University of Idaho/Eastern Idaho Technical CollegeManufacturing and Robotics Teaching Laboratory

(MRTL)

Safety Policy

Table of ContentsSafety Policy…………………………………………………………………………………...2

Policy Objectives………………………………………………………………………………2

Safety Provision……………………………………………………………………………….3

Training Policy………………………………………………………………………………..4

Record Keeping………………………………………………………………………………5

Definitions………………………………………………………………………………….....6

Access to Shop & Equipment………………………………………………………………..7

Inspection Requirements…………………………………………………………………….8

Responsibilities……………………………………………………………………………….9

General Standard Operating Procedures for Common Tool & Machining Equipment

General Safety……………………………………………………………………………….10

Lathe…………………………………………………………………………….........11

Mill……………………………………………………………………………………12

Drill Press…………………………………………………………………………….13

Pedestal Grinder…………………………………………………………………….14

3-D Printer…………………………………………………………………………...15

Bandsaw……………………………………………………………………………..16

Denso Robot………………………………………………………………………....17

Appendix A

Safety Check List………………………………………………………………..18-19

Appendix B

Hazardous Substances Inventory List…………………………………………….20

Appendix C

Machine Shop Fire Safety Exit Plan………………………………………………21

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Safety Policy

It is the policy of the University of Idaho (UI) that the Manufacturing and Robotics Teaching Laboratory (MRTL) equipment located at Eastern Idaho Technical College (EITC) is to be operated in a safe manner. This document will serve as a model for academic departments to use in compliance with OSHA and NIOSH regulations. The UI recognizes that hazards may be encountered while working in machine shops. Research employees and students will be provided training and information on how to protect themselves from shop and machine hazards. This policy applies to the MRTL at EITC that have designated shop areas and includes, but is not limited to the following equipment: fixed electrically, pneumatically, or hydraulically powered pieces of equipment: CDC, 3D printer, Denso robot, drill press, lathe, band saw, table saw, mill, milling machine, grinder, radial arm saw, and any other fixed powered equipment that will be operated. It is the policy of the MRTL shop is operated in a safe manner. The machine shop shall be evaluated for equipment requiring special restrictions and training. Access to such equipment shall be restricted to trained personnel, and the “buddy system” shall be employed by casual or inexperienced users when the shop is unmonitored by regular MRTL.

Policy Objectives

The policy objectives are: Only persons trained and knowledgeable in the use of a specific piece of equipment use

that equipment. All work is performed in accordance with applicable regulatory requirements. Recommended machinery maintenance is conducted and standard operating procedures

are in place for machinery and equipment use.

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Safety ProvisionsThe Machine Shop Safety program will include provisions to assist with protecting employees and students from hazards. To meet this objective, the effected students will:

Survey workplaces to identify and designate shop areas and equipment covered by this program.

Identify a Machine Shop Safety Coordinator (MSSC) to manage this program for the shop.

Develop and provide training to individuals who will work in shop areas or serve as Shop Safety Coordinators.

A Hearing Protection Program to assess the need and use of ear plugs. Ear plugs will be accessible to all employees and students upon entry to the machine shop. The requirement for use of ear plugs will be determined by the equipment used in conjunction with Machine Shop Safety Coordinator and Health, Safety and Environment persons.

Injury, Illness and Accident Reporting will be maintained using OSHA form 300 and attached instructions. This form can be obtained at OSHA recordkeeping and guide .

Any Hazardous Materials used or identified in the workplace will require a Material Safety Data Sheet (MSDS). A running list of all known Hazardous Materials will kept in appendix B with a MSDS of the Hazardous Material.

For fire safety a diagram of the facility is provided in appendix C. This shows the location of the fire alarm pull box, fire extinguisher, and list of contact numbers.

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Training Policy

Training will include length and type of training for specific machines and should be determined by the designated MSSC or other qualified person. Training of authorized users should be performed by the designated MSSC or other qualified person who has thorough knowledge of how individual machining tools and equipment are operated, the safety hazards associated with those machining tools and equipment, and specific actions to take in case of an emergency. The training will include:

General machine shop safety procedures, including general use of hand and portable power tools, the location of all machine room exits, and the location of the nearest telephone and fire alarm station.

Recognize hazards posed by the equipment. Know safety features of the equipment. Personal protective equipment necessary for safe use of the equipment. Basic guarding, operation, and maintenance of the equipment. Safety procedures and precautions for the equipment, including emergency shutdown

procedures. Establish an annual review of the effectiveness and use of the program and its

components. Length and type of training for specific machines should be determined by the

designated MSSC or other qualified person. Training of authorized users should be performed by the designated MSSC or other qualified person who has thorough knowledge of how individual machining tools and equipment are operated, the safety hazards associated with those machining tools and equipment, and specific actions to take in case of an emergency.

Individuals should be classified as "Authorized Machine Tool Users" upon completion of training and creation of documented departmental training records. The MSSC should determine what method of identification will be used to distinguish between authorized users and those who have not been authorized.

Re-training should be provided if there is a change in job assignment, change in machine tool or equipment use, or additional jobs present a new hazard. Re-training may also occur if the MSSC determines additional need.

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Record KeepingDepartments should maintain training records. Training records should include the specific machining tool or other equipment the on which individual was trained, date of training, and the signature of trainee and trainer. Training records should be submitted to proper authorities.

Injury, Illness, and Accident reporting will be maintained using OSHA form 300 and 301.

General Safety Training information should be accessible in the designated machine shop or in a central location.

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DefinitionsDefinitions:

Authorized Machine Tool User – any individual person who has received both general machine shop safety training and specific machine tool and equipment training by the designated Machine Shop Safety Coordinator or other designated trainer, and is thus authorized to access and use the specific machining tools and equipment. This person will be trained to shut down equipment in use, shut down room power (where possible), and summon medical assistance in the event of an emergency.

Guard - an enclosure designed to restrain pieces of abrasive wheels, wheel pulley assemblies, other moving parts or working stock, and to protect the employee in the event of breakage or accidental contact with the moving part.

Hand Tool - an instrument used or worked by hand.

Machine Shop - a department designated facility which may contain at least one piece of machining equipment.

Machine Shop Safety Coordinator (MSSC) - an employee who develops and implements administrative controls to ensure the safety of any person operating machining equipment.

Machining Equipment - any of the following fixed electrically, pneumatically, or hydraulically powered pieces of equipment: CDC, 3D printer, Denso robot, drill press, lathe, band saw, table saw, mill, milling machine, grinder, radial arm saw, and any other fixed powered equipment that must operate with proper PPE.

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Access to Shop and EquipmentAll University students and research employees (i.e. professors, researchers) should have received formal machine shop safety training and be a designated "Authorized Machine Tool User" prior to access and use of machining tools and machining equipment in machine shops.

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Inspection Requirements

Annual Inspection Requirements:

The MSSC should conduct annual machine tool, associated equipment, and facility safety inspections. Inspection criteria should be in accordance with federal and state safety regulations. To aid in the inspection process, a machine shop safety checklist can be found in attachment A.

All machine tools and equipment that are in violation of the safety regulations should be removed from service and locked out until properly repaired.

Documentation of the inspections shall be maintained by the department and copies provided to appropriate authorities.

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ResponsibilitiesDepartment Chairs, Faculty:

Implement a Machine Shop Safety Program. Designate and authorize an individual who has thorough knowledge of proper machine operation and safe working procedures as the Machine Shop Safety Coordinator. Actively support this Policy within individual units. Ensure an environment where supervisors and other personnel are encouraged to follow this Policy

Machine Shop Safety Coordinator: Manage all activities that impact machine shop safety. Examples of these activities

include user training, proper use of personal protective equipment, project set up, removal of unsafe machines from service, posting of appropriate signage at work areas, and approval of users in the shop. Conduct safety inspections of machining tools, equipment and facilities at a minimum of once a year. Train all employees and non-employees on machining tool and equipment use. Maintain training and injury, illness, and accident reporting documentation as stated. Maintain training documentation as stated. Limit student access to tools and equipment. Provide eye and ear protection to authorized machine tool users and visitors upon entry into a machine shop. Establish allowable material use specific for the type of machine, application, and environment.

Machine Tool Users: Comply with this Policy and any further recommendations initiated by the supervisor.

Conduct assigned tasks in a safe manner, wear appropriate personal protective equipment, and only use equipment for which they have been formally trained. Report any job related injuries or illnesses, questions on health and safety, or any unsafe or unhealthy working conditions to their supervisor. Individuals will be classified as "Authorized Machine Tool Users" upon completion of training and documented departmental training records. Operate only the specific machines, tools and equipment they have been trained to use. Must not wear loose clothing or exposed jewelry while using any machining tool or piece of equipment. Pull back and secure long hair prior to using machining tools and equipment. Report defective machinery, equipment and hazardous conditions to the MSSC. Do not remove guards from machinery and equipment except when necessary for servicing.

Health, Safety and Environment: Monitor conformance with this Policy, as well as state and federal regulations. Conduct

training on this Policy for designated MSSC(s). Conduct machining equipment and facility inspections upon request. Provide copies of MSDS, training records, and injury, illness and accident reports upon request. Provide technical support on all aspects of this Policy. Review and revise the Machine Shop Safety Policy, as needed. Conduct an incident investigation when appropriate.

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10

GENERAL STANDARD OPERATING PROCEDURES FOR COMMON TOOL

AND MACHINING EQUIPMENTThe following information is provided as a guide for the minimum safety training that shall be provided to personnel prior to any authorized use of any of the following machining tools or pieces of equipment:

GENERAL SAFETY IN MACHINING SHOP

Safety glasses with side shields must be worn at all times. Do not wear loose clothing, loose neckwear or exposed jewelry while operating

machinery. Do not work alone in a machine shop. (Implement the "buddy" system.) Long sleeves on shirts should be rolled up above the elbows. Pull back and secure long hair. Do not wear thin fabric shoes, sandals, open-toed shoes, and high-heeled shoes. A machinist's apron tied in a quick release manner should be worn. Always keep hands and other body parts a safe distance away from moving

machine parts, work pieces, and cutters. Use hand tools for their designed purposes only. Report defective machinery, equipment or hand tools to the MSSC.

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LATHE

All stock must be properly secured in the lathe chuck or mounted prior to the machining process taking place. Use the correct sized clamp or vise for the stock being machined.

Turn the chuck or faceplate by hand to ensure there is no binding or danger of the work striking any part of the lathe.

Check to ensure the cutting tool will not run into the chuck or lathe dog. If possible, feed away from the chuck or dogs.

Before starting the lathe, ensure the spindle work has the cup center imbedded; tail, stock and tool rests are securely clamped; and there is proper clearance for the rotating stock.

Prior to starting the lathe, ensure that small diameter stock does not project too far from the chuck without support from the tail stock center.

When using wood, do not mount a split work piece or one containing knots. When roughing stock, do not force the tool in the work piece or take too big a cut. The operator must always be aware of the direction and speed of the carriage or

cross-feed prior to engaging the automatic feed. Never leave the key in the chuck. Do not let go of the key until it is free of the

chuck and secured in its proper holding place. Select turning speed carefully. Large diameter stock must be turned at a very low

speed. Always use the lowest speed to rough out the stock prior to final machining. The correct speed and feed for the specific material and cutting tool must be used.

Stop the machine before making adjustments or measurements. Do not remove metal or wood chips from the table or stock by hand. Use a brush or

other tool to properly remove chips or shavings from the table or stock. Never attempt to run the chuck on or off the spindle head by engaging the power. Do not stop the rotation of the chuck by reversing the power to the lathe unless

tapping holes. Do not leave tools, bits or excess pieces of stock on the lathe bed. All belts and pulleys must be guarded. If frayed belts or pulleys are observed, the

lathe must be taken out of service and the belts or pulleys replaced. Stop the machine immediately if odd noise or excessive vibration occurs. Only properly sharpened drill bits and cutting tools in good condition should be

used. Dull drill bits and chipped or broken cutting tools must be removed from service.

Disconnect the lathe from power source when making repairs or servicing. When an operator has finished working on the lathe, and before leaving the lathe

for any reason, the power must be shut off and the machine must come to a complete stop.

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MILL

Keep all guards in place while operating the machine. While operating the milling machine allow no one else to touch it. Keep hands away from moving cutting tools. Do not make measurements of the stock while the milling machine is

powered. Do not allow large quantities of chips to accumulate around the work

piece or machine table. After stopping the machine, use a brush or rag to remove all excess chips from the mill bed and stock.

Use a rag or Kevlar gloves to handle sharp cutting tools. Cutting tools must be securely fastened in the machine spindle with the

proper accessory. Never try to tighten cutting bits or tools by hand. Do not power the machine to tighten or loosen cutting bits or tools. Work pieces and stock must be rigidly fastened to the mill bed with

clamps, a vise, or special fixtures. Use appropriate speeds and feeds for the type and size of cutter being used

and the material being machined. Make sure the cutting tool is clear of the work piece before starting the

machine.

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DRILL PRESS

Know the location of start and stop switches or buttons and keep the drill press table free of tools and other materials.

Use only properly sharpened drill bits, sockets and chucks in good condition. Remove dull drill bits, battered tangs, or sockets from service.

Do not remove by hand, metal or wood chips from the table or stock. Use brushes or other tools to properly remove chips.

Do not attempt to oil the machine or make adjustments to the work while the drill press is in motion.

Do not insert a drill chuck key into the chuck until the power is shut off and the machine has come to a complete stop.

All belts and pulleys must be guarded; if frayed belts or pulleys are observed, the drill press must be taken out of service and the belts or pulleys must be replaced.

All stock must be properly secured with a vise or clamps prior to a machining process.

If the stock slips in the vise or clamp, the operator must not attempt to hold the work with his/her hand or try to tighten the vise/clamp while the machine is in motion. Shutdown the power to the machine prior to re- tightening the loose stock.

Use the correct speed and drill for the type of stock being machined. Use the appropriate bit for the stock being machined. Bits with feed screw

or extremely long bits should not be used. The drill bit should be mounted the full depth and in the center of the

chuck. Position the table and adjust the feed stroke eliminating the possibility of

the bit striking the table. Feed the bit smoothly into the work. If the hole being drilled is deep,

withdraw the bit frequently to remove shaving on the bit. Never attempt to remove a broken drill with a center punch or hammer. When an operator has finished working on the drill press, and before

leaving the drill press for any reason, the power must be shut off and the machine must come to a complete stop.

When an operator observes an unsafe condition on the drill press, or stock that is being worked on, they must report it immediately to the designated MSSC and the press will be taken out of service until the problem has been corrected.

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PEDESTAL GRINDER

Inspect the wheels before turning on the power. Do not use wheels that are chipped or cracked.

Stand to one side of the wheel when turning on the power. Keep the tool rest as close to the grinding wheel as possible without

touching it. The tool rest must be minimally within 1/8 of an inch of the grinding wheel.

Prior to starting the grinder, ensure the tang at the top of the wheel opening is located within 1/4 inch of the wheel.

Prior to starting the grinder, ensure guards enclosing the outside of grinding wheel are in place.

Prior to adjusting the work rest or tang, unplug the power to the grinder from the wall receptacle.

Be alert and cautious when a grinding operation requires locating fingers close to the wheel.

Feed the stock into the wheel with light to medium pressure. Do not force the piece.

Do not use the side of the grinding wheel to shape stock. Stand erect in front of the grinder with both legs straight and slightly

apart. Avoid stooping or leaning into the machine.

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The 3-D Printer

CAD - Produce a 3-D model using computer-aided design (CAD) software. The software may provide some hint as to the structural integrity you can expect in the finished product, too, using scientific data about certain materials to create virtual simulations of how the object will behave under certain conditions.

Conversion to STL -- Convert the CAD drawing to the STL format. STL, which is an acronym for standard tessellation language, is a file format developed for 3D Systems in 1987. Most 3-D printers can use STL files in addition to some proprietary file types such as ZPR by Z Corporation and ObjDF by Objet Geometries.

Transfer to AM Machine and STL File Manipulation -- A user copies the STL file to the computer that controls the 3-D printer. There, the user can designate the size and orientation for printing. This is similar to the way you would set up a 2-D printout to print 2-sided or in landscape versus portrait orientation.

Machine Setup - Each machine has its own requirements for how to prepare for a new print job. This includes refilling the polymers, binders and other consumables the printer will use. It also covers adding a tray to serve as a foundation or adding the material to build temporary water-soluble supports.

Let the machine do its thing; the build process is mostly automatic. Each layer is usually about 0.1 mm thick, though it can be much thinner or thicker. Depending on the object's size, the machine and the materials used, this process could take hours or even days to complete. Be sure to check on the machine periodically to make sure there are no errors.

Removal - Remove the printed object (or multiple objects in some cases) from the machine. Be sure to take any safety precautions to avoid injury such as wearing gloves to protect yourself from hot surfaces or toxic chemicals.

Post-processing - Many 3-D printers will require some amount of post-processing for the printed object. This could include brushing off any remaining powder or bathing the printed object to remove water-soluble supports. The new print may be weak during this step since some

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materials require time to cure, so caution might be necessary to ensure that it doesn't break or fall apart.

Application - Make use of the newly printed object or objects.

BAND SAW

Ensure the guard doors are closed and the blade is properly adjusted prior to turning on the machine.

Adjust the upper guard assembly to within 1/4 inch of the stock prior to starting the machine. Set the band saw at the appropriate speed for the type of stock being machined.

Check to ensure the band saw blade is sharpened. Check to ensure the band saw is correct for the type of stock and correct

speed being used. Allow the saw to reach full set speed prior to cutting stock. Do not force stock into the saw blade. Let the speed of the blade cut stock

appropriately. Make “release” cuts before cutting long curves. Plan saw cuts to avoid backing out of curves in the stock. Never push a piece of stock with hands in front of the saw blade. Use a

push stick. Keep hands at a safe distance on either side of the stock being machined.

Use a push stick or board to push small or irregular sized stock. Small work pieces can also be secured with a tabletop vise or clamp.

All round stock must be secured in a tabletop vise or clamp prior to starting the cut.

Hold the stock flat on the table prior to starting the cut. If the saw blade binds on a piece of stock, turn the saw off and wait until

it comes to a complete stop before attempting to remove the blade from the stock.

Do not allow large quantities of chips to accumulate around the work piece or band saw table.

After stopping the machine, use a brush or rag to remove all excess chips from the band saw table and stock.

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Denso Robot

Before starting work inspects the following items Check for any damage to the sheath or cover of the external wiring or the

external device. Check the functioning of the emergency stop device. Check that the robot is functioning normally or not if any unusual noise or

vibration is observed stop robot operations. Check there is no leakage of air or oil from any pipes. Check there are no obstructive objects in or near the robot’s restricted

space. Check that the teaching pendant and tools are in their designated places. Check that no lamps indicating a malfunction on the robot or related

equipment are lit. Steps to be taken when a malfunction occurs; Should a malfunction occur

with the robot or related equipment and it is necessary to enter the robot’s restricted space to perform emergency maintenance, stop the robot’s operation by activating the emergency stop device. Take any necessary steps to indicate work is in progress to prevent anyone from accessing the robot.

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Appendix A UI MRTL SAFETY CHECKLIST

Room Building Date

Supervisor Inspected by

E YES NO N/A COMMENTSEmergency Phone Numbers posted near a phone

Exits and exit paths are free of obstruction

First aid kits available and stocked

Fire extinguishers accessible and inspected monthly

GENERAL YES NO N/A COMMENTSAdministrative responsibility for shop safety has been clearly definedMachine users have completed “Basic Machine Shop Safety” and specific training on individual tools and training are documented.

Protective (ANSI Z87.1 approved) eyewear worn at alltimes in areas where equipment is operatingSafety training documented and posted or maintainedin a central locationStudent access limited to regular hours of operation

After-hours access is prohibited, unless prior, writtenapproval obtainedMandatory student “buddy system” enforced at all times

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Long, loose hair must be contained in a scarf, cap or other appropriate fashion; long facial hair properly restrained

Loose clothing, loose neck wear and jewelry is not beingworn while operating, or in proximity to, machineryAcceptable shoes are worn by equipment users

Long shirt sleeves must be rolled up snugly above the elbows

Compressed air reduced to 30 psi and not used to clean person or clothesPersonal listening devices are prohibited.

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GENERAL MACHINE SAFETY YES NO NA CMachinery installed to prevent unintentionalmovement or trippingA brush is available to remove stock shavings and chips

Materials, scrap, and debris properly contained

Machinery located so that operators do not stand in an aisle or interfere with the operation of other equipmentPowered electrical equipment has an on-off switch

Actuating controls are guarded or located to prevent accidental actuation, and precautions have been taken to prevent a machine from automatically restarting upon the restoration of power after a power failureA red emergency stop device is provided where the machine workstation is remotely located from the machine controls

GENERAL MACHINE SAFETY YES NO NA CActuation of the controls requires continuous depressions during the hazardous portion of the machine cycle where the machine workstation is remotely located from the machine controls

ELECTRICAL SAFETY YES NO NA CAll electrical service cords are in good condition

Electrically powered machines are grounded

All electrical receptacles within 6’ of water source haveGFCI protectionExtension cords are not used as a permanent source of electricity

HOUSEKEEPING/HAZARD COMMUNICATION YES NO NA CStorage areas are free of accumulations of materials that constitute a hazard from fire, explosion, or pest harborage

Working dust collection system to minimize materials &debris around cutting, drilling & milling equipmentAll safety cans are red in color

All emergency stop devices on machines (exceptcables) are red in colorPhysical hazards are marked with yellow or yellow withblack stripesUnobstructed 3-foot aisle maintained between machines

Chemicals are properly labeled, and stored in designated area(s)

Appropriate safety signs, labels, tags & other postings are displayed in applicable areas

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Appendix B: UI MRTL Hazardous Substances Inventory List

UI Hazardous Substances Inventory List Date:Contact phone Number:Date of Inventory:

Index No.

Chemical Name

Common Name

Manufacture Quantity NFPA Rating Location MSDS

LBS GAL H F R S Y N

*MSDS’s will be posted in book by index number on proceeding pages.

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Appendix C:UI MRTL Fire Safety Exit Plan

List of contact numbers:Emergency - 911

Exit

ExitExit

Denso Robot

Eyewash Station

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"Injury and Illness - Recordkeeping." Injury and Illness - Recordkeeping. N.p., n.d. Web. 02 May 2014.

"Risk Management & Tort Defense." - Machine.mcpx. N.p., n.d. Web. 02 May 2014.

"Laboratory Safety Colloquium Series." Environmental Health & Safety. N.p., n.d. Web. 02 May 2014.

"General Machine Shop Safety." Machinistorg RSS. N.p., n.d. Web. 02 May 2014.

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