Engineering Innova,on Center Fabrica,on Shop Safety Training Introduc.on The Engineering Innova.on Center Fabrica.on Shop was established for support of undergraduate student course work. Every effort will be made to make the shop available for these projects. Students of Engineering who desire to use this equipment for educa.onally-­‐related ac.vi.es are required to aDend training. 8/28/15 Engineering Innova.on Center 2 Rules and Regula.ons Students are not allowed to use the equipment in the fabrica.on shop without: •  Going through safety training on each of the machines to be used •  Passing a wriDen safety test •  Comple.on of the “Student Request for Machine Shop Use” form (with appropriate approvals) Upon comple.on of the previous steps a student will be given one of the following badges: •  Limited Access – Red Badge •  AYer Hours Access – Green Badge Upon entering the fabrica.on shop, all students must sign in for the day and must sign out at the Fabrica,on Shop Kiosk when they complete their work for the day. 8/28/15 Engineering Innova.on Center 3 Red Badge – Limited Access Student is allowed access only if Fabrica.on Shop personnel are on duty. •  Prior approval of all jobs is required and drawings must be present at the work area. •  The student must clearly display their badge when working in the fabrica.on shop. •  Badges must NEVER be worn on a neck lanyard •  As a student progresses through the fabrica.on shop and is safety briefed and trained on individual machines they may have unsupervised access to only those machines on which they have completed the necessary training. 8/28/15 Engineering Innova.on Center Yes No 4 Green Badge-­‐ AYer Hours Access A student will be awarded a green badge indica.ng they have completed safety checks on all manual machines and have been cer.fied to operate manual equipment without addi.onal supervision from the machine shop staff. •  The student will s,ll need to get approval for aDer hours access with the machine shop manager •  Students will need to sign in at the EIC equipment check out to enter the Fabrica.on Shop aYer hours •  A minimum of two green badge students are required to work aDer normal opera,ng hours •  Prior approval of all jobs is required and drawings must be present at the work area •  Fabrica,on Shop is CLOSED to all students aDer 8 pm 8/28/15 Engineering Innova.on Center 5 Fabrica.on Request Students requiring the use of the PCB Circuit board CNC, CNC Mill, CNC Lathe, Universal Laser CuDer, and 3D Prin.ng must submit a request. Informa.on to be included in the request: •  All CNC work requests must be submiDed with CAD drawing files and the part model file. •  All 3-­‐D printed works must include an STL file •  Material type •  Quan.ty •  Due date 8/28/15 Engineering Innova.on Center Fabrica.on Shop Kiosk 6 First Aid •
First Aid kits are located in the Fabrica.on shop in the
following areas:
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Each side of the Fabrica.on Shop Managers office
EIC Equipment Checkout office
Emergency Eyewash sta.on is located on the door by
the PCB circuit board machines
If you are injured, no.fy the Fabrica.on Shop staff as
soon as possible
Watch First Aid video
8/28/15 Engineering Innova.on Center 7 Fire Ex.nguisher •
There are three ABC fire ex.nguishers located in the Fabrica.on Shop –  East wall across from Fabrica.on Shop Manager’s Office –  ***List other loca.ons •
Fire Ex.nguisher Training 8/28/15 Engineering Innova.on Center 8 General Shop Safety •
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Safety glasses or goggles must be worn at all ,mes in the shop area. Long hair, loose items of clothing, jewelry, etc., must be constrained so as not to be a hazard near rota,ng or otherwise moving machinery. All safety features of the machinery shall be properly u.lized. Long pants and sleeved shirts are required (no tank tops or shorts). Closed toe shoe are required. Extreme care must be exercised when using compressed air to blow chips off machines. 8/28/15 Engineering Innova.on Center 9 Safety Glasses Yes 8/28/15 No Engineering Innova.on Center 10 Personal Amre Yes No Hair not ,ed back Wearing Shorts Hair Tied back Long Pants Closed toe shoes 8/28/15 Engineering Innova.on Center 11 General Shop Safety •
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DO NOT use compressed air to blow off clothing or skin. No electronic player, cell phones, or headphones are permiDed in the Fabrica.on Shop Cameras may be used to document work progress. No one is allowed to use machinery alone. If Fabrica.on Shop personnel are not in the Shop, students are required to work in pairs. This is par,cularly important when using the machines aDer normal working hours. 8/28/15 Engineering Innova.on Center Yes No 12 General Shop Safety Yes You may record your work 8/28/15 No You cannot talk or text in the Fabrica,on Shop Engineering Innova.on Center 13 Work Cleanup The user of a machine shall be responsible for cleaning each machine aYer use. •  Clear machine of all chips, may use compressed air •  Wipe up coolant, tap fluid, or any other residue with shop cloths •  Sweep the floor and dispose of all chips created during work in the appropriate receptacle •  Leave it cleaner than it was before •  The student is responsible for returning all tools to their appropriate loca.ons. •  Viola,on of cleanup procedures will result in suspension from the shop. •  The Fabrica.on Shop is not a depository for junk. Any project or other material leY in the Fabrica.on Shop will be discarded, unless special permission is obtained from the Fabrica.on Shop Manager. 8/28/15 Engineering Innova.on Center 14 Fabrica.on Shop Tooling The fabrica.on shop provides all standard tooling which includes: •  Drills •  Taps •  Endmills •  Hand tools •  Portable drills and hand saws •  Turning and boring tools •  Welding equipment In the event that a student requires special tooling, the student will responsible for acquiring the tooling. 8/28/15 Engineering Innova.on Center 15 Fabrica.on Shop Machines Fabrica.on Shop machines are broken down into eight categories: •  Manual Mills •  Manual Lathes •  CNC Mills •  CNC Lathe •  Table Saws •  Band Saws •  Welding equipment •  Hand tools 8/28/15 Engineering Innova.on Center 16 Manual Mill Safety •
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Safety glasses must be worn Never wear long sleeves, gloves or any jewelry and always ,e your hair back. NEVER TAKE YOUR HAND OFF THE DRAW BAR WRENCH UNTIL THE WRENCH IS REMOVED FROM THE DRAW BAR. Make note of all pinch points before tuning on the spindle or moving the table. Never stop the spindle by hand, let the spindle coast to a stop or use the brake. Do not make contact with the revolving cuDer. 8/28/15 Engineering Innova.on Center 17 Manual Mill Safety Yes 8/28/15 No Engineering Innova.on Center 18 Manual Mill Safety •
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Never leave a drill chuck key in the chuck in the .ghtening posi.on. Always remove the chuck key aYer .ghtening the chuck. When storing the chuck, place the handle of the key in the chuck. Do not mill with a End Mill in the Drill Chuck. When semng up, install the cuDer last to avoid being cut. Ensure the spindle has come to complete stop before making any measurements. Clean dirt and chips from ma.ng parts when changing cuDers, collets, drill chucks, vises, rotary tables, or any other devise. Use the buddy system when moving heavy aWachments. 8/28/15 Engineering Innova.on Center 19 Manual Mill Safety 8/28/15 Engineering Innova.on Center 20 Buddy System Yes 8/28/15 No Engineering Innova.on Center 21 Manual Lathe Safety
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Never wear long sleeves, gloves or any jewelry and always ,e your hair back Never use the lathe when ,red or rushed for ,me Always remove the chuck wrench from chuck immediately aDer using Make sure that the chuck or faceplate is ALWAYS fully .ghtened onto the spindle Make sure your part is securely .ghtened in the chuck or collet Always check that the chuck or collet will clear the tool post before you start Keep rags away from the machine while it is in mo.on In a hurry? Come back later! 8/28/15 Engineering Innova.on Center 22 Manual Lathe Safety
8/28/15 Yes No Chuck clear of tools Chuck wrench leD in chuck Engineering Innova.on Center 23 Manual Lathe Safety •
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Move the tool bit, tool post and/or tailstock a safe distance from the chuck or collet when inser.ng or removing your work piece. Do not run the machine faster than the proper cumng speed. In semng up the tool holder, place it to the leY side of the compound slide to prevent the compound slide from running into the chuck or spindle aDachments. 8/28/15 Engineering Innova.on Center 24 Manual Lathe Safety •
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Always clamp the tool bit as short as possible in the tool holder to prevent it from breaking or chaDering. Always make sure that the tool bit is sharp, at the correct height and has the proper clearance. Filing work pieces in the lathe is only done in presence of Fabrica.on Shop Manager If work is turned between centers, make sure that the proper adjustments are made between centers and that the tailstock is locked in place. Do not grasp or touch chips or turnings with your fingers. It is safer to turn off the lathe before clearing chips with a brush or soD air blasts. 8/28/15 Engineering Innova.on Center 25 Manual Lathe Safety •
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Set the tool bit on the centerline of work to prevent work from climbing over tool or cumng above center and dragging. Do not cut work completely through when turning between centers. Turn chuck or face plate through by hand before turning on the power to be sure there is no binding or clearance problems. Stop the machine before taking any measurements. STUDENTS ARE NOT ALLOWED TO TEACH OTHER STUDENTS IN THE USE OF THE LATHE. Leave the en.re machine cleaner than when you found it! Be safe, ask if unsure, use your common sense, and look out for the safety of others. 8/28/15 Engineering Innova.on Center 26 CNC Mill and Lathe Safety •
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Safety glasses must be worn Never wear long sleeves, gloves or any jewelry and always ,e your hair back. Use the buddy system when moving heavy aWachments. Ensure all tools, chuck wrenches, vise handles, hammers, and other loose items are removed from the machine enclosure. Only authorized students and Fabrica.on Shop personnel should work on this machine. Untrained individuals present a hazard to themselves and the machine. 8/28/15 Engineering Innova.on Center 27 CNC Mill and Lathe Safety •
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Check for damaged parts and tools before opera.ng the machine. Any part or tool that is damaged should be properly repaired or replaced by authorized personnel. Do not operate the machine if any component does not appear to be func.oning correctly. Contact your shop supervisor. Do not operate with the doors open This machine can cause severe bodily injury. This machine is automa,cally controlled and may start at any ,me, be aware where you are rela,ve to it. 8/28/15 Engineering Innova.on Center 28 CNC Mill and Lathe Safety •
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The Emergency Stop buDon is the large, circular red switch located on the Control Panel. Pressing the Emergency Stop buDon will instantly stop all mo.on of the machine, the servo motors, the tool changer, and the coolant pump. Use the Emergency Stop buWon only in emergencies to avoid crashing the machine. The electrical panel should be closed and the key and latches on the control cabinet should be secured at all .mes except during installa.on and service. 8/28/15 Engineering Innova.on Center 29 Table Saw Safety •
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Safety glasses must be worn Never wear long sleeves, gloves or any jewelry and always ,e your hair back. DO NOT CUT METAL OR CONDUCTIVE MATERIAL WITH THE SAW STOP TABLE SAW Ensure work piece does not nails, screws, or any kind of metal debris Dust collector must be turned on when saw is in opera.on Follow the 3” rule; always keep your fingers at least 3” from the blade. Do not cut stock that is not flat on the boDom without a jig that will hold the work in a stable posi.on. Keep a balanced stance at the saw. 8/28/15 Engineering Innova.on Center Is it turned on? 30 Table Saw Safety •
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Never clear small pieces with your hand while the blade is moving. Use the guards provided whenever possible. If addi.onal guards are needed, discuss this with the Fabrica.on Shop Manager and make arrangements to acquire them. Never touch the blade when it is rota,ng, even if the saw is turned off. Never contact the blade with any metal object when it is rota,ng, even if it is turned off. Use a blade guard and spreader for every opera,on for which it can be used, including all through sawing. Use a push s,ck when required Keep the top of the saw clean and free from cluDer. 8/28/15 Engineering Innova.on Center 31 Table Saw Safety Yes No Where is the guard Blade way too high Fingers too close Weight over blade, not his feet 8/28/15 Engineering Innova.on Center 32 Radial Arm/Chop Saw Safety •
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Safety glasses must be worn Never wear long sleeves, gloves or any jewelry and always ,e your hair back. DO NOT CUT METAL WITH THE RADIAL ARM/CHOP SAWS Keep hands and fingers away from the path of the blade when cumng Crosscut only one piece of wood at a ,me. Hold the stock solidly against the fence when making a cut. Get Fabrica.on Shop Manager’s approval before running the saw when special set ups are involved. Do not walk away from the Radial Arm saw and leave it running. 8/28/15 Engineering Innova.on Center 33 Radial Arm/Chop Saw Safety •
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Do not pull or force the saw through the wood faster than the blade is able to cut. Hold the saw firmly when cumng. The blade may try to force its way through the cut faster than you want it to. This is called “riding up on the board”. Do not cut stock shorter than 6 inches unless you have received special permission from the Fabrica,on Shop Manager. At the finish of each cut, return the saw to the normal star.ng posi.on and beware of a bounce back tendency. Never reach near the blade to remove scrap. Turn the machine off and wait for blade to come to a complete stop before removing scrap pieces of wood from around or behind the blade. 8/28/15 Engineering Innova.on Center 34 Radial Arm/Chop Saw Safety •
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Be aware of people who are around you before making your cut. Someone could bump your stock while you are cumng and cause an accident. Do not remove any guards. Keep them in their proper posi.on. Do all measuring and marking of stock to be cut before turning the machine on. Only cut stock against the grain of the wood. Never cut stock with the grain of the wood. 8/28/15 Engineering Innova.on Center 35 Band Saw Safety •
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Safety glasses must be worn Never wear long sleeves, gloves or any jewelry and always ,e your hair back Use coolant when running the horizontal saw unless you are cumng wood or other porous material. The adjustable saw guide for the ver.cal saw should be as close to the work piece as possible. When sawing steel and thin materials (under 1/8”), use a fine toothed blade When sawing aluminum or thick material (over 1/8”), use a course tooth blade When sawing round material on the ver.cal saw, use a vise to hold the work piece. 8/28/15 Engineering Innova.on Center Ver.cal band saw Horizontal band saw 36 Band Saw Safety •
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When sawing thin material, use a piece of scrap wood under the piece being cut. Use a push s.ck on work pieces that are small. NEVER PUT YOUR FINGERS CLOSE TO THE BLADE WHILE THE MACHINE IS RUNNING. Clean machine aYer use Yes 8/28/15 Engineering Innova.on Center No 37 Arc Welding Safety •
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Safety glasses must be worn Welding hood, leather welding gloves, leather welding coat or heavy duty denim shirt, denim jeans, and leather boots are required APPROVAL FROM FABRICATION SHOP MANAGER IS REQUIRED TO PERFORM ARC WELDING OPERATIONS To prevent injury to personnel, extreme cau.on should be exercised when using any types of welding equipment. Injury can result from fire, explosions, electric shock, or harmful agents. Both the general and specific safety precau.ons listed must be strictly observed by students who weld or cut metals. Only trained and authorized students may use welding or cumng equipment. 8/28/15 Engineering Innova.on Center 38 Arc Welding Safety •
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Ensure proper ven.la.on is achieved and use fan to circulate air if necessary Remove all flammable material, such as coDon, oil, gasoline, etc., from the vicinity of welding. When welding is done near other personnel, screens should be used to protect their eyes from the arc or reflected glare. Before welding or cumng, warn those in close proximity who are not protected to wear proper clothing or goggles by saying “Arcing!” in a loud voice. 8/28/15 Engineering Innova.on Center 39 Arc Welding Safety •
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Remove any assembled parts from the component being welded that may become warped or otherwise damaged by the welding process. Do not leave hot rejected electrode stubs, steel scrap, or tools on the floor or around the welding equipment. Accidents and/or fires may occur. Keep a suitable fire ex.nguisher nearby at all .mes. Ensure the fire ex.nguisher is in operable condi.on. Mark all hot metal aYer welding opera.ons are completed. Soapstone is commonly used for this purpose. 8/28/15 Engineering Innova.on Center 40 Arc Welding Safety Yes No Arcing! No jacket No sleeves Flammables In welding area 8/28/15 Engineering Innova.on Center 41 Plasma CuDer Safety •
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Safety glasses must be worn Welding hood, leather welding gloves, leather welding coat or heavy duty denim shirt, denim jeans, and leather boots are required APPROVAL FROM FABRICATION SHOP MANAGER IS REQUIRED TO PERFORM ARC WELDING OPERATIONS Before welding or cumng, warn those in close proximity who are not protected to wear proper clothing or goggles by saying “Arcing!” in a loud voice. Ensure other people are protected from flashes by closing curtain to welding bay or erec.ng screens. 8/28/15 Engineering Innova.on Center 42 Plasma CuDer Safety •
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Ensure material to be cut poses no hazard. Where possible consult the manufacturers' Material Safety Data Sheets (MSDS) for specific technical data and precau.onary measures concerning any materials or coa.ngs on materials cut with this equipment. Do not weld or cut containers that have held combus.ble liquids or gases. Ensure no slip/trip hazards are present in workspaces and walkways. Ensure the work area is clean and clear of grease, oil, and any flammable materials. Keep the equipment, work area and gloves dry to avoid electric shocks. Ensure the gloves, handpiece and work leads are in good condi.on. 8/28/15 Engineering Innova.on Center 43 Plasma CuDer Safety •
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Ensure machine is used in a well-­‐ven.lated area, use fan to circulate air if needed. Ensure the work leads and hoses do not create a tripping hazard. Faulty equipment must not be used. Immediately report suspect equipment 8/28/15 Engineering Innova.on Center 44 Plasma CuDer Safety •
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OPERATIONAL SAFETY CHECKS Ensure machine is correctly set up for current and airflow. Ensure work return cables make firm contact to provide a good electrical connec.on. Metals coated with or containing materials that emit toxic fumes should not be heated or cut unless coa.ng is removed from the work surface. Do not leave the plasma cuDer running unaDended. HOUSEKEEPING Switch off the machine and fume extrac.on (where used). Turn of air supply and hang up handpiece, hose and welding cables. Leave the work area in a safe, clean and .dy state. 8/28/15 Engineering Innova.on Center 45 Grinder/Belt Sander Safety •
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Safety glasses must be worn and safety shield Never wear long sleeves, gloves or any jewelry and always ,e your hair back Do not grind aluminum, brass, wood or plas.c on the pedestal grinder. Grind only steel or iron on the pedestal grinder Aluminum, brass, wood, plas.c, and steel may be sanded on the belt sander. Do not use gloves or rags to hold parts while grinding or sanding. Quench parts that may become hot in water The tool rest on the pedestal grinder should never be more then 1/8” away from the wheel. Inspect grinding wheel before using for debris, chips, or cracks. Report any defects to the Fabrica.on Shop Manager 8/28/15 Engineering Innova.on Center Yes No 46 Hand Tool Safety •
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Safety glasses must be worn Wear the right safety equipment for the job Use tools that are the right size and type for the job Do not work with oily or greasy hands. Shop towels are located in the fabrica.on shop. Handle sharp edged and pointed tools with care Always carry pointed tools by your side and with the points and heavy ends down Never carry tools in your pocket Never use tools which have loose or cracked handles Keep punches and chisels in good condi.on. Mushroomed heads can chip and cause injuries 8/28/15 Engineering Innova.on Center 47 Hand Tool Safety •
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Do not use a file without a handle Do not pry or hammer with a file as it may shaDer Do not use screwdrivers as chisels or pry bars Do not try to increase your leverage with a cheater bar AYer using a tool, clean and return it to its proper storage loca.on If anything breaks or malfunc.ons, report it to the Fabrica.on Shop Manager and mark it as broken. Use the right tool for the right job Cut away from yourself when you chisels and other sharp tools Always pull a wrench; you have more control over the tool and there is less chance of injury 8/28/15 Engineering Innova.on Center 48 Hand Tool Safety -­‐ Wrong Use the right tool for the job 8/28/15 Engineering Innova.on Center 49 Hand Tool Safety -­‐ Correct Use the right tool for the job 8/28/15 Engineering Innova.on Center 50 Circular Saw Safety •
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Safety glasses must be worn Never wear long sleeves, gloves or any jewelry and always ,e your hair back Never wedge, wire, or otherwise jam the guard to prevent it from working. Whenever possible, objects being cut should be laid flat and stabilized by clamps. Never aWempt to hold a piece of wood in the air while cu_ng with the other hand. Adjust the depth of the cut 1/8” greater than material thickness. Ensure correct blade is being used (based on material being cut) and the blade .ghtness has been checked. 8/28/15 Engineering Innova.on Center 51 Circular Saw Safety •  Always begin opera.ng blade before making contact with material to be cut. •  Inspect for and remove all nails from lumber before cu_ng. •  Never cut with a dull blade •  Hold the saw with two hands while cumng •  Unplug the saw when semng depth of cut and changing the blade 8/28/15 Engineering Innova.on Center 52 Portable Drill Safety •
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Safety glasses must be worn Never wear long sleeves, gloves or any jewelry and always ,e your hair back Drilling boards with nails, paint, gravel, staples, or other foreign materials can dull the drill bit. Do not drill into unfixed work pieces Hold the portable electric drill firmly with both hands at all .mes when drilling. Make sure the chuck key has been removed before turning the power on. Use the proper speed for the material you are drilling. Feed the drill into the material at a constant rate. 8/28/15 Engineering Innova.on Center 53 Portable Drill Safety •
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Never make adjustments or aDempt to change bits while the drill is plugged in or running. Keep others away from the machine and out of the safety zone. Wearing gloves while using the drill is unsafe. Drilling into a container that may have once contained or does contain flammable materials could cause a fire or explosion. Use a "V" block to hold round or cylindrical stock. A cordless drill should be in the off posi.on (between forward and reverse) or have the baDery removed when changing bits or when it is not in use. 8/28/15 Engineering Innova.on Center 54 Conclusion Unsafe prac.ce or obvious abuse of equipment cons.tutes a danger to people and damages equipment. Therefore the Fabrica.on Shop Manager or any person observing an unsafe act should stop unsafe prac.ces in the Fabrica.on Shop. Students viola.ng any of these rules will have their Fabrica.on Shop privileges revoked for a period of at least two weeks. Longer periods may be assessed, depending upon the judgment of the Fabrica.on Shop Manager and the Engineering Innova.on Center Facility Manager. 8/28/15 Engineering Innova.on Center 55