1. Robert R. Shaw Center for S.T.E.A.M Basic Safety Training 2015 Katy ISD, Katy, Texas

2. Basic Safety Training Outline  Introductions  Safety Moment – RSC Orientation – Exits, Safety Features  Expectations of Teams Using the RSC  Safety Rules for Everybody  Tools Provided in Each Team Bay  Tools Provided by Teams  Specific, Hands-on Training on Band Saw and Drill Press  Training Your Team Members  Q & A  Closing

3. Introductions  Steve Adams – RSC Cordinator  Phone: Cell: 832-216-2530; Office: 281-396-7670  Email: stephencadams@katyisd.org  Mariam Manual – RSC Educational Specialist  eMail: mariammanuel@katyisd.org  Steve Treese – Team 624 Safety Mentor  832-247-5200  streese256@aol.com

4. Safety Moment: RSC Orientation A = Emergency Exits B = Extinguishers C = Fire Alarm Pull D = AED E = Safety Shower/ Eyewash F = First Aid Kit G = Goggle Sanitizing A A AA B B B B B B B B B B B C C C C D E F F F F F F F F F G G G G G G G G

5. Expectations of Teams Using RSC  Agreement to abide by Operating Guidelines  Comply with the KISD RSC Site Safety Rules  Train team members and mentors in safe use of tools  Maintain verifiable record of training  Conduct annual refresher training for all persons  Prevent damage to facilities and equipment  Maintain safety and security of facility users  Do not use tools that generate cuttings or debris on the central carpeted field – move to the bays to work

6. Safety Rules for Everybody  Adult supervision  KISD employee must be present in building  Two mentors required on site, one may be the KISD employee  No one-on-one student/adult work  No unsupervised student work  Building secured by KISD employee after work session  Safety glasses  Required in work bays  Required within 5 feet of field when in use (basically the carpet area)  Must meet OSHA Z-87  Side shields required (or compliant wrap-around glasses or goggles)  Normal glasses with side shields do NOT satisfy this requirement

7. Safety Rules for Everybody (continued)  Shoe requirements  Substantial, closed-toed shoes required in work areas  Required within 5 feet of central, carpeted field when in use  Prohibited: flip-flops, sandals, flats, “Crocs”, others  Sole of shoe must resist puncture  Other personal protective equipment (PPE)  Specific PPE required in areas defined by KISD and building administration  Individual teams may require additional PPE in their bays  Consider gloves when handling sharp materials  Open flames  No open flames in the building

8. Safety Rules for Everybody (continued)  Loose clothing, jewelry, and hair  Shall be kept out of the way when working with power tools  Do not wear long-sleeves or gloves when working with potentially entangling tools (e.g. mill, lathe, and drill press)  Tie back long hair; remove jewelry; roll up long sleeves  Training requirements  Proper training in safe use required to operate a power tool or the plasma cutter  Includes everyone working at the RSC (mentors and students)  Each team is expected to have key representatives trained by KISD (“train the trainer”)  Trained representatives can train others on their teams  Maintain records to show this requirement has been met  Team safety programs  Within their own bay, a team may have more strict safety requirements  Team requirements must be at least as strict as these rules

9. Safety Rules for Everybody (continued)  Housekeeping requirements  Keep areas clean and uncluttered  Keep emergency exits clear  Keep carpeted area clear of debris and cuttings  Chemicals and paint usage  No use of volatile or vapor emitting chemicals in the building  No spray painting in the building – OK out back with adult supervision  Proper PPE required when handling chemicals  Materials must be used in accordance with the manufacturers instructions  Have MSDSs (or SDSs) available for any chemicals used in your area  In the event of a spill, notify KISD representative and mentor  Behavior  No horseplay or rowdy behavior on the premises

10. Safety Rules for Everybody (continued)  Incident reporting requirements  Report any incident resulting in injury, fire, or damage to people, building, or equipment immediately  KISD representative and mentor  Includes minor first aid, like a band aid  Food and drinks  No food or drinks (except water) in the bays  Food is allowed around the central bay (not on the carpet) and outside the building (patios)  Be courteous to other users of the building

11. Safety Rules for Everybody (continued)  Visitors allowed with clearance by KISD representative  Same PPE and shoe restrictions apply  Visitor stickers required – generated by Raptor system  Visitors may not operate equipment  Use proper tools, in good condition, for each job  Team training in safety rules  Teams are required to ensure all team members and mentors know and comply with the safety rules.  If a team member from one team visits another team’s bay, they are expected to comply with the safety rules of the team they are visiting.

12. Tools Provided in Each Team Bay  Drill press – Jet 15” Floor Mounted, Model JDP-15MF  Band Saw – Jet 14” Vertical, Model J-8201K  Miscellaneous Hand Tools  Basic training provided for key team representatives on drill press and band saw (this class)  Each team is expected to provide equivalent training in the safe use of the drill press and band saw provided by KISD to all members of the team who will work in the RSC  Maintain a record of this training for auditing

13. Tools Provided by Teams  Each team is expected to provide additional tools as necessary and within the limitations of the safety rules (e.g. mills, lathes, other band saws or drill presses, etc.)  Each team is expected to provide necessary training in the safe use of these tools and maintain records of that training for auditing

14. Hands-on Training – Jet Band Saw Description  Capacities  6 inches under guide  13.5 inches throat  Speeds, SFPM  Wood and Aluminum: 3300  Steels: 39, 57, 78, 107, 142, 196, 278 (pulley adj.)  Blade size: 3/8” x 0.025” x 93.5”  Weight: 171 lbs

15. Hands-on Training – Jet Band Saw Parts Identification Lower blade guide and support assembly Lower drive wheel

16. Hands-on Training – Jet Band Saw Key Guidelines  Use the Operating Instructions and Parts Manual available online  Wear proper PPE – especially eye protection  Keep loose clothing, jewelry, and long hair away from saw  Do not wear gloves while cutting, but use them when changing blades  Keep hands away from blade  Use the rip fence and miter gauge when possible  For small pieces, use a pusher stick or paddles  Keep all doors closed in operation

17. Hands-on Training – Jet Band Saw Key Guidelines (cont’d)  Do not start the saw with the blade in contact with work piece  Wait for saw to stop fully before removing cuttings  Disconnect saw from power before any maintenance  Lower saw blade guides to about ¼ - ½” above work piece  Set saw blade speed appropriately for material being cut:  Wood – 3000 FPM  Aluminum – 3000 FPM  Steel (low carbon) – 160-165 FPM (down to 70 FPM for harder steels) (Normally should not have to change speed)

18. Hands-on Training – Jet Band Saw Making a Cut 1. Mark work piece to be cut 2. Ensure you are wearing proper PPE, especially eye protection 3. Clean off saw table 4. Adjust height of blade guide 5. Install rip fence or miter guide if needed 6. Place work piece on table, not contacting blade 7. Start the saw 8. Push the work piece slowly through the saw along mark – use pushers if necessary – keep hands away from blade 9. When through with cut, stop the saw 10. Wait for it to come to a complete stop 11. Remove work piece and cuttings – they will be hot! Watch for sharp edges

19. Hands-on Training – Jet Band Saw Common Maintenance Activities and Adjustments  Adjusting blade tension and tracking  Adjusting table angle and leveling  Adjusting miter slot parallelism  Adjusting blade speed (use table in manual)  Changing saw blades (use gloves)  Adjusting blade guides

20. Hands-on Training – Jet Band Saw Troubleshooting Common Problems  Excessive blade breakage: Material loose, incorrect speed or feed rate, teeth too coarse for material, incorrect blade tension, starting saw in contact with work piece, blade rubbing wheel flange (tracking), misaligned blade guides, cracking of blade weld  Premature blade dulling: Blade teeth too coarse, blade speed too high, hard spots or scale on work piece, work-hardening of material (esp. stainless), insufficient blade tension, operating saw without pressure on work piece  Bad cuts (out of square): Feeding too fast, guides out of adjustment, inadequate blade tension, dull blade, incorrect blade speed, loose blade guide assembly, loose blade guide bearing assembly, blade too far from wheel flanges, worn guide bearing  Bad cuts (rough): Blade speed too high for feed rate, blade too coarse  Blade twisting: Feeding too fast, blade tension too high  Unusual blade wear on back or sides: Worn blade guides, blade guide bearings not adjusted, blade guide bracket loose  Teeth missing or ripped from blade: Blade tooth pitch too coarse for material, feeding too slow or too fast, work piece vibrating, gullets loaded with chips  Motor running too hot: Blade tension too high, drive belt tension too high, blade too coarse or too fine, speed reducer needs lubrication  Excessive speed reducer noise or vibration: V-belt too tight  Slamming or banging sound when cutting: Missing teeth, gullets loaded with chips

21. Hands-on Training – Jet Drill Press Description  Swing: 15 inches  Spindle travel: 3-1/8 inches  Maximum chuck capacity: 5/8 inch  Maximum spindle to table distance: 29 inches  Table size: 16.5 x 13 inches  Speed range: 200-3630 RPM  Weight: 161 lbs

22. Hands-on Training – Jet Drill Press Key Parts Identification Table height crank handle Chuck On/Off Switch Table lock Crank lock (on opposite side) Work table Motor Downfeed handle Base Column Pulley cover and pulleys Depth stop adjustment Work light switch Return spring Work light (under) Quill (chuck connects to quill)

23. Hands-on Training – Jet Drill Press Drilling a Hole 1. Mark work piece to be drilled 2. Use an auto-punch or transfer punch to mark the center of the hole 3. Ensure you are wearing proper PPE, especially eye protection 4. Locate the correct drill bit and tighten it in the chuck 5. Adjust height (and angle if necessary) of the drill press table 6. Tighten locks on table height and angle adjustments 7. Align work piece mark with drill bit, using a piece of wood or spacer below piece to avoid drilling into table 8. Secure work piece to the table (a machine vise is a good investment) 9. Turn on drill press 10. Drill hole to required depth, avoid drilling into the table or machine vise 11. Pull drill out and stop motor 12. Allow drill to stop completely before reaching for work piece – watch for sharp cuttings

24. Hands-on Training – Jet Drill Press Maintenance and Adjustments  Refer to the Operating Instructions and Parts Manual available online  Return spring adjustment  Adjusting the depth stop gauge  Changing spindle speeds (higher for wood, lower for metals)  Replacing work light (underside of head)  Lubrication – gear, rack, table height crank, spindle grooves, quill

25. Hands-on Training – Jet Drill Press Troubleshooting Common Problems  Will not start: Unplugged, fuse blown or breaker tripped, cord damaged, bad starting capacitor  Does not come up to speed: Extension cord too light or too long, low current  Vibrates excessively: Uneven surface for base, bad belt  Noisy operation: Incorrect belt tension, dry spindle, loose spindle pulley, loose motor pulley  Work piece burns: Incorrect speed, chips not clearing hole or bit, dull bit, feeding too slowly  Drill bit wanders: Dull bit, bent bit, bit or chuck not installed properly, work piece moving or vibrating, did not use auto-punch to mark hole location  Wood splinters on underside: No backing board used  Drill bit binds in work piece: Work piece pinching bit (moving), excessive feed rate, chuck jaws not tight, improper belt tension  Excessive drill bit runout or wobble: Bent drill bit, worn spindle bearings, bit or chuck not installed properly  Quill returns too slowly or too fast: Improper spring return tension  Chuck or arbor does not stay in place: Dirt, grease, etc. on arbor, chuck, or spindle

26. Hands-on Training – Demonstrations  Identify the main parts of the drill press and band saw  Demonstrate use  Each person use the drill press and band saw

27. Training Your Team Members  Plan training for your team, including annual refreshers  Train your team members  Be sure you keep a record of who is trained  Have the record available in your bay  Online files available which include:  Copy of these presentation materials (Powerpoint)  Copy of suggested written test  Some example safety program materials  Copies of Operating Instructions and Parts Manuals

28. Q&A and Closing Questions and Discussion?