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Machine Shop Policy 2.7 Dept. of Mechanical Engineering

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MachineShopPolicy

PolicyNumber:2.7Supersedes:PolicyofDecember12,2011ImplementationDate:January18,2017Index:Introduction: ................................................................................................................................ 1SectionA:ShopOrganizationandCurrentResources .................................................................... 21.0PersonnelFunctions(CommontoAllShopStaff) ................................................................. 21.1FunctionsofShopManager(SM) ......................................................................................... 31.2FunctionsofMachinist(CS) ................................................................................................. 31.3FunctionsofLabManager(LM) ........................................................................................... 41.4MachineShopCommittee(MSC) .......................................................................................... 41.5CourseInstructors ............................................................................................................... 41.6SuperUserStatus ................................................................................................................. 42.0MachiningFacility ............................................................................................................... 4

SectionB:ShopUse ...................................................................................................................... 53.0RegularShopHours ............................................................................................................. 53.1SubmittingProjects ............................................................................................................. 53.2GraduateStudentShopUse.................................................................................................. 53.3UndergraduateProjectUse:MECH200,350,400,499andBME350 .................................... 63.4After-HoursShopUse ......................................................................................................... 73.5ShopCleanupandBorrowingofTools................................................................................. 74.0MachineShopCharges ......................................................................................................... 75.0Safety .................................................................................................................................. 86.0ShopConduct ...................................................................................................................... 8

SectionC:Forms&Appendices .................................................................................................... 9Introduction:TheMachineShopPolicyoutlinedheredescribesthefunctions,termsofuse,procedures,formsandresponsibilitiesoftheMechanicalEngineeringMachineShop.Anyone(i.e.Students,FacultyandClients)makinguseofthemachineshop,orthestaffoftheMachineShop,arecoveredbythispolicyandshouldbefamiliarwithit.TheprimarygoaloftheMechanicalEngineeringMachineShopistosupportandprovideinorderofpriority:

1) LearningandLaboratorySupportforUndergraduateMEStudents2) ResearchActivitiesofMEFaculty3) LearningandResearchActivitiesforGraduateMEStudents4) OtherMachiningActivities,wheretheydonotconflictwith(1),(2)or(3).

ThepolicyalsooutlinestherolesandresponsibilitiesoftheMachineShopstaff,andstrivestocreateaproductiveandsafeworkingenvironmentinthemachineshopforallstaffandusers.Italsooutlinesworkflowofjobs,andannualmaintenanceofUGlaboratoryequipment.


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SectionA:ShopOrganizationandCurrentResources

SeniorScientificAssistant(SM):RodneyKatzShopAssistants(SA):Co-opstudentsLabManager(LM):ArtMakosinskiMachineShopCommittee(MSC)

1.0PersonnelFunctions(CommontoShopStaff)

1. TotalcommitmenttosafetyintheMachineShopbyadherencetosafetyrulesandestablishedshopoperatingprocedures.

2. ObservingandassistingstudentsinthecorrectandsafeoperationofequipmentintheB103MachineShop.

3. Observanceandempathytowardsstudent’sneeds.4. SMtohaveFirstAidproficiencythroughOHScoursestakenwithinnotlessthan5years.5. HighlevelofproficiencyinCAD(SolidWorksorotherpackage)andMasterCamsoftware

(Abilitytoturn2Ddrawings,intoGcodefortheCNCmill.)6. Responsiblefortheuseandmaintenance(includingrepairs)ofequipmentinassigned

roomsandlabsoutlinedinSectionD.Keepingthemincleanandsafeworkingorderthroughregularinspectionsandrepair.

7. Ensuringthatstudentscleanuptheirrespectiveworkingarea

Dept. Chair

Lab Manager (LM)

Shop Assistant(s) (SA)

(Co-op students)

Shop Manager (SM)

Machine Shop Com. (MSC)


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1.1FunctionsofShopManager(SM)

1. Generaloperations,infrastructure,andworkassignmentintheMachiningFacility.2. ProjectmanagementthroughacceptanceandapprovalofProjectRequestForm(F2),cost

quotations,workdistribution,maintenanceofthequeue,communicationwiththeclientandsubmittingcompletedProjectRequestandChargeBackForm(F8)toLM.

3. ActingastheMachineShopSafetyCoordinator,providingtrainingsessionstostudentsonsafeandcorrectuseof(equipmentin)theShop,andonavoidinghazards.

4. UpdatingasetofwrittenMechEngineering“SafeandEfficientShopOperatingProcedures”(SESOP)fortheuseoftoolsandmachinery,andobservingthattheworkintheShopisdoneaccordingtothem.

5. Consultationwithgradstudentsandfacultyonprojectdesignissues.6. Initiatingregularseminars/demonstrationofnewequipment,design,andmachining

techniquesforgradstudents,facultyandstaff.7. Authoring,updatingthe“PrototypeDesignandManufacturingManual”usedinMECH/BME

350andmakingitavailabletoallshopusers.8. AssistingstudentsinundergradlabsessionsinB103forMECH200/350/400,andBME350

whenneeded.9. ProvidinginstructionsintheuseoftheCNCequipmentinB111,B103,andB119,when

requestedbythecourseinstructor.10. ProvidinginstructionsonhowtointegrateCADsoftwareintoMasterCam,CNCcontroller,

andtheLaserCutter.11. Providinglaserweldingservicetothedepartment.12. Participationinthedesignandconstructionofnewundergradlabequipmentasrequested

bytheLM.13. RepresentationattheFacultySafetyCommittee.14. ApprovalsofSuperUserStatus.15. Procurementofsupplies,tools,andequipment(withLM),forELWB103,B111,B123,A127.16. Initialsetupandtoolingofmachinesintheareaslistedabove.17. Generaladministrativeworkwhichincludes:

• Submittingchargeback’sforallworkintheShoptoLM.• Maintainingashopuserlogbook,forsigninginbeforeShopuse.• DistributingandcollectingShopUseandChargeBackForm(F6)• MaintainingaConsumablesCharge-BackLog(F8).

1.2FunctionsofShopAssistant(s)(SA)

1. UnderthesupervisionoftheShopManager,responsiblefortheuseandmaintenance(includingrepairs)oftheMachineShopinELWB103andB111.

2. Dailycheckandmaintenanceof3DprintersinELWA127,includingdistributionoffilamentstostudents,andimplementingchargesaccordingtothe“MechEng3DPrinterUsePolicy”ontheMachineShopwebsite.

3. AssistingtheShopManager,indeliveringin-shopsafetytalkstostudentsonsafeuseoftheShop,itsequipment,andonprotectingthemselvesfromShophazards.

4. AssistingUGstudentsduringcourselaboratorysessions.5. AssistingstudentsintheMachineShopintheabsenceoftheSMandwhenrequested.6. Maintaininganinventoryoffasteners,tapsandcuttersinB103.


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7. PreparingundergradlabsamplestogiventolerancesandservicingundergradlabequipmentasdesignatedinAppendixA,andwhenrequestedbySM.

8. NotifyingSMwhenthereislessthanaday’sworkintheWorkQueue.

1.3FunctionsofLabManager(LM)

1. Providesworkflowmanagementandreportingtothecommittee.2. Responsibleforapprovalofshoplayout,flooring,electrical,andmachineconfiguration.3. Makesperiodicalinspectionoftheshopfororderandcleanliness.4. Approvesofequipmentpurchaseforthefacility.5. MeetsregularlywithSMtodiscusssafetyandtechnicalshopissues.6. ReceivesandapprovescompletedWorkRequestForms(F2).7. ApprovalofprojectsusingCNCequipmentthatisoutsideoftheMachineShop,suchasthe

HAASmillinB123.1.4MachineShopCommittee(MSC)

1. MSCreviews,discussesandsetstheMachineShopPolicy.2. CollectsfeedbackontheMachineShopoperationfromstudentsandfaculty.3. Meetstoreviewproposedpolicychanges,andconsultswithfacultyasrequiredregarding

changes.

1.5SuperUserStatus

1. Wherethereisproofofsufficientskill/competencyandexperience,studentsmayqualifyforSuperUserstatus.ThisallowsthemtoutilizethemachiningfacilitywithoutSA/SMsupervision.(Forms;F3,F4).

2. ASuperUsercannotworkalone.Therealwaysneedstobeasecondpersonintheroomasa‘safetybackup’tohelp,orcallforhelpintheeventofanaccidentoradifficultsituation.

3. TheDepartmentdoesNOTgivetheSuperUsertheauthoritytosuperviseotherstudents. 2.0MachiningFacility

TheMechanicalEngineeringMachiningFacilityincludes:ELWB103/B111-MachineShopELWB119-CNCUndergraduateLabELWA127-UndergraduateDesignStudioELWB123-WoodworkingShop.


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SectionB:ShopUse

3.0ShopHours

ELWB103-MachineShop(1)–StudentUseEquipmentAvailable:Threemanualmillingmachines,threelathes,drillpress,bandsaw,metalbender,metalgrinder,clamps,worktables.TheShophoursare:• Undergraduatestudents: 1:00pm-6:00pm,whichincludesdesignatedLabsessions• Graduatestudents: 9:30am–5:30pm,exceptduringundergradLabsessions• SuperUsers: 5:30pm–10:30pm,underconditionsofSection3.4

ELWB111-MachineShop(2)–StaffUseOnlyEquipment:CNClathe,CNCmills(B111/103),laserwelder,cutter,MTS,Colchesterlathe. •Workhours:9:30am-12:30pm,and1:00pm-5:30pm.ELWA127-UndergraduateDesignStudio–StudentCourses(MECH/BME350,MECH400).Equipment:3Dprinters,drillpress,handtools,clamps,sander,worktables,materials.

•Studentaccesshours:7:00am–midnightduring350/400Designcourses.ELWB119-CNCUndergraduateLab–LaboratoryandStaffAccessOnlyEquipment:HAASCNCMillingMachineELWB123-WoodworkingShop–StafforSuperUserAccessOnlyEquipment:Tablesaw–Staffuseonly.

3.1SubmittingResearchProjects

1. Clients(researchers)mustsubmitaMechProjectRequestform(F2)alongwithjobdrawingstoSM.DrawingsmustadheretobasicShopstandards.ExampleinAppendixA.SMwillreviewF2anddrawings,provideajobcostquote,allocatethejob,andplacethejobintheShopworkqueue.

2. Workisstartedonlyafterclientapprovesthequoteandprovidestheiraccountnumber.3. Uponcompletionoftheproject,SMinformstheclientandsubmitsthecompletedMech

ProjectRequestformtoLM.4. Allmachiningtimemustbeaccuratelyrepresentedintheinvoices.

3.2GraduateandMech499StudentShopUse

1. Gradstudent’suseoftheMachineShopB103ispermittedunderthefollowingconditions.a. SMandSAhavebeennotifiedoftheuse,andhavegiventheirapproval.b. Theworkisconductedduringregularshophours(Section3.0).c. MECH200,350,400,BME350labsarenotrunningconcurrentlyduringtheweekd. ThereareatleasttwopeoplepresentintheMachineShop.e. TheuserfillsouttheShopUseForm(#5)andkeepstrackofhis/hertime.f. Shop’ssafetyandcleanupproceduresarefollowed.g. Theuserorhis/hersupervisoracceptsthefinancialresponsibilityfordamagingany

partsofmachinesortools.


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3.3UndergraduateCourseWork:MECH200,350,400,andBME350

1. UndergraduatestudentscanusetheB103MachineShopinordertocompletecourseworkasrequiredintheircourseoutline,forMECH200,350,400,andBME350.

2. Inordertocarryoutsuchwork,theMachineShopisavailableatthefollowingtimes:

Terms Date: Courses SessionA SessionBSpring Feb(weeks:2,3&4) 350,400Spring March(weeks:1,2,3,&4) 350,400

Summer June(weeks:2,3&4) 400Summer July(weeks:1,2,3,&4) 400

Fall Nov(weeks:2,3&4) 200

1:00-3:30pm

3:30-6:00pm

3. DuringaUGSession,amaximumofthree(3)studentgroupsarepermittedintheshop.

Only3-4studentsfromeachgroupmaybepresent.

4. Inordertoprovideequalaccess,eachUGTeamisallocatedeighttoten,2.5hourshopsessionsperterm,dependingonthesizeoftheclass.

5. Intotal,thereareabout180-210UGsessionsavailablepertermintheMachineShop.Thenumberofsessionsisdetermined&postedbyLMandSM,atthestartofeachterm.Example:6-7weeksx5days/weekx2sessions/dayx3Teams/session=180-210.Thesesessionsrepresentclassnumbersduringtheperiodsindicatedinthetableabove,andaresharedbyallUGTeamsenrolledincoursesusingtheshopduringthatterm.

6. A“UGSessionSign-upSheet”isavailableintheMachineShop.UGstudentTeamscansignupforamaximumoftwosessionsinadvance,providedthat:

a. Studentsareenrolledincoursesindicatedinthetableabove.b. Studentshavegonethroughsafetytrainingcourse.c. StudentsareencouragedtoprepareShopDrawings.SMwillthemadvisethemon

theirfeasibilityformanufacturing.ExamplesareavailablethroughAppendixA.

7. NOTE:TheMachineShopbecomesverybusyinthefinalweeksofacourse.StudentTeamsarestronglyencouragedtoeffectivelymanagetheirtimebyspreadingtheiruseoftheUGSessionsovertheterm.Inthefinalweeks,thereisnoguaranteeallstudentteamswillhavesufficientshopaccess.

8. Studentsareallowedtoimplementtheirdesignsintheirownway,aslongasitissafetodoso,anddoesnotdamagetheShopequipment.

9. Shopscheduleof1:00pmto6:00pmisatthediscretionoftheLMandSM.


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3.4After-HoursShopUseTheMachineShop(1)inB103canbeusedafterregularworkinghoursuntil10:30pm,bydesignatedstudents(SuperUsers)workingwithstudentinitiativegroups(SIG)suchasFSAE,AUV,EcoCar,andothers,providedthatthefollowingconditionsaremet:

1. TheSMhasapprovedthestudentasaSuperUser,andthestudenthascompletedtherequiredforms(F3andF8).Section1.6describesSuperUserStatus.

2. TheChairorSMhasapprovedtherequestedprojectassuitableforafter-hours.3. SuperusersintendingtousetheShopafterhoursmustfirstemailtheSM([email protected])of

theirintentionandbrieflydescribeworktobeperformed,andreportotherpersonnelinattendance.

4. Student’snameislistedontheapprovedSuperUserslistpostedinB103.5. Atleasttwopeoplearepresentintheshopatalltimes,andonemustbeaSuper-User.6. Thefacilityandtoolsarecleaned,andleftintheconditionfoundpriortouse.7. ShopSafetypolicies(5.0orlater)areadheredto.8. SuperUsersaccountforsuppliesusedandprovidethelisttoSMwithanaccountnumber.9. Anydamagetotheequipmentmustbenotedontheequipmentwithavisiblesign,and

reportedtotheSM.Thepartyinvolvedinthedamagetothemachine/facilitywillbechargedafairpricefortherepairorreplacement.TheDepartmentreservestherighttosuspendafter-houruseofthefacilityatanytime,andsuspenduseofthefacilitytoindividualswhohaveshownadisregardforpersonalsafety,equipment,and/ordisplayeddisrespectforothers.3.5ShopCleanupandBorrowingofTools

1. Everyuserisresponsiblefordailycleaningintheirrespectiveareas.Ex:Aftereveryuseofalatherormill,themachineshouldbecleanedandthewaysandchucksshouldbewipedandoiledbytheuser.EitherSMorSAcanremindusersoftheircleanupresponsibilities.

2. Handtoolscanbeborrowedforshortperiodsoftime,providedtheSMorSAareinformedandtheyaresignedoutintheLogBookinB111.Theborrowermustprovidetheirnameandemailaddress.Ifthetoolsaredamagedornotreturnedinareasonabletime,theMachineShopreservestherighttochargeborrowersforthereplacementcostoftools.

4.0MachineShopUsageCharges

1. Undergraduatestudentprojects,regularandafterhoursuseofELWB103,isatnocharge.2. ResearchprojectssubmittedtoMachineShoparebilledat$30/hourplusmaterials.3. StartingJanuary1ofeveryyear,eachSIGteamstartswithanannualcreditof12freehours

ofMachineShoppersonneltime.Afterthecreditisusedup,theteamsarebilled$30/hrforpersonneltime.

4. AnydamagetotheShopandtoolsbyaSIGmember,oragraduatestudent,willbebilledseparatelytotheSIGortheresearcher.


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4.1MachineShopMaterialCharge-Backs

1. Researchersandgraduatestudentsusingconsumableshopmaterialssuchassheetmetals,solidstock,fasteners,etc,mustenterthematerial,theamountbeingtaken,itscost,andtheiraccountnumberintheConsumablesCharge-BackLog(formF8).

2. It’stheresponsibilityoftheusertoobtaincostofthematerialstaken,fromtheMcMaster-Carrwebsite:http://www.mcmaster.com.

3. Accountswillbechargedmonthly.Thecharge-backwillincludetheenteredcostofmaterials,plus20%tocovertaxes,shippingandhandling.

5.0Safety Thefollowingfundamentalsafetyrulesapplytoallusers,atalltimes:

1. AnyoneworkingintheShoporusingequipmentinothershoplabs,musthavegonethroughsafetytrainingwiththeShopManagerorhis/herdesignate.

2. Allworkinthoseareasisapproachedanddoneaccordingtothe“SafeandEfficientShopOperatingProcedures”(tobeposted).

3. IfatanytimeSAorSMfeelsornoticesthattheequipmentisunsafetouse,heshouldstopworkandreportittoSM,(LMincaseoftheSM),whowillthendecideonthenecessaryaction.

4. AminimumoftwopeoplemustalwaysbepresentintheMachineShop.No-oneispermittedtousetheMachineShopalone!

5. AllShopUsersmustsign-inontheShopLog(Name,TimeIn/Out,MachineUsed)6. AllShopUsersandVisitorsmustwearapprovedSafetyGlassesatalltimes,whileinthe

MachineShop.7. Anyequipment,situationorareathatmaybehazardous,mustbeimmediatelyreported

totheMachineShopSupervisor.8. Familiaritywithprocedureslistedin:“SafetyFirst!”availableattheShopwebsite.9. Thefollowingitems/dress/conductarenotallowedintheMachineShop:

• Open-toefootwear,sandals,sleeve-lesstops.Teeshirtisminimum.• Ties,scarves.Longhairmustbesecurelytiedbackandconstrainedabovetheshoulders.• Ringsandjewelry.MustberemovedbeforeusingtheMachineShop.• Audiodistractionssuchasplayingofmusicthroughspeakers,orearphones.• Foodorbeverages.• Sittingorstandingonlabworkbenchesandtables.

6.0ShopConduct

1. WorkingwithinpoliciesandproceduresassetbytheUniversityofVictoriaandlistedat:http://web.uvic.ca/eqhr/policies.htm

2. Studentandworkersafetyisalwayspriorityone.Shoppersonnelsetsanexample.3. Alleffortmustbemadeformaintenanceofprofessionalbehavior,respect,andcivility

betweenstaffmembers,andbetweenstaffmembersandstudents.4. Theterm“professional”asdefinedbyUVicpolicyis:“respectforothers,commitmentto

quality,responsibility,andpersonalintegrity.“5. Useofslangandfoullanguageisnotacceptable.6. Technical,safety,workscheduling,orpolicyrelatedissuesaredirectlyaddressedwiththe

immediatesupervisor.


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7. Personalconfrontationshouldbeavoidedatalltimes.Inter-personalissuesmustbedocumentedinwritingandsubmittedtotheChair,whomayathis/herdiscretiondirectthemtoHR.

SectionC:Forms&Appendices

F2)MechProjectRequest/ChargeForm

F3)After-HoursMechShopSuperUser

F4)SuperUserExperienceForm

F8)ConsumablesCharge-BackLog

F1)MechShopEquipmentSign-OutLog(Internal)

F5)MechShopWorkLog(Internal)

F6)MechShopUseForm(Internal)

F7)MechShopWorkQueueSheet(Internal)

AppendixA:SampleShopdrawing(SeelinkonShopwebsite)


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After-Hours Mech Shop SuperUser F3

Department of Mechanical Engineering

Applicant: __________________________ Circle: Graduate Undergrad

Minimal Qualifications A, (B or C) Check

A Successfully completed Mech Eng. Shop course (Mech 200, or Mech 350, or Mech 400)

B Has demonstrated at least 50 hours of supervised work at the Mech Eng Machine Shop. Attach Experience Form (F4) specifying dates and projects worked on.

C Possesses a Recognized Machining Education Certificate (must provide copy)

Past equipment training / Request for Mech Shop use Check training

Permission to use given by:

Lathe

Mill

Drill, band saw

Sheet metal shears, benders

Welding

Other

Signature of Applicant: _________________________ Date: _______________________________

Has been instructed and tested by: Name Check

Handling of tools and equipment in the Mech Machine Shop

Basic safety rules specific to the Mech Machine Shop

Basic UVIC Emergency Procedures

Rodney Katz (initial): _______________ Date: ______________________

SuperUser privileges may be revoked at any time.


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SuperUser Experience Form F4

Department of Mechanical Engineering Machine Facility University of Victoria

Applicant: ___________________________ Location: ____________________ Phone: _________________ Supervisor _____________________________

Approx Date

d/m/y Work/Project Description Instructor /Shop

Supervisor Hours

=

=

Total hours

This is to certify that the information I here provide is true to the best of my knowledge. Signature _________________ Date _____________


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F8-ConsumablesCharge-BackLog

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