Lesson Plan
Course Title: Flexible Manufacturing
Session Title: Basic Safety
Performance Objective:
After completing this lesson, the students will demonstrate they know basic safety rules for
using hand tools, equipment, and machines following OSHA regulations; and how to dispose of
hazardous materials according to EPA requirements, in the Flexible Manufacturing Lab, by
taking the Flexible Manufacturing Basic Safety Test.
Specific Objectives:
The students will be able to:
 demonstrate they know general and hand tool safety rules for the Flexible Manufacturing
Lab
 explain general safety rules and why they should be used.
 explain safety rules for the basic machines used in the lab.
 explain the safe use of sheet metal equipment used in the lab.
 explain how to dispose of and recycle hazardous materials used in the lab.
Preparation
TEKS Correlations:
This lesson, as published, correlates to the following TEKS. Any changes/alterations to the
activities may result in the elimination of any or all of the TEKS listed.
Flexible Manufacturing:

130.327(c)(5)(A)(B)
...safely use hand and power tools and equipment commonly employed in metal
manufacturing;
...properly handle and dispose of environmentally hazardous materials used in metal
manufacturing.

130.327(c)(10)(A)(B)
...safely use equipment;
...properly dispose of environmentally hazardous materials used in sheet metal
manufacturing.
Interdisciplinary Correlations:
Chemistry:

112.35(c)(1)(A)(C)
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1
...demonstrate safe practices during laboratory and field investigations, including the
appropriate use of safety showers, eyewash fountains, safety goggles, and fire
extinguishers;
...demonstrate an understanding of the use and conservation of resources and the
proper disposal or recycling of materials.
Occupational Correlation (reference: O*Net – www.onetonline.org):
Industrial Safety and Health Engineers 17-2111.01
Similar Job Titles: Safety and Health Consultant, Environmental Safety Specialist and Chief
Security and Safety Officer (CSO)
Tasks:
 Inspect facilities, machinery, and safety equipment to identify and correct potential
hazards, and to ensure safety regulation compliance.
 Install safety devices on machinery, or direct device installation.
 Maintain and apply knowledge of current policies, regulations, and industrial processes.
Soft Skills: Critical thinking; Complex problem Solving; Judgment and decision making
Teacher Preparation:
The teacher will need to review the Flexible Manufacturing Basic Safety PowerPoint
presentation. The teacher may want to research some of the safety links listed in the reference
section. The safety review material and exam will need to be printed for each student.
References:
• http://safety.dri.edu/Programs/MachineShopRules.pdf
• http://me.ucsb.edu/course_pages/me12s/safety_handbook.pdf
• http://www.epa.gov/
Instructional Aids:
1. Flexible Manufacturing Basic Safety PowerPoint presentation
2. Parent Approval Form For Use of Materials, Hand Tools and Power Equipment handout
3. Flexible Manufacturing Basic Safety Test and Key
Materials Needed:
1. Parent Approval Form For Use of Materials, Hand Tools and Power Equipment handout
for each student
2. Flexible Manufacturing Basic Safety Test for each student
3. Pencil or pen
4. Paper
Equipment Needed:
1. Computer
Copyright © Texas Education Agency, 2012. All rights reserved.
2
2. Data
D
Projecto
or
Learner Preparation
n:
No advan
nce preparation is requirred.
Inttroduction
Introduc
ction (LSI Quadrant I):
SAY: A Flexible Manufacturing Lab has to use
u basic sa
afety rules fo
or personal p
protection.
ASK: Ca
an you tell me
m some of the
t safety re
egulations fro
om the team
mwork lesson
n?
(ANSWE
ER: eye prottection, hand
d and foot prrotection, he
earing protecction)
SAY: We
W are going to review otther safety ru
ules basic to
o this course
e.
ASK: What
W
type of hand
h
tools and
a equipme
ent do you th
hink will be u
used in Flexible
Manufacturing course?
SHOW: hammers, files, portable
e grinder, ha
acksaws
SHOW: chop saw, horizontal
h
ba
and saw, grin
nders and sh
heet metal e
equipment
Outline
Outline (LSI
(
Quadra
ant II):
Instructors can use the PowerPo
oint presenta
ation, slides, handouts, a
and note pag
ges in
conjunctiion with the following ou
utline.
MI
e
Notes to
o Instructorr
Outline
I. Intrroduction
A. Perso
onal Protectiv
ve Equipme nt (PPE)
requirrements
B. Generral and hand
d tool safety rules
C. Paren
nt Approval Form
F
For Usse of
Materrials, Hand Tools
T
and Po
ower
Equipment hando
out
D. Stude
ents will not be
b allowed t o work in
the lab
b without a permission
p
fform
signed
d by parent or
o guardian
Begin the F
Flexible
Manufacturing Basic
Safety Pow
werPoint
presentation
n.
Slides 1-7
Review the need to use
e
Personal Prrotective
Equipment (PPC) in the
e
n the genera
al
lab. Explain
safety ruless for your lab
b
and teach th
he way the
safety ruless should be
followed by your studen
nts.
The studentts do not
understand how quick
something ccan happen
around toolss and
equipment.
Distribute and explain the
Parent Approval Form F
For
Use of Mate
erials, Hand
Tools and P
Power
Equipment handout and
d
have studen
nts return a
Copyright © Texas Education Agency, 20012. All rights rreserved.
3
parent or gu
uardian signed
permission form from each
student befo
ore they start
working in lab.
.
II. Ba
asic Equipm
ment Safety
A. Grinde
er
B. Portab
ble grinder
C. Drill press
p
D. Horizontal band saw
s
E. Chop saw
Slides 8-19
Explain the safety ruless for
the basic m
machines use
ed in
the lab. De
emonstrate th
he
equipment a
after the
presentation
n.
III. Sh
heet Metal Equipment
E
A. Bender
B. Brake
C. Shear
D. Slip Ro
oller
Slides 20-25
Explain the safety ruless for
the basic m
machines use
ed in
the lab. De
emonstrate th
he
equipment a
after the
presentation
n.
H
materials
m
IV. Hazardous
A. Recyc
cling scrap metal
m
B. Dispos
sal of cutting
g fluids
Slides 26-28
Explain the way you wa
ant
to handle sccrap metal a
and
its recycling
g.
V. References
Slide 29
VI. Fllexible Manu
ufacturing Ba
asic Safety T
Test
he Flexible
Distribute th
Manufacturing Basic
Safety Testt and have
students takke the test.
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4
Verbal
Linguistic
Logical
Mathematical
Visual
Spatial
Musical
Rhythmic
Bodily
Kinesthetic
Intrapersonal
Interpersonal
Naturalist
Existentialist
Application
Guided Practice (LSI Quadrant III):
The teacher will guide the students through class discussion about safety rules and class
expectations.
Independent Practice (LSI Quadrant III):
The students will study the lab safety rules and take the Flexible Manufacturing Basic Safety
Test.
Summary
Review (LSI Quadrants I and IV):
Question: How does the enforcement of the safety rules and regulations protect you and
others in the lab?
Answer: Any answer that includes protecting the student and other people in lab.
Question: What should happen to a student that refuses to follow the safety rules?
Answer: Listen to the answers to use if a student will not use the tools and machines
correctly.
Evaluation
Informal Assessment (LSI Quadrant III):
The students will have to explain the lab safety rules and how the rules affect each of them.
Formal Assessment (LSI Quadrant III, IV):
The students will have to pass the Flexible Manufacturing Basic Safety Test over the safety
rules.
Extension
Extension/Enrichment (LSI Quadrant IV):
The students could make posters about safe use of tools and equipment.
Copyright © Texas Education Agency, 2012. All rights reserved.
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Parent Approval Form
For
Use of Materials, Hand Tools and Power Equipment
School:________________________________________________________________
Your student is enrolled in Flexible Manufacturing. The course is equipped with tools
and equipment to cut, form and shape metal and other materials. The equipment and
tools are maintained for their safe use. The use of the equipment and tools will be
demonstrated. This demonstration will include the safety rules and proper use of the
equipment in the lab.
Your student will be permitted to use said equipment after passing a comprehensive
safety test. The tools and equipment are kept in good working order: safety guards are
present where needed and precautions are taken to make the lab the safest work place
as possible. However, there is always a danger when using such equipment and
materials in a Flexible Manufacturing Lab.
With the above in mind and with the knowledge that the school district and its
employees cannot assume responsibility for any injury, please give your permission for
your student to use the materials, tools, equipment in this lab by signing below.
Date: _________________________________________________________________
Student Name: _________________________________________________________
Student signature: ______________________________________________________
Parent Name: __________________________________________________________
Parent signature: _______________________________________________________
Parent phone number: ___________________________________________________
This form, duly signed, must be received by the Flexible Manufacturing teacher before
any student may participate in any lab activity.
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Name ______________________________________
Date___________ Period ___
Flexible Manufacturing Basic Safety Test
Circle the letter beside the correct answer.
1. In a Flexible Manufacturing lab the students and teacher must wear:
A. eye protection
B. Personal Protection Equipment
C. open toed shoes
D. cap
2. The work area that is being used should be:
A. clean
B. cluttered
C. oily
D. messy
3. When working in the flexible manufacturing lab the students should:
A. play around
B. run
C. watch for hazards
D. sleep
4. When a person is working with metal other students should:
A. crowd around the person
B. allow plenty of room to work
C. leave the room
D. talk to the person
5. When picking up metal a student should make sure it is:
A. hot
B. not scrap
C. cool
D. old
6. When working all materials should be held:
A. in your hands
B. by some other person
C. on the floor
D. in a vise or clamped to the table
7. Tools should be pointed:
A. toward yourself
B. away from yourself
C. to the right
D. toward the left
Copyright © Texas Education Agency, 2012. All rights reserved.
7
8. Do not check the sharpness of a cutting tool by using:
A. a piece of paper
B. your eyes to look at them
C. your finger
D. a piece of wood
9. When moving heavy objects you should:
A. bend over and pick it up
B. have someone help
C. scoot it with your foot
D. roll it
10. Your hands are protected while working with metal by:
A. work or welding gloves
B. a rag
C. paper
D. latex gloves
11. The tool rest on a grinder should be set how close to the grinding wheel?
A. ¼”
B. ½”
C. 1/8”
D. 3/8”
12. When grinding metal the metal should be held:
A. in a clamp
B. in both hands
C. on the right side
D. on the bottom
13. You should use what part of the grinding wheel to grind?
A. side
B. face
C. bottom
D. top
14. When leaving the grinder, make sure the machine is:
A. turned off
B. coasting
C. completely stopped
D. still spinning
15. When making adjustments to the portable grinder it should be:
A. plugged in
B. turned on
C. unplugged
D. not turning
Copyright © Texas Education Agency, 2012. All rights reserved.
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16. Grinder sparks should not be aimed at:
A. a wall
B. a person
C. the floor
D. the ceiling
17. When finished with the portable grinder you should:
A. turn in off
B. lay it on its back
C. unplug it
D. all of the above
18. The material being drilled on the drill press should be held:
A. in a vise or clamp
B. in your hands
C. by someone else
D. above the table
19. Round or irregular shaped material should be held in a:
A. vise
B. your hands
C. a set of V- blocks
D. a clamp
20. Remove chips from the drill press with:
A. a brush
B. your hands
C. a stick
D. a rag
21. The horizontal band saw should be turned off and stopped before:
A. adjusting blade tension and guides
B. measuring material
C. clamping material in vise
D. all of the above
22. When starting the horizontal band saw you should set the blade:
A. to touch the material
B. below the material
C. above the material
D. beside the material
23. While running the chop saw the operator should wear their PPE along with what
other item?
A. hat
B. coveralls
C. face shield
D. a coat
Copyright © Texas Education Agency, 2012. All rights reserved.
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24. Cutting on the chop saw the operator should keep what items out of the cutting
area?
A. hands and fingers
B. material
C. cutoff wheel
D. metal
25. While cutting on the chop saw the material should be:
A. freehand
B. clamped in the vise
C. pushed in to the wheel
D. bolted to the table
26. When finished with the chop saw the machine should be:
A. turned off
B. completely stopped
C. blade lifted
D. all of the above
27. When bending sheet metal your fingers should be kept away
from what part of a brake or folder?
A. handle
B. opening
C. the clamp
D. the base
28. What two Personal Protection Equipment must be worn at all times:
A. hat and ear plugs
B. eye protection and latex gloves
C. welding gloves and an apron
D. eye protection and work or welding gloves
29. What part of the sheet metal break should you be aware of?
A. folding bar
B. clamping bar
C. counterweight
D. none of the above
30. What types of materials should not be cut on the sheet metal shear?
A. small pieces
B. large pieces
C. square pieces
D. angular pieces
31. Fingers should be kept away from the slip roller:
A. clamp
B. roller path
C. crank
D. lever
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32. What should be removed from the sheet metal before using the slip roll?
A. oil
B. layout marks
C. grease
D. the bur
33. Where should your feet be when operating the sheet metal shear?
A. both on the treadle
B. one on the treadle and one under it
C. both clear of the treadle
D. one on the treadle and one clear of it
34. The operator and helper of a sheet metal brake should talk about:
A. the project
B. when to close and start the operation
C. the class
D. the school assembly
35. What should always be worn when handling metal?
A. hats
B. work or welding gloves
C. garden gloves
D. latex gloves
Copyright © Texas Education Agency, 2012. All rights reserved.
11
Name ______KEY_____________________________
Date___________ Period ___
Flexible Manufacturing Basic Safety Test
1. In a Flexible Manufacturing lab the students and instructor must wear:
A. eye protection
B. Personal Protection Equipment
C. open toed shoes
D. cap
2. The work area that is being used should be:
A. clean
B. cluttered
C. oily
D. messy
3. When working in the flexible manufacturing lab the students should:
A. play around
B. run
C. watch for hazards
D. sleep
4. When a person is working with metal other students should:
A. crowd around the person
B. allow plenty of room to work
C. leave the room
D. talk to the person
5. When picking up metal a student should make sure it is:
A. hot
B. not scrap
C. cool
D. old
6. When working all materials should be held:
A. in your hands
B. by some other person
C. on the floor
D. in a vise or clamped to the table
7. Tools should be pointed:
A. toward yourself
B. away from yourself
C. to the right
D. toward the left
Copyright © Texas Education Agency, 2012. All rights reserved.
12
8. Do not check the sharpness of a cutting tool by using:
A. a piece of paper
B. your eyes to look at them
C. your finger
D. a piece of wood
9. When moving heavy objects you should:
A. bend over and pick it up
B. have someone help
C. scoot it with your foot
D. roll it
10. Your hands are protected while working with metal by:
A. work or welding gloves
B. a rag
C. paper
D. latex gloves
11. The tool rest on a grinder should be set how close to the grinding wheel?
A. ¼”
B. ½”
C. 1/8”
D. 3/8”
12. When grinding metal the metal should be held:
A. in a clamp
B. in both hands
C. on the right side
D. on the bottom
13. You should use what part of the grinding wheel to grind?
A. side
B. face
C. bottom
D. top
14. When leaving the grinder make sure the machine is:
A. turned off
B. coasting
C. completely stopped
D. still spinning
Copyright © Texas Education Agency, 2012. All rights reserved.
13
15. When making adjustments to the portable grinder it should be:
A. plugged in
B. turned on
C. unplugged
D. not turning
16. Grinder sparks should not be aimed at:
A. a wall
B. a person
C. the floor
D. the ceiling
17. When finished with the portable grinder you should:
A. turn in off
B. lay it on its back
C. unplug it
D. all of the above
18. The material being drilled on the drill press should be held:
A. in a vise or clamp
B. in your hands
C. by someone else
D. above the table
19. Round or irregular shaped material should be held in a:
A. vise
B. your hands
C. a set of V- blocks
D. a clamp
20. Remove chips from the drill press with:
A. a brush
B. your hands
C. a stick
D. a rag
21. The horizontal band saw should be turned off and stopped before:
A. adjusting blade tension and guides
B. measuring material
C. clamping material in vise
D. all of the above
Copyright © Texas Education Agency, 2012. All rights reserved.
14
22. When starting the horizontal band saw you should set the blade:
A. to touch the material
B. below the material
C. above the material
D. beside the material
23. While running the chop saw the operator should wear their PPE along with what
other item?
A. hat
B. coveralls
C. face shield
D. a coat
24. Cutting on the chop saw the operator should keep what items out of the cutting
area?
A. hands and fingers
B. material
C. cutoff wheel
D. metal
25. While cutting on the chop saw the material should be:
A. freehand
B. clamped in the vise
C. pushed in to the wheel
D. bolted to the table
26. When finished with the chop saw the machine should be:
A. turned off
B. completely stopped
C. blade lifted
D. all of the above
27. When bending sheet metal your fingers should be kept away
from what part of a brake or folder?
A. handle
B. opening
C. the clamp
D. the base
28. What two personal protection equipment must be worn at all times:
A. hat and ear plugs
B. eye protection and latex gloves
C. welding gloves and an apron
D. eye protection and work or welding gloves
Copyright © Texas Education Agency, 2012. All rights reserved.
15
29. What part of the sheet metal break should you be aware of?
A. folding bar
B. clamping bar
C. counterweight
D. none of the above
30. What types of materials should not be cut on the sheet metal shear?
A. small pieces
B. large pieces
C. square pieces
D. angular pieces
31. Fingers should be kept away from the slip roller:
A. clamp
B. roller path
C. crank
D. lever
32. What should be removed from the sheet metal before using the slip roll?
A. oil
B. layout marks
C. grease
D. the bur
33. Where should your feet be when operating the sheet metal shear?
A. both on the treadle
B. one on the treadle and one under it
C. both clear of the treadle
D. one on the treadle and one clear of it
34. The operator and helper of a sheet metal brake should talk about:
A. the project
B. when to close and start the operation
C. the class
D. the school assembly
35. What should always be worn when handling metal?
A. hats
B. work or welding gloves
C. garden gloves
D. latex gloves
Copyright © Texas Education Agency, 2012. All rights reserved.
16