Despite advances in mechanization, mining remains among the most physically demanding and hazardous of all occupations. Traumatic injuries resulting from machinery, powered haulage, and falls have long been identified as a significant problem for the mining industry. According to the Mine Safety and Health Administration (MSHA), during 1995–2004 there was a 42% decrease in days lost due to machinery injuries, a 51% decrease in days lost due to powered haulage injuries, and a 34% decrease in days lost due to falls.

NIOSH contributed to this significant improvement through its machine safety research program. NIOSH-developed research products and recognized experise are being used by our stakeholders to further reduce the risk of machine-related injuries. Examples include:

• A close-proximity warning device: The research product (HASARD - Hazardous Area Signaling and Ranging Device) has been recently licensed to three firms that manufacture the system for their own use and commercial sales.
• Technical guidance in the application of proximity warning systems: MSHA and equipment manufacturers make use of NIOSH expertise to aid in decision-making on effective proximity warning systems and technologies to prevent accidents.
• A set of best practices for system safety: NIOSH collaborative research has developed a set of documents relating to the safety life cycle for programmable electronic mining systems. The research has been integrated into the national and international mining communities.
• A computer program that evaluates mine illumination systems: NIOSH-developed software (called the Crewstation Analysis Program) is routinely used by MSHA’s Approval and Certification Center in the approval process for mine lighting systems.

Miners interact with a wide assortment of machinery and tools in the course of their work. They work in an environment that is dynamic and often unforgiving. Work environments involving extraction, bolting, and haulage require the integration of large mobile machinery working in confined space. It is a recipe for danger as the consequence of small errors can be serious. According to MSHA, 10 miners on average are killed each year by being run over or pinned by mobile mining equipment. Therefore, a systematic study of the interaction of miners, their tools and equipment, and their work environment is needed to reduce the risk of serious injury.

Both labor and industry have expressed the need for a "systems perspective" to reduce the risk of serious injury. A systems perspective requires the integration of human-centered design principles with new mining technology. Little research has been done in this area partially because of the difficulty and potential dangers in collecting sufficient data in the underground and surface work environments. However, with advances in computer modeling and simulation methods, coupled with the unique test facilities of the NIOSH Mining Program, most of the data can be collected either virtually or in simulated environments. This allows for the integration of human-centered design principles into work system and machinery design.

The basis for current and future work is risk assessment. Proactively researching issues that can integrate a large number of system variables (e.g., visibility, work station and control design, computerized control of machinery, and maintenance and repair tasks) will promote the better design of new technology to reduce risk. Partnering with the United Mine Workers of America, original equipment manufacturers (e.g., Joy Mining Machinery, Inc., J. H. Fletcher & Co., DBT America), and government agencies (MSHA) will proactively develop and disseminate science-based solutions to the mining industry.

Reducing accidents associated with machinery, powered haulage, and falls in mining requires full-scale testing and analysis of equipment and apparatus. Without a regulatory impetus, manufacturers are often unwilling to invest in finding solutions to these safety hazards. The NIOSH Mining Program is unique in its test facilities for full-scale evaluation of mining machinery. Our record of partnering with industry and labor will help to proactively develop and disseminate injury prevention strategies.