This document outlines the process and requirements for a practical machine exam involving a planer, thicknesser, and rip saw. Students will be tested on their ability to safely operate each machine to process a given cutting list from stock material. There are 15 scoring elements that evaluate tasks like correctly setting fences and guards, safe material handling procedures, and returning machines to a safe state. Students must score 85/100 to pass and avoid critical failures related to personal protective equipment, machine isolation, or blade guard settings.

2. Lecturer: Mr. Joseph Lyster

3. joseph.lyster@ul.ie

4. Notes prepared by: Mr. Donal Canty, Mr. Des Kelly and Mr. Joseph Lyster

6. Note: Stock size is 650mm x 70mm x 50mm Rough Sawn material

7. All dimensions are in millimetres

8. Use the surface planning machine, thickenessing machine and rip saw to process the cutting list.

9. Important points to note:

10. Surface Planer: Know how to safely and correctly check the fence for square in relation to the in-feed table, set the bridge guard and guides for planing face side and face edge and the correct and safe hand positions when planning.

11. Thickness Planer: Know the correct starting procedure for this machine and the appropriate depth of cut to take in each pass through the machine.

12. Rip Saw: Know how to set both the SEDGWICK and JET rip saws for cross cut and rip operations. You must also raise and lower the blade/guard on the JET saw in relation to the material height as it is fed into the saw blade.Department of Manufacturing & Operations Engineering

13. WT4603 Marking Scheme: Department of Manufacturing & Operations Engineering

14. WT4603 Explanation: A score of 85/100 is required to pass the practical machine exam Critical Fail: There are 5 critical fail elements within the marking scheme as follows: Selection and use of appropriate PPE Isolate machine prior to setting fences Correct setting of blade guard and blade exposure Correct and safe procedure when surfacing material (Hand Positions) Correct setting of rip fence for crosscutting Should you fail to demonstrate any of the outlined critical fail elements then your exam will be terminated and you will have failed. Students who score below 85/100 marks or produce a critical fail will be required to repeat the exam at the end of the semester (Week 12/13) Department of Manufacturing & Operations Engineering

16. Safety Glasses/Goggles

17. Additional non-PPE:

18. Measuring Tape

19. Pencil

20. Process Sheet

21. Cutting ListDepartment of Manufacturing & Operations Engineering

24. Adjust blade guard to appropriate position

25. Demonstrate adjustment of the bridge guard to the appropriate position for face side and face edgeDepartment of Manufacturing & Operations Engineering

28. Body position

29. Feed rateDepartment of Manufacturing & Operations Engineering

31. Setting appropriate depth

32. Correct feed of materialDepartment of Manufacturing & Operations Engineering

34. Demonstrate appropriate adjustment and lock of fence position

36. Demonstrate that hands never enter the machine table are when ripping

37. Demonstrate appropriate use of push sticks (positions)

38. Demonstrate appropriate feed and follow through of materialDepartment of Manufacturing & Operations Engineering

40. Demonstrate appropriate adjustment and locking of fence position

42. Demonstrate appropriate feed and follow through of material

43. Demonstrate appropriate use of push sticks (positions) to clear waste15. Return machine to safe settings Department of Manufacturing & Operations Engineering

44. WT4603 Cutting List: Sketch + Dimension B1.1 Rail 1 Sketch + Dimension Rail 2 B2.1 Rail 3 Rail 3 Sketch + Dimension B2.2 Sketch + Dimension B2.3 Department of Manufacturing & Operations Engineering

45. WT4603 2 44 50 1 3 18 70 38 20 Department of Manufacturing & Operations Engineering

46. WT4603 Processing Procedure: Material Given: 650 x 70 x 50 Inspect material Select appropriate face side/ face edge (preliminary marking) Surface plane face side and face edge Thickness (P.A.R) material to 66 x 44 Rail 1 Rip 1: 22mm Rail 2/3 Rip 2: 20mm (2 rails produced from one rip) Rail 1 Thickness 1: 20mm Rail 2/3 Thickness 2: 18mm x 2 Rail 1 Cross cut A: 630mm x 1 Rail 2 Cross cut B: 300mm x 2 Rail 3 Cross cut D: 150mm x 2 Rail 3 Cross cut C: 310mm x 1 2 1 3 Department of Manufacturing & Operations Engineering

47. WT4603 VIDEO WILL BE UPLOADED TO www.slideshare.net/WT4603 BY TOMORROW EVENING 21-10-2010 Department of Manufacturing & Operations Engineering