wt4603 unit2 week3_19-09-2011

WT4603 Wood Processing Safety & PracticeAutumn 2011Lecture Unit 2 (Week 3)

Personal Protective Equipment (PPE) & Week 3 Labs (Component A - Processing) Lecturer: Mr. Joseph Lyster [email protected] Notes prepared by: Mr. Joseph Lyster Notes available on www.slideshare.net/WT4603

mailto:[email protected]

http://www.slideshare.net/WT4603

WT4603 Wood Processing Safety and Practice

PPEPERSONAL PROTECTIVE EQUIPMENT

Department of Manufacturing & Operations Engineering

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Personal Protective Equipment (PPE)


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Personal protective equipment• For centuries, people have

employed the use of Personal Protective Equipment (PPE).

▫ Cowboys wore leather chaps.▫ Eskimos wear thick gloves and

coats.▫ Medieval knights wore Armour.▫ Soccer players wear shin guards.


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What is PPE?

“All equipment which is held or worn at work to protect a person from any

harm or environmental hazards encountered.”

http://en.wikipedia.org/wiki/Personal_protective_equipment


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Environmental Hazards

Noise Dust Smoke Unsafe Machinery Etc.

• There are 5 main classes of environmental hazard:1.Chemical2.Physical3.Mechanical4.Biological5.PsychologicalDepartment of Manufacturing & Operations Engineering

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Hierarchy of risk control

1. Eliminate the Hazard Completely.2. Substitute Hazard with a safer alternative.3. Isolate the Hazard.4. Use engineering controls to reduce risk at the source

(Guarding).5. Provide training on how to avoid risks.

& if all that fails…

6. Use PPE.

MOST PREFERABLE SOLUTION


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Using P.P.E.The use of PPE is a last resort!

• It should only be relied upon for protection when all other means of controlling a hazard have been eliminated as possibilities.

• It is much more desirable to completely eliminate the hazard than to safeguard against it.

• Prevention is better than cure!!!

PPE should be used:▫ Where Engineering (Guarding) or Administrative (Training, Rules) controls are not

feasible.▫ As a short-term measure during periods of time when engineering or

administrative controls are being implemented.▫ During emergency response situations.


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PPE Legislation• Safety Health and Welfare at Work (Control of Noise at Work)

Regulations 2006.▫ Act specifically outlining the requirements to protect the hearing of

employees in the workplace.

• Safety, Health and Welfare at Work Act 2005. (Formerly 1989 Act)▫ General Act Governing health and Safety at work in Ireland

• The Safety, Health and Welfare at work (General Application) Regulations 2007.▫ Among other things, this Act outlines the legal responsibilities in relation

to the use of PPE in the workplace & schools.

• European Communities (Personal Protective Equipment) Regulations, 1993.▫ Aimed more specifically at the selection, use and manufacturing quality of

PPE.Department of Manufacturing & Operations Engineering

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Responsibilities of Employers*• All employers must conduct a Hazard Identification and risk assessment

to determine if the use of PPE is necessary.

• Risk control; this may be through the use of PPE.

• Provision of PPE on the basis of the Hazard Identification.

• Provision of Training on using necessary PPE.

• The Safety, Health and Welfare at work (General Application) Regulations 2007 requires schools to provide suitable PPE if a risk to health and safety cannot be avoided or sufficiently controlled through other means.

*The Safety, Health and Welfare at Work Act 2005.*The Safety, Health and Welfare at work (General Application) Regulations 2007.


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Responsibilities of Principals• They should:

▫ Carry out a risk assessment to identify the possible need for PPE.▫ Provide, free of charge, adequate PPE to employees (Teachers) who may be

exposed to hazards at work that have not been controlled by other means.▫ Make an assessment before choosing any form of PPE.▫ Ensure that PPE is well maintained and cared for.▫ Provide storage for PPE when not in use.▫ Provide teachers with training in the use, limitations and care of their of

PPE


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Responsibilities of Teachers (Employees)

•Employees must:▫Attend PPE training.▫Make full and proper use of PPE.▫Ensure PPE is correctly stored

and cared for.▫Follow all directions and heed all

warnings.▫Report any defects in or loss of

PPE to employer.


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Provision of P.P.E. • The employer should shoulder the cost of all PPE

required by the employee.

• In schools, this means that any teachers requiring it, should be provided with a full set of PPE by the school.

• It should be made mandatory that all pupils should be required to provide their own PPE (to the appropriate standard).

• Wearing of this PPE should be strictly enforced by the teacher.

• Employer must maintain and replace broken or un-usable PPE.▫ However, it is the responsibility of each employee to

respect and care for their PPE and report any damage or defects present in it to the employer.


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PPE Training*• Employers must provide the following training

in relation to PPE:▫ Proper use of PPE.▫ When to use PPE.▫ Adequate PPE Storage.▫ Importance of using PPE.▫ How to spot defects in PPE

• Teachers should also provide training to their pupils on how to use their PPE correctly.

• Part of a teachers demonstrations should place an emphasis on ▫ The correct use of PPE▫ Importance of PPE▫ Care of PPE.


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Sharing PPE • Under no circumstances should pupils be allowed to share PPE.

Why Not?• Associated hygiene issues.• Swapping PPE may limit the level of

protection offered:▫ Different size/Setting.

Make sure everyone has their own!!!


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PPE Selection• In schools, the selection of PPE is generally the

responsibility of the teacher.

• For this reason, it is vital that teachers are capable of making the correct selection of PPE both for themselves and the pupils left in their care.

• When selecting PPE, always think of the worst case scenario – What is the worst that could happen?

• The existence of the “CE” marking on a piece of equipment should indicate that its manufacturer has met all relevant safety standards and requirements.▫ ALWAYS look for this mark when buying PPE (as

well as other equipment, tools and machinery.)


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PPE – Some Factors to Consider• DEGRADATION

▫ Harmful change of physical properties of a protective clothing material when subjected to a chemical or wear and tear over time.

• PENETRATION▫ Flow of chemicals/ hazardous substances through

seals such as zips, seams or pinholes.

• PERMEATION▫ Movement of the hazardous substance through the

protective material itself.

Always consult manufacturer’s instructions.Department of Manufacturing & Operations Engineering

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Eye & Face Protection• Thousands of people are blinded in

the workplace every year for no reason.

• Simple and inexpensive face and eye protection could have prevented it.

• The human eye is very sensitive organ and is highly susceptible to injury from many sources:▫ Impact ▫ Chemicals▫ Dust/ foreign particles.▫ Etc..


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The eye• The Cornea & Lens focus light.• The Iris controls the amount of light entering the eye.

All are made up of very soft, delicate and easily damaged tissue.

Damage is often irreparable!


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Common Eye Injury Causes

• Objects hitting the eye ▫ Swarf.▫ Flying particles (Sawdust).▫ Flying objects (Projected materials/

tools!)

• Intense Light (Lasers, Welding)• Contact with Chemicals.• Falling onto or walking into stationary

objects.


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Chemicals/ fumes/ mists• Spray Paint.• Fumes from welding and other heat

processes.• Smoke.• Aerosol Cans.• Liquid droplets.

• Airborne Hazardous chemicals can enter and damage the eye.


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Flying particles• Grinding • Hammering • Welding• Splashes of chemicals and

molten metals

• Physically injure the eye, tearing or scratching the cornea.

• Very painful and difficult to correct.


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Thermal

•Heat and glare from molten metals, furnaces and other heat processes such as welding or soldering can burn the cornea.


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Intense light levels

• Lasers• Exposures to excessive

glare or bright lights • Damage the retina and

optic nerve located deep within the eye as opposed to swarf or dust just damaging the cornea.▫A much more serious

injury.


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Safeguarding against Eye Injuries

• Eye protection should be worn when spray painting, grinding, drilling, welding, sawing, working in a dusty environment, or handling chemicals.

• One should also develop the good habit of protecting the eyes whenever working with hand or power tools.

WHEN IN DOUBT, WEAR EYE PROTECTION ANYWAY!


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Machinery Guarding

• Because it is much more preferable to eliminate the hazard at the source, guarding is often added.

• This is not usually enough to fully reduce the risk so wear safety glasses as well!!


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Ventilation• Ventilation is the movement of air, usually

between the inside and outside of enclosed spaces.

• Ventilation is necessary when people or animals are present to remove carbon dioxide and replace it with oxygen.

• Ventilation must also be used to remove dangerous pollutants such as smoke, fumes, chemicals and fine particles suspended in the air.


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Safety Glasses/goggles

• Safety glasses usually have frontal protection only.

• Safety goggles fit closer to the face and protect the eyes from frontal as well impact from all other directions.▫ Much more resistant to airborne hazards

• Airborne hazards such as fine particles and dust may by-pass safety glasses.

• Check for “CE” marking.

• Different Grades available for different hazard levels.

• Prescription safety glasses also available.


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Face Shields• Should be used in conjunction

wit glasses or goggles where possible.

• Not considered suitable eye protection on its own.

• Offers very little protection against strong impact ▫ More suitable for dust and small

flying particles (Lathe Work).


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NOTE: “CE” Marking


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Welding Goggles/Shield/Helmet• The brilliant light from welding can cause

serious damage to the eye even when exposed to it for a short period of time.

• A welding helmet is fitted with a special lens to filter extreme bright light from welding while the helmet itself protects against hot sparks.

• Anyone watching the welding should also utilise suitable PPE.

• When chipping slag, ensure that you, as well as anybody else watching, is wearing suitable eye protection!


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Care of Eye Protection

•Clean with wipes or water.•Don’t use abrasive soaps.•Store in a clean, dry and

dust-free place.


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Eyewash Stations• Install and Maintain

▫ Display instructions.▫ Train on how to use.▫ Keep fully stocked.

• Some chemicals react with water – ▫ Consult Material Safety Data

Sheet (MSDS)


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Of course, wearing safety glasses doesn’t

necessarily mean you are going to be safe from everything!!

USE YOUR COMMON SENSE!!!


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Respiratory Protection


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The Breathing Process• To best understand the hazards one should

take a look at how breathing works

• Take a breath and air rushes from the external environment, down the windpipe and into the alveoli in the lungs.▫ Alveoli in lungs are tiny air sacs which

transfer oxygen into blood and CO2 from it.

• The lung is a very delicate organ and can be easily damaged by hazardous dusts, fumes and chemicals when inhaled.

• Damaged lungs are also much more susceptible to contracting further diseases.


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Dust• Dust is formed when material is broken

down into tiny particles.▫ Grinding.▫ Sanding.▫ Cutting.

• The Safety, Health and Welfare at Work (Chemical Agents) Regulations 2001 requires all schools to assess and determine the risk posed by any chemical agent including wood dust.


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Wood Dust

•Machining Processes:▫MDF and hardwood dust

is considered to be a significant hazard.

•Sanding – ▫Fine dust that may even

stay airborne for hours after work has ended.


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Carcinogens • A carcinogen is any substance or agent that promotes cancer.▫ Softwood dust – Non-Carcinogenic.▫ Hardwood dust – Carcinogenic.▫ MDF - Carcinogenic.

• Due to the carcinogenic nature of these materials, they should be phased out completely in the technology classrooms.▫ At a minimum, PPE and dust extraction should be

available.

• It is the responsibility of the employer to monitor and control the use of carcinogenic materials and substances in the workplace.*▫Storage.▫Training.▫Control Measures or suitable PPE.

*Safety, Health & Welfare at Work (Carcinogens) Regulations, 2001.


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Vapors• A vapor is created when a liquid or

solid evaporates.

EXAMPLES▫ Petrol vapors.▫ Wood finishes▫ Paint.▫ Thinners▫ Solvents


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Mists and Sprays

•Mists and sprays are made up of small droplets suspended in the air.

•Aerosols and spray guns, by design, create fine sprays and mists.

EXAMPLES▫Paint▫Water


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Gases, fumes & SmokeGAS

• May or may not have a smell.• May or may not be visible.

FUMES• Occur during high heat process such as

welding or soldering.

SMOKE• The suspension in air of small particles

resulting from the incomplete combustion of a fuel.


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Respiratory Protection

• Hazardous substances which have become airborne pose a significant threat to the lungs and therefore we must protect ourselves against them in some way

• The aim should always be to prevent the substance from getting into the air in the first place but when this is not possible, Respiratory Protection should be used.


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Respirators

• All respirators have some form of face piece which is held to the face with straps, usually around the head.

• Half-face respirators cover the nose and mouth only and are for use where the contaminants are not a threat to the eyes or face.

• A full-face respirator covers all the face and should be used where contaminants may be a hazard to eyes and the face as well as the respiratory system.


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Respirators

• A respirator is a device which is designed to protect the wearer from inhaling harmful dusts, gases, fumes or vapours.

Two main types of respirator exist:1. Air Purifying Respirators.2. Atmosphere Supplying

Respirators


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Air Purifying Respirators

• Used against contaminants such as smoke, dust, vapours and fumes.

• Acts passively to remove contaminants from the air.

• The device renders the contaminated air breathable.

• Usually has a filter for particulates or a cartridge for gasses and vapours (or a mixture of both).

•Not suitable where the levels of oxygen in the air are deficient.


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Filter Mask - Disposable• A filter mask offers protection to its wearer

against airborne substances.

• It usually covers only the nose and mouth and works by restricting the flow of air, forcing it through a filter which removes harmful particles or dusts.

• The most common type is the white disposable N95 filter mask as shown.

• Cannot protect against:▫ Gasses▫ Vapors▫ Low O2 levels


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Filter Mask - Reusable

• Reusable filter masks fitted with disposable filter cartridges are also available.

• When filters become saturated or worn, or if air flow is restricted they must be replaced.

• Mask cartridges are filled with certain resins or chemicals that will absorb certain fumes, eliminating them from the inhaled air.

• Different cartridges are available for filtering different contaminants from the air. ▫ Check manufacturer’s instructions & Use by date.


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Atmosphere Supplying Respirators• Air supplied respirators use reserve tanks to supply a constant flow of air

to the wearer’s face/lungs.• The contaminated air is not purified in any way nor is it inhaled by the

wearer.• Fire Fighters• S.C.B.A. – Self Contained Breathing Apparatus• S.C.U.B.A. – Self Contained Underwater Breathing Apparatus


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Respirator Selection• Hazard level should be determine and

adequate level of protection selected accordingly by a competent person.▫ Determined largely by the hazard present.▫ E.g. - Dust PPE will give no protection against

fumes and vapours.

• Supplied air respirators in schools SHOULD NOT BE USED.

• If any such risk should exist, find an alternative for it!


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Inspection Before Use

•Check Respirators before you them every time.

• Look out for;▫Wear and damage.▫Cracks▫Loose fittings.▫Use by dates.


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Monitoring the Respirator

• As you work- you must stay aware of your respirators operation.

• Signs of it not working are:▫ Feeling dizzy or sick.▫ Being able to smell or taste the contaminant

in the air.▫ Difficulty breathing.▫ Filter/ cartridge has expired.▫ Respirator is damaged.


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Storing • When not using respirators, they must be carefully stored in order to prevent deterioration in their effectiveness.

• Store in a sealable plastic bag and away from:▫ Dust▫ Moisture▫ Direct Sunlight▫ Heat▫ Extreme cold▫ Chemicals▫ Germs/fungal growth▫ Sources of infection.


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Hearing Protection


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Noise• Noise is often described as being sound that people would prefer not to

hear.

• What may be important or welcome sound to you may be noise to others exposed to it.


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Is Noise harming you?

• If you experience any of the following, you may be exposed to excessive noise levels on a daily basis:

• You experience ringing or other noises in your ears.

• You have difficulty hearing people talking.

• You are unable to hear high pitched or soft sounds.


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Remember!Becoming used to a loud noise is a sign of gradual hearing

loss.

You do not become used to it, you merely lose your ability to hear it!!


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Ear Protection Zones

• If the risk assessment reveals areas of high noise levels in which ear protection is required, they must designated as Hearing Protection zone

• These zones must be marked clearly using adequate signage.

• The sign should show the following:▫ That you are entering an ear protection

zone.▫ Ear protection must be worn in this area.▫ Nobody may enter the zone without

wearing appropriate hearing protection.

Safety Health and Welfare at Work (Control of Noise at Work) Regulations 2006


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As a Rule!

If you must shout in order for someone 2 meters away from you to hear you,

YOU SHOULD BE WEARING HEARING PROTECTION!


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Hearing Protection Devices• Tinnitus and Noise Induced Hearing Loss

can be prevented with the use of appropriate Hearing Protection Devices (HPD’s).

• These devices provide a barrier between the ear and the noise.

• Some ear defenders work on the principle of absorbing the sound waves before they reach the ear.


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Selecting Hearing Protection

• Ensure a “CE” Marking is present.• Every person is different. – Some find different things more

comfortable than others.• In processes where hands become dirty, inserting and removing

earplugs can lead to dirt and bacteria being introduced into the ear canal causing ear infections.

• Provide and encourage the use of a variety of hearing PPE and let people select most comfortable for themselves.

If PPE is uncomfortable or irritating, It will not be used!!


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Noise Reduction Ratings• Earplugs and earmuffs come rated with “Noise

Reduction Ratings” (NRR’s).

• This rating tells the user what level of sound protection they can expect from the device in a noisy environment.

• The NRR of hearing protection devices should be consulted when selecting them for use.

• However, NRR’s are developed under controlled laboratory conditions and the “real-life” NRR rating is usually lower. Therefore it is always best to error on the side of caution and select the PPE with a higher NRR than is required.


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Hearing P.P.E.• If the noise cannot be reduced to

suitable levels at the source, hearing PPE must be used to achieve this.

• Many types of hearing protection devices are available each carrying with them various advantages and disadvantages.

• Popular types of hearing protection devices are:

1 Earplugs 2 Earmuffs


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When to Wear Hearing Protection.You should consider wearing Hearing Protection if;

• You work in an environment where you are exposed to continuous decibel levels of 80dB or greater over an 8 hour period.

• You are unusually fatigued after being in a noisy area.

• You experience ringing in your ears after being in a noisy area.

• You feel nervous or anxious after being in a noisy area.

• In order to be fully effective, hearing protection devices must be worn at all times in noisy environments.

• Removing for even a short period of time can decrease their effects substantially.


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Earplugs

• An earplug is a protective device which is inserted into the ear canal to protect the inner ear from being exposed to excessive levels of noise or the intrusion of foreign bodies or excessive wind.


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http://upload.wikimedia.org/wikipedia/commons/b/b8/Disposable_foam_earplugs.jpg

Earplugs • Most earplugs are cylindrical in shape and are made from memory foam.

• The earplug is rolled into a tightly compressed cylinder between the fingers and inserted into the ear canal.

• When released, the earplug expands to its original size, sealing the ear canal and preventing sound vibrations from reaching the eardrum.

• Other earplugs are custom made with moulds from the user’s ear to provide a more snug and noise resistant fit.


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Advantages & Disadvantages of Earplugs

ADVANTAGES• Inexpensive• Small & Lightweight• Comfortable in warm, humid environments.• Easily used with other equipment.

DISADVANTAGES• May work themselves loose and require

adjustment or refitting.• Frequently become soiled.• Require specific fitting instructions.• Awkward to remove and replace when noise is

inconsistent.• Easily Misplaced.• May irritate the ear canal.• Difficult to monitor the use of.


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Earmuffs• Earmuffs are objects which are designed to

cover the ears for protection.• Earmuffs come in two different kinds;

Thermal Earmuffs• Worn in cold environments to keep the ears

warm.

Acoustic Earmuffs• Also known as ear defenders.• Cups lined with sound-absorbent material

which fit over the ears.• Protect the ears from excessive noise levels.


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Advantages & Disadvantages of EarmuffsADVANTAGES:

• Easy to supervise the wearing of.• More comfortable for long periods of

use.• One size fits all.• Quickly put on & removed.• May be worn with minor ear

infections.

DISADVANTAGES• May fit loosely on the head.• Uncomfortable in a warm

environment.• Difficult to use with some other

equipment.• Less portable and convenient.


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Wearing Earmuffs

• Earmuffs must fit fully over the outside of the ears.

• Their effectiveness is determined by the quality of the seal around the ear.

• Ensure hair, hats, glasses, jewellery, etc. does not interfere with the seal around the ear.

• A combination of earplugs and earmuffs should be used as an extra precaution if glasses, earrings, facial hair, etc, prevents the earmuffs forming a good seal around your ears.


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Hearing Protection Overkill

•Wearing excessive levels of hearing protection can also be hazardous!!!

•Employees may not be able to hear vital warning alarms such as fire alarms.

• It also promotes users removing ear protection to talk.


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Caring for hearing protection devices - Earplugs

• When not using earplugs, they should be stored in a clean, cool and dry place.

• If Foam earplugs become soiled, they should be discarded and replaced with a clean pair.

• Soiled PVC earplugs can often be cleaned with soap and water.

• Replace PVC earplugs if they become torn or brittle.

• Check manufacturer’s instructions regarding washing earplugs.


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Caring for hearing protection devices - Earmuffs• Always follow manufacturers instructions.

• Check headband regularly for wear and tear-replace or repair immediately if needs be.

• Ensure tension in headband is not reduced.

• Store earmuffs in a clean, cool and dry place when not in use.

• Always replace when a snug fit in or around ear is not achieved.

• Wash earmuffs with a mild liquid detergent. ▫ Do not wet sound-attenuating material within the ear

muffs.


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Hand Protection


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Hand Protection• Look at your hands! They are the only two you will ever

have. SO MIND THEM!

• Without the use of your fingers or hands, your ability to work or lead a normal life would be dramatically reduced.


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Possible Hazards

• Cuts and Abrasions.• Crushing.• Extremes of temperatures.• Contact with toxic or corrosive

substances.• Skin Irritation & Dermatitis.• Electric shock.• Absorption of chemicals.


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Dermal Hazard Categories• Skin on the hands may come into contact

with a lot of unknown materials and substances from day to day.

• Chemical▫ Irritants.▫ Corrosives.▫ Carcinogens.

• Physical ▫ Fire.▫ Radiation.▫ Vibration.

• Biological▫ Human, animal or environmental pathogens

(Hepatitis, AIDS, etc)

NOTE: poisons and toxins can be

absorbed through the skin in the

hands and into the body.


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Possible Hazard: Traumatic injury• Sharp tools and machines

may cut your hands.

• Staples, wire, nails chisels etc. can puncture your hands.

• Hands may become caught in machinery causing them to become sprained, crushed or amputated.


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Selection of Gloves• The correct glove must be selected in

order to achieve an adequate level of protection. The following should be considered:

▫Chemical Resistance.▫Cut/Tear Resistance.▫Manual Dexterity/Flexibility.▫Extremes of Temperature.▫Cost▫Fit.▫Comfort.


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Types of Gloves

• Metal mesh & Kevlar gloves protect against cuts and sharp objects.

• Leather gloves offer protection against rough objects, chips, sparks and low moderate heat.


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Types of Gloves• Cotton fabric gloves protect the hands from

dirt, abrasions and splinters.

• Cotton gloves also improve grip when handling slippery objects.

• Offers very little protection against cuts.

• Rubber & Vinyl gloves protect the wearer’s hands from dirt, chemicals and environmental pathogens.▫ Wear around blood

• Should always check packaging and manufacturer’s instructions.


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Use of gloves

• When wearing gloves;▫ Remove any rings, watches or bracelets that may damage

the gloves or reduce their ability to do their job.▫ Inspect gloves for holes and cracks that might leak.

• Replace gloves that are torn or worn out.

• After working with chemicals, leave gloves on hands and wash under running water to remove any chemicals before you remove gloves from your hands.

• Store gloves in a clean, cool, dry and well ventilated area.

• NEVER wear gloves around powered rotating equipment such as drills or lathes etc…(May become tangled)

• Always follow manufacturer’s instructions.


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Welding PPE• While working with heat processes such as welding additional

protection will be necessary.

• Infrared radiation produced during welding is a cause of retinal burning and cataracts.

• To protect against this, a proper welding helmet should be worn which incorporates the correct grade of filter plate.

• To protect the body from welding spatter and arc flash, the following protective clothing may be utilised:▫ Flame-proof apron.▫ Gloves.▫ Long sleeves.▫ Fire resistant capes for overhead work.▫ Appropriate footwear

• Keep clothes free of grease and oil.


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LAB COAT

• A lab coat is a knee-length overcoat worn by those involved in significant work to protect their street clothes.

• The garment is usually made from cotton or linen and is usually white in colour.▫ known not to react with any chemicals.▫ No loose elements.▫ Hygienic.

• Lab coats are much easier to take off than regular street clothes if they get splashed with chemicals, catch fire or become entangled in machinery.


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Encouraging use of PPE• Students should benefit from good example.

▫ Teacher should wear PPE whenever appropriate.

• Signage.▫ Highlight importance of PPE using

strategically placed safety signs.

• Teach safety as part of working, not just an add-on.


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Encouraging use of PPE

• The use of suitable signage should be employed to help encourage safe practices and the appropriate use of PPE.


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Process Sheets


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Creating a Cutting List


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Creating a cutting list• A cutting list is a document that allows the material processor to

calculate volumes of material and to formulate a processing procedure

• The list must contain the critical dimensions of the material

• Cutting lists must have a standard format to enable the processor to operate efficiently

• The next slide shows the UL format for compiling a cutting list.

• This template must be used when making a submission for material.• Lists that are outside this template will not be processed.


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Cutting list template


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Standards• Cutting list must be submitted on an A4 sheet(s) of paper

• Students must use the UL template

• Submissions must be printed or typed• Submissions that are sloppy, untidy, scribbled, crossed out or outside the standard

format will not be accepted.

• The descriptions section must illustrate the shape and detail of the piece.• Secondary processing should be illustrated in this section e.g. grooving etc.

• Lists should be filled out beginning with larger cross-sections and working your way down in cross-sectional size.

• (This can aid material optimisation)


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Good Example


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Unacceptable examples


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Working Drawings

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Select & Position Dimensions Correctly

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Arrows & Dimension Lines

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Consider best location and view

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Include all details

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Include Component labelling

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Exploded View or Assembled View???

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LABS WEEK 3Processing plan for Section A of the Table project.


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Table project.


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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.


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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)


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Step 1: Produce Cutting List

• Correct cutting list: should show:▫ Item.▫ Number.▫ Length.▫ Width.▫ Thickness.▫ Material.▫ Machine

Processing Waste▫ & Description.


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Work out how pieces will be removed from material correctly.

#NB: Grey is waste/excess material on drawingDepartment of Manufacturing & Operations Engineering

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XXXXXXXXXXXXX

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.)


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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.


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Square Face Side

#NB- notice position of guide on guard, and distance from fence.


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Square Edge Side

#NB- notice position of guide on guard, and distance from fence.Department of Manufacturing & Operations Engineering

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Step 3A: Planning material.1. Plane edges parallel to each other.

2. 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).


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Step 3A. Plane Parallel Edge.


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Step 3B: Material Thickness to 46mm


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Step 4: Rip Saw


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Step 4: Rip Saw

1

2

3

8

6

7

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


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4

5

6

109

8

4 Blade Adjustment Wheel

5 Power Isolator

6 Start/Stop

8 Crown Guard

9 Riving Knife

10 Saw Blade

Step 4: Rip Saw


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OUTFEED

TABLE SLILDING

TABLE

Step 4: Rip Saw


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Cross Cutting

Ripping

Step 4: Rip Saw

#NB: Ensure correct use of PPE and push sticks are practiced.Department of Manufacturing & Operations Engineering

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Mark Line across end grain:1. Horizontal when cutting2. Vertical when planing

Step 4: Rip Saw – Ripping Material


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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)


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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.


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Step 5A: Rip Saw – Processing Leg Material


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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.


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Step 5B: Rip Saw – Processing Rail Material


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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.


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#NB: Ensure guards and guides are set-up and used correctly and safely.


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Your Processing plan should have:


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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.


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Mortiser


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Mortiser

1

9

7

8

10

6

5

3

2

4

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

http://upload.wikimedia.org/wikipedia/en/1/14/Chiselandbit.jpg


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Mortiser

ESCAPE WINDOW

MORTISE

CHISEL


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Mortiser

wt4603 unit2 week3_19-09-2011

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