HACKSAW CUTTER MACHINE IN - 01

Work Instructions
1. 1. Safety First:
Always wear appropriate safety gear, including gloves, eye protection, and ear
protection, when operating a hacksaw cutting machine.
2. 2. Prepare the Material:
Ensure the material to be cut is securely clamped in the vice or on the machine's
support.
3. 3. Select the Right Blade:
Choose a blade that is appropriate for the material and thickness you are cutting. A
blade with the correct teeth per inch is essential for a clean cut.
4. 4. Adjust the Settings:
If using a power hacksaw, adjust the speed and feed rates according to the
material and blade type. Some machines have adjustable stroke speed and
hydraulic control.
5. 5. Initiate the Cut:
Start the cutting process slowly to allow the blade to settle into the
material. Maintain consistent pressure and feed rate.
6. 6. Coolant (if applicable):
If the machine uses a coolant system, ensure it is properly functioning and the
coolant is applied to the blade to reduce heat and friction.
7. 7. Maintain the Machine:
Regularly clean the machine, inspect the blade, and ensure all parts are functioning
correctly.
8. 8. Proper Disposal:
Dispose of scrap metal and waste materials responsibly.

CNC LATHE MACHINE IN - 03

1. Pre-Operational Safety Checks:

 Ensure familiarity with CNC software: Understand how to use the software for
nesting, tool-pathing, and other function
 Locate and know the operation of emergency stop and power ON/OFF: This is
crucial for safety.
 Verify that safety guards and devices are in position and secured: These
prevent accidents.
 Confirm that only suitable materials for the turning process are used: Ensure
the material is appropriate for the cutting tool and machine.
2. Pre-Operational Procedures:
 Check oil and coolant levels: Ensure they are adequate for operation.
  Check for loose tools or equipment in the work area: Clear any obstacles before
starting.
 Start the machine and control: Turn on the power at the back of the machine and
on the control panel.
 Load tools into the tool carousel: Follow the order listed in the CNC program tool
list.
 Mount the workpiece: Place the workpiece in the vise or chuck and tighten it
securely.
 Set tool length offsets: Set the tool length offsets for each tool used in the
program.
 Set part offsets: Once the workpiece is mounted, set the fixture offset to locate the
part's datum.
3. Program Loading and Operation:
 Load the CNC program:
Load the program into the machine control using a USB flash drive or other
method.
 Perform a dry run:
Run the program in the air, above the workpiece, to verify the program's
correctness.
 Run the program:
Once the dry run is successful, start the machine and run the program to create the
part.
4. Post-Operational Procedures:
 Clean the machine and surrounding area: Ensure the work area is tidy and clean.
 Store tools and equipment: Place tools and equipment in their designated storage
locations.

INJECTION MOULDING MACHINE IN - 02

1. 1. Preparation:
 Ensure the machine is switched on and the heaters and chiller are running.
 Verify that the material is dry and suitable for the mold.
2. 2. Manual Setup:
 Open the mold and ensure it is clean.
 Retract the injection unit nozzle.
 Purge the barrel (if needed) to remove any old material.
3. 3. Automatic Operation:
 Adjust the injection pressure, speed, and cooling time according to the material and
mold.
 Set the desired shot count and other parameters.
 Start the machine in either semi-automatic or automatic mode.
4. 4. Monitoring and Adjustment:
 Closely observe the mold filling and cooling process.
 Make necessary adjustments to parameters if needed to achieve optimal results.
5. 5. Ejection and Cleanup:
 After the cycle is complete, open the mold and carefully remove the finished parts.

 Clean the nozzle and machine after each run to ensure proper operation.

MANUAL CNC LATHE MACHINE IN - 04

1. 1. Pre-Start:
 Ensure the machine is clean and free of debris.
 Check for any obstructions or potential hazards.
 Verify that all safety devices (e.g., guards, emergency stop) are in place and
functioning.
2. 2. Start/Home:
 Power on the machine.
 If using a manual override, activate it.
 Initiate the machine's homing sequence, which moves the axes to their home position
(zero point).
3. 3. Tool Loading:
 Select the appropriate cutting tool for the desired operation.
 Load the tool into the tool holder, ensuring it is securely fastened.
 If using a tool carousel, load the tools into their respective positions.
4. 4. Workpiece Mounting:
 Securely mount the workpiece on the lathe's chuck or tailstock.
 Ensure the workpiece is properly centered and aligned.
 Check that the workpiece is stable and will not move during machining.
5. 5. Tool Length Offsets (Z-Axis):
 Set the tool length offsets using the machine's control panel.
 This ensures the tool reaches the correct depth for machining.
6. 6. Part Offset (XY-Axes):
 Set the part origin using the machine's control panel.
 This defines the starting point for the machining program.
7. 7. Program Loading:
 Load the appropriate CNC program into the machine's controller.
 Verify that the program is correct and matches the desired part geometry.
8. 8. Dry Run:
 Perform a dry run of the program without the cutting tool engaged.
 This helps to identify any errors or issues in the program.
9. 9. Program Execution:
 Once the program has been verified, engage the cutting tool and run the program.
 Monitor the machining process closely and make any necessary adjustments.
10. 10. Adjust Offsets (As Needed):
 If necessary, adjust the tool length offsets or part origin to fine-tune the machining
process.
11. 11. Shut Down:
 After completing the program, shut down the machine.
 Clean and tidy the machine and surrounding area.
12. 12. Safety:
 Always wear appropriate personal protective equipment (PPE) when operating the
lathe.
 Never leave the machine unattended while it is running.
 Exercise caution when handling sharp cutting tools and workpiece materials.

CNC SHEET BENDING MACHINE IN- 05

1. Safety First:
 Personal Protective Equipment (PPE): Always wear appropriate PPE, including
safety glasses, gloves, and ear protection.
 Machine Awareness: Be aware of the machine's operating parameters and safety
features.
 Emergency Stop: Know the location and operation of the emergency stop button
and how to use it.
 Clear Working Area: Ensure the work area is free from obstructions and hazards.
2. Pre-Bending Setup:
 Tooling Selection:
Select the appropriate die and punch based on the material thickness, bending
angle, and desired bend radius.
 Die Installation:
 Install the tooling securely on the machine's worktable, ensuring it is properly
aligned.
 Backgauge Adjustment:
Adjust the backgauge to accurately position the sheet metal for the desired bend
location.
 Material Preparation:
Clean the metal sheet and ensure it is free from burrs or debris.
3. Bending Process:
 Program Selection: Select the appropriate CNC program for the desired bending
operation.
 Sheet Loading: Carefully load the metal sheet into the machine, ensuring it is
aligned with the backgauge and tooling.
 Bending Cycle: Initiate the bending cycle and monitor the process, paying attention
to the machine's behavior and any potential issues.
 Springback Compensation: CNC systems can often compensate for springback,
allowing for more precise bending.
 Unloading: Carefully remove the bent sheet metal from the machine.
4. Post-Bending Inspection:
 Dimensional Check: Verify the bend angle and dimensions against the
specifications.
 Quality Control: Inspect the bent part for any defects or imperfections.
 Documentation: Record the bending parameters, material specifications, and any
necessary adjustments.
5. Machine Maintenance:
 Cleaning: Regularly clean the machine and tooling to remove debris and prevent
corrosion.
 Lubrication: Maintain the machine's hydraulic and mechanical components with
appropriate lubrication.
 Calibration: Periodically calibrate the machine's CNC system and measuring tools.
6. Safety Precautions During Operation:
 Avoid contact with moving parts: Keep hands and body parts away from the
bending area during operation.
 Follow safety procedures: Adhere to all safety protocols and instructions provided
by the machine manufacturer.
 Report any abnormalities: Immediately report any unusual sounds, vibrations, or
malfunctions to the supervisor.
7. Troubleshooting:
 Consult the operator's manual: Refer to the machine's operator's manual for
troubleshooting tips and procedures.
 Seek expert assistance: If problems persist, seek assistance from qualified
technicians.
8. Best Practices:
 Proper Tooling: Use the correct tooling for the job to ensure optimal bending
results.
 Accurate Programming: Ensure the CNC program is accurate and reflects the
desired bend geometry.
 Regular Maintenance: Maintain the machine's tooling and CNC system to ensure
reliable operation.
 Continuous Improvement: Continuously seek to improve the bending process
through experimentation and feedback.

CNC FIBER LASER SHEET CUTTING MACHINE IN – 06

1. 1. Safety First:
Ensure all safety measures are in place, including wearing appropriate safety gear
and having a well-ventilated workspace.
2. 2. Power Up:
Turn on the machine's power supply and ensure all systems are online.
3. 3. Material Preparation:
Load the sheet metal onto the machine's worktable, ensuring it is securely fastened
and aligned with the cutting path.
4. 4. Parameter Setting:
Configure the machine's parameters, including laser power, speed, focus, and
assist gas (if applicable), based on the material thickness and desired cut quality.
5. 5. Test Run:
Perform a test cut on a small area of the material to verify that the parameters are
correctly set.
6. 6. Commence Operation:
Start the CNC program to execute the cutting path. Monitor the process and make
adjustments if needed.
7. 7. Post-Processing:
 Remove any burrs or edges from the cut pieces, and clean the machine for the
next operation.

8. 8. Maintenance:
Regularly maintain the machine to ensure its optimal performance and longevity.

AUTOMATIC POWDER COATING MACHINE IN – 07

1. 1. Pre-treatment:
 Clean and prepare the parts to be coated, often including degreasing, rinsing, and
optionally a phosphating process to create a good surface for powder adhesion.
 Ensure the parts are dry and free of contaminants before moving to the powder
application stage.
2. 2. Powder Application:
 Select the desired powder color and type.
 The machine will automatically move parts through the spray booth.
 Adjust the machine settings (e.g., powder feed rate, voltage, gun settings) according to
the powder type and desired coating thickness.
 The automatic spray guns will apply the powder to the parts.
3. 3. Curing:
 Move the coated parts into a curing oven, which is often a convection oven.
 Maintain the oven temperature and time according to the powder manufacturer's
recommendations to ensure proper curing and a durable finish.
4. 4. Post-curing inspection:
 Inspect the finished parts for any defects or issues.

 If necessary, perform touch-up or finishing touches manually using a manual spray

gun.
2 TON CRANE MACHINE IN – 8

1. Pre-Operation Checks:
 Inspect the crane: Check for any damage, wear, or malfunctions on the crane's
components, including the lifting mechanism, boom, hooks, and safety devices.
 Load capacity: Verify the crane's load capacity and ensure the load to be lifted
does not exceed this limit.
 Surroundings: Ensure the crane is stable, leveled, and positioned on a safe, clear
area.
 Personal Protective Equipment (PPE): Wear appropriate safety gear, such as a
helmet, safety glasses, and gloves, before starting any operation.
2. Load Handling:
 Hook up: Attach the load securely to the crane's hook, ensuring the connection is
strong and safe.
 Lifting: Raise the load slowly and steadily, avoiding sudden movements or jerks.
 Movement: If moving with the load, do so carefully, keeping the load as low as
possible and avoiding abrupt changes in direction.
Lowering: Lower the load slowly and steadily, using the crane's controls carefully

to ensure smooth descent.
3. Safety Precautions:
 Load weight: Never lift a load that exceeds the crane's capacity.
 Load center: Ensure the load is centered on the hook to prevent imbalance.
 Clearance: Maintain adequate clearance between the crane and overhead
obstructions.
 Communication: Use clear communication with other personnel involved in the
operation.
Emergency stop: Be familiar with the location and function of the emergency stop

button.
4. Post-Operation Checks:
 Clearance: Ensure the area is clear of obstructions after completing the lift.

 Equipment: Store the crane properly, ensuring it is clean and ready for the next
use.
 Review: Review the operation and identify any areas for improvement or safety
concerns.
AUTOMATIC PIPE CUTTING MACHINE IN – 09

1. . Prepare the Machine:

 Ensure the machine is powered on and ready for operation.
 Check the cutting blade is properly installed and lubricated.
 Verify the safety guards and controls are functioning correctly.
2. Set the Cutting Length:
 Use the machine's control panel or software to input the desired pipe length.
 Confirm the settings are accurate before proceeding.
2. 3. Load the Pipe:
 Place the pipe on the infeed conveyor or loading platform, as instructed by the
machine's manual.
 Ensure the pipe is properly aligned and secure before clamping.
3. 4. Start the Cutting Cycle:
 Initiate the automatic cutting cycle by pressing the start button or following the
instructions on the machine's control panel.

4. 5. Monitor the Process:

 Observe the cutting process to ensure it is proceeding as expected.
 Be prepared to address any issues that may arise, such as blade malfunctions or
material feeding problems.
5. 6. Unload the Cut Pipe:
 Once the cutting cycle is complete, the cut pipe will be automatically unloaded from the
machine.
 Handle the pipe with care and ensure it is properly stored or transported.
6. 7. Clean Up:
 Remove any debris or waste from the machine's work area.
 Check the cutting blade for signs of wear and replace it if necessary.
7. 8. Safety Considerations:
 Always wear appropriate safety gear, such as gloves and safety glasses, when
operating the machine.
 Never reach into the machine while it is in operation.
 Familiarize yourself with the emergency stop controls and their location.

HYDRAULIC SHEET PUNCHING MACHINE IN – 10

1. 1. Machine Setup:
 Tool Installation: Install the punch and die, ensuring proper alignment and distance
setting.
 Hydraulic System: Check and maintain the hydraulic oil level and cleanliness.
 Pressure Adjustment: Use trial and error to determine the correct pressure for the
job.
 Test Run: Perform a test bend on waste material to verify settings.
2. 2. Safety Precautions:
 Power Off: Always cut off the power supply when installing or disassembling the mold.
 Safety Zones: Avoid placing hands or tools in dangerous areas during operation.
 Abnormalities: If the machine operates abnormally or makes noise, stop feeding and
check the cause.
 Protection: Ensure safety devices are in place and functioning properly before
operation.
3. 3. Operation:
 Material Placement: Position the sheet metal correctly under the punch.
 Punching: Actuate the hydraulic system to punch the hole.
 Repeat: Repeat the process for multiple holes or shapes.
4. 4. CNC Machines:
 Programming: For CNC machines, use software to program punching patterns.
 Automated Operation: Allow the machine to automatically punch according to the
programmed settings.
5. 5. Maintenance:
 Regular Checks: Perform regular checks on the hydraulic system, including oil level
and pressure.
 Lubrication: Ensure proper lubrication of moving parts.
 Tooling Maintenance: Regularly inspect and maintain the punch and die.

MANUAL SHEET PUNCHING MACHINE IN - 11

1. 1. Preparation:
 Ensure the machine is clean and free of debris.
 Check the lubricant level and replenish if needed.
 Verify the punch and die are properly aligned and secured.
 Clean the area around the machine to prevent damage to other items.
2. 2. Material Handling:
 Place the material to be punched on the punch press platform.
 Ensure the material is correctly aligned with the desired hole positions.
 Secure the material to prevent movement during punching.
3. 3. Punching:
 Actuate the machine's lever or pedal to engage the punch.
 Monitor the punching process and stop if any issues arise.
 Ensure the material is punched correctly and removed safely.
4. 4. Post-Punching:
 Remove the punched material from the machine.

 Clean the machine, including the punch and die, to remove debris.
 Ensure the machine is stored properly to prevent damage.

C – TYPE POWER PRESS MACHINE IN – 12

1. 1. Safety First:
 Always ensure the machine is shut off and the safety guard is in place before
performing any maintenance or modifications.

2. 2. Preparation:
Before starting, verify the machine is properly grounded, the work area is clear, and
the necessary safety equipment (e.g., gloves, safety glasses) is available.
3. 3. Tooling and Material Setup:
 Die and Punch: Select the appropriate die and punch for the desired operation,
ensuring they are properly mounted and secured to the machine.
 Material: Place the material to be pressed on the bed, making sure it is properly
aligned with the die.
 Locking: Secure the die bottom bolster to the bed plate using T-bolts, which are slid
into T-slots on the plate.
4. 4. Adjustments (if necessary):
 Stroke: Adjust the stroke length as needed for the operation (e.g., shorter strokes for
blanking, longer for forming).
 Speed: If available, adjust the press speed to suit the operation.
5. 5. Operation:
 Initiate Pressing: Activate the machine's controls (e.g., foot pedal, lever) to initiate the
pressing cycle.
 Monitor: Observe the machine's operation and ensure the material is being pressed
correctly.
 Adjust: If necessary, adjust the pressure or speed during the operation.
6. 6. Post-Pressing:
 Material Removal: Carefully remove the pressed material from the die.
 Cleanup: Clean the press and die area to prevent contamination.
7. 7. Maintenance:
 Lubrication: Regularly lubricate moving parts of the machine.

 Inspection: Inspect the machine for any signs of wear or damage.

 Repair: Address any maintenance needs promptly.

IRON WORKER MACHINE IN – 13

1. 1. Preparation:
 Measure and mark the material using a square measurement tool.
 Use a center punch to mark the material if it will be punched.
2. 2. Machine Setup:
 Position the material at the appropriate station (e.g., punching, shearing).
 Ensure the machine is in the correct mode (manual or automatic).
 If changing tooling, push the stop button and lockout/tagout the machine.
3. 3. Operation:
 Punching:
 Slide the foot pedal to activate the punch.
 Adjust the punch stroke using the rod and bar.
 Shearing:
 Use the hand crank to grip the material and shear it safely.
 Bar Shearing:
 Position the material on the feed table.
 Angle Shearing:
 Ensure precise shearing at any angle as needed.
4. 4. Troubleshooting:
 If experiencing issues, consult the operator's manual or a qualified technician.

PILLAR DRILL MACHINE IN - 14

1. 1. Prepare the Machine:

 Safety First: Ensure the machine is properly grounded and that all safety guards are in
place.
 Workpiece Preparation: Clean the workpiece and ensure it is firmly secured to the
table or with clamps, preventing movement during drilling.
 Drill Bit Selection: Choose the correct drill bit based on the material and hole
size. Ensure the bit is properly inserted and secured in the chuck.
 Speed Adjustment: Select the appropriate spindle speed for the material and drill
bit. Consult the machine's manual for speed recommendations.
2. 2. Adjusting the Drill Head:
 Height Adjustment: Raise or lower the drill head to the desired drilling depth using the
vertical adjustment mechanism.
 Drilling Depth Stop (if applicable): Use the depth stop to ensure consistent drilling
depths, especially for multiple holes.
3. 3. Positioning and Drilling:
 Accurate Placement: Align the drill point with the marked drilling location on the
workpiece.
 Start Drilling: Engage the power and slowly feed the drill into the material.
 Maintain Constant Pressure: Apply consistent pressure, but avoid excessive force,
which can damage the drill bit or workpiece.
 Coolant (if necessary): Use a coolant to lubricate the drill bit and prevent overheating,
especially when drilling metal.
4. 4. Finishing:
 Drill Removal: Once the hole is drilled, slowly remove the drill bit.

 Workpiece Handling: Ensure the workpiece is handled carefully to avoid damage.

 Cleanup: Clean the machine and work area.

20 HP COMPRESSOR IN – 15

1. 1. Installation:
 Location: Choose a clean, dry, well-ventilated indoor space with sufficient room for
maintenance.
 Ambient Temperature: Ensure the compressor operates within the manufacturer's
specified temperature range.
 Foundation: If required, install the compressor on a stable and level foundation.
 Electrical Connections: Follow the manufacturer's instructions for electrical
connections and grounding.
 Piping: Ensure proper piping for air intake and discharge, minimizing leaks and
pressure drops.
2. 2. Pre-Operation Checks:
 Oil Level: Verify the oil level in the compressor crankcase.
 Air Intake Filter: Check and clean or replace the air intake filter.
 Safety Devices: Ensure all safety devices (relief valves, pressure switches) are
properly installed and functional.
 Belts and Connections: Inspect belts, couplings, and other mechanical connections
for proper tightness and condition.
3. 3. Operation:
 Starting: Follow the manufacturer's instructions for starting the compressor.
 Monitoring: Regularly monitor the compressor's pressure, temperature, and oil level
during operation.
 Loading/Unloading: Understand the compressor's loading and unloading cycle and
adjust operation based on demand.
 Safety Precautions: Adhere to all safety precautions, including wearing appropriate
personal protective equipment (PPE).
4. 4. Maintenance:
 Daily: Perform daily checks on oil level, air intake filter, and safety devices.

 Regular: Follow the manufacturer's schedule for oil changes, filter replacements, and
other maintenance tasks.
 Troubleshooting: Refer to the manufacturer's manual for troubleshooting common
issues.
 Professional Servicing: Schedule professional servicing and overhauls as
recommended by the manufacturer.

5 HP COMPRESSOR IN - 16

1. Pre-Operation Checks:
 Safety First:
Ensure the compressor is placed on a stable, level surface and that the area is free
of obstructions and flammable materials.
 Oil Level:
Check the compressor oil level before each use and add oil if needed. Ensure the
oil is at the correct fill level, as indicated in the manual.
 Belt Tension:
If applicable, check the belt tension and adjust or replace it if it's too loose or
damaged.
 Electrical Connections:
Verify that the electrical cord is in good condition and is properly rated for the
compressor's power requirements.
 Air Tank Pressure:
Check the pressure gauge and ensure the tank pressure is within the
recommended range.
2. Operation:
 Power On:
Turn on the compressor and allow it to build up pressure.
 Connect Tools:
Attach the desired pneumatic tool to the air hose and ensure it is properly
connected.
 Control Airflow:
Adjust the pressure regulator to the required pressure for the tool being used.
 Monitor Operation:
Observe the compressor during operation for any unusual noises or vibrations.
3. Post-Operation Maintenance:
 Cool Down: Allow the compressor to cool down before performing any maintenance
or storage.
  Drain the Tank: Open the drain valve on the air tank to release any accumulated
moisture.
 Clean the Compressor: Wipe down the exterior of the compressor and remove any
dust or debris.
 Check for Leaks: Inspect the compressor for any air leaks and address them
promptly.
 Store Properly: Store the compressor in a clean, dry location, away from extreme
temperatures.
DRILLING MACHINE IN- 17

1. Before Operation:
 Safety Check:
Ensure all guards are in place and functional. Check for any frayed belts or
damaged pulleys. Inspect the drill bit for sharpness and proper mounting.
 Workpiece Preparation:
Secure the workpiece firmly in a vise or with clamps to prevent movement during
drilling. If drilling metal, create a starting indentation with a center punch.
 Material Compatibility:
Select the appropriate drill bit for the material being drilled (e.g., high-speed steel
for metal, brad-point for wood).
 Speed and Feed Rate:
Choose the correct speed and feed rate based on the material and drill bit
size. Refer to a speed and feed chart or the machine's manual for guidance.
2. During Operation:
 Start Slowly:
Begin drilling at a low speed and gradually increase to the desired speed as the bit
penetrates the material.
 Maintain Pressure:
Apply steady and even pressure while drilling. Avoid excessive force, which can
damage the bit or motor.
 Coolant (if needed):
Use a cutting lubricant when drilling metals, except for iron and brass, which can
be drilled dry.
 Hole Break Through:
Be prepared for a sudden breakthrough when the bit pierces the
workpiece. Reduce pressure and hold the tool firmly.
 Withdraw the Bit:
When drilling deep holes, withdraw the bit periodically to clear chips and prevent
overheating.
3. After Operation:
 Clean the Machine: Remove any chips or debris from the machine and the
surrounding area.
 Lubricate Moving Parts: Apply lubricant to moving parts as recommended by the
manufacturer.
 Store the Drill Bits: Properly store drill bits in a designated area to prevent
damage.
4. Safety Precautions:
 Eye Protection: Always wear safety glasses or a face shield to protect your eyes
from flying debris.
 Hearing Protection: Use earplugs or earmuffs when operating loud drilling
machines.
 Hand Protection: Avoid contact with moving parts. If using gloves, ensure they are
not loose or bulky.
 Power Disconnection: Always unplug the machine before making any adjustments
or maintenance.
 Keep Work Area Clean: Maintain a clutter-free workspace to prevent tripping or
accidents.
POWER PRESS IN – 18

 Pre-operation:
 Inspect the machine for any defects or damage.
 Check electrical connections and ensure all moving parts are properly lubricated.
 Verify that the locking mechanism is functioning correctly.
 Wear appropriate safety gear, such as gloves, shoes, and eye protection.
 During Operation:
 Ensure the workpiece is correctly positioned within the dies.
 Maintain focus on the task to prevent accidents.
 Do not operate the machine with faulty guards or safety devices.
 Avoid overloading the machine.
3. Setting/Adjustments:
 Cut off power before installing or removing dies.
 Adjust the machine height manually and in small increments.
 Do not connect the machine until adjustments are confirmed.
4. Post-operation:
 Clean the machine and return tools to their designated storage.
 Dispose of scrap and waste materials properly.
 Switch off the machine and all electrical equipment.
5. Troubleshooting:
 If problems arise during operation, consult a supervisor or qualified technician.
 Reject any defective parts in the designated area.

PIPE BENDING MACHINE IN – 19

1. Preparation:
 Safety First: Ensure the work area is clean and clear of obstructions.
 Machine Check: Verify the bending dies and clamps are in good condition.
 Die Selection: Choose the correct bending die based on the desired bend radius
and pipe diameter.
 Pipe Placement: Position the pipe on the die and secure it with clamps.
2. Bending Process:
 Angle Adjustment: Set the bending angle on the machine.
 Pressure Application: Start the machine and gradually apply pressure to bend the
pipe.
 Manual Operation: For manual machines, carefully apply pressure using the
machine's handle or lever.
 Hydraulic Operation: For hydraulic machines, the hydraulic pressure will bend the
pipe.
3. Post-Bending:
 Inspection: Remove the pipe and check the bend for accuracy.
 Adjustment: If needed, make fine adjustments and repeat the process.
 Safety Precautions: Always keep hands and body parts away from the bending
area.
CUTTER MACHINE IN – 22

1. 1. Safety First:
Before starting, ensure the machine is properly grounded and that all safety guards
are in place and functional.
2. 2. Power On:
 Turn on the machine's power supply and any necessary auxiliary systems like
coolant pumps.
3. 3. Material Preparation:
 Secure the material: Clamp the material to be cut in the machine's vice or on the
cutting table, ensuring it is stable and properly aligned.
 Adjust cutting parameters: Set the cutting depth, speed, and other relevant
parameters according to the material and desired outcome.
4. 4. Cutting Process:
 Start the cutting process: Initiate the cutting action, either manually by pressing a
button or automatically by initiating the programmed cutting path.
 Monitor the cut: Observe the cutting process to ensure it is progressing smoothly and
that the material is being cut according to the set parameters.
 Use coolant: If applicable, ensure the cutting area is adequately lubricated with
coolant to prevent overheating and blade damage.
5. 5. Post-Cutting:
 Stop the machine: Once the cutting is complete, stop the machine and turn off the
power supply.
 Unclamp and remove material: Carefully unclamp and remove the cut material from
the machine.
 Clean the machine: Clean any debris or residue from the cutting area and machine
components.
HAND GRINDER IN – 23
1. 1. Safety First:
 Read the Manual: Always refer to the manufacturer's instructions for your specific
grinder model.
 Personal Protective Equipment (PPE): Wear safety glasses or a face shield, gloves,
and hearing protection.
 Secure the Workpiece: Ensure the material being worked on is properly clamped or
secured to prevent movement.
 Check the Wheel: Inspect the grinding wheel for cracks, damage, or wear before each
use. Do not use a damaged wheel.
 Proper Guarding: Ensure the guard is correctly installed and adjusted to protect
against flying debris.
 Avoid Overexertion: Do not force the grinder or apply excessive pressure.
 Keep Work Area Clear: Ensure the area around the grinder is free of clutter and
obstructions.
 Proper Ventilation: Ensure adequate ventilation to remove dust and debris, especially
when working with materials that produce harmful dust.
 Disconnect from Power: Always disconnect the grinder from the power source before
changing accessories or performing maintenance.
2. 2. Preparation:
 Select the Right Wheel: Choose the correct grinding wheel or disc for the material
being worked on and the intended task (cutting, grinding, polishing).
 Mount the Wheel: Securely mount the wheel using the appropriate flanges and
spindle lock. Ensure the wheel is properly seated and tightened.
 Attach Side Handle: Attach the side handle for better control and stability.
3. 3. Operation:
 Start the Grinder: Turn on the grinder and allow it to reach full speed before
contacting the workpiece.
 Apply Gentle Pressure: Use a controlled, even pressure when grinding. Do not force
the grinder or apply excessive pressure.
 Maintain Proper Angle: Hold the grinder at the correct angle to the workpiece to avoid
binding or kickback.
 Work in a Safe Zone: Ensure the grinding wheel is moving away from you and others.
 Avoid Side Pressure: Do not apply side pressure to cutting discs, as this can cause
them to shatter.
 Stop and Inspect: Periodically stop the grinder and inspect the wheel for damage or
wear.
 Cool Down: Allow the grinder to cool down after use before storing.
4. 4. Maintenance:
 Clean Regularly: Clean the grinder after each use to remove dust and debris.

 Inspect Regularly: Regularly inspect the grinder for wear and damage.
 Store Properly: Store the grinder in a safe, dry place.
 Follow Manufacturer's Recommendations: Refer to the manufacturer's instructions
for specific maintenance recommendations.

SPOT MACHINE IN - 24

Work Instruction Steps for a Spot Welding Machine:

1. Preparation:
 Safety First:
Ensure all personnel are wearing appropriate Personal Protective Equipment (PPE)
including safety glasses, gloves, and appropriate clothing (long pants, closed-toe
shoes, non-flammable garments).
 Machine Setup:
 Verify the spot welder is properly connected to a power source and that the
electrode tips are clean and in good condition.

 Material Preparation:
Ensure the metal pieces to be welded are clean, free of rust, and properly aligned.
 Workpiece Positioning:
Securely clamp the metal pieces between the electrodes, ensuring proper contact
and alignment.
2. Welding:
 Adjust Settings:
Set the appropriate welding current, time, and pressure according to the material
type and thickness.
 Initiate Welding Cycle:
Engage the welding cycle, which will typically involve the application of pressure
and current to create a weld nugget.
 Cooling:
Allow the weld to cool sufficiently before removing the workpiece from the
machine.
3. Shutdown:
 Turn off the machine: Turn off the power switch on the machine and any
associated control panels.
 Clean the machine: Remove any debris or spatter from the machine and
surrounding area.
 Secure the area: Ensure the work area is clean and safe.

TIG MACHINE (WELDING) IN – 25

TUNGSTEN INERT GAS
1. 1. Preparation:
 Safety First: Wear appropriate personal protective equipment (PPE) including a
welding helmet with a suitable lens shade, gloves, and fire-resistant clothing.
 Cleanliness: Ensure the work area is free of flammable materials and the workpiece is
clean and free of rust, oil, and other contaminants.
 Set up Equipment: Connect the gas supply, power source, and TIG torch.
 Select Tungsten: Choose the correct tungsten electrode size and grind it to a point (or
a ball for AC welding).
 Set Welding Parameters: Determine the appropriate amperage, gas flow rate, and
other settings based on the material and thickness.
2. 2. Welding:
 Strike the Arc: Initiate the arc by touching the tungsten electrode to the workpiece and
then quickly lifting it to create a gap.
 Maintain Arc Length: Keep a consistent arc length (typically 1/16 to 1/8 inch) for
optimal control.
 Control Travel Speed: Move the torch along the joint at a consistent speed to create a
uniform weld bead.
 Add Filler Material (if needed): Feed the filler rod into the weld pool at the leading
edge of the molten pool.
 Shield the Weld: Ensure the shielding gas is flowing properly to protect the weld from
oxidation.
3. 3. Completion:
 Cool Down: Allow the weld to cool down before moving it or applying additional heat.

 Clean the Weld: Remove any spatter or slag from the weld area.
 Inspect the Weld: Check the weld for any defects and ensure it meets the required
standards.
 Shut Down: Turn off the welding machine and gas supply.

ELECTRA WELDING IN - 28
1. Safety First:
 Personal Protective Equipment (PPE): Wear a welding helmet with the correct
shade lens, safety glasses, welding gloves, and flame-resistant clothing.
 Ventilation: Ensure adequate ventilation to remove welding fumes and gases.
 Grounding: Properly ground the welding machine to prevent electrical shock.
 Hot Surfaces: Be aware of hot surfaces and avoid contact with the workpiece,
welding wire, or electrode.
2. Machine Setup:
 Power Source:
Connect the welding machine to a suitable power source, ensuring the voltage
matches the machine's requirements.
 Welding Cables:
Attach the welding cables, ensuring a secure connection to the electrode holder
and ground clamp.
 Wire Feed (if applicable):
If using a wire feed welder, load the appropriate wire and adjust the wire feed
speed and tension according to the manufacturer's instructions.
 Gas Supply (if applicable):
Connect the gas cylinder (if required for the welding process) and adjust the flow
rate according to the welding parameters.
 Settings:
Set the welding parameters (amperage, voltage, wire feed speed, etc.) based on
the material being welded and the desired weld characteristics.
3. Workpiece Preparation:
 Cleanliness: Clean the workpiece thoroughly to remove any rust, paint, or
contaminants that could affect the weld quality.
 Joint Preparation: Prepare the joint edges according to the welding procedure for
optimal weld penetration and strength.
 Clamping: Securely clamp the workpiece to prevent movement during welding.
4. Welding Process:
 Arc Initiation:
Initiate the welding arc by touching the electrode to the workpiece (for stick
welding) or by striking the arc with the torch (for MIG/TIG welding).
 Welding Technique:
Maintain a consistent arc length and travel speed to create a smooth, even weld
bead.
 Travel Angle:
Keep the correct travel angle (the angle at which the torch or electrode is held) to
ensure proper weld penetration.
 Stitch or Continuous Welding:
Decide whether to use a stitch weld (short, overlapping weld segments) or a
continuous weld based on the application and material.
5. Post-Weld:
 Cooling: Allow the weld to cool down naturally.
 Slag Removal: If applicable, remove any slag from the weld bead using a chipping
hammer and wire brush.
 Inspection: Inspect the weld for any defects, such as cracks, porosity, or incomplete
penetration.
Specific Instructions for Electra Welding Machines:
 Consult the manufacturer's manual for specific instructions related to your Electra
welding machine model.
 Pay close attention to the machine's control panel and indicators.
  Familiarize yourself with any unique features or settings of your particular Electra
machine.
HY. POWER PRESS SHEET BENDING MACHINE IN - 29

1. 1. Safety Precautions:
 Always wear appropriate personal protective equipment (PPE), including safety
glasses, gloves, and closed-toe shoes.
 Ensure the work area is clean and free of obstructions.
 Familiarize yourself with the machine's safety features, such as emergency stop
buttons.
 Never place your hands or any part of your body in the bending area during operation.
2. 2. Machine Setup:
 Select the appropriate punch and die for the desired bend angle and material
thickness.
 Securely mount the punch and die onto the machine.
 Set the machine's parameters, such as bend angle, back gauge position, and stroke
length, according to the bending specifications.
 Verify the machine is properly calibrated and all sensors are functioning correctly.
3. 3. Material Preparation:
 Ensure the sheet metal is properly cleaned and free of any burrs or sharp edges that
could damage the tooling.
 Position the sheet metal on the die, aligning it with the back gauge for accurate
positioning.
 Secure the sheet metal in place using clamps or hold-downs.
4. 4. Bending Process:
 Activate the machine to initiate the bending cycle.
 The punch will move downwards, pressing the sheet metal against the die and creating
the bend.
 Monitor the bending process closely to ensure the desired angle is achieved and that
the material is bending correctly.
 If springback (the material returning slightly to its original shape) occurs, adjust the
machine settings accordingly.
5. 5. Quality Control:
 Inspect the finished part for accuracy and consistency.
 Compare the bent part with the required specifications and dimensions.
 Adjust the machine settings if necessary to improve accuracy.
6. 6. Maintenance:
 Regularly inspect the machine for wear and tear.
 Lubricate moving parts as recommended by the manufacturer.
 Keep the machine clean and free of debris.
 Follow the manufacturer's recommendations for maintenance and repair.

FIXED BUFFING MACHINE IN – 30

01 Pre-operation:
 Safety:
Ensure all guards are in place, secure, and functional. Wear appropriate safety
gear, including eye protection and close-fitting clothing (no loose clothing, jewelry,
or gloves).
 Machine Setup:
Inspect the buffing wheel for cracks or damage. Ensure the machine is properly
grounded and the power supply is within the machine's specifications.
 Tire Mounting:
Mount the tire onto the machine's hub, ensuring it's securely fastened and properly
aligned.
02 Operation:
 Start-up:
Activate the machine using the designated start controls.
 Buffing Process:
Guide the tire against the buffing wheel, applying even pressure to achieve the
desired buffing depth and profile.
 Monitoring:
Continuously monitor the buffing process, making adjustments to the pressure
and/or speed as needed to maintain consistent results.
 Cooling:
Allow the tire to cool down after buffing if necessary, especially if it has become hot
during the process.
03 Post-operation:
 Shutdown: Turn off the machine using the designated stop controls.
 Tire Removal: Carefully remove the buffed tire from the machine.
 Cleaning: Clean the buffing wheel and the machine area to remove any debris.
 Maintenance: Regularly inspect the buffing wheel and machine components for
wear and tear, and perform any necessary maintenance or repairs.
 BUFFING GRINDING MACHINE IN – 31
1. 1. Safety First:
 Personal Protective Equipment (PPE): Wear safety glasses or goggles, gloves, and
appropriate clothing to protect against flying debris and dust. Hearing protection may
also be needed.
 Machine Guarding: Ensure all guards and shields are in place and properly adjusted
to prevent accidental contact with moving parts.
 Power Supply: Verify the machine is connected to a stable power supply with the
correct voltage and grounding.
 Emergency Procedures: Be aware of the location of emergency stop buttons and
know how to shut down the machine quickly in case of an incident.
 Material Compatibility: Avoid grinding aluminum on a wheel used for steel, as it can
lead to overheating and wheel failure.
2. 2. Machine Setup:
 Wheel Selection: Choose the correct abrasive wheel for the material and task (e.g.,
grinding, buffing, polishing).
 Wheel Mounting: Mount the wheel securely on the spindle, ensuring it is properly
balanced and aligned.
 Workpiece Preparation: Secure the workpiece properly on the machine's table or
clamping mechanism.
 Clearance: Ensure adequate clearance around the work area for safe operation and
material handling.
3. 3. Operation:
 Start-up: Turn on the machine and allow it to reach operating speed.
 Feed Rate: Control the speed and pressure at which the workpiece is fed into the
abrasive wheel.
 Material Removal: Maintain a consistent feed rate and pressure to achieve desired
material removal and surface finish.
 Coolant: Use coolant where appropriate to prevent overheating and extend wheel life.
 Regular Inspection: Periodically check the workpiece and abrasive wheel for any
signs of damage or wear.
4. 4. Post-Operation:
 Clean-up: Thoroughly clean the machine and work area to remove dust, debris, and
grinding residue.
 Wheel Inspection: Inspect the abrasive wheel for damage and replace if necessary.
  Maintenance: Perform any required maintenance tasks according to the
manufacturer's instructions.
COMPRESSOR 1 IN – 32
1. 1. Safety First:
 Always wear appropriate personal protective equipment (PPE) like safety glasses and
gloves.
 Ensure the compressor is placed on a stable, flat surface and in a well-ventilated area.
 Familiarize yourself with the compressor's manual and safety instructions.
 Never direct compressed air towards yourself or others.
2. 2. Setup and Connection:
 Connect the air hose to the compressor and the desired tool.
 Ensure all connections are secure and leak-free.
 If using a quick-connect coupling, ensure it is compatible with your hose assembly.
3. 3. Pressure Adjustment:
 Start the compressor and allow it to build pressure.
 Locate the pressure regulator on the hose or compressor.
 Adjust the regulator to the pressure required by your tool. Consult the tool's manual for
the correct pressure setting.
 Do not exceed the maximum pressure rating of either the compressor or the tool.
4. 4. Operation:
 Monitor the pressure gauge to ensure it remains within the recommended range.
 Use the air tool as intended, following the manufacturer's guidelines.
5. 5. Shutdown:
 Turn off the compressor.

 Release the air pressure from the tank and hose by opening the drain valve.
 Disconnect the hose and store it properly.

TAPING MACHINE IN – 33
1. Power and Safety:
 Ensure the machine is properly connected to a power source and that all safety guards
are in place.
2. Machine Setup:
 Adjust the machine's conveyor and carton guides to match the dimensions of the boxes
to be taped.
 Ensure the tape dispenser is loaded with the correct type and width of tape.
 Adjust the tape overlap as needed for proper sealing.
3. Loading:
 Position the box on the conveyor, ensuring it is properly aligned with the carton
guides.
 The conveyor will then move the box through the machine.
4. Taping Process:
 The machine will automatically dispense and apply the tape to the box flaps.
 Some machines may have settings for different taping patterns (e.g., top and bottom
flaps, or just top flaps).
5. Output:
 The taped box will exit the machine and be ready for the next stage of the packaging
process.
6. Maintenance:
 Regularly clean the machine to remove any tape residue or debris.
 Check the tape dispenser for proper functionality and replace the tape roll when
necessary.
STICHING MACHINE IN – 35

1. Machine Setup:
 Power: Turn on the main power switch and ensure the machine is properly plugged
in.
 Needle Position: Raise the needle to its highest point using the handwheel.
 Presser Foot: Lift the presser foot lever to allow fabric placement.
 Fabric Placement: Position the fabric under the presser foot, ensuring the needle is
at the desired starting point.
 Thread Placement: Guide the threads under the presser foot and hold them to
prevent tangling during initial stitches.
2. Stitch Selection:
 Stitch Type:
Choose the desired stitch pattern (e.g., straight stitch, zigzag, decorative stitches)
using the stitch selection dial or buttons.
 Stitch Length and Width:
Adjust the stitch length and width settings according to the fabric and desired
effect.
3. Sewing Process:
 Lower the Presser Foot: Lower the presser foot lever to secure the fabric.
  Foot Pedal: Use the foot pedal to control the sewing speed. Start slowly to get a feel
for the machine.
 Guidance: Keep your hands steady and guide the fabric under the needle, following
your seam line.
 Backstitching: At the beginning and end of a seam, use the backstitch lever (if
available) to reinforce the stitches and prevent them from unraveling.
 Stopping: Lift the presser foot and use the thread cutter to cut the threads.
4. Fabric Handling:
 Tension: Ensure the thread tension is appropriate for the fabric to avoid puckering
or loose stitches.
 Seam Allowance: Maintain a consistent seam allowance for neat and accurate
seams.
 Fraying: Finish raw edges using pinking shears or a zigzag stitch to prevent fraying.
5. Maintenance:
 Cleaning: Regularly clean the machine, especially the bobbin area, to remove lint
and dust.
 Oiling: Lubricate moving parts according to the manufacturer's recommendations.
 Needle Replacement: Replace the needle when it becomes dull or damaged.
 Professional Servicing: Schedule regular maintenance checks with a qualified
technician.
6. Troubleshooting:
 Thread Breaking: Check for proper threading, correct tension, and a sharp needle.
 Skipped Stitches: Ensure the needle is correctly installed and the fabric is being fed
evenly.
 Bobbin Issues: Verify the bobbin is correctly wound and inserted, and that the
bobbin case is clean.
 Machine Not Sewing: Check for power issues, needle position, and thread tension.

1HP BUFFING MACHINE IN – 38

1. Safety First:
 Eye Protection:
Wear safety glasses or goggles to protect your eyes from flying debris, buffing
compounds, and other particles.
 Hand Protection:
Wear gloves to protect your hands from abrasions and potential injuries.
 Secure the Workpiece:
Ensure the workpiece is securely held or clamped to prevent it from being pulled
into the machine or causing injury.
 Proper Lighting:
Ensure the work area is well-lit to allow for proper visibility and safe operation.
 Loose Clothing:
Avoid wearing loose-fitting clothing or accessories that could get caught in the
machine.
 Disconnect Power:
Before making any adjustments or maintenance, switch off the machine and
disconnect the power supply.
2. Machine Setup:
 Buffing Wheel Selection:
Choose the appropriate buffing wheel and polishing compound for the material and
desired finish.
 Wheel Mounting:
Ensure the buffing wheel is securely mounted on the machine and balanced for
smooth operation.
 Speed Adjustment:
If your machine has variable speed control, adjust the speed appropriately for the
material and application.
3. Buffing Process:
 Prepare the Workpiece:
Clean the workpiece to remove any dirt, debris, or grease.
 Apply Compound:
Apply the buffing compound to the buffing wheel according to the manufacturer's
instructions.
 Workpiece Application:
Gently bring the workpiece into contact with the rotating buffing wheel, applying
even pressure.
 Motion:
Move the workpiece smoothly and evenly across the buffing wheel to avoid
creating uneven surfaces or excessive heat.
 Check Progress:
 Regularly check the progress of the buffing process and adjust the pressure or
compound application as needed.
 Cool Down:
If the workpiece gets too hot during buffing, allow it to cool down before continuing.
4. Finishing:
 Clean the Workpiece:
Once the desired finish is achieved, clean the workpiece to remove any remaining
buffing compound.
 Inspect:
Inspect the finished surface for any remaining imperfections or areas that may
need additional buffing.
 Final Polish:
For an extra-smooth finish, you may want to use a finer buffing wheel and
compound.
CNC PIPE BENDING MACHINE IN - 40
1. 1. Preparation:
 Safety First: Ensure all safety measures are in place. This includes wearing
appropriate personal protective equipment (PPE) such as safety glasses, gloves, and
ear protection.
 Work Area: Clear the area around the machine of any obstacles that could interfere
with the bending process or cause accidents.
 Machine Check: Verify that the CNC pipe bending machine is in good working
condition. Check the bending dies, clamps, and other components for any signs of
wear or damage.
 Material Check: Ensure the pipe to be bent is the correct material, size, and type
specified for the job.
2. 2. Tooling and Programming:
 Die Selection: Choose the appropriate bending die based on the pipe diameter and
the desired bend angle. Consult the machine's manual or a tooling chart for guidance.
 Die Installation: Install the selected die on the machine's worktable, ensuring it is
securely fixed. Follow the machine's specific instructions for die installation.
 Programming: Input the bending parameters (angle, radius, length) into the CNC
controller. This may involve using a specific software interface or entering data directly
into the controller.
3. 3. Bending Process:
 Pipe Placement: Position the pipe on the die, aligning it with the clamping
mechanism.
 Clamping: Securely clamp the pipe to the machine to prevent movement during the
bending process. Ensure the clamps are properly tightened.

 Start Bending: Initiate the bending cycle through the CNC control system. The
machine will automatically move the pipe and apply the necessary force to create the
bend.
 Monitoring: Observe the bending process closely to ensure it is proceeding as
planned. Pay attention to any feedback from the machine's sensors or displays.
4. 4. Verification and Adjustment:
 Inspection: After the bending cycle, carefully remove the bent pipe from the machine.
 Angle Check: Measure the bend angle using appropriate measuring tools (e.g.,
protractor, angle gauge) to verify that it meets the specified requirements.
 Adjustment: If the bend angle is not within tolerance, make fine adjustments to the
CNC program or clamping mechanism and repeat the bending process until the
desired result is achieved.
5. 5. Finalization:
 Clean-up: Remove any scrap material or debris from the work area.

 Machine Maintenance: Perform any necessary maintenance tasks on the machine,

such as lubricating moving parts or cleaning the tooling.
 Documentation: Record any relevant information about the bending process, such as
the part number, bend specifications, and any adjustments made.

DRILL CUM MILLING MACHINE IN - 41

1. Machine Setup:
 Foundation:
If required, secure the machine to the floor using anchors to prevent vibrations.
 Leveling:
Use a spirit level to ensure the machine is level in all directions.
 Power:
Connect the machine to the correct power supply (typically 3-phase, 415V, 50Hz).
 Lubrication:
Ensure the machine is properly lubricated, especially gears that run in an oil bath.
2. Workpiece Preparation:
 Clamping: Securely clamp the workpiece to the machine's table using appropriate
clamps.
  Positioning: Ensure the workpiece is positioned correctly for the intended drilling or
milling operation.
 Zero Setting: Set the machine's zero point for accurate measurements and
positioning.
3. Tool Selection and Setup:
 Drilling:
Select the appropriate drill bit for the desired hole size and material, and mount it
securely in the chuck.
 Milling:
Choose the correct milling cutter for the desired milling operation (e.g., end mill,
face mill) and mount it in the spindle.
4. Performing the Operation:
 Drilling:
Engage the drilling function, adjust the feed rate, and carefully lower the drill bit into
the workpiece.
 Milling:
Engage the milling function, adjust the feed rate, and move the workpiece or the
milling cutter to perform the desired milling operation (e.g., slotting, shaping,
surfacing).
 Speed and Feed:
Adjust the spindle speed and feed rate according to the material being worked on
and the type of operation.
5. Safety Precautions:
 Personal Protective Equipment (PPE): Wear appropriate safety glasses, gloves,
and other necessary PPE.
 Machine Guards: Ensure all machine guards are in place and functioning correctly.
 Emergency Stop: Familiarize yourself with the location of the emergency stop
button and know how to use it.
 Cleanliness: Keep the work area clean and free of obstructions.
 Vibration: Avoid excessive vibration during operation.
6. Post-Operation:
 Clean the Machine: Remove any chips or debris from the machine and work area.
 Lubricate: Ensure the machine is properly lubricated.
 Shutdown: Turn off the machine and disconnect it from the power supply.