Wt4603 unit1 week2-17-09-2010

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Wood Processing Safety & Practice

Lecture Unit 1

Machine Provision, Hazard Identification, Risk Assessment & Week 3 Labs Lecturer: Mr. Joseph Lyster [email protected] Notes prepared by: Mr. Donal Canty, Mr. Des Kelly and Mr. Joseph Lyster Notes available on www.slideshare.net/WT4603

mailto:[email protected]

http://www.slideshare.net/WT4603

Department of Manufacturing & Operations Engineering

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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.

CE Mark


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• 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.

CE Mark


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• 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.

CE Mark


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The existance of the “CE” marking on a piece of machinery should indicate that its manufacturer has met all relevant standards and requirements.

CE Mark


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Never assume that machinery is safe just because it has a “CE” marking

CE Mark


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A brief look at Safety Signage

Mandatory/Action

Regulatory/Prohibited

Emergency/Permission

Warning/Caution-Danger


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• 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.

Supervision & Access

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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.


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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.


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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

Guarding

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• 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.

Exclusion Zones

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Lighting

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Emergency Isolators and Emergency Stops

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Start/Stop• Are there appropriate start / stop controls ?

• Location

• Colour

• Flush mounted

• Mushroom head

▫ Turn release

▫ Key release

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Stop control must have priority over the Start control.

Start Control

Flush

Recessed

Stop Control

Mushroom Head

Push Bar

Start/Stop


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Some machines may have two stopping devices.

Hand Operated

Foot/Knee Operated

Emergency Stop


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Push Sticks


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Material Preparation


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Maintenance of Machinery


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Preventative Maintenance


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Maintenance Records


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Inspection of Machinery


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• 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.

Inadvertent Starting


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Inadvertent Starting


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Machinery Rundown Time


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• 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

Health & Safety Management


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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.

Unsafe Workplaces


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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.

Safe Workplaces


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The Key steps of any Health & Safety Management scheme are:

1. Policy2. Hazard identification3. Risk Assessment4. Control Measures.5. Recording Findings (Safety Statement)6. Monitoring, Review and Auditing

Safety Management


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Importance of being able to Assess Risk


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Required Reading


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The Safety Management Process


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Health & Safety Policy


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Identify Hazards (Hazard Identification)


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Assess Risk (Risk Assessment)


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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.

Hierarchy of Risk Control


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• 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)

Risk Assessment Considerations


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• 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)



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• 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)



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▫ Knowledge

▫ Skills

▫ Training

▫ Experience

▫ Attitude

▫ Motivation

▫ Risk perception

▫ Mental condition

▫ Physical condition

▫ Accident proneness

Factors Effecting Likelihood & Occurrence

Individual Factors


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▫ Condition of equipment/tools

▫ Maintenance regime

▫ Guarding/hazard controls

▫ Workload

▫ Patterns of work

▫ Emergency arrangements

▫ Training/ information/ instruction

▫ Supervision

▫ Communications

▫ PPE

Task factors

Factors Effecting Likelihood & Occurrence


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Risk Assessment


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Factors Effecting Likelihood of Occurrence


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Risk Magnitude


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Risk Magnitude Matrix


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Risk Magnitude Matrix: Severe Cut/Amputation from Bandsaw


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Which Poses the Greatest Risk?


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More information can be found byconsulting manufacturer’s manual


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Health & Safety at Work Act 2005

Pg. 30 of Health & Safety at Work Act

2005


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Scroll Saw Risk Assessment


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• Hazard

• means anything that can cause harm (egchemicals, electricity, working from ladders,

etc)

• Risk

• is the chance, high or low, that somebody will be harmed by the hazard.

Hazard & Risk


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• 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

Risk:


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Risk Assessment template as laid out by State Claims Agency

Risk Assessment Template:


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Scroll Saw Risk Assessment


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Hazards in the Workplace


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Some Possible Hazards


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Definition: Hazard


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Common Machinery/Mechanical Hazards


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Wrap Point: (Entanglement)


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Shear Point and Cutting Hazards


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Crush Points


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Ejection Hazards


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Other Hazards


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Hazards


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• 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

Classroom Risk Assessment:


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Room Layout

LABS WEEK 3Processing plan for Section A of the

Table project.


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Table project.


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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.

Section A

• Processing material from raw, list out the required measurements of table parts to be acquired from material section A.


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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)


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Step 1: Produce Cutting List

• Correct cutting list: should show:▫ Item.

▫ Number.

▫ Length.

▫ Width.

▫ Thickness.

▫ Material.

▫ Machine Processing Waste

▫ & Description.


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Work out how pieces will be removed from material correctly.

#NB: Grey is waste/excess material on drawing


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Blue = Rail Material

Grey= Waste Piece –Plane to 10mm for additional use

Red = Saw Waste – Cross Cut

Green = Saw Waste - Rip

Yellow = Leg Material

Step 2: Assessing material

• Check material for the following:▫ Cupping.

▫ Bowing.

▫ Warping.

▫ Defects (stress fractures, dead knots, honey combing, etc.)


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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.


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Square Face Side

#NB- notice position of guide on guard, and distance from fence.


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Square Edge Side

#NB- notice position of guide on guard, and distance from fence.Department of Manufacturing & Operations Engineering

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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).


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Step 3A. Plane Parallel Edge.


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Step 3B: Material Thickness to 46mm


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Step 4: Rip Saw


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Step 4: Rip Saw

1

2

3

4

5

1 Outfeed Table

2 Sliding Table

3 Emergency Foot-stop

4 Blade Adjustment Wheel

5 Power Isolator

6 Start/stop

7 Guide Fence Assembly

8 Crown Guard


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4

5

6

9

8

4 Blade Adjustment Wheel

5 Power Isolator

6 Start/Stop

8 Crown Guard

9 Riving Knife

10 Saw Blade

Step 4: Rip Saw


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OUTFEED

TABLE SLILDING

TABLE

Step 4: Rip Saw


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Cross Cutting

Ripping

Step 4: Rip Saw

#NB: Ensure correct use of PPE and push sticks are practiced.


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Mark Line across end grain:1. Horizontal when cutting2. Vertical when planing

Step 4: Rip Saw – Ripping Material


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Step 4: Rip Saw – Ripping 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)


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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.


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Step 5A: Rip Saw – Processing Leg Material


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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.


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Step 5B: Rip Saw – Processing Rail Material


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Step 5B: Rip Saw – Thicknessing Rail Material

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.


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#NB: Ensure guards and guides are set-up and used correctly and safely.


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Your Processing plan should have:


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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.


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Mortiser


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Mortiser

7

5

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

CHISEL

CLEARANCE

AUGER

http://upload.wikimedia.org/wikipedia/en/1/14/Chiselandbit.jpg


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Mortiser

ESCAPE WINDOW

MORTISE

CHISEL


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Mortiser

Wt4603 unit1 week2-17-09-2010

Education

Transcript of Wt4603 unit1 week2-17-09-2010