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Wt4603 unit1 week2-17-09-2010

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Lecture Unit 1 Week 2: Machine Provision, Hazard Identification, Risk Assessment & Week 3 Labs.

Lecture Unit 1 Week 2: Machine Provision, Hazard Identification, Risk Assessment & Week 3 Labs.

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  • 1. WT4603 Wood Processing Safety & Practice Lecture Unit 1 Machine Provision, Hazard Identification, Risk Assessment & Week 3 Labs  Lecturer: Mr. Joseph Lyster  joseph.lyster@ul.ie  Notes prepared by: Mr. Donal Canty, Mr. Des Kelly and Mr. Joseph Lyster  Notes available on www.slideshare.net/WT4603
  • 2. WT4603 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. Department of Manufacturing & Operations Engineering
  • 3. WT4603 CE Mark • 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. Department of Manufacturing & Operations Engineering
  • 4. WT4603 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. Department of Manufacturing & Operations Engineering
  • 5. WT4603 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. Department of Manufacturing & Operations Engineering
  • 6. WT4603 CE Mark Never assume that machinery is safe just because it has a “CE” marking Department of Manufacturing & Operations Engineering
  • 7. WT4603 A brief look at Safety Signage Mandatory/ Emergency/ Action Permission Warning Regulatory/ /Caution Prohibited -Danger Department of Manufacturing & Operations Engineering
  • 8. WT4603 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. Department of Manufacturing & Operations Engineering
  • 9. WT4603 Supervision & Access Department of Manufacturing & Operations Engineering
  • 10. WT4603 Supervision & Access 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. Department of Manufacturing & Operations Engineering
  • 11. WT4603 Supervision & Access Department of Manufacturing & Operations Engineering
  • 12. WT4603 Supervision & Access 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. Department of Manufacturing & Operations Engineering
  • 13. WT4603 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 Department of Manufacturing & Operations Engineering
  • 14. WT4603 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. Department of Manufacturing & Operations Engineering
  • 15. WT4603 Lighting Department of Manufacturing & Operations Engineering
  • 16. WT4603 Emergency Isolators and Emergency Stops Department of Manufacturing & Operations Engineering
  • 17. WT4603 Start/Stop • Are there appropriate start / stop controls ? • Location • Colour • Flush mounted • Mushroom head ▫ Turn release ▫ Key release Department of Manufacturing & Operations Engineering
  • 18. WT4603 Start/Stop Stop control must have priority over the Start control. Start Control  Flush  Recessed Stop Control  Mushroom Head  Push Bar Department of Manufacturing & Operations Engineering
  • 19. WT4603 Emergency Stop Some machines may have two stopping devices. Hand Operated Foot/Knee Operated Department of Manufacturing & Operations Engineering
  • 20. WT4603 Push Sticks Department of Manufacturing & Operations Engineering
  • 21. WT4603 Material Preparation Department of Manufacturing & Operations Engineering
  • 22. WT4603 Maintenance of Machinery Department of Manufacturing & Operations Engineering
  • 23. WT4603 Preventative Maintenance Department of Manufacturing & Operations Engineering
  • 24. WT4603 Maintenance Records Department of Manufacturing & Operations Engineering
  • 25. WT4603 Inspection of Machinery Department of Manufacturing & Operations Engineering
  • 26. WT4603 Inadvertent Starting • 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. Department of Manufacturing & Operations Engineering
  • 27. WT4603 Inadvertent Starting Department of Manufacturing & Operations Engineering
  • 28. WT4603 Machinery Rundown Time Department of Manufacturing & Operations Engineering
  • 29. WT4603 Health & Safety Management • 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 Department of Manufacturing & Operations Engineering
  • 30. WT4603 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. Department of Manufacturing & Operations Engineering
  • 31. WT4603 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. Department of Manufacturing & Operations Engineering
  • 32. WT4603 Safety Management The Key steps of any Health & Safety Management scheme are: 1. Policy 2. Hazard identification 3. Risk Assessment 4. Control Measures. 5. Recording Findings (Safety Statement) 6. Monitoring, Review and Auditing Department of Manufacturing & Operations Engineering
  • 33. WT4603 Department of Manufacturing & Operations Engineering
  • 34. WT4603 Importance of being able to Assess Risk Department of Manufacturing & Operations Engineering
  • 35. WT4603 Required Reading Department of Manufacturing & Operations Engineering
  • 36. WT4603 The Safety Management Process Department of Manufacturing & Operations Engineering
  • 37. WT4603 Health & Safety Policy Department of Manufacturing & Operations Engineering
  • 38. WT4603 Health & Safety Policy Department of Manufacturing & Operations Engineering
  • 39. WT4603 Identify Hazards (Hazard Identification) Department of Manufacturing & Operations Engineering
  • 40. WT4603 Department of Manufacturing & Operations Engineering
  • 41. WT4603 Assess Risk (Risk Assessment) Department of Manufacturing & Operations Engineering
  • 42. WT4603 Hierarchy of Risk Control 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. Department of Manufacturing & Operations Engineering
  • 43. WT4603 Risk Assessment Considerations • 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) Department of Manufacturing & Operations Engineering
  • 44. WT4603 Risk Assessment Considerations • 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) Department of Manufacturing & Operations Engineering
  • 45. WT4603 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) Department of Manufacturing & Operations Engineering
  • 46. WT4603 Factors Effecting Likelihood & Occurrence Individual Factors ▫ Knowledge ▫ Motivation ▫ Skills ▫ Risk perception ▫ Training ▫ Mental condition ▫ Experience ▫ Physical condition ▫ Attitude ▫ Accident proneness Department of Manufacturing & Operations Engineering
  • 47. WT4603 Factors Effecting Likelihood & Occurrence Task factors ▫ Condition of ▫ Emergency equipment/tools arrangements ▫ Maintenance regime ▫ Training/ information/ ▫ Guarding/hazard instruction controls ▫ Supervision ▫ Workload ▫ Communications ▫ Patterns of work ▫ PPE Department of Manufacturing & Operations Engineering
  • 48. WT4603 Risk Assessment Department of Manufacturing & Operations Engineering
  • 49. WT4603 Department of Manufacturing & Operations Engineering
  • 50. WT4603 Factors Effecting Likelihood of Occurrence Department of Manufacturing & Operations Engineering
  • 51. WT4603 Department of Manufacturing & Operations Engineering
  • 52. WT4603 Risk Magnitude Department of Manufacturing & Operations Engineering
  • 53. WT4603 Risk Magnitude Matrix Department of Manufacturing & Operations Engineering
  • 54. WT4603 Risk Magnitude Matrix: Severe Cut/Amputation from Bandsaw Department of Manufacturing & Operations Engineering
  • 55. WT4603 Department of Manufacturing & Operations Engineering
  • 56. WT4603 Department of Manufacturing & Operations Engineering
  • 57. WT4603 Which Poses the Greatest Risk? Department of Manufacturing & Operations Engineering
  • 58. WT4603 Department of Manufacturing & Operations Engineering
  • 59. WT4603 Department of Manufacturing & Operations Engineering
  • 60. WT4603 Department of Manufacturing & Operations Engineering
  • 61. WT4603 More information can be found by consulting manufacturer’s manual Department of Manufacturing & Operations Engineering
  • 62. WT4603 Health & Safety at Work Act 2005 Pg. 30 of Health & Safety at Work Act 2005 Department of Manufacturing & Operations Engineering
  • 63. WT4603 Scroll Saw Risk Assessment Department of Manufacturing & Operations Engineering
  • 64. WT4603 Scroll Saw Risk Assessment Department of Manufacturing & Operations Engineering
  • 65. WT4603 Scroll Saw Risk Assessment Department of Manufacturing & Operations Engineering
  • 66. WT4603 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 be harmed by the hazard. Department of Manufacturing & Operations Engineering
  • 67. WT4603 Risk: • 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 Department of Manufacturing & Operations Engineering
  • 68. WT4603 Department of Manufacturing & Operations Engineering
  • 69. WT4603 Risk Assessment Template: Risk Assessment template as laid out by State Claims Agency Department of Manufacturing & Operations Engineering
  • 70. WT4603 Scroll Saw Risk Assessment Department of Manufacturing & Operations Engineering
  • 71. WT4603 Scroll Saw Risk Assessment Department of Manufacturing & Operations Engineering
  • 72. WT4603 Scroll Saw Risk Assessment Department of Manufacturing & Operations Engineering
  • 73. WT4603 Scroll Saw Risk Assessment Department of Manufacturing & Operations Engineering
  • 74. WT4603 Hazards in the Workplace Department of Manufacturing & Operations Engineering
  • 75. WT4603 Hazards in the Workplace Department of Manufacturing & Operations Engineering
  • 76. WT4603 Some Possible Hazards Department of Manufacturing & Operations Engineering
  • 77. WT4603 Department of Manufacturing & Operations Engineering
  • 78. WT4603 Department of Manufacturing & Operations Engineering
  • 79. WT4603 Department of Manufacturing & Operations Engineering
  • 80. WT4603 Department of Manufacturing & Operations Engineering
  • 81. WT4603 Department of Manufacturing & Operations Engineering
  • 82. WT4603 Department of Manufacturing & Operations Engineering
  • 83. WT4603 Department of Manufacturing & Operations Engineering
  • 84. WT4603 Department of Manufacturing & Operations Engineering
  • 85. WT4603 Department of Manufacturing & Operations Engineering
  • 86. WT4603 Department of Manufacturing & Operations Engineering
  • 87. WT4603 Department of Manufacturing & Operations Engineering
  • 88. WT4603 Department of Manufacturing & Operations Engineering
  • 89. WT4603 Definition: Hazard Department of Manufacturing & Operations Engineering
  • 90. WT4603 Common Machinery/Mechanical Hazards Department of Manufacturing & Operations Engineering
  • 91. WT4603 Wrap Point: (Entanglement) Department of Manufacturing & Operations Engineering
  • 92. WT4603 Shear Point and Cutting Hazards Department of Manufacturing & Operations Engineering
  • 93. WT4603 Crush Points Department of Manufacturing & Operations Engineering
  • 94. WT4603 Ejection Hazards Department of Manufacturing & Operations Engineering
  • 95. WT4603 Other Hazards Department of Manufacturing & Operations Engineering
  • 96. WT4603 Hazards Department of Manufacturing & Operations Engineering
  • 97. WT4603 Classroom Risk Assessment: • 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 Department of Manufacturing & Operations Engineering
  • 98. WT4603 Room Layout Department of Manufacturing & Operations Engineering
  • 99. WT4603 Room Layout Department of Manufacturing & Operations Engineering
  • 100. WT4603 Room Layout Department of Manufacturing & Operations Engineering
  • 101. WT4603 Room Layout Department of Manufacturing & Operations Engineering
  • 102. WT4603 LABS WEEK 3 Processing plan for Section A of the Table project. Department of Manufacturing & Operations Engineering
  • 103. WT4603 Table project. 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. Department of Manufacturing & Operations Engineering
  • 104. WT4603 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
  • 105. 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
  • 106. 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
  • 107. WT4603 Work out how pieces will be removed from material correctly. Grey= Waste Piece – Red = Saw Waste – Cross Cut Plane to 10mm for additional use Blue = Rail Material Green = Saw Waste - Rip Yellow = Leg Material #NB: Grey is waste/excess material on drawing Department of Manufacturing & Operations Engineering
  • 108. WT4603 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
  • 109. 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
  • 110. WT4603 Square Face Side #NB- notice position of guide on guard, and distance from fence. Department of Manufacturing & Operations Engineering
  • 111. WT4603 Square Edge Side #NB- notice position of guide on guard, and distance from fence. Department of Manufacturing & Operations Engineering
  • 112. WT4603 Department of Manufacturing & Operations Engineering
  • 113. 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
  • 114. WT4603 Step 3A. Plane Parallel Edge. Department of Manufacturing & Operations Engineering
  • 115. WT4603 Step 3B: Material Thickness to 46mm Department of Manufacturing & Operations Engineering
  • 116. WT4603 Department of Manufacturing & Operations Engineering
  • 117. WT4603 Step 4: Rip Saw Department of Manufacturing & Operations Engineering
  • 118. WT4603 Step 4: Rip Saw 1 Outfeed Table 1 2 Sliding Table 3 Emergency Foot-stop 2 4 Blade Adjustment Wheel 5 Power Isolator 6 Start/stop 7 Guide Fence Assembly 5 8 Crown Guard 3 4 Department of Manufacturing & Operations Engineering
  • 119. WT4603 Step 4: Rip Saw 4 6 4 Blade Adjustment Wheel 5 5 Power Isolator 6 Start/Stop 8 Crown Guard 9 Riving Knife 8 10 Saw Blade 9 Department of Manufacturing & Operations Engineering
  • 120. WT4603 Step 4: Rip Saw OUTFEED TABLE SLILDING TABLE Department of Manufacturing & Operations Engineering
  • 121. WT4603 Step 4: Rip Saw Cross Cutting Ripping Department of Manufacturing & Operations Engineering
  • 122. WT4603 Mark Line across end grain: Step 4: Rip Saw – Ripping Material 1. Horizontal when cutting 2. Vertical when planing #NB: Ensure correct use of PPE and push sticks are practiced. Department of Manufacturing & Operations Engineering
  • 123. WT4603 Step 4: Rip Saw – Ripping Material Department of Manufacturing & Operations Engineering
  • 124. WT4603 Step 5A: Rip Saw – Processing Leg 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
  • 125. 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
  • 126. WT4603 Step 5B: Rip Saw – Processing Rail Material Department of Manufacturing & Operations Engineering
  • 127. 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
  • 128. WT4603 Step 5B: Rip Saw – Thicknessing Rail Material Department of Manufacturing & Operations Engineering
  • 129. WT4603 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
  • 130. WT4603 Step 5C: Formulate cross-cutting plan Department of Manufacturing & Operations Engineering
  • 131. 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
  • 132. WT4603 Your Processing plan should have: 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
  • 133. WT4603 Mortiser Department of Manufacturing & Operations Engineering
  • 134. WT4603 Mortiser 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 5 CHISEL 7 AUGER CLEARANC E Department of Manufacturing & Operations Engineering
  • 135. WT4603 Mortiser MORTISE ESCAPE WINDOW CHISEL Department of Manufacturing & Operations Engineering
  • 136. WT4603 Mortiser Department of Manufacturing & Operations Engineering