Machine Tool Technology Week - 1 Notes

1. MACHINE TOOL
TECHNOLOGY
20ME32P

2. 2
1week
1. Educate about Safety standards Practiced in the machine Shop - Importance of
housekeeping and good Shop floor Practices(5S)
2. Understand the Principles of First Aid. Preventive measures to be taken during Fire
and Electrical emergency. Types of Fire extinguisher (Class A,B,C,D)
3. Knowledge about Safety and Environment Regulations

3. 3
Machine Shop Safety Tips & Safety Guidelines
1. Safety glasses with side shields must be worn at all times.
2. Do not wear loose clothing, loose neckwear or exposed jewelry while operating machinery.
3. Pull back and secure long hair.
4. Do not wear thin fabric shoes, sandals, open-toed shoes, and high-heeled shoes.
5. A machinist's apron tied in a quick release manner should be worn ideally.
6. Always keep hands and other body parts a safe distance away from moving machine parts,
work pieces, and cutters.
7. Use hand tools for their designed purposes only.
8. Report defective machinery, equipment or hand tools to the lab Instructor.

4. 4
Machine Shop Safety Tips & Safety Guidelines
9. Do not attempt to oil, clean, adjust, or repair any machine while it is running.
10. Do not set up or operate machinery if you are not trained and familiar with that setup.
11. Do not try to stop the machine with your hands or body.
12. Check tools and machines before use to assure they are safe to use.
13. Only one person should operate a given machine and its switches.
14. Do not lean against a machine.
15. Concentrate on the work and do not talk unnecessarily while operating the machine.
16. Do not talk to others when they are operating a machine. A distraction may lead to an injury.

5. 5
Housekeeping and good Shop floor Practices(5S)
5S is amongst the first and fundamental steps implemented by an
enterprise towards the path of implementing Total Quality Management and
continuous improvement at the operation level. 5S is a process designed to
organize the workplace, keep it clean, maintain effective and standard conditions.
It implants the discipline required to enable each individual to achieve and maintain
a world-class environment.
The 5S is a house keeping technique on effective work place organization
and standardized work procedure for productive and quality environment in an
organization . Implementing 5S results in a well organized work place with
efficient, more productive operation, reducing waste , improves level of safety. 5S
improves morale of employees promoting sense of pride in their work and
ownership responsibility thus increasing companies profit.

6. 6
Sl. No. Japanese word English equivalent Meaning
1 SEIRI Tidiness Throw away all rubbish and unrelated materials in the
work place.
2 SEITON Orderliness Keep everything in proper place for quick retrieval and
storage.
3 SEISO Cleanliness Sweeping, washing and cleaning everything around
working area immediately
4 SEIKETSU Standardization Standardize the way of maintaining cleanliness.
5 SHITSUKE Discipline Make five “S” as a daily practice. Everyone
understands, obeys and practices the rules in the plant
5S is the acronym for five Japanese words: Seiri, Seiton, Seiso, Seiketsu and Shitsuke and they
represent the five steps for a systematic technique for good housekeeping as indicated in the
table below:
What is the meaning of 5S

7. 7
• The workplace becomes cleaner, safer, well-organized and more pleasant
• Floor space utilization is improved
• Workflow becomes smoother and more systematic and non-value added activities are reduced.
• Time for searching tools, materials and document is minimized.
• Machine breakdowns are reduced since clean and well-maintained equipment. therefore
extending equipment life.
• Errors are minimized leading to making defect-free products.
• Consumables and material wastage are minimized.
• The morale and satisfaction of employees improves.
• The productivity of the organization improves together with the quality of products and services.
Why do we practice the 5S? (Benefits of implementing 5S)

8. 8
In spite of the necessary precautions, an accident may still occur due to human negligence or
some sort of other failure, which may result in an injury to a workman. Usually, a dispensary is
provided within the factory premises and adequate medical aid is always available for cases of
accidents. However, it may take some time before the medical team arrives at the accident site or
the injured person is shifted to dispensary. As such, First Aid is always necessary to be given to
the injured to prevent the case from worsening before regular medical aid is available to him.
For this, First Aid Boxes, properly equipped with required medicines, bandages, etc., are
always kept in each shop and department. Also, a selected number of staff and workers are duly
trained in this job to attend to such emergencies. These people are duty bound to provide first aid
to the persons who meet with accidents.
The usual injuries resulting from an accident may be :
1. An electric shock.
2. A wound or cut, resulting in bleeding.
3. A burn on any part of body.
4. An injury to eye.
5. Suffocation due to fumes or leaked gases.
6. Some internal injury or sprain in muscles.
FIRST AID MEASURES

9. 9
Principles of First Aid
The basic principles of First Aid are as follows:
(i) Preserve life: This includes preserving the life of the victim and the rescuer.
(ii) Ensure protection of the casualty from further harm: The treatment area needs to
be safe and must not have excess people.
(iii) Provide pain relief: This includes the use of ice packs or applying a sling.
(iv) Prevent the condition from worsening: Ensure that the First Aid procedures do not
worsen the patient’s condition.

10. 10
There are different types of fire extinguishers designed to put out the different classes of
fire. Selecting the appropriate fire extinguisher is an important consideration for a roofing
contractor. The wrong extinguisher actually may make a fire emergency worse. For example, failing
to use a Crated extinguisher on energized electrical components may endanger workers by causing
the extinguishing material to be electrified by the energized components that are on fire. C-rated
fire extinguishers put out the fire by using a chemical that does not conduct electricity. The
following table illustrates the types of extinguishers, fire classes for which each is used and the
limitations of each extinguisher.
Fire Extinguishers

11. Types of Fire extinguisher (Class A,B,C,D)
11
Portable fire extinguishers are classified by the type of fires they are designed to extinguish.
There are five basic classifications of fuel and extinguishers, and extinguishers are labeled with either
letter-shaped or pictorial symbols that indicate what types of fires they are intended for.

12. 12
Class A
Class A fires involve ordinary combustible materials, such as cloth, wood, paper, rubber, and many plastics.
Extinguishers with an A rating are designed to extinguish fires involving these ordinary combustible materials.
Class B
Class B fires involve flammable and combustible liquids such as gasoline, alcohol, oil-based paints. Therefore,
extinguishers with a B rating are designed to extinguish fires involving flammable and combustible liquids.
Class C
Class C fires involve energized electrical equipment. Extinguishers with a C rating are designed for use with
fires involving energized electrical equipment.
Class D
Class D fires involve combustible metals, such as magnesium, titanium, and sodium. Extinguishers with a D
rating are designed to extinguish fires involving combustible metals.
Class K
Class K fires involve vegetable oils, animal oils, or fats in cooking appliances. Extinguishers with a K rating are
designed to extinguish fires involving vegetable oils, animal oils, or fats utilized in commercial cooking
appliances.
Types of Fire extinguisher (Class A,B,C,D)

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Preventive measures to be taken during Fire and Electrical
Emergency
1. Persons carrying out electrical work should wear proper dress and should not wear loose dress, open
sleeves, metallic ornaments and metallic buttons, etc.
2. Only authorized persons, well versed with possible dangers and related precautions, should carry out
electrical works.
3. All metallic parts of electrical machinery and equipment should be adequately earthed and should be
regularly checked for the same.
4. Broken fittings ; like switches, plugs, etc., should always be promptly replaced.
5. Electric wires should not be used as hangers for clothes, etc.
6. No electrical work should be carried out while wearing wet clothes or with moistened hands.
7. Electrical appliances with damaged or frayed leads should never be used.
8. One should never try to tamper with electric control panels, cables, wires, equipment, etc.
9. Unauthorized persons should never be allowed to enter the electric control room.
10. Inflammable material should never be allowed to be collected near the electric machinery, equipment, live
wires, control panel, main switch, etc.

14. 14
11. Bare wires are no replacement for a plug top. a plug top should always be used to connect an appliance
12. Danger signs, safety boards, etc, should always be displayed required locations and the instructions
contained therein always followed
13. All the electrical tools should be regularly checked for proper insulation and damaged tools should never be
used,
14. The floor under the panel board should always be covered with rubber insulation sheets,
15. Safety devices like circuit breaker, limit switches, timer, over tripping switch, etc., should always be used
where necessary to ensure safety to the workers and equipment both
16. Safety equipment like safety belt, helmet, face shield, rubber gloves, boots with rubber soles, etc, should
always be used as necessary according to the nature of work,
17. The fuses used should be of correct rating
18. The main switch should always be 'put off before pulling out the 'cut out' for replacing a burnt fuse,
19. All portable electric tools and appliances should be properly checked for earthling before being used.
20. While handling or repairing an electric appliance, like a heater, fan, iron, kettle, etc., it should be ensured that
it is disconnected from the main supply,

15. 15
TREATMENT FOR ELECTRICAL SHOCK
If the victim is still in contact with live wires the first job should be to separate him from the circuit.
The following steps should be taken immediately in either case :
1. The electric supply line should be 'cut off at once.
2. If that is not feasible, the victim should be pulled away (separated) by force. For this, he can
either be knocked away by means of a dry stick of wood or by means of a rope or cloth. The
person performing this operation should insulate himself by standing on a rubber mat and
should ensure that the stick or rope used is perfectly dry.
3. The separated victim should then be made to lie on dry ground or floor.
4. If there are any sparks still in the clothes, they should be extinguished
5. If there are burns or an injury on the body, first aid should be given immediately and efforts
should be made to carry the victim to hospital or call the doctor.
6. Check if the victim is still breathing or not.
7. If there is no breathing, resort to artificial respiration at once.