You need to read and understand Reg 11 of PUWER - dangerous parts of machinery.

Follow the machine guarding hierarchy.

Note that machine guarding is required to the extent 'practicable' NOT 'reasonably practicable'.

This is a higher legal standard.

Guidance as regards machine guarding can be found in BS publication PD5304 (no longer the main guidance, but still useful)

HSG 129? H&S in Engineering Workshops

Training of operators is important, but it is way down the control hierarchy

I would agree with Jim. You have been asked to do a risk assessment, i.e. to establish the risks and potential consequences of operating the machine in its current condition. Your risk assessment can then recommend various control measures so as to prevent an accident (or damage to health) to meet legal/regulatory requirements. It is then up to the person who has the authority to implement such measures to do so or to allow the press to be operated in its current condition to make the decision as to what to do, bearing in mind that this is then his responsibility.

Not knowing exactly your situation, should you have the authority to stop the work, you could then implement some measure to prevent the press being operated until appropriate safety controls are in place.

Chris

The option to be able to post pictures on here of the press might have been useful. Thanks for all the responses.

What do your insurers say ?
It is them who will pay.
Restrict flow rate..weird, since hydraulic presses already have a slow action compared to brake presses.
Tell you what, put a workpiece in the press.....leave about 2 metres showing at the front, and bend it. Watch the fast rise of the piece. It is not only the gap betwen the tools you have to consider.
I've seen a guy, doing multiple bends on one workpiece, get thrown across the floor when he forgot about the part that was a foot above the floor at bend start.
That's why light guards are moveable between vertical or horizontal.
And don't allow one guy/gal to position the work with another operating the press.

John Murray
I asked the insurance company to send in an engineer to discuss the issues regarding the machine.
His suggestions were
1. Slow down the vertical speed of the press to below 10mm/sec
2. Cut the top tooling into sections and when setting up the press make sure the top tooling is only slightly wider than the plate to be bent
3. Restrict the use of the machine to a number of operators who are trained and fully aware of the safe working operation of the machine
4. Install side fencing units to exclude any unauthorised access to the moving parts/tooling
5. Install a key switch into the electrical system to lock the machine when not in use
6. Increase the supervision level during the operation periods.
During his visit he also noticed that the control buttons in the pendant were operated by a 440 volt supply from the control board. He recommended that it was converted to 110 Volts.
Thanks for everybody's assistance with this.

SP900308
Thanks for the reply. I am just scratching the surface so far. I have come to the conclusion that ISO 18001 is far too sophisticated for this company.
I am working on the asbestos register at the minute, and you really just don't want to know about that!
Accident stats, 4 factories, 180 full time workers, 100 agency workers, day shift and night shift, 21 accidents this year, only one reportable. We have ordered 200 first aid dressings and 150 eyewash sachets to replenish stocks so far this year, so something is not happening.
Onwards and all that.....

Defeat is not one of the options available....... thanks for the support.