Safety Certification By: John Mosunic

Course Description Machine shops are inherently dangerous environments. What you do not know can seriously injure you. The purpose of this lesson is to provide specific safety rules but also to develop an attitude of safety awareness. This awareness should lead to wariness; which is your best defense against injury. Nurture this wariness. Develop a habit of always working in a thoughtful, methodical and deliberate way. Read this word for word

Safety in General Safety is defined as freedom from danger or hazards. Safety is a personal responsibility. Most accidents are caused by one person and happen to one person. Poor safety attitudes are the biggest hazards in most cases. 1st and 2nd points are important

Accidents are Preventable Accidents are a result of attitudes and of actions which you can eliminate. Safety is a state of mind. People could prevent over 90% of all accidents if they wanted to because over 90% of all accidents are caused by people--not mechanical failures or freaks of nature. Be your own safety expert by knowing how to prevent accidents. Come to work relaxed and well-rested, good health is a factor in accidents. Fatigue is a frequent factor in accidents. Know and follow the safety rules of your job--be familiar with the operation of all machines and equipment that you use. First two points are important

Accidents are Preventable Know yourself--your abilities, skills, and limitations. Watch out for the practical joke with tools; “clowning” is a major cause of accidents. Know what to do in an emergency; know first aid and emergency procedures. Know whether your area responds to the 911 telephone call number for emergencies. Know what information you should give. First two points. Talk about always having a phone near by in case of an emergency

Personal Conduct & Shop Etiquette It is important to follow strict of rules of personal conduct and etiquette in the shop. This will keep you and your peers safe and promote a professional and hospitable environment: Know where your hands are at all times. Pockets are a great place for idle hands. Move deliberately and always look where your hands are going. Always be aware of what could happen if your hand slips. For example, when tightening a bolt, think: “What would happen if the wrench slipped? Would my hand or arm contact a tool or pile of sharp chips?” Always be aware of what could happen if you slipped and lost your footing and fell. Would your momentum or center of gravity cause you to fall into a sharp tool or other hazard? No horseplay or practical jokes are allowed in the shop. None. Ever. Talk about keeping a hand inventory; knowing where the blade, metal, waste, and your hands will be before and after the cut.

Personal Conduct & Shop Etiquette Do not interrupt others working at the machine. This could cause them to make a mistake. Never borrow tools from a private tool box without first asking the owner. If they refuse, accept it graciously. Respect professional Machinists. There is much you can learn from them. Do not make unreasonable demands (“I need it yesterday” etc.). Clean up after yourself. Leave the machine and surrounding area at least as clean as you found it. Always put tools and equipment where you found them. Never talk to someone operating a machine. Never walk out of arms reach of a machine. Be considerate. Do not engage in loud or unnecessarily talk. Talk mostly about putting drill bits and tools back where you found them.

Shop Clothing Follow these rules of personal dress for the shop: Wear ANSI approved safety glasses or ANSI safety approved glasses with side shields. You must wear safety glasses at all times in the shop, not just when at the machine. If machining operations are loud, use hearing protection. Do not wear flip flops or sandals. Leather shoes are best. Steel toe shoes are not necessary unless handling heavy objects that would crush regular shoes. Do not wear long sleeve shirts because these could get caught in equipment. Wear short sleeves or T-shirts. Remove all jewelry before using a machine. Long hair should be tied back or under a hat to prevent it being caught in the machine spindle. Never wear gloves as they can be caught in the machine. Latex gloves are acceptable. Avoid loose clothing, necklaces, gloves, or jewelry that could become caught in moving parts. Use a face or dust mask if cutting operation is dusty. When using a metal grinder you will generate sparks. Always use a full face shield and goggles for these operations. Glasses, close toed shoes, hair up, hoodie strings tucked in, no jewelry, long sleeves pulled up.

Talk about what he is wearing and what he is not

General Safety Never use any equipment which you have not been trained to operate by a qualified person. Never tamper with a machine safety guard or switch. Get into the habit of constantly tidying the workspace. A clean workplace is safer. Random metal can not only scratch and ruin finished parts, they can cause severe cuts. Use caution when handling cutting tools. They are very sharp. Never handle a tool by its cutting flutes. Never start the machine until you have checked that the work area is clear. Never push the start button on the machine unless you are certain your setup is capable of safely holding the part against all cutting forces during machining. Never run a machine alone or without other people within hearing distance. Never have one person touching the control while the other is working in the cutting area. Use a paint brush to sweep away sharp chips. Never use your hands or a rag. Most of this is being aware of your surroundings, every point needs to be touched on

General Safety Never use an air hose to clear chips from a machine. Flying chips are dangerous to you and others. Liquids spills are slipping hazards. Clean spills immediately. Lift with your legs, not your back. Never lift anything more than you can comfortably handle. Get help handling heavy or bulky objects. Never leave a running machine untended. Avoid contact with coolant. Water-based coolant contains microbes that can cause infection. Immediately treat and cover even minor cuts. Report any injuries immediately. Tell them that they’re not body builders, and if they need help lifting something, they should ask.

General Safety Always tell someone that you are working in the shop, you are making sure that nobody disturbs you at a critical moment, startling you from behind. Have a working phone in reach. Don’t use a tool for a purpose it was not designed for.  Don’t modify a tool yourself. Don’t push a tool beyond the limits it was designed for. Don’t modify the electrical connections of your tools. If a tool is equipped a with three-prong plug, then it should be plugged into a three-hole receptacle. Make sure switch is "OFF" before plugging in a power cord. Double check. Don’t work when you are tired. Metal work requires your full attention, even if it is a hobby. Don’t mess with the tools’ insides

General Safety Make it a habit of checking to see that keys and adjusting wrenches are removed from the chuck before turning on any machine/lathe. Keep work area well illuminated. All visitors should be kept at a safe distance from the work area. Do not force tools or attachments to do a job for which they were not designed. Use the proper tool for the job. Use clamps or a vise to hold work. It is much safer than using your hand and frees both hands to operate the tool. Keep your proper footing and balance at all times. Keep tools clean. Unplug tool before servicing and when changing accessories such as blades, bits or cutters. Everything on the slide

Portable Power Tools in the Pit Hand-held portable tools have specific functions. Check to be sure you have the correct tool for the job. Treat all portable tools with the same respect as any power tool. Eye protection is required at all times. Do not talk with observers while operating machines. Keep work area near hand tools clean and junk free. Use the right tool for the job. Do not abuse electric cords. Talk about the Dremel here.

Portable Power Tools in the Pit Keep hands clear of machine path. Secure work to bench when using electric hand tools. Do not over reach with electric hand tools. Make all adjustments on the tool with the power cord unplugged. Remove wrenches and check keys after adjusting. Do not carry plugged in tools with finger on power switch. Touch on hand inventory again

Portable Power Tools in the Pit Use only grounded extension cords. Keep guards in place and working properly. Keep hands away from cutting portions of tools. Seek help if you are unsure of tool operating procedures. Unplug, clean and put away idle tools or when finished using tools.

Tools in the Shop

Drill Press Function Cutting holes in wood, metal or plastic (using the proper cutter). Drilling to depth or through stock

Drill Press Safety Eye protection is required at all times. Do not talk with observers while operating machines. General Rule: The larger the bit, the slower the speed. Fast speed is for wood; slow speed for metal Always remove chuck key before starting the drill. Make all other adjustments with power off. Securely lock all bits into the chuck. Have wood plate on metal table top. Adjust table or depth stop to avoid drilling into table. Hold material to be drilled securely. Plastic and metal must be clamped. When making deep cuts, pull bit back to clean out hole, peck drill. Shut off power; remove bit, and clean machine when done.

Vertical Band Saw Function For cutting solid or hollow non-ferris metals For straight cuts Used in the upright position.

Vertical Band Saw Safety Eye protection is required at all times. Do not talk with observers while operating machines. Make all saw adjustments with power off. Adjust blade guides prior to use. Stop saw before putting in or removing stock from vise. Always have stock firmly clamped. Make sure blade is not touching stock when turning power on. Keep hands and fingers away from blade when saw is running. Never let saw blade drop on the work piece. Stop machine before removing waste. Make sure you tell them that it is for small cuts

Bench Grinder / Grindstone Function Grind ferrous metals (mild steel and hard steel).

Bench Grinder / Grindstone Safety Safety glasses and full-face shield are required at all times. Do not talk with observers while operating machines. Wear gloves, the metal is sharp and can get hot. Do not grind non-ferrous metals (copper, aluminum, brass, etc.). Clean area when finished.

Belt Sander Function Smoothing out softer metals and wood.

Belt Sander Safety Eye protection is required at all times. Do not talk with observers while operating machines. Wear gloves, the metal is sharp and can get hot. Do not grind ferrous metals Clean area when finished.

Horizontal Bandsaw Function For cutting solid or hollow metals (brass, aluminum, copper, etc.). For straight cuts. Used in the horizontal position.

Horizontal Bandsaw Safety Eye protection is required at all times. Do not talk with observers while operating machines. Make all saw adjustments with power off. Adjust blade guides prior to use. Stop saw before putting in or removing stock from vise. Always have stock firmly clamped. Make sure blade is not touching stock when turning power on. Keep hands and fingers away from blade when saw is running. Never let saw blade drop on the work piece at full speed. Stop machine before removing waste. Tell them that it is for large cuts

HYDRAULIC PRESS Function Flattens, bends, and punctures hefty materials. Broaching methods are used mostly to create different holes in different materials precisely.

Hydraulic Press Safety Eye protection is required at all times. Do not talk with observers while operating machines. Make sure piece is secure in a vice. When using a broch make sure you oil it. Keep hands and fingers away from lowering piston. Raise piston before removing parts.

Manual Mill Function For finishing solid or hollow metals and wood. For complicated and precise cuts. Used with hand wheels to move the metal.

Manual Mill Safety Eye protection is required at all times. Do not talk with observers while operating machines. Make all adjustments with power off. Adjust vice prior to use. Stop machine before putting in or removing stock from vise. Always have stock firmly clamped. Make sure cutter is not touching stock when turning power on. Keep hands and fingers away from bit when the mill is running. Stop machine before removing waste. Clean the bit after each use with the metal hook.

How to Unplug a Power Cord Make use they know how to unplug a power cord.

How not to Unplug a Power Cord