wt4603 unit 0-week1_nv

WT46 3

Wood Processing Safety & Practice

Lecture Unit 0

WT4603: Introduction & Lab 1 Activity Lecturer: Mr. Joe Lyster [email protected] Department of Manufacturing & Operations Engineering Lecture notes prepared by Mr. Donal Canty, Mr. Des Kelly & Mr. Joseph Lyster

mailto:[email protected]

Module Outline

Lecturer: Joseph Lyster Teaching Assistant: Michael Crehan Technicians: Joseph Murray

Louise Madden Lab Groups 2A-2B-2C-2D-2E-2F Courses Involved: LM094 Materials & Architectural Technology LM067 Wood Science & Technology

Lecture Times Friday 2-4pm in P1001 (PESS Building)....Be on time!!!

Lecture Notes Available @ www.slideshare.net/WT4603

Department of Manufacturing & Operations Engineering

WT4603

http://www.slideshare.net/WT4603

Module Outline


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Lectures Labs

Aim

1. To underline and explain the legislative and technical material associated with wood processing safety and practice.

1. To underline and develop best practice approaches and use in wood processing safety and practice.

Objectives

a. Standardizeddocumentation, legislation and accountability

a. Safe wood processing procedures and practice

b. Machine anatomy, performance and terminology

b. Develop safety culture

c. Develop safety culture and supervising for safety

c. Supervising for safety

d. Safe wood processing procedures and practice

d. Confident andcompetent machinists

The aim of WT4603 is wood processing safety and best practice. This is a core module and a requirement for second year teaching practice (TP).

Module Assessment Module Assessment:

35% Laboratory Work (Table Project/Lab book)

35% Written Exam (Terminal)

20% Term Assignments (Risk Assessments/Information posters)

10% Lecture Worksheets

Machines Practical Exam (Pass / Fail Basis)

Note: Students must pass all assessment elements to obtain a pass in the module. Students that fail the practical machines exam will automatically fail the entire

module.


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Module Outline

Nature of Project work: Laboratory Work: Table project

Lab Booklet

Term Assignments: Risk Assessments

Information Poster

Lecture Work: Worksheets


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Module Outline – Coursework Table project Purpose of the table project is to reflect your use of woodworking

machinery through wood processing safety and best practice Project enables you to purposely process material to construct an

artefact (table) from a raw plank state in the most efficient and safe manner possible

Use of the surface planer, thicknesser, rip saw, mortiser, bandsaw, panel saw as part of this project

Produce appropriate cutting lists, plans and procedures with the awareness of material processing waste, which is an important element for the sustainable use of material and procurement of bulk raw plank material for class projects

Develop hand skills in preparation for teaching practice by producing a series of hand-crafted joints to construct the table

Develop your awareness of machine safety through risk assessment procedures including aspects such as hazard identification and risk magnitude. This is a critical aspect regarding the safe operation of any second level technology classroom.


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Module Outline – Coursework


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Table project requirements:1. Produce fully constructed and finished table

2. Produce an orthographic plan, elevation and end view of table showing component detail. Can be done using hand or CAD/Solidworks

3. Produce a cutting list for components

4. Produce a graphical procedure handbook of project material processing safety & best practice. Templates will be provided for this aspect.

Module Outline – Coursework


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Lab book: The purpose of the lab book is to record your in lab

exposure to wood processing safety and best practice.

It is advised that you complete the lab book during your lab time as it intends to capture your initial exposure to using wood processing machinery

You will not be permitted to the lab without your lab book

Lab book can be purchased from snap printing at a cost of €6.

Module Outline – Coursework Term Assignments:

Risk Assessments Create an A3 booklet to include the following:

Lab Machines:1. Risk assessment 1 – Surface planer2. Risk assessment 2 – Thicknesser3. Risk assessment 3 – Rip saw4. Risk assessment 4 – Bandsaw5. Risk assessment 5 – Mortiser 6. Risk assessment 6 – Pillar Drill7. Risk assessment 7 – Router You will each be assigned and required to perform 3 risk assessments of staged (hazard

induced) machines. This will account for 3 of your 7 individual risk assessments outlined above. In case of staged machines you will be provide with an image and scenario and you will be required to perform your risk assessment based on this information.

Information Poster1. Create an appropriately designed A2 laminated poster on an assigned machine.2. Must be accompanied by a user information sheet3. You must also develop a work activity sheet that addresses machine safety and best

practice to reinforce operant knowledge, understanding and safety culture

• All assigned machine lists, as discussed in both cases above, can be viewed in the lab.


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Module Outline – Coursework Lecture Worksheets: Each week you will be given an activity sheet to be

completed during the lecture. The aim of the lecture worksheets is to reinforce wood

processing safety and best practice. The worksheet will prepare you in advance of activities

taking place in forthcoming labs. It will provide you with a theoretical understanding of

wood processing safety and best practice that will strengthen your knowledge and understanding in preparation for labs.

The worksheets will also involve reflection on the use of machinery in previous labs


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Module Outline


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Timetable:

Lecture Content – 24hrs

Unit 0: Introduction + Labs W2Unit 1: Machine Provision + Labs W3 Unit 2: Risk Assessment + Labs W4 Unit 3: PPE + Labs 4 W5Unit 4: Planing Machines + Labs W6Unit 5: Circular saws + Labs W7Unit 6: Routers + Labs W8Unit 7: Dust, Noise, Manual Handling + Labs W9


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Laboratory Sessions

Permitted entry to timetabled labs only! Labs will take place in SR2058 & SR2047. Lab coat and safety glasses are a prerequisite to gaining

entry to the lab. You must have your lab booklet during all labs. Groups are divided and timetabled Labs will begin on Week 2

Labs are mandatory – 100% attendance Absence in the case of illness must be explained with a

doctors note. Other reasons must be explained to the lecture/TA.


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Laboratory Sessions 2 X 2 Hours per Week (Week 2 --- Week 13 incl.) Labs begin on the hour and finish at 10 minutes before

the hour, e.g. 9:00am to 10:50am Late arrivals will not be permitted to join the lab session. Lab Rules and Requirements:

Report for lab on time White lab coat Safety glasses Students must sign the attendance sheet Students will be assigned a work bench I.D. cards to be submitted to T.A. for locker keys Students must follow instructions of T.A. Students under the influence of alcohol will not be permitted.


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Laboratory Sessions House Keeping Students have a responsibility for the care of the tools in their locker At thee beginning and end of the lab students must:

Check tools list and condition Report to T.A. if any tools are missing Report to T.A. if tools are damaged

At the end of each lab session: Benches must be brushed down Bench hooks returned to the underneath of each bench. Vices must be in the closed position. The floor area is swept and/or all waste material is removed from the ground area. Wood waste and paper waste to be segregated. If stools are used during a lab session, they must be removed from the floor and

placed on top of the bench. I.D. cards will only be returned to students when they have complied with these

regulations.

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Health & Safety

Lab coats must be worn at all times in the workshop. Safety glasses must be worn at the appropriate times as

laid out by the T.A. in charge. Students must report damage to tools and equipment to

the T.A. in charge. Students must immediately report any personal injury

(nicks, cuts etc.) to the T.A. in charge. Failure to comply with safety regulations will result in

removal from the lab session. Any malicious damage to University property or

equipment will result in removal from the lab and University disciplinary procedures will be put in place.

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Lab Requirements – Week 2

Students must present at labs on Week 2 with the items requested on the 2nd Year Tools List

Failure to present this equipment at the beginning of the lab will result in you not being able to participate in the lab

You must bring all equipment & PPE to all labs

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Date Lab 1 Tech. Students Lab 2 Tech. Students

Week 1 No Labs No Labs

06-Sep No Labs No Labs

10-Sep No Labs No Labs

Week 2 Planer and Thicknesser TECH 6 SR2-047 Planer and Thicknesser TECH 6 SR2-047

13-Sep Planer and Thicknesser TECH 6 SR2-047 Planer and Thicknesser TECH 6 SR2-047

17-Sep Band Saw TA 12 SR2-058 Band Saw TA 12 SR2-058

Week 3 Cutting List/Plans/Procedure TECH 6 SR2-047 Rip Saw TECH 6 SR2-047

20-Sep Cutting List/Plans/Procedure TECH 6 SR2-047 Rip Saw TECH 6 SR2-047

24-Sep Cutting List/Plans/Procedure TA 12 SR2-058 Morticer TA 12 SR2-058

Submission 1 TA ALL

Week 4 Rip Saw TECH 6 SR2-058 Cutting List Component B TA 24 SR2-058

27-Oct Rip Saw TECH 6Router 1

24

01-Oct Morticer TA 12

Week 5 Marking TA 12 SR2-058 Marking TA 12 SR2-058

04-Oct Router 2 TECH Router 2 TECH

08-Oct Processing Component B TECH 2 SR2-047 Processing Component B TECH 2 SR2-047

Week 6 TA 12 SR2-058 Pillar Drill TA 8 SR2-058

11-Oct Table Manufacture TECH Table Manufacture TA 8 SR2-058 Tue & Wed Open days

15-Oct Table conponent processing TECH 12 SR2-047 Table conponent processing TECH 8 SR2-047

Project Manufacture

Week 7 TA 8 SR2-058 Submission 2 TA ALL SR2-058

18-Oct Table Manufacture TA 8 SR2-058 Table Manufacture TA 8 SR2-058

22-Oct Table conponent processing TECH 8 SR2-047 Table conponent processing TECH 8 SR2-047

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Project Manufacture Project Manufacture

Week 8 TA SR2-058 TA SR2-058

25-Nov Table Manufacture LOUISE SR2-058 Table Manufacture SR2-058 Bank Holiday Monday

29-Oct Table conponent processing Table conponent processing SR2-058

Project Manufacture Project Manufacture

Week 9 Router 3 TA SR2-058 Router 3 TA SR2-058

01-Nov Table Manufacture SR2-058 Table Manufacture SR2-058


Week 10 Table Manufacture TA SR2-058 Submission 3 TA ALL SR2-058


12-Nov Table Manufacture TECH SR2-058 Table Manufacture TECH SR2-058

Week 11 Machines Exam TECH SR2-047 Machines Exam TECH SR2-047

15-Nov Table Manufacture TA SR2-058 Table Manufacture TA SR2-058

19-Nov

Week 12 Machines Exam TECH SR2-047 Machines Exam SR2-047

22-Nov Table Manufacture TA SR2-058 Table Manufacture SR2-058

26-Nov Table Manufacture Table Manufacture

Week 13 Submission 4 TA ALL

Machines Repeat Exam29-Nov

Machines Repeat Exam

03-Dec

Week2: Lab 1 & 2• Table

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Week 2: Lab 1 & 2• Machine Exposure:

▫ Surface Planer▫ Planer Thicknesser▫ Bandsaw

• Material Process – Component A:▫ Each student will receive an unprocessed plank of red deal

measuring 740 x 242 x 50 (mm)

▫ Aim of week 2 labs is to square the material to a clean workable condition of required dimension.

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740

242

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Surface Planer

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Surface Planer1 Guide Fence

2 Infeed Table

3 Isolator

4Infeed Dept Adjustment Wheel

5 Start/Stop Control

6Infeed Adjustment Lock Handle

7 Blade Guard

8Blade Guard Clamp/Release Mechanism

9 Outfeed Table

10Guide Fence Adjustment Wheel

11 Guard Guide

12Guide Fence Lock Handle

2

8

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Step 1:Isolate machine

Step 2: Squaring guide fence•Set up surface planer guide fence @ 90⁰ to table surface•Note infeed and outfeed table. •Square to infeed using right angle square.•Use red lock handles to open and adjust fence.•Lock gently when fence is perpendicular to infeed table.

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Step 3: Setting infeed dept•This machine is calibrated in metric.•Maximum recommended material removal is 1-2mm/pass•Dept stop to be set at 2mm•Open infeed lock handle•Turn wheel to left to drop table to 2mm•Lower you drop, the more the planer cutting block is exposed•Close infeed lock handle when required dept is achieved.•* Do not adjust outfeed table level, this is for maintenance purposes only*

Infeed Infeed

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Step 4: Setting the guide fence width•Minimum blade exposure•Width of material + 10mm is recommended•This results in 10mm blade exposure - Safety•Adjust lock handle to wind in or out guide fence•Lock in appropriate position

242 + 10

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Step 5: Guard adjustment•Guard set for face side = handle up – 10mm blade exposure•Guard set for face edge = handle flat – no blade exposure

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Step 6: Material Inspection•Inspect material for the following defects

•Cupping•Bowing•Twist•Knots•Loose grain

•Example - if material is bowed, set the bowed face to the surface planer table surface and process. Material should never be run through hump side down.

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Step 7: Determining face side and face edge•Use machine surface to check square•Select appropriate face side and face edge based on inspection•Preliminary surface marking using an ‘X’ with no less than a HB pencil•Ensure extraction gate valve is open and extraction is on•Proceed to plane material – face side and face edge only!

Gate Valve locate on extractor pipe just above surface planer

X X

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Step 7: Planing face side•Material position •Hand positions

Ensure Guard Guide is in a vertical position to plane face side

Dept of Hand Dept of Hand

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Note Hand Positions in relation to material

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Step 8: Planing face edge•Material position•Hand position

Ensure Guard Guide is in a horizontal position to plane face edge

Dept of Hand Dept of Hand

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Note Hand Positions in relation to material

Split second blade ExposureBlade guard flat onto table

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Thicknesser

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Thicknesser

1

1 Extractor Pipe

2 Control Panel

3 Adjustment Lever

4 Thicknesser Bed

• Lab sequence – Thicknesser• Step 1:

1. Unlock twist release stop mechanism

2. Press green button to start

3. Allow machine to build up, this can be determined by noise consistency

4. When noise is consistent flip delta switch to on position

5. Feed rate, i.e. Speed at which material is passed, is set.

6. Adjust table height as required

7. Feed material as directed

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Delta Switch

Twist Release Stop

Display Panel

Feed Rate Control

Stop/Start

Thicknesser Bed Adjustment

Control

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Bandsaw

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The bandsaw

See you all next week!

• Next week:▫ Machine Provision

▫ Risk assessment

▫ Week 3 ripsaw labs

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wt4603 unit 0-week1_nv

Education

risk assessment procedures

risk magnitude

wt4603 module outlinethe

wt4603 module outline

lab machines

wood processing machinery

best practice project

safety culturec