Abstract: Employee #1 was working as an electrician at an auto assembly plant. He noticed that a part that had been spot welded by robots at a previous station was out of position. Employee #1 broke a light curtain, disabling another robot, and climbed up on an auto/cab shuttle transfer to hit the part into place. As the shuttle transfer device completed a cycle it caught Employee #1's right leg between the top and bottom rail. In order to extricate Employee #1, the leg had to be amputated by rescue personnel. No lockout procedures were used by Employee #1, although he had received training and was an authorized employee.