Safe Use of Utility Knives and Box Cutters

SAFETY TRAINING BRIEF
BETTER COMMUNICATION. SAFER WORKPLACE

Hazard Overview

Utility knives and box cutters are common tools found in many workplaces, but their familiarity can lead to complacency and an increased risk of injury. These tools use sharp blades that can cause serious injuries in a fraction of a second. Most injuries occur when blades slip, when team members cut toward their body or when dull blades require excessive force.

Many of the injuries associated with utility knives and box cutters happen during routine tasks, such as opening boxes, cutting shrink wrap or trimming materials. Distractions, rushed actions, awkward cutting positions and improper storage increase the risk. By using the correct knife and cutting techniques, keeping blades sharp and maintaining control of the cutting path, team members can significantly reduce the likelihood of injuries.

Safe Work Procedures

The following procedures can help keep workers safe when using utility knives and box cutters:

• Use the right tool for the task. Choose a knife or box cutter designed for the material being cut.
• Check that the blade is sharp, properly seated and not damaged.
• Use sharp blades. Dull blades require more force and are more likely to slip.
• Extend the blade only as far as necessary to make the cut. Retract the blade fully when not actively cutting.
• Cut away from your body and keep your free hand, arms, legs and body out of the cutting path.
• Maintain a stable stance and secure footing before cutting.
• Keep materials stable and supported while cutting.
• Wear appropriate personal protective equipment, such as cut-resistant gloves and safety glasses.
• Always hand utility knives and box cutters to co-workers with the handle first and the blade retracted.
• Engage blade locks or safety features when available.
• Store knives in designated holders, sheaths or tool pouches.
• Dispose of used blades immediately in an approved sharps container.
• Stay focused and avoid distractions while using a knife.
• Follow the manufacturer’s instructions when changing blades.
• Report damaged knives, missing safety features, or injuries right away.
• Report all utility knife and box cutter injuries/cuts and seek medical attention/first aid.

What Not to Do

Workers must not do the following when working with utility knives and box cutters:

• Do not use excessive force to cut materials.
• Do not cut toward your body or another person.
• Do not place your free hand in front of the blade.
• Do not use knives or box cutters with loose blades or damaged handles.
• Do not use utility knives or box cutters for purposes they are not designed for, such as turning screws or prying open containers.
• Do not carry knives with exposed blades in pockets or waistbands.
• Do not leave knives unattended with blades extended or in areas where customers could access them.
• Do not toss knives into toolboxes, drawers or trash containers.
• Do not modify knives or box cutters or use makeshift blades.
• Do not rush through cuts or try to “power through” resistance.
• Do not cut overhead or at awkward angles that reduce control.
• Do not dispose of old blades in the trash.
• Do not bypass, disable or tape down safety features.

Take Action

Complete one or more of the following activities with workers to reinforce the safety messaging. The following activities are sample activities that can be performed.

Demonstrate: Safe cutting direction, body positioning and correct hand placement to keep the noncutting hand out of the cutting path.

Point of Emphasis: Always cut away from your body and keep hands out of the line of fire.

Review: Go over the safety features on the utility knives and box cutters used in your workplace and which knives and box cutters are used for common tasks in your workplace.

Group Discussion: Review causes of utility knife and box cutter injuries, such as rushing, dull blades and cutting toward the body. Focus on prevention techniques.

Group Discussion: What are some do’s and don’ts of working with utility knives and box cutters?

Group Discussion: Have you ever had a close call or near miss with a utility knife or box cutter? How could it be prevented in the future?

Applicable Standards/Regulations/Policies

The following list provides notable applicable standards, regulations and guidance. Please note that additional federal and state rules may apply, as well as company safety policies.

• OSH Act, Section 5(a)(1) (General Duty Clause)
• OSHA 29 CFR 1910.132 (Personal Protective Equipment)
• OSHA 29 CFR 1910.242 (Hand and Portable Powered Tools and Other Hand-Held Equipment)

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THE HOLT GROUP LLC | www.theholtgroupllc.com

This Safety Matters document is not intended to be exhaustive, nor should any discussion or opinion be construed as legal advice. Readers should contact legal counsel for appropriate advice. © Zywave, Inc., The Holt Group LLC All rights reserved. All images are from Google Images and Story Blocks. Revised 2026