I would terminate the manager that made that decision.
    If there was a gate, then the question was how did it get closed. In any event, there was apparently an accident waiting to happen. If IOSHA couldn’t justify a willful, it should have cited the employer for each provision of the LOTO standard that+was not implemented

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