SOG 2205 WORKSHOP PRACTICE II

Objectives
1. Learn how to use tools correctly for dimensioning.

2. Teach learners the proper use of equipment/machines to avoid accidents in

the workplace.

3. How to identify , use and care about tools and equipment.

 Course Outline
[Link] of workshop Safety
[Link] and Forming processes
[Link] to machining processes
[Link] Processes and Machine Tools
a)Shaping
b)Grinding operations
c)Turning
d)Drilling
e)Milling
f)Sheet-metal operations
[Link] Processes
 Review of important aspects
What is a Workshop?

What do you understand by Workshop practice?

What is a hazard?

What are hazard points?

What are the types of hazards?

What are the four categories of workplace hazards?

Revision of Workshop Safety
 Safety in the workshop
Safety in its simplest form is a state of being at little or no risk of injury
resulting from a harmful external impact, inhalation, or contact.

 It is a holistic approach to a state of wellbeing that requires people to

feel they are free from being harmed in addition to actually being safe.

 To be safe in any work environment, you must think about the nature of
your job and plan ahead to avert hazards that could be associated with
it.
 Safety in the workshop Cont’d
 It reduces the chances of any accident happening at the workplace
with workers or any other.

 In the field of safety, it is generally recognized that consequences are

only negative and therefore the management of safety risk is focused
on prevention and mitigation of harm.
 Aims of workshop safety
1. Creating safe workplace.

2. Increase workers safety.

3. Always have emergency plans.

4. Check all the possible chances of accidents for preventing loss of life
and permanent disability of any industrial employee, any damage to
machine and material as it leads to the loss to the whole establishment.
 Aims of workshop safety Cont’d
5. Eliminate accidents causing work stoppage and production loss.

6. Prevent accidents in industry by reducing any hazard to minimum.

7. Reduce workman’s compensation, insurance rate and all the cost of accidents.

8. Educate all members regarding the safety principles to avoid accidents in

industry.

9. Achieve better morale of the industrial employees.

 Aims of workshop safety Cont’d
10. Have better human relations within the industry.

11. Increase production means to a higher standard of living.

 3-step approach to safety at workplaces
 A person having control of the workplace or a person having control of
access to the workplace must, as far as practicable employ the three step
approach to safety at work. This approach involves three steps as follows:

Step 1 Recognition: Identify hazards to which a person at the

workplace is likely to be exposed;

Step 2 Evaluation: Assess the risk of injury or harm to a person

resulting from each hazard if any is identified in step 1; and
 3-step approach to safety at workplaces Cont’d

Step 3 Control: Consider the means by which the risk may be

reduced.

 Note:
 It takes effort to recognize, evaluate, and control hazards.
 If you do not recognize, evaluate, and control hazards, you may be
injured or killed by machinery, electricity, electrical fires, or falls.
 If you use the safety model to recognize, evaluate, and control
hazards, you will be much safer.
 Safety obligations
Every workplace partners have an obligation to ensure safety at every
stages of their involvement. You can have more than one set of obligations,

 For example, if you are an employer and a principal contractor (a sole

proprietor) at the same time within the same workplace. In this case,
you would have two sets of obligations - those of an employer on one
hand and an employee on the other.

 You must meet all the safety obligations. This can be done through
the following ways:
 Safety obligations Cont’d
1. Regulations

Issue regulations that either prohibit exposure to a risk

or prescribe ways to prevent or minimize exposure to such risks and you must
comply with such regulations.

2. Codes of practice

Code of practice is a document which gives practical advice about ways to

manage exposure to risks identified as typical in workplace.
This document states ways to manage exposure to risks within workplace and
job practices.
To meet your obligations, you must follow codes of practice or adopt another
way that offers at least the same.
 Safety obligations Cont’d
3. Where there is no regulation or code of practice about exposure to a
risk,

You can meet your obligations by choosing any appropriate way to

minimize exposure to a risk and you must take reasonable precautions
and exercise proper diligence in making sure the risk is managed.
To properly manage exposure to risks, the risk management process
must be undertaken to identify hazards and determine appropriate
control measures.
Such processes are set out in a document called the risk management
code of practice
 Safety obligations Cont’d
4. Safety planning

Plan your work and plan for safety.

Take time to plan your work, not alone, but with others.
Safety planning is an important part of any task.
It is hard to take the time to plan for safety. But, you must plan.
Plan to be safe!
 Ensuring safe work environment
Employers have a duty to minimize the risk of injury at their workplace by
ensuring a safe work environment through inductions training and re-
training.

Induction and training

Supervisors, workers and newly employed workers should be

formally trained or retrained to have the required requisite
knowledge for the application of safe practices in the use of
machinery in their pool. This is particularly important for new
employees or inexperienced people undergoing training.
 Areas of training and education
1. Machinery safety procedures, including emergency procedures;

2. Correct and safe way of operating machinery;

3. Knowledge and understanding of spotting possible dangers within and

around workshop and machinery;

4. The purpose and function of safety;

 Areas of training and education Cont’d
5. Reporting of faults (troubleshooting procedure) in machinery including
detection of defects and malfunction in machine parts and operation
especially guard defects;

6. The importance of wearing and care of PPE;

7. Need for good house and safe workstation keeping- workshop

organization and management to keep workplace and staff safe;

8. Other statutory requirements

 Types of safety
 The following general types of safety are considered in the workshop;

 Safety of self.

 Safety of job.

 Safety of machines tools.

 However there are general safety precautions to be adopted while

working in any workshop
 General Safety Precautions while Working in a Workshop

1. One should not leave the machine ON even after the power is OFF and
until it has stopped running completely. Someone else may not notice that
the machine is still in motion and be injured.

2. Operator should not talk to other industrial persons when he is operating a

machine.

3. One should not oil, clean, adjust or repair any machine while it is running.
Stop the machine and lock the power switch in the OFF position.
 General Safety Precautions while Working in a Workshop Cont’d

4. One should not operate any machine unless authorized to do so by

the authorized person in the shop.

5. Always check that work and cutting tools on any machine are
clamped securely before starting.

6. The floor should be kept clean and clear of metal chips or curls and
waste pieces.

7. One should not lean against the machines.

 General Safety Precautions while Working in a Workshop Cont’d

8. Put them in the container provided for such things. Scraps and chips or
curls may cut through a shoe and injure the foot.

9. Defective guards must be replaced or repaired immediately.

10. One should not operate any machinery when the supervisor or instructor
is not in the shop.

11. All set screws should be of flush or recessed type. Projecting set screws
are very dangerous because they catch on sleeves or clothing.
 General Safety Precautions while Working in a Workshop Cont’d

12. One should not try to stop the machine with hands or body.

13. Only trained operator should operate machine or switches as far as

possible.

14. Always take help for handling long or heavy pieces of material.

15. Always follow safe lifting practices.

16. No one should run in the shop at work time.

 General Safety Precautions while Working in a Workshop Cont’d

17. Always keep your body and clothes away from moving machine parts. Get
first aid immediately for any injury.

18. Never talk to anyone while operating the machine, nor allow anyone to
come near you or the machine.

19. Stop the machine before making measurements or adjustments.

20. Operator should concentrate on the work and must not talk unnecessarily
while operating the machines.
 General Safety Precautions while Working in a Workshop Cont’d

21. Never wear necktie, loose sweater, wristwatch, bangles, rings, and loose fitting
clothing while working in workshop.

22. Always wear overcoat or apron.

23. Stop machines before attempting to clean it.

24. Make sure that all guards are in their place before starting to operate a
machine.

25. Do not attempt to operate a machine until you have received operating
instructions.
 General Safety Precautions while Working in a Workshop Cont’d

26. Be thoroughly familiar with the ‘stop’ button and any emergency stop
buttons provided on the machines.

27. Remove burrs, chips and other unwanted materials as soon as possible.
They can cause serious cuts.

28. Do not leave loose rags on machines.

29. Wash your hands thoroughly after working to remove oils, abrasive
particles, cutting fluid, etc.
 General Safety Precautions while Working in a Workshop Cont’d

30. Report all injuries to the foreman, howsoever small. Cuts and burns
should be treated immediately.

31. Keep the work area clean.

32. Keep your mind on the job, be alert, and be ready for any
emergency.

33. Always work in proper lighting.

 General Safety Precautions while Working in Machine Shop

 The following safety precautions or guidelines are generally adopted for every metal
cutting or machining shop. They must be strictly followed for safety.

1. One should use the correct tools and work holding devices recommended for the
process.

2. One should hold the work piece and tool securely on the machine.

3. One should clamp the tool correctly. An overhanging tool may cause catastrophic
failure of the tool, work piece or the machine tool.

4. One should not try to remove chips from the machine with your hands.
General Safety Precautions while Working in Machine Shop Cont’d

5. Never use compressed air from mouth. Use brush.

6. One should not touch a job-piece with bare hands while doing inspection or removing
it from the machine. Use gloves always.

7. One should operate the machine at recommended operating conditions based on

work material and tool material combination and other cutting conditions specified.

8. One should use recommended coolant depending upon work-tool material

combination.

9. During machining ductile materials, use chip breakers and chip guards.
General Safety Precautions while Working in Machine Shop Cont’d

10. One should re-sharpen the tools immediately when it starts producing rough
surfaces on the job-piece or produces chatter.

11. One should not run the machines at speed higher than recommended. It
may produce vibrations and chatter and damage job-piece, tool, or both.

12. Provide sufficient approach and over travel distances wherever necessary.

13. In case of power failures, switch off the machine and retrieve tool from the
workpiece.
General Safety Precautions while Working in Machine Shop Cont’d

14. One should wear goggles to protect eyes from flying chips.

15. Machines are governed by the old clinch; garbage input, garbage
output. The skill of the operator is often the limiting factor for the
machining operation.

16. Stop machine before attempting to clean, removing tool or workpiece.

Instant action checklist in a machine workshop
Instant action checklist in a machine workshop Cont’d
 How most accidents happen when Machining
Most accidents at all types of machine, including automatic and CNC
machines, happen to operators during normal operation when:

Loading/unloading components

Removing swarf

Taking measurements and making adjustments (to the coolant supply in

particular)
 How most accidents happen when Machining Cont’d
On manually operated machines, the most dangerous machine movements
are the rotating, cutting, shearing, sawing or pressing movements of tools,
particularly on:

Presses

Drilling machines

Milling machines

Lathes
 How most accidents happen when Machining Cont’d
Metal cutting saws

Guillotines

Grinding machines

 Hands are most frequently injured, the most numerous injuries being cuts
and abrasions, many of which are severe. Broken bones and dislocations
are numerous. Amputations of fingers and hands are not infrequent and
there are some fatalities, often arising from entanglements, every year. Eye
injuries are also common.
 How most accidents happen when Machining Cont’d

 On automatic and computer controlled machinery, a larger proportion of

accidents happens at automatically and computer controlled clamps, axes,
tables, swarf removal equipment, chucks and other work handling
equipment.

 At all types of machinery, a large number of accidents happen to setters,

electricians and maintenance personnel during set-up, inspection, fault-
finding, maintenance and repair.
 First Aid in the workshop
Even after taking all necessary safety precautions and measures,
sometimes accidents may also occur in industries.

 After major or minor accidents, an injured worker requires immediate

preliminary treatment in the absence of same his condition may
become highly critical.

 The minimum first aid provision for any workplace is:

 A suitably stocked first aid box

 First Aid in the workshop Cont’d
 An appointed person to take charge of first aid arrangements

 Information for employees about first aid arrangements

 An appointed person is someone the employer chooses to:

 Take charge when someone is injured or becomes ill, including

calling an ambulance if required
 First Aid in the workshop Cont’d
 Look after the first aid equipment, e.g. restocking the first aid box.

 Appointed persons do not need first aid training though emergency first aid
courses are available.

 Depending on the category of risk and the number of people employed, it

may be necessary to appoint a first-aider.
 First Aid in the workshop Cont’d
 A first-aider is someone who has undertaken training by a competent
training provider, appropriate to the circumstances, and must hold a valid
certificate of competence in one of the following:

 First aid at work (FAW);

 Emergency first aid at work (EFAW);
 Any other level of training or qualification that is appropriate to the
circumstances.
 First Aid Box
 For first aid services, a first-aid box containing the following items is always
kept ready during working hours in the shops or nearby working places
where there are chances accidents to occur.

[Link]. Name Quantity

1 Pair of scissors 1
2 Large size sterilized dressings 12
3 Medium size sterilized dressings 12
4 Small sized sterilized dressings 24
5 Large size burn dressings 12
 First Aid Box Cont’d
[Link]. Name Quantity
6 Packets of sterilized cotton wool 2
7 Rolled bandages 10 cm wide 12
8 Rolled bandages 5 cm wide 12
9 Bottle (4 oz) of salvolative having the doze and 1
made of administration indicated on label
10 Safety pins 2 Pkts
11 Eye drops 1 Small bottle
 First Aid Box Cont’d
[Link]. Name Quantity
12 Adhesive plaster 2 rolls
13 4 oz bottle containing KMnO4 crystals, etc. 2
14 4 oz bottle containing a 2% alcoholic solution 1
15 Betadine ointment (50mg) 1
16 Saframycine ointment (50mg) 1
17 Detol 1