StandardOperatingProcedure MachineShopSafetyandOperationsProtocol

I.Purpose This Standard Operating Procedure (SOP) outlines requirements to be considered by an authorized user of the Machine Shop as well as describes the normal operation of the equipment and any hazards that may be encountered during normal operation. Finally, the SOP explains how to minimize any hazards and how to respond in an emergency situation. This document is to be reviewed one year from the date of approval or as conditionswarrant,whicheveristheshortertimeperiod. Personnel AuthorizedPersonnel:TheMachineShopmaybeoperatedonlybyauthorizedpersonnelwhoarefullycognizant ofallsafetyissuesinvolvedintheoperationofsuchadevice.Thesepersonnelaretoensurethattheequipment isonlyoperatedinthemannerlaidoutinthisdocument.Tobecomeanauthorizeduser,onemust: CompleteSafetyOrientation. ReadandfullyunderstandtheSOP Receivetrainingontheequipmentbyanauthorizeduser. Signtheauthorizedusersheettoaffirmthattheabovestepshavebeencompleted.

Unauthorized personnel: No unauthorized personnel may enter machinery area during operations unless accompanied by an authorized user. All visitors must be briefed on proper safety protocol and must wear appropriateprotectiveeyewearlocatedonthepremises. III.Hazards Safety is not often thought about as you proceed through your daily tasks. Often you expose yourself to needless risk because you have experienced no harmful effects in the past. Unsafe habits become almost automatic.Youmaydriveyourcarwithoutwearingaseatbelt.Youknowthistobeunsafe,butyouhavedoneit before and so far no harm has resulted. None of us really likes to think about possible consequences of an unsafeact. A).IdentifyingshopHazards A machine shop is not so much a dangerous place as a potentially dangerous place. One of the best ways to be safe is to be able to identify shop hazards before they can involve you in an accident. By being aware of potentialdanger,youcanbettermakesafetypartofyourworkinthemachineshop. B).EyeProtection Eye protection is a primary safety consideration around the machine shop. Machine tools produce metal chips that may be very sharp, and there is always a possibility that these metal chips may be ejected from a machine athighvelocity.Sometimestheycanflymanyfeet. Eye protection MUST be worn at all times in the machine shop. There are several types of eye protection available. Plainsafetyglassthesehaveshatterprooflenses.Themostcommontypeofeyeprotectionworninthe machineshop. Sideshieldsafetyglassesthesemustbewornaroundanygrindingoperation.

Safetygogglethetypethatonlycoverstheeyes,oriswornoverprescriptionnonsafetyglasses. Thefullfaceshieldmostoftenwornonworkproducinghotsparksorotherflyingdebris.

C).FootProtection Shoes must be worn at all times in the machine shop. A solid leather shoe is recommended. SANDALS should notbeWORN. D).EarProtection Safety regulations are quite strict regarding exposure to noise. Several types of sound suppressors and noise reducingearplugsmustbeworn.Noiseisconsideredanindustrialhazardifitiscontinuallyabove85decibels.If it is over 115 decibels for short periods of time ear protection must be worn. Ear muffs or ear plugs should be used wherever high intensity noise occurs. Sudden sharp or highintensity noises are the most harmful to your eardrums. Sound level monitoring and assessment is available through Campus EH&S. Contact your Safety Department to scheduleanEH&Ssitevisit. THEDECIBELLEVELOFVARIOUSSOUNDS Painfulsounds:Jetenginesonground Airplaneonground:reciprocatingengine. Boilerfactory.Pneumaticriveter. Maximumstreetnoise Loudshout DieseltruckPianopracticeAveragecitystreet DogbarkingAverageconversation Averagecityoffice Averagecityresidence Onetypewriter Averagecountryresidence TurningpageofnewspaperPurringcat Rustleofleavesinbreeze Gastrointestinaloutgassing Faintestaudiblesound

E).GrindingDustandHazardousFumes Grinding dust is produced by abrasive wheels and consists of extremely fine metal particles and abrasive wheel particles.Theseshouldnotbeinhales.

You should wear an approved respirator if you are exposed to dangerous metals, such as beryllium, or the presenceofradioactivityinnuclearsystems.Inthesesituations,thespreadofgrinding dustmustbecarefullycontrolled.Notethatonemustobtainpropersafetytraining,healthexam,andrespirator fittestingpriortousingarespirator;contactEH&Sfordetails. Somemetalssuchaszincgiveofftoxicfumeswhenheatedabovetheirboilingpoint.Someofthesefumeswhen inhaled cause only temporary sickness, but other fumes can be severe or even fatal. The fumes of mercury and lead are especially dangerous, as their effect is cumulative in your body and can cause irreversible damage. Cadmiumandberylliumcompoundsarealsoverypoisonous. F).Clothing,Hair,andJewelry Avoidentanglementwiththemovingpartsofthemachinery. Wear shortsleeved shirt or roll up long sleeves above the elbow. Keep your shirt tucked in. It is recommended that you wear a shop apron. If you do wear a shop apron, keep it tied behind you. If apron strings become entangled in the machine, you may be reeled in as well. A shop coat may be worn as long as you roll up ling sleeves.Donotwearfuzzysweatersaroundmachinetools. If you have long hair, keep it secured properly. In industry, you may be required to wear a hair net so that your haircannotbecomeentangledinamovingmachine.Theresultofthiscanbedisastrous. Removeyourringsbeforeoperatinganymachinetool.Thesecancauseseriousinjuryiftheyshouldbecaughtin amovingmachinepart. G).HandProtection There is really no device that will totally protect your hands from injury. Next to your eyes, your hands are the most important tools that you have. It is up to you to keep them out of danger. Use a brush to remove chips fromamachine.Donotuseyourhands.Chipsarenotonlyrazorsharp,theyareoftenextremelyhot. Resistthe temptation to grab chips as they come from a cut. Long chips are extremely dangerous. These can often be eliminated by properly sharpening your cutting tools. Chips should not be removed with a rag. The metal particles becomeimbeddedin the clothand they maycutyou.Furthermore,therag may becaughtin amoving machine. Gloves must not be worn around most machine tools, although they are acceptable when working with a hand saw blade and when removing sharp chips from lathes and mills. If a glove should be caught in a moving part, it willbepulledin,alongwiththehandinsideit. Various cutting oils, coolants and solvents may affect your skin. The result may be a rash of an infection. Avoid DIRECTcontactwiththeseproductsasmuchaspossibleandwashyourhandsassoonaspossibleaftercontact. H).Lifting Improper lifting can result in a permanent back injury that can limit your physical activity the rest of your life. Back injury can be avoided if you lift properly at all times. If you must lift a large or heavy object, get some help oruseaforklift.Donttrytobeasupermanandliftsomethingthatyouknowistooheavy.Itisnotworththe risk. Objectswithinyourliftingcapabilitycanbeliftedsafelybythefollowingprocedure: Keepyourbackstraight. Squatdown,bendingyourknee.

Lift smoothly, using the muscles in your legs to do the work. Keep your back straight. Bending over the loadputsanexcessivestressonyourspine. Positiontheloadsothatitiscomfortabletocarry.Watchwhereyouarewalkingwhencarryingaload. Ifyouareplacingtheloadbackatthefloorlevel,loweritinthesamemanneryoupickeditup.

I).Carryingobjects If material is over six feet long it should be carried in the horizontal position. If it must be carried in the vertical position, be careful of light fixtures and ceilings. If the material is both long and over 25 kg in weight, it should becarriedbytwopeople,oneateachend.Heavystock,evenifitisshort,shouldbecarriedbytwopeople. J).ScufflingandHorseplay The machine shop has no place for scuffling and horseplay. This activity can result in serious injury to you, a fellowstudent,orworker.Practicaljokingisalsoveryhazardous.Whatmightappeartobeacomicalsituationto you could result in a disastrous accident to someone else. In industry, horseplay and practical joking are often groundsfordismissalofanemployee. K).CompressedAir Most machine shops have compressed air. This is needed to operate certain machine tools. Often flexible air hoses are hanging about the shop. A large amount of energy can be stored in a compressed gas such as air. When this energy is released, extremely danger may be present. You maybe tempted blow chips from a machine tool using compressed air. This is not recommended. The air will propel metal particle at high velocity. The can injure you orsomeone on the other side ofthe shop. Use a brush to clean chips from the machine. Do notblowcompressedaironyourclothingorskin.Theaircanbedirtyandtheforcecanimplantdirtandgerms into your skin. Air can be a hazard to ears as well. An eardrum can be ruptured. A broken air hose will whip aboutwildlyandmaycauseinjuryifyouhappentobestandingnearbyandarestruck. L).Electrical Electricity is another potential danger in a machine shop. Your exposure to electrical hazard will be minimal unlessyoubecomeinvolvedwith the machinemaintenance.A machinistismainlyconcernedwithto onandoff controlswitchonamachinetool. M).MachineHazards There are many machine hazards. Remember that a machine cannot distinguish between cutting metal and cutting fingers. Do not think that you are strong enough to stop a machine should you become tangled in movingparts.YOUARENOT.Whenoperatingamachine,thinkaboutwhatyouaregoingtodobeforeyoudoit. IV.NormalOperation The operational procedures for each piece of equipment may be attached to the back of this document or will beonfileinthemachineshopSOPinstructionmanuals. V.EmergencyProcedures A).Injuries:Ifyoushouldbeinjured,reportitimmediatelytoyoursupervisor. B).Poweroutage:Ifthereisapoweroutage,turnofftheequipmenttoavoidahazardoussituationwhenpower is restored. It is advised that all personnel in the machine shop exit the shop area until proper lighting is restored.

C). Earthquake: If there is an earthquake, turn off the equipment and immediately take cover either beneath a table or door frame. Avoid areas where equipment and materials may fall, dislodged, or become projectiles. When the shaking has subsided, check for the safety of others and yourself, and if possible exit the building immediately. D). Emergency Evacuation Alarms: If there is an emergency alarm, turn off the equipment immediately, check for other occupants in the machine shop, exit the building immediately, and report to the building evacuation stagingarealocatedinthefrontofthebuilding.(AssemblyPoint) AuthorizedUsers IhavereadandunderstoodtheStandardOperatingProceduresfortheMachineShop. S.No. AppendixASHOPCLEANUPPOLICY At the end of your work time you are expected to clean up the machines you worked on including the area aroundthem:base,chippans,etc. Each drill area must be left clean, so if you drill a hole on the drill press, and then go to use the mill you must cleanthedrillpressfirst,beforeyouusethemill. After using a machine, tear down all setups and return the machine to its standard setup. Milling machines shouldbeleftwithavisesecurelymountedonthecenterofthetable. The machine shop is a potentially dangerous environment. By following a few safety rules and applying a lot of common sense you will be able to safely produce quality machine work. We encourage you to plan your machiningtasksbeforeyoucomeintotheshop.Thinkbeforeyoucut!Wealsoencourageyoutotakeyourtime in the shop. You will find that if you work slowly and carefully you will obtain the desired results more quickly that if you hurry. The following is a list of shop rules to help you safely produce machine work of consistent quality. Federalandstatelawsrequiresafetyglassesbewornatalltimesintheshoparea.Allcorrectiveglasseswiththe exception of contact lenses provide adequate eye protection. Glasses must be worn whenever you are in the shopregardlessofwhetheryouareworkingornot.Lasersafetyglassesandsunglassesarenotacceptablesafety devicesbecauseoftheirtinting. To safely work in the machine shop, you need to be properly dressed. You must wear closed shoes on your feet toprotectyoufromfallingobjectsandmetalchips.Sandalsarenotacceptable.Alsolongsleevesmustberolled up and long hair tied up or contained in a cap so they do not become caught in any rotating machinery. Rings Nameoftheemployee Date Signature SupervisorsSign

should be taken off. Gloves are not allowed to be worn in the shop except for handling dirty or sharp material. Theyarenevertobewornwhenrunninganymachines.Thisalsoincludesrubbergloves. It is strongly recommended that a minimum of two people be present in the student shop in case there is an accident.Ifyouneedtoworklateatnightorontheweekendanditisnotpossibletohavesomeoneaccompany you,letsomeoneknowwhereyouaregoingandwhenyouplantoreturn.Besurethatallpeopleyoubringinto the shop with you have safety glasses, appropriate shoes, and that they know where the emergency power shutoffswitch,thefireextinguisherandthephonearelocated. The machine shop is not a place to experiment. Since the machine shop is a potentially dangerous environment no operations that you are not entirely sure will work, should never be tried. If you are not absolutely sure you knowwhatyouaredoing,ask. Asauserofthemachineshopitisyourresponsibilitytoimmediatelytendtoanypotentiallydangeroussituation that you come across regardless of whether or not you have caused it. Encourage your shopmates to wear safetyglasses.Cleanupspilledoilbyspreadingoilsorbonthespill. Chipsshouldberemovedfromthetslotsofthetable.Lathesshouldbeleftwithanemptycolletchuckorthree jaw on the spindle. Nothing should be in the tailstock and the cutting tool should be removed from the tool post. Brush all of the chips off the machine and place them in the trash. Do not use compressed air for this. Once mostofthechipisremovedgoaheadandblowtheonesyoumissedonthefloor.Whenthechipsareremoved, wipealloilanddustfromthemachinewitharag.Besuretocleanthechippanorthelatherandthebaseofthe mill.Thensweeptheflooraroundyourworkareaandthrowthesweepingintothetrash. If the supervisor determines that any person neglected to clean a machine or shop area that he or she was using,thatpersonmustimmediatelyreturnandperformtherequiredcleanuptothesupervisorssatisfaction. AppendixBProcedureforMachineShopAccidents Intheeventofamachineshopaccident,followtheprocedurebelow: Ensurethatthemachineisshutoff. Provide for the safety of the personnel (first aid, evacuation, etc.) as needed. Note if an eye injury is suspected, have the injured person keep his/her head upright and still to reduce bleeding in the eye. A physicianshouldevaluatemachineinjuriesassoonaspossible. Obtainmedicalassistanceforanyonewhomaybeinjured. If there is a fire, pull the alarm, and contact the fire department by calling from a cell phone. Do not fightthefireunlessitisverysmallandyouhavebeentrainedinfirefightingtechniques. InformtheOfficeofEnvironmentHealth,&Safety(EH&S)assoonaspossible. After the incident, do not resume use of the machinery until the EH&S has reviewed the incident and approvedtheresumptionofwork.

AppendixCImportantFactorstoRemember 1. Allshopusersareresponsibleforcleanupasdescribedbelow. 2. Donotwalkoutofarmsreachofarunningmachine.

3. Report any broken or missing tools to BNC Director or supervisor, so they can be repaired. Never use anything but sharp, unbroken tools. A dull tool requires higher cutting forces to do the same work as a sharptoo.Increasedforcecausesaccidentsanddamagedworkpieces. 4. Allworkmustbesecurelyclampedinthemachinebeforeanyworkisdone. 5. Resistthetemptationtopullchipsawayfromthecutterwithyourfingers.Theyaresharpandhot.Ifyou mustremovethechipsuseapairofpliers. 6. Neverblowcompressedairintoalargepileofchips.Useabrushtoremovemostofthechipsthanblow. Neverblowairtowardsanotherworker.Neverblowcompressedairontoyourskinorhair. 7. Do not grind nonferrous material on the grinder. It eventually causes the grinding wheel. To crack and fly apart. The grinder is for sharpening cutting tools only. Use the belt sander if you want to grind something that is not a cutting tool. When turning the grinder on do not stand directly in front of the wheels, wait until they have come up to full speed. Never ever clean any grinder or sander with compressedair! 8. Latheanddrillchuckkeysmustneverbeleftrestinginachuck. 9. Do not leave a machine set up and unattended for any longer than a half hour without the consent of theshopsupervisor.Ifleftforlongerthesetupwillbetorndownwhenthemachineisneeded. AppendixD.GOOVERSAFETYCHECKLIST 1. DoIknowhowtooperatethismachine? 2. Whatarethepotentialhazardsinvolved? 3. Areallguardsinplace? 4. Aremyproceduressafe? 5. AmIdoingsomethingthatIprobablyshouldnotdo? 6. HaveImadealltheproperadjustmentsandtightenedalllockingboltsandbolts? 7. Istheworkpiecesecuredproperly? 8. DoIhavepropersafetyequipment? 9. DoIknowwheretheSTOPSWITCHis? 10. DoIthinkaboutsafetyineverythingIdo?