wt4603 unit1 week2-17-09-2010
DESCRIPTION
Lecture Unit 1 Week 2: Machine Provision, Hazard Identification, Risk Assessment & Week 3 Labs.TRANSCRIPT
WT4603
Wood Processing Safety & Practice
Lecture Unit 1
Machine Provision, Hazard Identification, Risk Assessment & Week 3 Labs Lecturer: Mr. Joseph Lyster [email protected] Notes prepared by: Mr. Donal Canty, Mr. Des Kelly and Mr. Joseph Lyster Notes available on www.slideshare.net/WT4603
Department of Manufacturing & Operations Engineering
WT4603
The CE Marking is not a mark indicating conformity to a standard but rather a mark indicating conformity to the legal requirements of EU Directives.
CE Mark
Department of Manufacturing & Operations Engineering
WT4603
• CE Marking is the symbol as shown on the top of this page.
• The letters "CE" are the abbreviation of French phrase "Conformité Européene" which literally means "European Conformity".
• The term initially used was "EC Mark" and it was officially replaced by "CE Marking" in the Directive 93/68/EEC in 1993.
CE Mark
Department of Manufacturing & Operations Engineering
WT4603
• Machinery must bear the “CE” mark in order to be deemed in compliance with these regulations.
• Must not add to machinery – must be there… criminal offence to try to add it.
• Also an offence to reduce the visibility of the “CE” Marking on a machine.
CE Mark
Department of Manufacturing & Operations Engineering
WT4603
The existance of the “CE” marking on a piece of machinery should indicate that its manufacturer has met all relevant standards and requirements.
CE Mark
Department of Manufacturing & Operations Engineering
WT4603
Never assume that machinery is safe just because it has a “CE” marking
CE Mark
Department of Manufacturing & Operations Engineering
WT4603
A brief look at Safety Signage
Mandatory/Action
Regulatory/Prohibited
Emergency/Permission
Warning/Caution-Danger
Department of Manufacturing & Operations Engineering
WT4603
• Students should only work in a high risk area when it is fully under the control of a person competent to work in and supervise that area.
• Close monitoring of students using machinery.
• Students must not be permitted to use equipment while unsupervised.
• It is the responsibility of the schools to ensure that the machines are not accessible to unauthorised persons
▫ Cleaners
▫ Visitors
▫ Unsupervised students.
Supervision & Access
WT4603
Department of Manufacturing & Operations Engineering
Supervision & Access
WT4603
Department of Manufacturing & Operations Engineering
Power operated equipment and tools should be locked in the “OFF” position in the following situations:
▫ When left unattended for any period of time.
▫ When the competent person (supervisor) is not in the work area.
▫ Before cleaning out any blockage.
▫ Before the machine is cleaned.
▫ Before any maintenance work is carried out on the machine.
▫ Before guards are adjusted.
▫ Before tools or accessories are adjusted or changed.
▫ Before removing waste or swarf.
▫ When a machine is awaiting repair or maintenance.
Supervision & Access
WT4603
Department of Manufacturing & Operations Engineering
Supervision & Access
WT4603
Department of Manufacturing & Operations Engineering
Machines not to be used while pupils are in the classroom:
• Spindle Moulder
• It is recommended that the use of the circular saw and planer thicknesser machines while the students are in the classroom should be strictly prohibited.
• All preparatory work involving these machines should take place before class.
• May not be achievable immediately but plans should be made to try…in the interim control measures should be put in place to reduce exposure to as low levels as possible.
Supervision & Access
WT4603
Department of Manufacturing & Operations Engineering
Machine guards must:
▫ Be of robust construction.
▫ Not give rise to any additional hazard.
▫ Not be easily removed or rendered inoperative.
(Removed with the use of a tool)
▫ Be situated a sufficient distance from the danger zone.
▫ Not restrict more than necessary the view of the operating cycle of the equipment
Guarding
WT4603
Department of Manufacturing & Operations Engineering
• An assessment of each workshop should be carried out in order to determine the safe operational area around each machine.
• Hard wearing and clearly visible markings should be set down on the floor to indicate these safe operation areas.
• If necessary, machines should be moved to accommodate this safe operational area.
Exclusion Zones
WT4603
Department of Manufacturing & Operations Engineering
Lighting
WT4603
Department of Manufacturing & Operations Engineering
Emergency Isolators and Emergency Stops
WT4603
Department of Manufacturing & Operations Engineering
Start/Stop• Are there appropriate start / stop controls ?
• Location
• Colour
• Flush mounted
• Mushroom head
▫ Turn release
▫ Key release
WT4603
Department of Manufacturing & Operations Engineering
Stop control must have priority over the Start control.
Start Control
Flush
Recessed
Stop Control
Mushroom Head
Push Bar
Start/Stop
Department of Manufacturing & Operations Engineering
WT4603
Some machines may have two stopping devices.
Hand Operated
Foot/Knee Operated
Emergency Stop
Department of Manufacturing & Operations Engineering
WT4603
Push Sticks
Department of Manufacturing & Operations Engineering
WT4603
Material Preparation
Department of Manufacturing & Operations Engineering
WT4603
Maintenance of Machinery
Department of Manufacturing & Operations Engineering
WT4603
Preventative Maintenance
Department of Manufacturing & Operations Engineering
WT4603
Maintenance Records
Department of Manufacturing & Operations Engineering
WT4603
Inspection of Machinery
Department of Manufacturing & Operations Engineering
WT4603
• If the power supply to a machine is interrupted during operation the machine motor will stop.
• When this happens the machine should automatically switch itself to the off setting.
• When the voltage supply has been restored the machine should not automatically restart.
• If the machine automatically restarts the switching mechanism should be upgraded or changed to prevent this inadvertent start.
Inadvertent Starting
Department of Manufacturing & Operations Engineering
WT4603
Inadvertent Starting
Department of Manufacturing & Operations Engineering
WT4603
Machinery Rundown Time
Department of Manufacturing & Operations Engineering
WT4603
• Section 8(2)e of the 2005 Act states that it is the duty of every employer
“to provide systems of work that are planned, organised, performed and maintained so as to be, so far as is reasonably practicable, safe and without risk to health.”
• Health and safety management is a practical and systematic approach to identifying hazards and evaluating the extent of associated risk
Health & Safety Management
Department of Manufacturing & Operations Engineering
WT4603
Can be identified by:▫ High accident/injury rates.
▫ Poor machinery guarding.
▫ Poor cleaning and housekeeping arrangements.
▫ Limited interest of OHS by employers/management.
▫ Lack of care/respect for safety rules.
▫ Poor safety culture.
Unsafe Workplaces
Department of Manufacturing & Operations Engineering
WT4603
Can be identified by:
• Regular inspection of workplace
• Consultation between employer and employees.
• Clearly defined structure of responsibilities….
• Employees are trained…
• Exceeds the specific requirements of the law –manages safety not for fear of being reprimanded but for the employees.
Safe Workplaces
Department of Manufacturing & Operations Engineering
WT4603
The Key steps of any Health & Safety Management scheme are:
1. Policy2. Hazard identification3. Risk Assessment4. Control Measures.5. Recording Findings (Safety Statement)6. Monitoring, Review and Auditing
Safety Management
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Importance of being able to Assess Risk
Department of Manufacturing & Operations Engineering
WT4603
Required Reading
Department of Manufacturing & Operations Engineering
WT4603
The Safety Management Process
Department of Manufacturing & Operations Engineering
WT4603
Health & Safety Policy
Department of Manufacturing & Operations Engineering
WT4603
Health & Safety Policy
Department of Manufacturing & Operations Engineering
WT4603
Identify Hazards (Hazard Identification)
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Assess Risk (Risk Assessment)
Department of Manufacturing & Operations Engineering
WT4603
A. Eliminate the Hazard Completely.
B. Substitute Hazard with a safer alternative.
C. Isolate the Hazard.
D. Use engineering controls to reduce risk at the source (Guarding).
E. Provide training on how to avoid risks.
& if all that fails…
F. Use PPE.
Hierarchy of Risk Control
Department of Manufacturing & Operations Engineering
WT4603
• Exposure to hazard
▫ Very Infrequent (< once per annum or less)
▫ Quite Infrequent (annually/biannually)
▫ Frequent (quarterly/monthly)
▫ Quite Frequent (weekly/daily)
▫ Highly Frequent (continuous daily)
Risk Assessment Considerations
Department of Manufacturing & Operations Engineering
WT4603
• Likelihood▫ Highly Unlikely (practically impossible)
▫ Quite Unlikely (conceivable but very unlikely)
▫ Likely (conceivable and could possibly happen)
▫ Quite Likely (almost certain to happen)
▫ Highly Likely (certain to happen)
Risk Assessment Considerations
Department of Manufacturing & Operations Engineering
WT4603
• Consequences
▫ Minor Injury/Ill Health ( minor cuts, abrasions etc.)
▫ Injury/Ill Health (burns, sprains, minor fractures etc.)
▫ Serious Injury/Ill Health (breaks, deafness etc.)
▫ Major Injury/Ill Health (amputations, cancer, multiple breaks etc.)
▫ Fatality (one or more fatalities)
Risk Assessment Considerations
Department of Manufacturing & Operations Engineering
WT4603
▫ Knowledge
▫ Skills
▫ Training
▫ Experience
▫ Attitude
▫ Motivation
▫ Risk perception
▫ Mental condition
▫ Physical condition
▫ Accident proneness
Factors Effecting Likelihood & Occurrence
Individual Factors
Department of Manufacturing & Operations Engineering
WT4603
▫ Condition of equipment/tools
▫ Maintenance regime
▫ Guarding/hazard controls
▫ Workload
▫ Patterns of work
▫ Emergency arrangements
▫ Training/ information/ instruction
▫ Supervision
▫ Communications
▫ PPE
Task factors
Factors Effecting Likelihood & Occurrence
Department of Manufacturing & Operations Engineering
WT4603
Risk Assessment
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Factors Effecting Likelihood of Occurrence
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Risk Magnitude
Department of Manufacturing & Operations Engineering
WT4603
Risk Magnitude Matrix
Department of Manufacturing & Operations Engineering
WT4603
Risk Magnitude Matrix: Severe Cut/Amputation from Bandsaw
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Which Poses the Greatest Risk?
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
More information can be found byconsulting manufacturer’s manual
Department of Manufacturing & Operations Engineering
WT4603
Health & Safety at Work Act 2005
Pg. 30 of Health & Safety at Work Act
2005
Department of Manufacturing & Operations Engineering
WT4603
Scroll Saw Risk Assessment
Department of Manufacturing & Operations Engineering
WT4603
Scroll Saw Risk Assessment
Department of Manufacturing & Operations Engineering
WT4603
Scroll Saw Risk Assessment
Department of Manufacturing & Operations Engineering
WT4603
• Hazard
• means anything that can cause harm (egchemicals, electricity, working from ladders,
etc)
• Risk
• is the chance, high or low, that somebody will be harmed by the hazard.
Hazard & Risk
Department of Manufacturing & Operations Engineering
WT4603
• High (H)
• Probability of fatality, serious injury or significant loss, possibility of minor injury to a number of people.
• Medium (M)
• Unlikely possibility of fatality, serious injury or
significant material loss, possibility of minor injury to a small number of people.
• Low (L)
• Injury or material loss unlikely though conceivable
Risk:
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Risk Assessment template as laid out by State Claims Agency
Risk Assessment Template:
Department of Manufacturing & Operations Engineering
WT4603
Scroll Saw Risk Assessment
Department of Manufacturing & Operations Engineering
WT4603
Scroll Saw Risk Assessment
Department of Manufacturing & Operations Engineering
WT4603
Scroll Saw Risk Assessment
Department of Manufacturing & Operations Engineering
WT4603
Scroll Saw Risk Assessment
Department of Manufacturing & Operations Engineering
WT4603
Hazards in the Workplace
Department of Manufacturing & Operations Engineering
WT4603
Hazards in the Workplace
Department of Manufacturing & Operations Engineering
WT4603
Some Possible Hazards
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Definition: Hazard
Department of Manufacturing & Operations Engineering
WT4603
Common Machinery/Mechanical Hazards
Department of Manufacturing & Operations Engineering
WT4603
Wrap Point: (Entanglement)
Department of Manufacturing & Operations Engineering
WT4603
Shear Point and Cutting Hazards
Department of Manufacturing & Operations Engineering
WT4603
Crush Points
Department of Manufacturing & Operations Engineering
WT4603
Ejection Hazards
Department of Manufacturing & Operations Engineering
WT4603
Other Hazards
Department of Manufacturing & Operations Engineering
WT4603
Hazards
Department of Manufacturing & Operations Engineering
WT4603
• You will need to develop a template for your lesson risk assessment.
• Strategies will need to be developed to: Reduce or eliminate risk
Demonstrate safe use of machine(s)
Teach key learning points relating to machine or process
Assess and record pupil learning and competence
Ensure adequate supervision of activities
Classroom Risk Assessment:
Department of Manufacturing & Operations Engineering
WT4603
Room Layout
Department of Manufacturing & Operations Engineering
WT4603
Room Layout
Department of Manufacturing & Operations Engineering
WT4603
Room Layout
Department of Manufacturing & Operations Engineering
WT4603
Room Layout
LABS WEEK 3Processing plan for Section A of the
Table project.
Department of Manufacturing & Operations Engineering
WT4603
Table project.
Department of Manufacturing & Operations Engineering
WT4603
To be submitted by end of first lab of week 3.
•Orthographic plan, elevation & end view of table
•Cutting List for Component A
•Isometric drawing of Component A (with pieces marked out).
•The different processing stages highlighted with the relative sketches / notations on crucial points / aspects.
•Safety procedures listed for each machine, and correct PPE used with these machines / processes.
Section A
• Processing material from raw, list out the required measurements of table parts to be acquired from material section A.
Department of Manufacturing & Operations Engineering
WT4603
Table parts
• From Section A material the following parts are achievable:▫ Table legs (X4, yellow
on drawing)▫ Top rail (X1,blue,
dovetail)▫ Mid rail (X1, blue,
finger joint)
Department of Manufacturing & Operations Engineering
WT4603
Step 1: Produce Cutting List
• Correct cutting list: should show:▫ Item.
▫ Number.
▫ Length.
▫ Width.
▫ Thickness.
▫ Material.
▫ Machine Processing Waste
▫ & Description.
Department of Manufacturing & Operations Engineering
WT4603
Work out how pieces will be removed from material correctly.
#NB: Grey is waste/excess material on drawing
Department of Manufacturing & Operations Engineering
WT4603
Blue = Rail Material
Grey= Waste Piece –Plane to 10mm for additional use
Red = Saw Waste – Cross Cut
Green = Saw Waste - Rip
Yellow = Leg Material
Step 2: Assessing material
• Check material for the following:▫ Cupping.
▫ Bowing.
▫ Warping.
▫ Defects (stress fractures, dead knots, honey combing, etc.)
Department of Manufacturing & Operations Engineering
WT4603
Preparing material for processing.
• The material will have to planned on the Face and Edge to ensure flat surfaces and square cut edges.
• #NB- check that the fence on the planner is square.
Department of Manufacturing & Operations Engineering
WT4603
Square Face Side
#NB- notice position of guide on guard, and distance from fence.
Department of Manufacturing & Operations Engineering
WT4603
Square Edge Side
#NB- notice position of guide on guard, and distance from fence.Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Step 3A: Planning material.
1. Plane edges parallel to each other.
1. Thickness material to accommodate the largest piece/part required (in this case, material should be reduced to 46mm to allow for legs, (1mm extra for future planning).
Department of Manufacturing & Operations Engineering
WT4603
Step 3A. Plane Parallel Edge.
Department of Manufacturing & Operations Engineering
WT4603
Step 3B: Material Thickness to 46mm
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Step 4: Rip Saw
Department of Manufacturing & Operations Engineering
WT4603
Step 4: Rip Saw
1
2
3
4
5
1 Outfeed Table
2 Sliding Table
3 Emergency Foot-stop
4 Blade Adjustment Wheel
5 Power Isolator
6 Start/stop
7 Guide Fence Assembly
8 Crown Guard
Department of Manufacturing & Operations Engineering
WT4603
4
5
6
9
8
4 Blade Adjustment Wheel
5 Power Isolator
6 Start/Stop
8 Crown Guard
9 Riving Knife
10 Saw Blade
Step 4: Rip Saw
Department of Manufacturing & Operations Engineering
WT4603
OUTFEED
TABLE SLILDING
TABLE
Step 4: Rip Saw
Department of Manufacturing & Operations Engineering
WT4603
Cross Cutting
Ripping
Step 4: Rip Saw
#NB: Ensure correct use of PPE and push sticks are practiced.
Department of Manufacturing & Operations Engineering
WT4603
Mark Line across end grain:1. Horizontal when cutting2. Vertical when planing
Step 4: Rip Saw – Ripping Material
Department of Manufacturing & Operations Engineering
WT4603
Step 4: Rip Saw – Ripping Material
• After the legs have be cut from section material on circular saw, they are then planned to the required 45mm X 45mm.
• This ensures square edges with a good finish (i.e. no saw marks)
Department of Manufacturing & Operations Engineering
WT4603
Step 5A: Rip Saw – Processing Leg Material
• Centre material is then planned again on the edge to give a smooth finish and ensure that the edge is square.
Department of Manufacturing & Operations Engineering
WT4603
Step 5A: Rip Saw – Processing Leg Material
Department of Manufacturing & Operations Engineering
WT4603
Step 5B: Rip Saw – Processing Rail Material
• Rail material is then planned down to the required 20mm.
• This produces a better finish than the circular saw, so less time is spent on sanding parts.
Department of Manufacturing & Operations Engineering
WT4603
Step 5B: Rip Saw – Processing Rail Material
Department of Manufacturing & Operations Engineering
WT4603
Step 5B: Rip Saw – Thicknessing Rail Material
Step 5C: Formulate cross-cutting plan
• Refer back to your cutting list to make sure you cut pieces to the correct length.
• After the material has been ripped and surface planned into correct / required sizes, you then have to cross-cut the sections to the required length. For this, you will have to set up the fence on the sliding table to achieve this.
Department of Manufacturing & Operations Engineering
WT4603
Department of Manufacturing & Operations Engineering
WT4603
Step 5C: Formulate cross-cutting plan
#NB: Ensure guards and guides are set-up and used correctly and safely.
Department of Manufacturing & Operations Engineering
WT4603
Step 5C: Formulate cross-cutting plan
Your Processing plan should have:
Department of Manufacturing & Operations Engineering
WT4603
To be submitted by end of first lab of week 3.
1. Orthographic plan, elevation & end view of table
2. Cutting List for Component A
3. Isometric drawing of Component A (with pieces marked out).
4. The different processing stages highlighted with the relative sketches / notations on crucial points / aspects.
5. Safety procedures listed for each machine, and correct PPE used with these machines / processes.
Department of Manufacturing & Operations Engineering
WT4603
Mortiser
Department of Manufacturing & Operations Engineering
WT4603
Mortiser
7
5
1 Engagement Lever
2 Power Isolator
3 Start/Stop
4 Depth Stop
5 Material Bed
6 Machine Bed
7 Guide Wheel
8 Material Clamp
9 Mortice Chisel Bit
10 Head Motor
CHISEL
CLEARANCE
AUGER
Department of Manufacturing & Operations Engineering
WT4603
Mortiser
ESCAPE WINDOW
MORTISE
CHISEL
Department of Manufacturing & Operations Engineering
WT4603
Mortiser