Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop 1

Institute of Applied Technology

Year 12

Machining

Semester 1

September 2013

Module 2: Safety in Machine shop Prepared by : Mechanical Teacher 2

Machining

Module 2: Safety in the Machine shop

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

Video 1 – Machine Shop Safety

Lets Warm Up – Think, Pair, Share

Minds On Activity

Video 2 – Lathe Safety

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop 4

Objectives

After the completion of this unit, you will be able to:

Recognize safe and unsafe work practices in a shop.

Identify and correct hazards in the shop area.

Perform his job

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop 5

Introduction

All hand and machine tools can be dangerous if used improperly or carelessly.

Working safely is one of the first things a student should learn because the safe way is usually the correct and most efficient way.

Any one learning to operate machine tools must first learn the safety regulations and precautions for each tool or machine.

Too many accidents are caused by careless work habits.

Fig. 2.1 (a) shows a clean and safe machine

shop, while Fig.2.1 (b) shows untidy and unsafe machine shop

Untidy and unsafe machine shop

Tidy and safe machine shop

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1.0 Safe Work Habits

Safety is everyone’s business and responsibility.

Modern machine tools are equipped with safety features, but it is still the operator’s responsibility to use these machines wisely and safely.

Accidents can be avoided, and a person learning the machine tool trade must first develop safe work habits.

Accidents don’t just happen; they are caused.

Fig. 2.1 (b) : untidy and unsafe machine shop

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1.0 Safe Work Habits

A safe worker should: Be neat, tidy, and safely dressed for the job he or she is doing. Develop responsibility for personal safety and the safety of fellow workers. Think safely and work safely at all times. Fig. 2.2 Safety in a machine shop may be divided into two broad categories: Those practices that will prevent injury to workers. Those practices that will prevent damage to machines and tools.

Always safety first

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2.0 Personal Grooming

1. Always wear approved safety glasses in any area of the machine shop.

a. The most common are plain safety glasses with side

shields as shown in Fig. 2.3 (a). The lenses are made of shatterproof glass.

b. Plastic safety goggles (Fig.1.3 - b) are generally worn by anyone wearing prescription eyeglasses. These goggles are soft, flexible plastic and fit closely around the upper cheeks and forehead.

Safety Glasses

The following rules should be observed when working in a machine shop:

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2.0 Personal Grooming

2. Never wear loose clothing when operating any machine:

a. Always roll up your sleeves or wear short sleeves. Fig.2.4.

b. Clothing should be made of hard, smooth material that will not catch easily in a machine.

c. Remove your necktie before starting a machine.

3. Gloves: a. Hand Gloves should be worn during machine setup, cleaning and when handling machine’s attachments and

tools.

b. Gloves should not be used while operating the machine as it may get caught by the rotating parts. Fig. 2.5

Safety short sleeve overall

Hand Gloves

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2.0 Personal Grooming

4. Safety shoes:

a. Wear safety shoes. Fig. 2.6.

5. Long hair:

a. Long hair must be protected by a hair net or an approved

protective shop cap.

b. One of the most common accidents on a drill press is caused by

long, hair.

6. Remove wrist watches and rings these:

a. These can get caught in the machine, causing painful and often serious injury.

Safety shoes

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

Safe Working Practice

(Drilling Machine)

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Safety Hazards…

http://www.youtube.com/watch?v=2eRietVVWT0

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3.0 Housekeeping

1. Always stop the machine before you attempt to clean it.

2. Always keep the machine and hand tools

clean and tidy.

3. Always use a brush, not a piece of cloth to remove any metal

chips. Fig. 2.7 (a) and (b).

4. Oily surfaces can be dangerous. Oily surfaces should be cleaned with a cloth.

4. Keep floor and hand tools free from oil and grease Fig. 2.8.

Metal chips result during machining

The following points should be observed.

Use brush to remove metal chips

Oily surfaces are very dangerous

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3.0 Housekeeping

5. Never place tools or materials on the floor

close to a machine.

6. Sweep up the metal chips on the floor frequently.

7. Do not place tools and materials on the

machine table; use a bench near the machine. Fig.2.9

Never place tools on the machines

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

4.0 Safe Work Practices

1. Do not operate any machine before understanding its mechanism and knowing

how to stop it quickly.

2. Before operating any machine, be sure

that the safety devices are in place and in

working order. Fig. 2.11

3. Always disconnect the power when making

repairs to any machine.

4. Always be sure that the cutting tool and the

workpiece are properly mounted before starting the machine.

Machine guard is one of the machine safety devices

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4.0 Safe Work Practices

5. Never use a rag near the moving parts of a machine. The rag may be drawn into the

machine, along with the hand that is holding it. Fig. 2.12.

6. Keep hands away from moving parts. It is dangerous practice to “feel” the surface of

revolving work or to stop a machine by hand.

7. Never measure, clean, or make any adjustment

unless the machine has come to a complete

stop. Fig. 2.13.

It is dangerous to use a rag near moving parts

Stop a machine to take measurements

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

4.0 Safe Work Practices

8. Never have more than one person operate a machine at the same time.

9. Never start a machine until you are sure that the cutting tool and machine parts will clear the

workpiece. Fig. 2.14.

10. Before you handle any workpiece, remove all

burrs and sharp edges with a file. Fig. 2.15.

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Machine parts clear the workpiece

File is used to remove sharp edges

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

4.0 Safe Work Practices

11. Do not attempt to lift heavy or odd shaped objects that are difficult to handle on your own.

12. For heavy objects, follow safe lifting practices:

a. Assume a position in which you keep your knees

bent and back straight. Fig.2.16 – b.

b. Grasp the object firmly.

c. Lift the object by straightening your legs and keeping your back straight.

This procedure uses the leg muscles and prevents injury to the back.

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Fig. 2.16 – a: wrong way to lift an object. Fig. 2.16 – b: right way to lift an object.

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4.0 Safe Work Practices

13. Be sure the work is clamped securely in the vise or to a

machine table.

14. Get first aid immediately for any injury, no matter how small.

Report to your instructor.

15. Use the proper wrench for the job, and replace nuts with worn corners.

16. It is safer to pull on a wrench than to push. Fig. 2.17

Pull on a wrench, don’t push

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

Captain Safety Episode 4

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Safety Hazards…

http://www.youtube.com/watch?v=oJHy2239CcU

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

5.0 Fire Prevention

1. Always dispose oily rags in proper metal containers. Fig. 2.18.

2. Know the location and the operation of every fire extinguisher in the shop. Fig. 2.19 3. Know the location of the nearest fire exit. 4. Know the location of the nearest fire alarm box and its operating procedure.

Safety container

Fire extinguisher

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6.0 Electric hazards

The student must stick to the rules and procedures regarding the electric

hazards and safety provided through out the electrical course.

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

7.0 Safety contract

All students should read,

understand and sign the following

safety contract before starting any

work in the machine shop.

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

Consolidate…

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Pulling the safety thoughts together…

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

References

1. Technology of Machine Tools. Seventh Edition, McGraw-Hill Companies,

2. Machine tool and Manufacturing technology, Steve F. Krar, Mario Rapisarda, Albert F. Check., Delmar Publishers.

3. championmedicalservices.wordpress.com.

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Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

IN CLASS WORKSHEET 2 – back of Module 2

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Finish in class worksheet

- Share your answers

and thoughts with your

partner – worksheet was

done in class.

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

Homework 2 – Lab Safety

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In group of 4 –Design/Build a poster or a product

on lab safety

Topics: 1. Personal grooming 2. Housekeeping 3. Safe work practices 4. Fire & Electrical Prevention

NO Copy & Paste or you will get a Zero!

Prepared by : Mechanical Teacher Module 2: Safety in the Machine shop

Quiz Module 2

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Sunday Sep 29, 2013