Lecture Notes Unit 0 (Week 1-Autumn) AY10-11

1. WT46 3
Wood Processing Safety &
Practice
Lecture Unit 0
 WT4603: Introduction & Lab 1 Activity
 Lecturer: Mr. Joe Lyster
 joseph.lyster@ul.ie
 Department of Manufacturing & Operations Engineering
 Lecture notes prepared by Mr. Donal Canty, Mr. Des Kelly & Mr. Joseph Lyster

2. WT4603
Module Outline
 Lecturer: Joseph Lyster
 Teaching Assistant: Michael Crehan
 Technicians: Joseph Murray
Louise Madden
 Lab Groups 2A-2B-2C-2D-2E-2F
 Courses Involved:
 LM094 Materials & Architectural Technology
 LM067 Wood Science & Technology
 Lecture Times
 Friday 2-4pm in P1001 (PESS Building)....Be on time!!!
 Lecture Notes
 Available @ www.slideshare.net/WT4603
Department of Manufacturing & Operations Engineering

3. WT4603
Module Outline
The aim of WT4603 is wood processing safety and best practice. This is a
core module and a requirement for second year teaching practice (TP).
Lectures Labs
1. To underline and explain 1. To underline and
the legislative and develop best practice
technical material approaches and use in
Aim associated with wood wood processing safety
processing safety and and practice.
practice.
a. Standardized a. Safe wood processing
documentation, legislation procedures and practice
and accountability
b. Machine anatomy, b. Develop safety culture
performance and
Objectives terminology
c. Develop safety culture c. Supervising for safety
and supervising for safety
d. Safe wood processing d. Confident and
procedures and practice competent machinists
Department of Manufacturing & Operations Engineering

4. WT4603
Module Assessment
 Module Assessment:
 35% Laboratory Work (Table Project/Lab book)
 35% Written Exam (Terminal)
 20% Term Assignments (Risk Assessments/Information posters)
 10% Lecture Worksheets
 Machines Practical Exam (Pass / Fail Basis)
 Note:
 Students must pass all assessment elements to obtain a pass in the module.
 Students that fail the practical machines exam will automatically fail the entire
module.
Department of Manufacturing & Operations Engineering

5. WT4603
Module Outline
 Nature of Project work:
 Laboratory Work:
 Table project
 Lab Booklet
 Term Assignments:
 Risk Assessments
 Information Poster
 Lecture Work:
 Worksheets
Department of Manufacturing & Operations Engineering

6. WT4603
Module Outline – Coursework
 Table project
 Purpose of the table project is to reflect your use of woodworking
machinery through wood processing safety and best practice
 Project enables you to purposely process material to construct an
artefact (table) from a raw plank state in the most efficient and safe
manner possible
 Use of the surface planer, thicknesser, rip saw, mortiser, bandsaw,
panel saw as part of this project
 Produce appropriate cutting lists, plans and procedures with the
awareness of material processing waste, which is an important element
for the sustainable use of material and procurement of bulk raw plank
material for class projects
 Develop hand skills in preparation for teaching practice by producing a
series of hand-crafted joints to construct the table
 Develop your awareness of machine safety through risk assessment
procedures including aspects such as hazard identification and risk
magnitude. This is a critical aspect regarding the safe operation of any
second level technology classroom.
Department of Manufacturing & Operations Engineering

7. WT4603
Module Outline – Coursework
 Table project requirements:
1. Produce fully constructed and finished table
2. Produce an orthographic plan, elevation and end
view of table showing component detail. Can be
done using hand or CAD/Solidworks
3. Produce a cutting list for components
4. Produce a graphical procedure handbook of project
material processing safety & best practice.
Templates will be provided for this aspect.
Department of Manufacturing & Operations Engineering

8. WT4603
Module Outline – Coursework
 Lab book:
 The purpose of the lab book is to record your in lab
exposure to wood processing safety and best
practice.
 It is advised that you complete the lab book during
your lab time as it intends to capture your initial
exposure to using wood processing machinery
 You will not be permitted to the lab without your lab
book
 Lab book can be purchased from snap printing at a
cost of €6.
Department of Manufacturing & Operations Engineering

9. WT4603
Module Outline – Coursework
 Term Assignments:
 Risk Assessments
 Create an A3 booklet to include the following:
 Lab Machines:
1. Risk assessment 1 – Surface planer
2. Risk assessment 2 – Thicknesser
3. Risk assessment 3 – Rip saw
4. Risk assessment 4 – Bandsaw
5. Risk assessment 5 – Mortiser
6. Risk assessment 6 – Pillar Drill
7. Risk assessment 7 – Router
 You will each be assigned and required to perform 3 risk assessments of staged (hazard
induced) machines. This will account for 3 of your 7 individual risk assessments outlined
above. In case of staged machines you will be provide with an image and scenario and you
will be required to perform your risk assessment based on this information.
 Information Poster
1. Create an appropriately designed A2 laminated poster on an assigned machine.
2. Must be accompanied by a user information sheet
3. You must also develop a work activity sheet that addresses machine safety and best
practice to reinforce operant knowledge, understanding and safety culture
• All assigned machine lists, as discussed in both cases above, can be viewed in
the lab.
Department of Manufacturing & Operations Engineering

10. WT4603
Module Outline – Coursework
 Lecture Worksheets:
 Each week you will be given an activity sheet to be
completed during the lecture.
 The aim of the lecture worksheets is to reinforce wood
processing safety and best practice.
 The worksheet will prepare you in advance of activities
taking place in forthcoming labs.
 It will provide you with a theoretical understanding of
wood processing safety and best practice that will
strengthen your knowledge and understanding in
preparation for labs.
 The worksheets will also involve reflection on the use of
machinery in previous labs
Department of Manufacturing & Operations Engineering

11. WT4603
Module Outline
Timetable:
Department of Manufacturing & Operations Engineering

12. WT4603
Lecture Content – 24hrs
Unit 0: Introduction + Labs W2
Unit 1: Machine Provision + Labs W3
Unit 2: Risk Assessment + Labs W4
Unit 3: PPE + Labs 4 W5
Unit 4: Planing Machines + Labs W6
Unit 5: Circular saws + Labs W7
Unit 6: Routers + Labs W8
Unit 7: Dust, Noise, Manual Handling + Labs W9
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13. WT4603
Laboratory Sessions
 Permitted entry to timetabled labs only!
 Labs will take place in SR2058 & SR2047.
 Lab coat and safety glasses are a prerequisite to gaining
entry to the lab.
 You must have your lab booklet during all labs.
 Groups are divided and timetabled
 Labs will begin on Week 2
 Labs are mandatory – 100% attendance
 Absence in the case of illness must be explained with a
doctors note.
 Other reasons must be explained to the lecture/TA.
Department of Manufacturing & Operations Engineering

14. WT4603
Laboratory Sessions
 2 X 2 Hours per Week (Week 2 --- Week 13 incl.)
 Labs begin on the hour and finish at 10 minutes before
the hour, e.g. 9:00am to 10:50am
 Late arrivals will not be permitted to join the lab session.
 Lab Rules and Requirements:
 Report for lab on time
 White lab coat
 Safety glasses
 Students must sign the attendance sheet
 Students will be assigned a work bench
 I.D. cards to be submitted to T.A. for locker keys
 Students must follow instructions of T.A.
 Students under the influence of alcohol will not be permitted.
Department of Manufacturing & Operations Engineering

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Laboratory Sessions
 House Keeping
 Students have a responsibility for the care of the tools in their locker
 At thee beginning and end of the lab students must:
 Check tools list and condition
 Report to T.A. if any tools are missing
 Report to T.A. if tools are damaged
 At the end of each lab session:
 Benches must be brushed down
 Bench hooks returned to the underneath of each bench.
 Vices must be in the closed position.
 The floor area is swept and/or all waste material is removed from the ground area.
 Wood waste and paper waste to be segregated.
 If stools are used during a lab session, they must be removed from the floor and
placed on top of the bench.
 I.D. cards will only be returned to students when they have complied with these
regulations.
Department of Manufacturing & Operations Engineering

16. WT4603
Health & Safety
 Lab coats must be worn at all times in the workshop.
 Safety glasses must be worn at the appropriate times as
laid out by the T.A. in charge.
 Students must report damage to tools and equipment to
the T.A. in charge.
 Students must immediately report any personal injury
(nicks, cuts etc.) to the T.A. in charge.
 Failure to comply with safety regulations will result in
removal from the lab session.
 Any malicious damage to University property or
equipment will result in removal from the lab and
University disciplinary procedures will be put in place.
Department of Manufacturing & Operations Engineering

17. WT4603
Lab Requirements – Week 2
 Students must present at labs on Week 2 with the
items requested on the 2nd Year Tools List
 Failure to present this equipment at the beginning of
the lab will result in you not being able to participate
in the lab
 You must bring all equipment & PPE to all labs
Department of Manufacturing & Operations Engineering

18. WT4603
Date Lab 1 Tech. Students Lab 2 Tech. Students
Week 1 No Labs No Labs
06-Sep No Labs No Labs
10-Sep No Labs No Labs
Week 2 Planer and Thicknesser TECH 6 SR2-047 Planer and Thicknesser TECH 6 SR2-047
13-Sep Planer and Thicknesser TECH 6 SR2-047 Planer and Thicknesser TECH 6 SR2-047
17-Sep Band Saw TA 12 SR2-058 Band Saw TA 12 SR2-058
Week 3 Cutting List/Plans/Procedure TECH 6 SR2-047 Rip Saw TECH 6 SR2-047
20-Sep Cutting List/Plans/Procedure TECH 6 SR2-047 Rip Saw TECH 6 SR2-047
24-Sep Cutting List/Plans/Procedure TA 12 SR2-058 Morticer TA 12 SR2-058
Submission 1 TA ALL
Week 4 Rip Saw TECH 6 SR2-058 Cutting List Component B TA 24 SR2-058
27-Oct Rip Saw TECH 6 24
Router 1
01-Oct Morticer TA 12
Week 5 Marking TA 12 SR2-058 Marking TA 12 SR2-058
04-Oct Router 2 TECH Router 2 TECH
08-Oct Processing Component B TECH 2 SR2-047 Processing Component B TECH 2 SR2-047
Week 6 TA 12 SR2-058 Pillar Drill TA 8 SR2-058
11-Oct Table Manufacture TECH Table Manufacture TA 8 SR2-058 Tue & Wed Open days
15-Oct Table conponent processing TECH 12 SR2-047 Table conponent processing TECH 8 SR2-047
Project Manufacture
Week 7 TA 8 SR2-058 Submission 2 TA ALL SR2-058
18-Oct Table Manufacture TA 8 SR2-058 Table Manufacture TA 8 SR2-058
22-Oct Table conponent processing TECH 8 SR2-047 Table conponent processing TECH 8 SR2-047
Department of Manufacturing & Operations Engineering

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Project Manufacture Project Manufacture
Week 8 TA SR2-058 TA SR2-058
25-Nov Table Manufacture LOUISE SR2-058 Table Manufacture SR2-058 Bank Holiday Monday
29-Oct Table conponent processing Table conponent processing SR2-058
Project Manufacture Project Manufacture
Week 9 Router 3 TA SR2-058 Router 3 TA SR2-058
01-Nov Table Manufacture SR2-058 Table Manufacture SR2-058
05-Nov Table Manufacture SR2-058 Table Manufacture SR2-058
Week 10 Table Manufacture TA SR2-058 Submission 3 TA ALL SR2-058
08-Nov Table Manufacture SR2-058 Table Manufacture SR2-058
12-Nov Table Manufacture TECH SR2-058 Table Manufacture TECH SR2-058
Week 11 Machines Exam TECH SR2-047 Machines Exam TECH SR2-047
15-Nov Table Manufacture TA SR2-058 Table Manufacture TA SR2-058
19-Nov
Week 12 Machines Exam TECH SR2-047 Machines Exam SR2-047
22-Nov Table Manufacture TA SR2-058 Table Manufacture SR2-058
26-Nov Table Manufacture Table Manufacture
Week 13 Submission 4 TA ALL
Machines Repeat Exam
29-Nov
Machines Repeat Exam
03-Dec
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20. WT4603
Week2: Lab 1 & 2
• Table
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21. WT4603
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 740 x 242 x 50 (mm)
242
740
▫ Aim of week 2 labs is to square the material to a clean workable
condition of required dimension.
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22. WT4603
Surface Planer
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23. WT4603
Surface Planer 1 Guide Fence
2 Infeed Table
3 Isolator
Infeed Dept
4
Adjustment Wheel
8 5 Start/Stop Control
2
Infeed Adjustment
6
Lock Handle
7 Blade Guard
Blade Guard
8 Clamp/Release
Mechanism
9 Outfeed Table
Guide Fence
10
Adjustment Wheel
11 Guard Guide
Guide Fence Lock
12
Handle
Department of Manufacturing & Operations Engineering

24. WT4603
Step 1:
Isolate machine
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.
Department of Manufacturing & Operations Engineering

25. WT4603
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*
Department of Manufacturing & Operations Engineering

26. WT4603
Step 4: Setting the guide fence width 242 + 10
•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
Department of Manufacturing & Operations Engineering

27. WT4603
Step 5: Guard adjustment
•Guard set for face side = handle up – 10mm
blade exposure
•Guard set for face edge = handle flat – no
blade exposure
Department of Manufacturing & Operations Engineering

28. WT4603
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.
Department of Manufacturing & Operations Engineering

29. WT4603
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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30. WT4603
Step 7: Planing face side Dept of Hand Dept of Hand
•Material position
•Hand positions
Ensure Guard Guide is in a
vertical position to plane
face side
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Department of Manufacturing & Operations Engineering

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Note Hand Positions in relation to material
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Step 8: Planing face edge Dept of Hand Dept of Hand
•Material position
•Hand position
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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Thicknesser
1
1 Extractor Pipe
2 Control Panel
3 Adjustment Lever
4 Thicknesser Bed
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37. WT4603
• Lab sequence – Thicknesser Delta Switch
Stop/Start
• Step 1: Twist Release
Stop
1. Unlock twist release stop mechanism
2. Press green button to start
3. Allow machine to build up, this can be determined by
noise consistency
4. When noise is consistent flip delta switch to on
position
5. Feed rate, i.e. Speed at which material is passed, is set.
6. Adjust table height as required
7. Feed material as directed
Display Panel
Thicknesser Bed
Adjustment
Feed Rate
Control
Control
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38. WT4603
Bandsaw
Department of Manufacturing & Operations Engineering

39. WT4603
The bandsaw
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See you all next week!
• Next week:
▫ Machine Provision
▫ Risk assessment
▫ Week 3 ripsaw labs
Department of Manufacturing & Operations Engineering