Wt4603 unit1 week2-12-09-2011

WT4603Wood Processing Safety & PracticeAUTUMN 2011Lecture Unit 1
Machine Provision, Hazard Identification, Risk Assessment & Week 2 Labs
Lecturer: Mr. Joseph Lyster
joseph.lyster@ul.ie
Notes prepared by: Mr. Joseph Lyster
Notes available on www.slideshare.net/WT4603

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Health & Safety Management
Section 8(2)e of the 2005 (Now 2007) 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
Department of Manufacturing & Operations Engineering

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Unsafe Workplaces
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.

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Safe Workplaces
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.

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Safety Management
The Key steps of any Health & Safety Management scheme are:
Policy
Hazard identification
Risk Assessment
Control Measures.
Recording Findings (Safety Statement)
Monitoring, Review and Auditing

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Importance of being able to Assess Risk

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Required Reading

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The Safety Management Process

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Health & Safety Policy

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More information can be found by
consulting manufacturer’s manual

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Health & Safety at Work Act 2005
Pg. 30 of Health & Safety at Work Act 2005

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Identify Hazards (Hazard Identification)

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Hazards in the Workplace

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Definition: Hazard

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Hazards in the Workplace

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Some Possible Hazards

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Common Machinery/Mechanical Hazards

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Wrap Point: (Entanglement)

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Shear Point and Cutting Hazards

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Crush Points

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Ejection Hazards

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Other Hazards

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Hazards

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Classroom Risk Assessment:
You will need to develop a template for your lesson riskassessment.
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

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Room Layout

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Assess Risk (Risk Assessment)

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Hierarchy of Risk Control
Eliminate the Hazard Completely.
Substitute Hazard with a safer alternative.
Isolate the Hazard.
Use engineering controls to reduce risk at the source (Guarding).
Provide training on how to avoid risks.
& if all that fails…
Use PPE.

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Risk Assessment

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Difference Between A Hazard & Risk
Hazard
means anything that can cause harm (eg chemicals,electricity, working from ladders, etc)
Risk
is the chance, high or low, that somebody will beharmed by the hazard.

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Importance of being able to Assess Risk

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Risk Assessment Considerations
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)

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Factors Effecting Likelihood & Occurrence
Individual Factors
Knowledge
Skills
Training
Experience
Attitude
Motivation
Risk perception
Mental condition
Physical condition
Accident proneness

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Risk Magnitude

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Factors Effecting Likelihood of Occurrence

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Risk Magnitude Matrix

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Risk Magnitude Matrix: Severe Cut/Amputation from Bandsaw

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Which Poses the Greatest Risk?

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Department of Design & Manufacturing Technology

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Risk Assessment Template

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CLASSROOM MANAGEMENT: Health & Safety…

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Supervision & Access
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.

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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.

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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.

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CE Mark
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.

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CE Mark
CE Marking is the symbol as shown on the top of this page.
The letters "CE" are the abbreviation of French phrase "ConformitéEuropéene" 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.

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CE Mark
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.

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CE Mark
The existance of the “CE” marking on a piece of machinery should indicate that its manufacturer has met all relevant standards and requirements.

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CE Mark
Never assume that machinery is safe just because it has a “CE” marking

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Guarding
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

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Exclusion Zones
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.

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Lighting

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Emergency Isolators and Emergency Stops

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Start/Stop
Are there appropriate start / stop controls ?
Location
Colour
Flush mounted
Mushroom head
Turn release
Key release

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Start/Stop
Stop control must have priority over the Start control.
Start Control
Flush
Recessed
Stop Control
Mushroom Head
Push Bar

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Emergency Stop
Some machines may have two stopping devices.
Hand Operated
Foot/Knee Operated

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Push Sticks

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Material Preparation

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Maintenance of Machinery

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Preventative Maintenance

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Maintenance Records

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Inspection of Machinery

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Inadvertent Starting

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Machinery Rundown Time

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A brief look at Safety Signage
Emergency/Permission
Mandatory/Action
Warning/Caution-Danger
Regulatory/Prohibited

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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 750 x 245 x 50 (mm)
Aim of week 2 labs is to square the material to a clean workable condition of required dimension.
242
740

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Surface Planer

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1
9
8
2
7
3
4
6
5
Surface Planer
10
11
12

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Step 1:
Isolate machine
Out feed Table
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.
Infeed Table

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Infeed
Infeed
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*

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242 + 10
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 8: Planing face side
Material position
Hand positions
Dept of Hand
Dept of Hand
Ensure Guard Guide is in a vertical position to plane face side

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Note Hand Positions in relation to material

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Step 9: Planing face edge
Material position
Hand position
Dept of Hand
Dept of Hand
Ensure Guard Guide is in a horizontal position to plane face edge

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Note Hand Positions in relation to material
Split second blade Exposure
Blade guard flat onto table

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Thicknesser

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1
2
3
4
Thicknesser

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Lab sequence – Thicknesser
Step 1:
Unlock twist release stop mechanism
Press green button to start
Allow machine to build up, this can be determined by noise consistency
When noise is consistent flip delta switch to on position
Feed rate, i.e. Speed at which material is passed, is set.
Adjust table height as required
Feed material as directed
Delta Switch
Stop/Start
Twist Release Stop
Display Panel
Thicknesser Bed Adjustment Control
Feed Rate 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 unit1 week2-12-09-2011

by Joseph Lyster

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Wt4603 unit1 week2-12-09-2011 Presentation Transcript