safety for mechanical engineering and machine work

1. MECHANICAL SAFETY
TTC/RCF

2. • Mechanical workshops can be very dangerous places
especially for the untrained and inexperienced
• Some machine tools can be operated after only a small amount
of training, but others need a lot of training and experience to
be operated safely.

3. Risk Assessment
A risk assessment must be undertaken on all operations or
processes which may be hazardous to the operator.
• Those using such processes must familiarise themselves
with the risk assessment before starting work

4. Eye Protection
Each permanent member of the workshop staff must be
supplied with a personal issue of safety spectacles or goggles.
They must be worn whenever flying chips, swarf, turnings, and
coolant splashes etc
Most workshops should be regarded as "eye protection" areas.
Eye protection should be made available to visitors where
necessary.

5. housekeeping
• Good housekeeping is essential for working in workshops
• Workshop users should replace tools and equipment
immediately after use and remove swarf.
• Tools should not be left in machine beds while the machine is
running
• The floor should be kept clear of obstructions, and spillage
must be cleaned up immediately..

6. Personal Protection
• Everyday clothes should normally be covered while working in
mechanical workshops.
• provided that they are in good condition, close-fitting at the
wrists and are kept fastened at the front.
• Prolonged contact of the skin with oil, grease, cutting fluids etc.
can cause skin problems
• Solvents can cause dermatitis and should not be used to
remove oil from the skin
• Long hair can easily be caught in moving machinery and must
be secured

7. • Suitable gloves should be worn when handling rough, sharp or
dirty objects.
• rotating machinery could be very dangerous.
• Protective shoes or boots should be supplied and used by
those engaged in regular heavy lifting.
• Danger can also strike upwards, so boots or shoes should have
strong soles. Sandals and similar
• Suitable hearing protection, such as ear defenders or ear plugs
should be worn near a source of loud/prolonged noise,
particularly if it is over 85dB.

8. • All jewellery should be removed before work commences
• All workshops should have available clear safety glasses and
ear
• defenders/disposable ear plugs for workers and casual users.
• Every workshop should maintain a first aid box, which should
be checked on a regular basis
• Light weight footwear should never be worn in workshops

9. Storage of Materials
• Proper racking facilities should be provided for the storage of
sheet materials, rod bars, etc.
• Vertical racking requires a safety chain or bar.
• the protruding ends of rods and the sharp corners of sheet
materials should be sheathed to prevent injury.
• Gangways
• Gangways, through and around the workshop, should be
clearly marked and kept clear of obstructions at all times.

10. Fumes and Dust
• Areas where fumes or dust are created as part of a workshop
process are subject to strict regulation.
when using the following processes
• a. welding, soldering, burning/cutting etc.
• b. Using a shot/garnet blasting machine
• c. Using woodworking machinery (including portable
• equipment)
• d. Machining of materials which may cause a fine dust.
• e. in paint shop.

11. Electrical Equipment
• Electrical equipment must be kept in good condition. Only
qualified staff must rectify defects in the equipment.
• Loose cables should be kept off the floor as far as possible and
where this is not possible, cable protectors should be used.
• Machinery and appliances must be electrically isolated when
not in use and when changing tools/accessories.
• All portable electrical equipment should be clearly marked with
a sticker.
• if there is any visible damage to the cable do not use
equipment. Remove it from service, and inform the workshop
supervisor

12. Emergency Isolation Buttons
• Most machines are fitted with an emergency stop button.
• Before commencing work in a machine shop, the location of
any such emergency isolation button should be established.
• In some cases specific machines may not be connected to the
universal isolation button, these machines should have a
separate emergency stop of their own.
• The location of such emergency stop buttons should also be
established before work begins.

13. Manual Handling
• All operations where lifting is required are covered by the
Manual Handling Regulations.
• All workshop staff should attend basic manual handling
training,
Lifting Aids
• The correct lifting aid must be used for each lifting operation.
• Shackles, slings, eyebolts hooks etc. should all be marked with
the Safe Working Load and be inspected and certified annually
by a qualified University approved engineer.

14. Storage and Disposal of Waste Solvents
• Solvents used as part of workshop processes should be
disposed of in properly labelled containers as specified in the
guidelines from Safety Services.
• The Workshop Supervisor will have a copy. Care should be
taken not to mix solvents from different groups in the same tin.
• Waste coolant/cutting fluid must also be disposed off in the
same manner.
• It should never be poured into a drain.
• Solvents, oils, cutting fluids cleaners etc. should always be kept
in marked containers, and never in jars, tins, bottles or other
containers

15. Machinery Guarding
• Most workshop machinery is fitted with guards or other safety devices
• designed to prevent access to dangerous parts of the machine. While
• the Department has a responsibility to ensure that guards are in
place,
• Guards or other safety devices must not be removed or over-ridden
for any reason without the written permission of the workshop
supervisor.
• The person concerned who have removed the guard must ensure
that the machine is electrically isolated and made safe.
• The person about to use the machinery is responsible for ensuring
that all safety equipment is in position.
• Where it is necessary to move or remove a guard to make routine
adjustments or measurements, the guard must be replaced back
before the machine is restarted.

16. Compressed Air
• compressed air never be used for cleaning purpose or for
ventilation purposes.
• A jet of compressed air directed onto the body may introduce
air into the bloodstream, produce blindness or other eye injuries
or cause a burst eardrum
• The operator and anyone else in the immediate vicinity must
wear eye protection.
• They must be used only with the lowest air pressure possible.
• This can only be used for the removal of swarf from blind
holes.
• A compressed air supply must never be connected to a sealed
container or be used to pressurize a sealed vessel, other than
certified air receivers.

17. Handtools
General
Sharp edges or points of tools to be carried or stored, should be protected.
Files
Files must never be used without a handle. Wooden handled
should be renewed if they show signs of splitting.
Screw drivers
Screwdriver blades should be kept in good condition.
The correct type and size of screw driver should be used for the job.
Both hands should be kept behind the blade when applying pressure.
Screw drivers should not be used as levers or chisels.

18. Hammers
Hammer heads must be kept tightly wedged in place.
Punches and Chisels
Punches or chisels that have mushroomed heads must not be used.
They must be reground.
Spanners
The correct size spanner to fit the nut or bolt head should
always be used.

19. Welding - Electric Arc
• Exposure of the naked skin to the heat and light radiation from an electric
arc should be avoided.
• The radiation from the arc includes infrared and ultra-violet light.
• Screens or welding curtains must be used to protect bystanders from electric
arc flashes.
• Goggles do not give adequate protection from the arc. A hand-held shield
that covers the head, face, neck, wrist.
• Protective clothing should give cover from the throat to the knees.
• Goggles or a face shield must be used when using a chipping hammer to
remove slag and spatter.
• Hoses and leads must be kept clear of hazards - sharp edges, hot metal, etc
• Welding return leads must be securely connected by bolting or clamping to
prevent contact resistance.
• Power tools must not be left on an electric-arc-welding bench.

20. Welding /Cutting - Oxy-acetylene
• Cylinders must be handled with care.
• Cylinders must be used in an upright position and secured to
prevent them falling or being knocked over.
• When turning on a cylinder, the valve should be opened very
slowly. While doing this, no one should stand in front of the
gauges.
• Care must be taken to ensure that there are no gas leaks.

21. • Heat sources must never be allowed near the cylinders
• Oil or grease must not be allowed to come into contact with the
cylinder valves or fittings, especially on oxygen cylinders.
Flashback arrestors should be fitted both at the blowpipe end
and the gauge end of both hoses.
Cylinder valves must be closed when not in use, and hoses
drained of any remaining gas.
• Appropriate goggles, fitted with the correct filter glass, must be
worn.

22. Goggles should be worn when removing flux residue or scale.
• toxic materials must not be cut or welded until they have been
thoroughly cleaned and made safe.
Care should be taken to ensure that off-cut pieces cannot fall
and cause injury or damage.
• Proper safeguards should be ensured before cutting sealed
barrels.

23. GENERAL SAFETY CHECKLIST
• Do not attempt to operate any machinery until you are sure you
know how to use it.
Ensure that you know how to stop the machine before starting
it.
Ensure that all appropriate guards are in position before
starting the machine.
• Check, where appropriate that the direction of rotation of the
work piece or cutter is correct.
Ensure that any feed mechanisms are in neutral before
starting the machine.

24. • Ensure that all tools, work pieces, etc. are secure before
starting the machine.
• Do not walk away and leave the machine running.
• Wear appropriate personal protection - safety glasses, shoes,
etc.
• Do not remove swarf with bare hands - wear gloves and use a
rake or brush.
• Do not wear gloves near rotating machinery.

25. Lathes
Always remove the chuck key from the lathe chuck.
Do not use cracked or damaged tools
.
Keep all tools sharp.
Do not touch revolving chucks or work pieces.
Keep the lathe-bed clear: Do not allow a build-up of swarf.
Always use the correct tools for the job.

26. Milling Machines
• Ensure that the feed mechanism is disengaged before starting
the machine.
• Position guards to deflect chips to a safe area.
• Do not use cracked or damaged cutters
• Do not touch revolving cutters.
• Do not attempt to clear swarf from the cutter area while it is
rotating.

27. Pedestal/Radial Arm Drills
• Ensure that long hair is restrained.
• Rotating drive shafts must be guarded.
• Lock adjustable tables and arms before drilling commences.
• Clamp the material to be drilled in a vice or to the machine
table.
Use the correct speed range for the size of the drill in use.

28. Shapers/Planers
• Check the speed and stroke length before starting.
• Check that the clutch is disengaged before starting the drive
motor.
• Check that the work piece is securely fastened and if using a
vice, this is also secure before starting.
• Do not use excessive stroke length.
• Use guards, where possible, to stop or deflect chips into a
collecting tray.
• Check that the space occupied by the ram on its return stroke is
clear.
• Keep the hands away from the work piece even when using a
very low ram speed.
Always stop the ram before gauging the work piece.

29. •Thank you