SOP: Table Saw - UNC Asheville

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NC State
Engineering
Programs
at UNC
Asheville
This manual was developed by the Engineering
Programs to ensure safe operation for users of
their Design Studio.
March 24
2015
Design Studio Safety Manual
Contents
Designated Design Studio Supervisor(s): ...................................................................................................... 2
Controlled Access To Design Studio:............................................................................................................. 2
Safe Work Practices: ..................................................................................................................................... 2
Training ......................................................................................................................................................... 3
Training Outline: ....................................................................................................................................... 4
Engineering Design Studio Standard Operating Procedures (SOPs) ............................................................. 4
Welding ......................................................................................................................................................... 5
Auditing and Inspections .............................................................................................................................. 7
Training Certificates .................................................................................................................................. 7
Machine/Equipment ................................................................................................................................. 7
Eyewash .................................................................................................................................................... 7
Fire Extinguishers ...................................................................................................................................... 7
Mechatronics Design Studio Safety Manual ............................................................................................. 7
Appendix A: NCSU/UNCA Design Studio Safety Orientation Training Certificate ....................................... 8
Appendix B: Standard Operation Procedures (SOPs) for machinery ........................................................... 1
SOP: Band Saw ......................................................................................................................................... 2
SOP: Bench Grinder .................................................................................................................................. 4
SOP: Belt/Disk Sander .............................................................................................................................. 2
SOP: Chop Saw ......................................................................................................................................... 4
SOP: Drill Press ......................................................................................................................................... 6
SOP: Jig Saw ............................................................................................................................................. 8
SOP: Metal Lathe.................................................................................................................................... 10
SOP: Milling Machine ............................................................................................................................. 12
SOP: Miter Saw....................................................................................................................................... 14
SOP: Sand Blaster ................................................................................................................................... 16
SOP: Table Saw ....................................................................................................................................... 18
1
Designated Design Studio Supervisor(s):
Design Studio Supervisors are responsible for the safe operations of the Engineering Program’s Design
Studio. They have the authority to grant or deny access to the Design Studio over all Faculty, Staff and
students. Design Studio Supervisors are responsible for user training and supervision.
Controlled Access To Engineering Design Studio:
Use of machines in the Engineering Program’s Design Studio is restricted to the Design Studio’s hours of
operation when Design Studio Supervisors are present.
Design Studio hours of operation for Spring Semester 2015:
Monday
1:00 - 5:00
Tuesday
1:00 - 5:00
Wednesday
1:00 - 5:00
Thursday
1:00 - 5:00
Friday
10:00-12:00
For access outside of open hours, contact Design Studio Manager
sjsander@unca.edu or 828 250 3836.
Safe Work Practices/ Studio Orientation:
The Engineering Design Studio in Rhoades Hall is available to support the research of faculty, staff, and
students. Access to the Design Studio, tools and equipment will be granted on an individual basis, upon
completion of the safety orientation by a Design Studio Supervisor. The privilege of access and use of
the facilities requires that every user adheres to the safety regulations outlined in this document. Any
2
violation of Design Studio rules may revoke that person’s access to the Design Studio until further
notice. These guidelines ensure safe working conditions for you and those around you.
1. The shop may only be used by those who have completed the shop safety orientation
2. No one is to work in the shop alone.
3. Always ask for assistance if you are unsure about a setup or operation.
4. Only use equipment on which you have been trained, and only for its intended use.
5. Safety glasses are provided and must be worn at all times.
6. Closed-heel, closed-toe shoes must be worn at all times. Leather Shoes or shoe covers must be worn
in welding areas.
7. Long hair must be tied back, secured at all times.
8. No loose clothing, jewelry, or headphones allowed while using tools.
9. Hearing protection is provided and should be used at your discretion.
10. Always report accidents, broken equipment, unsafe conditions to the supervisor.
11. Never leave a running machine unattended.
12. Always disconnect power when changing bits, blades, etc.
13. Always remove wrenches, chuck keys, etc. before turning on a machine.
14. No food or drink allowed in shop.
15. Keep a clean work area, free of clutter and debris. Keep pathways clear.
16. Gloves are available for moving material and hot work only. Do not use gloves when operating
motorized equipment.
17. The shop is to be used for university-related projects.
18. Do not enter the shop under the influence of drugs or alcohol.
19. Before leaving the shop, clean up your work area and replace all tools.
Training
Design Studio training will be conducted on an individual basis by a Design Studio supervisor. No one
will be allowed to use any of the machines in the Design Studio without being trained on the equipment
first. Training records will be specific as to what machines the individual has been trained on. Training
records will be kept on file in the Engineering Program’s Design Studio.
Appendix A
NCSU/UNCA Engineering Design Studio Training Certificate
3
Training Outline:
Safety Manual: Location and contents of the safety manual will be discussed.
Safe Work Practices: Safe work practices of the Design Studio will be reviewed.
Machinery: Demonstrations for each piece of machinery will be conducted with emphasis on the
machine’s function, safety mechanisms, PPE requirements and safe operating procedures. Training is
based off of the Standard Operating Procedure for that piece of equipment.
Welding: Demonstrations for welding will be conducted with emphasis on different welding techniques,
safety mechanisms, PPE requirements and safe operating procedures. Welding will only be performed
under strict Design Studio supervision by competent individuals. Otherwise welding will be done by a
designated Design Studio Supervisor.
Engineering Design Studio Standard Operating Procedures (SOPs)
Every piece of equipment in the Engineering Program’s Design Studio has a written Standard Operating
Procedure (SOP). SOPs should be referenced before each use of the machinery.
4
Appendix B
(SOPs) for Machinery
Welding
Welding, soldering, and brazing are commonly known as “hot work”. Hot work presents increased
potential for fire and explosion hazards, especially when performed in confined and enclosed spaces.
You must be aware of these hazards to work safely and avoid accidents and injuries.
All welding, brazing, and soldering operators must be trained on each piece of equipment they use. You
must be trained by your supervisor or another qualified person before conducting any type of hot work.
All training must be documented and kept on file.
COMMON HAZARDS
Air Contaminants
Hot work produces air contaminants. The most common contaminants include metal fumes and gases.
Hazardous fumes may be produced from heating toxic metals found in common alloys. Some examples
are beryllium, cadmium and nickel. The fume particles created are small and can deposit deep in the
lungs.
The adverse health effects of overexposure to welding fumes and gases can range from systemic
poisoning to respiratory tract irritations. These effects can be short or long term, depending on the level
of exposure. Setting up an appropriate work environment and using the appropriate goggles, face
shields, and/or respirators will protect you from contaminants.
Radiation
Both visible ultraviolet (UV) and infrared (IR) radiation are produced when welding and cutting. These
types of radiation can cause skin damage (sunburn and cancer) and eye damage (welder’s flash,
cataracts, and burns). You may not be aware of these injuries until after they occur since UV and IR
radiation is not detectable by the senses. Appropriate clothing and filter lenses will protect you from
radiation damage.
Burns and Fires
Hot work can be a fire hazard. Burns, fires, or explosions can result from flames, arcs, molten metals,
heated surfaces, or metal splatters. Sparks from welding operations have been known to travel as far as
35 feet horizontally from the welding sight. Be aware of fire hazards when welding and remember that
you can cause fires or be burned when working. Unplug and place soldering irons or guns in holders or
stands when not in use. Always assume that a soldering iron or gun is hot. Give equipment time to cool
down before touching tongs and tips. A fire watch should be posted for at least 30 minutes after
the welding operations have ceased to ensure that no fires will be started.
5
Electrical Shocks
Every year welders die from electric shock. Electric shocks can occur when proper precautions are not
taken. Equipment must meet Underwriters Laboratories (UL) code and be checked and serviced
regularly. Servicing and installation must only be undertaken by a qualified licensed electrician.
Never tamper with electrical supply circuits or systems. Welders are only responsible for making
connections in the welding circuit and for setting external welding machine controls.
Be aware of your work environment. Do not work in wet conditions or on noninsulated surfaces. Use
wooden platforms and rubber mats for protection, especially in confined spaces.
Always use fully insulated electrode holders and never touch an energized electrode when in contact
with the work circuit. Remember, hot work increases the risk of electrocution due to the reduced skin
resistance when sweating occurs. If you sweat profusely, stop working. Don’t touch electrodes or
welding wire with your bare hands. And never place holders or welding guns under your armpits.
For your protection, make sure all work areas are well ventilated. Use hoods or local exhaust
ventilation (LEV) to minimize exposure to hazardous fumes, gases, and heat.
Consider the safety of other workers around you. Use light filters and welding screens. And always have
fire extinguishers readily available.
Do not work around sources of ignition. Keep flammable chemicals in approved storage cabinets. Keep
combustible material at least 35 feet (11 meters) away from hot work operations. If this is not possible,
then make sure these items are properly shielded. Remember that walls, ceilings, and floors are also
combustible. Shield these areas as necessary. Seal or guard any cracks and holes where hot sparks might
fall.
Always use appropriate guards when welding. Do not put fingers between tongs or linkages when spot
welding. Make sure that guards are always in place, and follow Lock out/Tag out procedures when
welding energized or powered equipment.
Gas welding and cutting tasks pose a high level of fire and explosion hazards due to the flammability
of the gas cylinders. Always use appropriate pressure and backflow prevention devices when using gas
systems. Ignite torches with approved friction devices. Remember to close gas valves before removing
regulators.
Protect cylinders from hot metal and sparks by positioning them away from your point of operation.
Always secure cylinders from falling over using cylinder racks or other means to secure the cylinder such
as having the cylinders chained to the wall.
Personal Protective Equipment (PPE) Requirements:
Welding, soldering, or brazing without the proper personal protective (PPE) equipment is dangerous and
unhealthy. Because hot work involves an open electric arc or flame, the risk of burns is significant. To
prevent burns, you must wear the proper PPE, such as heavy leather gloves and protective long sleeve
jackets. Additionally, the brightness of the weld area can lead to a condition called arc eye, in which
ultraviolet light causes inflammation of the cornea and can burn the retinas of the eyes. Goggles and
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welding helmets with dark face plates prevent this exposure. To protect bystanders, translucent
welding screens can be placed around the welding area. These curtains, made of a polyvinyl chloride
plastic film, shield nearby workers from exposure to the UV light from the electric arc, but should not be
used to replace the filter glass used in helmets.
Auditing and Inspections
Training Certificates
Training certificates will be kept on file in the Engineering Program’s Design Studio. Design Studio
Supervisors will review safe work practices for the Design Studio to Design Studio users at the beginning
of each semester.
Machine/Equipment
Machines will be visually inspected at the start of each day by Design Studio Supervisors and prior to use
by the machine operator. A documented equipment maintenance/inspection log will be maintained for
each machine.
Eyewash
Eyewash stations will be activated on a weekly basis by Design Studio Supervisors to ensure operation
and to flush the plumbing lines. Eyewashes will be kept clear from debris and have a sign posted
identifying their location.
Fire Extinguishers
Fire Extinguishers will be visually inspected on an annual basis to ensure that servicing has been
completed and that they are securely mounted to the wall. Fire extinguishers should be kept clear from
debris.
Engineering Program Design Studio Safety Manual
The Engineering Program’s Safety Program and Manual will be evaluated on an annual basis by Design
Studio supervisors to ensure that all hazards are accounted for and that the manual has been updated
with new hazards that have been introduced into the Design Studio.
7
Appendix A: NCSU/UNCA Engineering Design Studio Training Certificate
I have completed the Engineering Design Studio’s Safety Orientation and agree to do my best to ensure
safe working conditions for myself and others in the Design Studio. I understand that failure to do so
may result in loss of access to the Design Studio and equipment. The Safety Orientation includes the
following:
Location of Safety Manual
Location of Safety Equipment
Safe Work Practices/Orientation
Signature
Date
Design Studio Supervisor
Date
Approved:
I
, have been trained on and understand the following
safety practices and procedures implemented for working in the Design Studio and I have been
trained on the following machine Standard Operating Procedures (SOPs).
Date Certified
Design Studio Supervisor
Band Saw
_____________________
________________________
Bench Grinder
_____________________
________________________
Belt/Disk Sander
_____________________
________________________
Chop Saw
_____________________
________________________
Drill Press
_____________________
________________________
Jig Saw
_____________________
________________________
Metal Lathe
_____________________
________________________
Milling Machine
_____________________
________________________
Miter Saw
_____________________
________________________
Sand Blaster
_____________________
________________________
Table Saw
_____________________
________________________
Signature
I have been trained to safely use the welding equipment and am considered by the Design
Studio supervisor as a competent welder.
Design Studio Supervisor Signature and Date:
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Appendix B: Standard Operation Procedures (SOPs) for machinery
Never Leave a Running Machine Unattended
Appendix B includes Standard Operating Procedures (SOPs) for the following machines:
Band Saw
Bench Grinder
Belt/Disk Sander
Chop Saw
Drill Press
Jig Saw
Metal Lathe
Milling Machine
Miter Saw
Sand Blaster
Table Saw
SOP: Band Saw
Never Leave a Running Machine Unattended
PPE Requirements:
Safety glasses
Pre-Inspection:
Ensure that the machine has been unplugged before making any adjustments.
Check the blade tension and tracking before starting.
The teeth of the band saw blade should point down toward the table.
The blade should be 1/32” from the rear roller bearing.
The blade alignment tracking should be at the center of the wheel.
Use of Band Saw:
Keep your hands away from the path of the blade.
Make sure that the upper and lower wheel guard doors are closed when running the machine.
Keep the blade guard and guide only 1/4” above your stock.
To control the stock, use push sticks, or other safety device when cutting short stock.
Use a “V” block when cutting cylindrical stock.
Cut at a moderate feed rate into the blade. Do not force a cut. Forcing a cut can result in kickback.
Cut relief cuts prior to cutting long or tight curves. The relief cuts will free the blade of the tension.
If you need to back out of a cut, cut the machine off first, wait for the blade to stop and then back out.
If a blade breaks, shut the machine off and stand clear until everything stops.
When shutting the band saw off, wait until the blade comes to a complete stop by itself.
Maintenance/Inspection Log
Band Saw
DATE
ACTION ITEM
SIGNATURE/INITIALS
SOP: Bench Grinder
Never Leave a Running Machine Unattended
PPE Requirements:
Safety Glasses
Leather gloves for handling hot metals
Face Shield
Long sleeve shirt
Pre-Inspection:
Ensure that the machine has been unplugged before making any adjustments.
Adjust wheel guards to be close to the grinding disc.
Do not fit a grinding disc that has been damaged or is wet.
Be sure blotters and wheel flanges are used to mount the grinding wheels onto the shaft of the grinder.
Tool rests should be adjusted close to the wheels and thoroughly tightened in place so they cannot shift
position while in use.
Use of Bench Grinder:
Stand to one side of the wheel when turning on power.
Ensure your work piece is firmly secured and supported.
Keep fingers, hands and power cord clear of the disk.
Allow the grinder to reach operating speed, then apply load gradually.
When grinding, use the face of the wheel only.
Maintain a constant pace to avoid uneven surfaces.
Maintain complete control. Always operate with both hands and maintain proper and steady footing.
Do not apply excessive force.
Be aware of flying hot sparks.
Shut off power when finished and remove guards.
Maintenance/Inspection Log
Bench Grinder
DATE
ACTION ITEM
SIGNATURE/INITIALS
SOP: Belt/Disk Sander
Never Leave a Running Machine Unattended
PPE Requirements:
Safety Glasses/goggles
Pre-Inspection:
Ensure that the machine has been unplugged before making any adjustments.
Inspect the sandpaper disk to ensure that it is not dull or loose. Notify the instructor if it is.
The rest should be adjusted so that it is no more than 1/8” from the disk/belt.
Use of Belt/Disk Sander:
Always sand on the downward motion side of the disc/belt.
Attempt to place your work against the rest on the disc and belt sanders and hold the work securely.
Keep fingers away from the abrasive surface on the sander.
Avoid pressure against the disc.
Stock that is 1” or smaller in length should not be sanded using this machine.
Maintenance/Inspection Log
Belt/Disk Sander
DATE
ACTION ITEM
SIGNATURE/INITIALS
SOP: Chop Saw
Never Leave a Running Machine Unattended
PPE Requirements:
Safety glasses
Face shield
Pre-Inspection:
Ensure that the machine has been unplugged before making any adjustments.
Check and tighten the blade and the blade-attachment mechanism.
Ensure that the blade and its related washers and fasteners are correctly positioned and secured on the
saw's arbor.
All guards must be in place and operating. If a guard seems slow to return to its normal position or
hangs up, adjust it or repair it immediately.
Use only the recommended RPM and sizes of blades.
Use of Chop Saw:
To avoid losing control or placing hands in the blade path, hold or clamp all material securely against the
fence when cutting. Do not perform operations freehand.
Hands and fingers must be kept clear of the path in which the blade travels.
Clean the lower guard frequently to help visibility and movement.
Do not re-cut small pieces of material. Long material should be supported at the same height as the saw
table.
After completing a cut, release the trigger switch and allow the blade to come to a complete stop, and
then raise the blade from the work piece.
Maintenance/Inspection Log
Chop Saw
DATE
ACTION ITEM
SIGNATURE/INITIALS
SOP: Drill Press
Never Leave a Running Machine Unattended
PPE Requirements:
Safety glasses
Pre-Inspection:
Ensure that the machine has been unplugged before making any adjustments.
Use only properly sharpened drill bits, sockets and chucks that are in good condition.
All belts and pulleys must be guarded. If frayed belts or pulleys are observed, inform the Design Studio
Supervisor so that the machine can be taken out of service.
The drill bit should be mounted the full depth and in the center of the chuck.
Position the table and adjust the feed stroke eliminating the possibility of the bit striking the table.
Use of Drill Press:
All stock must be properly secured with a vise or clamps. If the stock material slips in the vise or clamp,
the machine must be shut down. Do not attempt to hold the work to make necessary adjustments
while the machine is running.
Use the appropriate bit for the stock being machined. Bits with feed screw or extremely long bits should
not be used.
Use the correct speed and drill for the type of stock being machined.
Feed the bit smoothly into the work. If the hole being drilled is deep, withdraw the bit frequently to
remove shavings on the bit.
Never attempt to remove a broken bit with a center punch or hammer.
When an operator has finished working on the drill press, turn the power off and wait for the machine
to come to a complete stop.
Clean metal shavings from the machine using a brush, not your hands.
Maintenance/Inspection Log
Drill Press
DATE
ACTION ITEM
SIGNATURE/INITIALS
SOP: Jig Saw
Never Leave a Running Machine Unattended
PPE Requirements:
Safety glasses
Pre-Inspection:
Ensure that the machine has been unplugged before making any adjustments.
Make sure the blade is intact and suits the material to be cut.
Plan a sawing strategy to minimize backing the blade out.
Use of Jig Saw:
Ensure the material is secure and well supported.
Allow the machine to reach full speed before starting a cut. Always saw at a moderate rate.
Keep hands away from the blade.
Take care when cutting curves to ensure that the blade does not twist or bind. Drill small holes if
necessary to aid blade movement.
If the blade binds, turn off the machine immediately. Free the blade and inspect if for damage.
Keep the machine free from accumulating saw dust.
Maintenance/Inspection Log
Jig Saw
DATE
ACTION ITEM
SIGNATURE/INITIALS
SOP: Metal Lathe
Never Leave a Running Machine Unattended
Supervision Required
PPE Requirements:
Safety glasses
Pre-Inspection:
Ensure that the machine has been unplugged before making any adjustments.
All belts and pulleys must be guarded. If frayed belts or pulleys are observed, the lathe must be taken
out of service and the belts or pulleys replaced.
All stock must be properly secured in the lathe chuck or mounted prior to the machining process taking
place. Use the correct sized clamp or vise for the stock being machined.
Turn the chuck or faceplate by hand to ensure there is no binding or danger of the work striking any part
of the lathe.
Only properly sharpened drill bits and cutting tools in good condition should be used. Dull drill bits and
chipped or broken cutting tools must be removed from service.
Use of Metal Lathe:
Select turning speed carefully. Large diameter stock must be turned at a very low speed. Always use the
lowest speed to rough out the stock prior to final machining.
The correct speed and feed for the specific material and cutting tool must be used. Stop the machine
before making adjustments or measurements.
Do not remove chips from the table or stock by hand. Use a brush or other tool to properly remove
chips or shavings from the table or stock.
When an operator has finished working on the lathe, and before leaving the lathe for any reason, the
power must be shut off and the machine must come to a complete stop.
Maintenance/Inspection Log
Metal Lathe
DATE
ACTION ITEM
SIGNATURE/INITIALS
SOP: Milling Machine
Never Leave a Running Machine Unattended
Supervision Required
PPE Requirements:
Safety glasses
Pre-Inspection:
Ensure that the machine has been unplugged before making any adjustments.
Ensure all guards are in place.
Securely fasten all cutting tools in the machine spindle with the appropriate accessory.
Use of Milling Machine:
Work pieces and stock must be rigidly fastened to the mill bed with clamps, a vise, or special fixtures.
Make sure the cutting tool is clear of the work piece before starting the machine.
Keep hands away from moving cutting tools.
Use appropriate speeds and feeds for the type and size of cutter being used and the material being
machined.
Do not make measurements of the stock while the milling machine is powered.
Do not allow large quantities of chips to accumulate around the work piece or machine table. After
stopping the machine, use a brush or rag to remove all excess chips from the mill bed and stock.
Maintenance/Inspection Log
Milling Machine
DATE
ACTION ITEM
SIGNATURE/INITIALS
SOP: Miter Saw
Never Leave a Running Machine Unattended
PPE Requirements:
Safety glasses
Pre-Inspection:
Ensure that the machine has been unplugged before making any adjustments.
Make sure all guards are in place and operating correctly.
Ensure the blade rotates in the correct direction and that the teeth at the bottom of the blade are
pointing to the rear of the miter saw.
Ensure the blade moves freely and the kerf plate is in good condition.
Use of Miter Saw:
All materials should be inspected for defects such as warps, knots and foreign objects.
Hold the stock firmly against the fence and the table keeping your fingers at least 150 mm (6”) away
from the blade.
Allow the blade to reach full operating speed before letting the blade enter into the stock.
Be aware that the saw moves up or down slightly upon start-up and stopping.
Return carriage (cutter head) to its full rear position after each cross-cut.
If the blade begins to bind while cutting stop immediately.
When finished, turn off the miter saw and wait for the blade to come to a complete stop before
retracting from the work piece.
Maintenance/Inspection Log
Miter Saw
DATE
ACTION ITEM
SIGNATURE/INITIALS
SOP: Sand Blaster
Never Leave a Running Machine Unattended
PPE Requirements:
Safety glasses
Pre-Inspection:
Ensure that the machine has been unplugged before making any adjustments.
Ensure gloves are in good condition.
Check and tighten sand hose clamps and check other fittings for leaks and wear.
Check for loose or worn hose and fittings.
Use of Sand Blaster:
Prior to adding abrasive, fully pressurize the unit to check all hose and pipe fittings for tightness.
Check for air leaks and tighten as necessary.
Turn the sandblaster on and off several times to become familiar with the operation.
Add abrasive and start to sandblast.
Maintenance/Inspection Log
Sand Blaster
DATE
ACTION ITEM
SIGNATURE/INITIALS
SOP: Table Saw
Never Leave a Running Machine Unattended
PPE Requirements:
Safety glasses
Pre-Inspection:
Ensure that the machine has been unplugged before making any adjustments.
Check the blade for chips or cracks and make sure it is the correct type of blade for the cut to be made.
Ensure the blade is adjusted to the appropriate height.
Ensure the saw teeth are sharp so they will cut. Dull teeth are more likely to cause a kickback.
Ensure all guards are in place and attached securely.
Use of Table Saw:
Keep hands away from the saw blade.
Use saw blade at high speed when entering or removing material from a cut.
Never force a piece of material through the saw, as a “kick-back” of the material could result.
Always be watchful for blade-pinching situations.
Always use splitter and anti-kickback fingers when ripping.
Always hold the work firmly against the miter gage or fence.
Always use a push stick for ripping narrow stock.
Move the rip fence out of the way when cross cutting.
Never run the stock between the fence and molding cutter head when cutting molding.
Shut off power and clean the saw before you leave it.
Maintenance/Inspection Log
Table Saw
DATE
ACTION ITEM
SIGNATURE/INITIALS
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