Recently we lost a member, Mike Poulton, due to an accident in his shop. At this stage it is unknown exactly what happened, only that he was experimenting with something. Mike was very knowledgible and active in pursuing many technical interests that went beyond the scope of most shops. His loss is both sad and troubling. We may or may not eventually learn the details of his accident, but even if we do not, it would be good for everyone to consider their operations and how to reduce the risks involved.
In addition to neon shop work, I spent many years in an aviation related environment--in aircraft, in the repair shop, and in management. During that time I saw a variety of minor and some major accidents and also learned a few things about preventing them.
The often taught mitigation technique involves the so-called "swiss cheese" model. It is used to illustrate the concept that most accidents are the result of a culmination of factors rather than just one problem. For example, one slice (with its holes, of course) might be human factors--are you tired?...healthy?...preoccupied with some other matter? (getting home from a flight is an often cited example) ....another factor might be equipment. Is it functioning properly?....was it just serviced but not yet tested? (you'd be surprised how often a new problem crops up after a mechanic works on another system) ...how about training? ...are you familiar with the piece of equipment? (be it an aircraft or anything else) and are you current and updated on any relevant procedures? Etc.
In the often taught model...any one or two of these might be passable. The "holes" in one slice are blocked by a lack of a hole in the next slice. But if you have too many factors ("holes") the likelihood of them aligning is increased and (as the slide in the aviation risk management class shows) you pass through all of the holes and arrive at your accident.
No model is perfect. But the concept is valid. In the shop, one can mitigate hazards but only if one can first identify that something is a hazard. This is where one must take a step back and look at their situation. What are you trying to accomplish? Are you using the right tool for the job? Are you using it correctly? Are you (and any bystanders) wearing appropriate protective gear? Are there any objects nearby that could pose an additional hazard if you move suddenly (cords or hoses to trip over?.....imagine the minor annoyance of bumping your aging transformer--it's not deadly...but if you reflexively jump back and then trip over something you could be injured far more seriously than the initial "bite") etc. Any of these aspects can be a dedicated lecture in and of itself.
One item we often tend to overlook is perhaps the most valuable-- before undertaking a task that is new or unfamiliar, not only should you practice it in a controlled manner, maybe even do a dry run of the motions with power off if it is applicable, but you should seek out the assistance of someone who has done it, or at least something very similar, before. That extra set of eyes can easily be a lifesaver before the first valve is opened or the first switch is thrown. Let someone look over your system and your plan. Video calls and photos are nice and all, and I have used them as a tool to aid others, but nothing can substitute for a second set of trained eyeballs looking for potential hazards.
Even if we never learn what happened to Mike, I hope that everyone is at least giving more thought to how to manage the familiar and the unfamiliar risks that exist in their shops. I'd like to think that Mike would have approved of this message.