MCE 514: Auto Workshop Practice

LECTURE 1
1.0 DEFINITIONS
Automotive Engineering
This is a part of Mechanical Engineering that deals with the design and operation of
vehicles that move on land, sea and air.
What is an automobile?
An automobile is a basically a four wheeled, self-powered motor vehicle which runs
on road and it is used to transport passengers (the driver with an addition of passengers with
numbers ranging from 1 to 7) and a little amount of load.
Automobile Engineering
Automobile engineering is a branch of engineering which deals with everything about
automobiles and practices to propel them.
What is an automobile workshop?
An automobile workshop is a place where repairs and servicing of automobiles and
automobile systems are done.

1.1 WORKSHOP SAFETY AND PREVENTIVE PROCEDURES IN THE AUTO-

WORKSHOP
In an auto-workshop various services are rendered by the technical staff during repairs
and servicing of automobile systems and parts. The technical staff and others in the workshop
are expected to observe some laid down rules to be safe and to ensure the safety of others in
the workshop.
The rules to obey are peculiar to the activities and services being rendered and are to
be obeyed while working on automobiles in the workshop or outside the workshop. They are
grouped as follows:-
(i) When working with vehicles in the workshop
(ii) When working with vehicles on the roadside
(iii)When working with lifting equipment
(iv) Storage and racking of parts
(v) Awkward postures
(vi) Handling heavy parts
1.1.1 When Working with Vehicles in the Workshop
Hazards: Moving vehicles may cause injuries to employees and members of the public.
Therefore, appropriate measures must be taken to guard against this.

Figure 1.1: Low risk workshop: A neat and tidy workshop area

Table 1.1: When Working with Vehicles in the Workshop

TASK / ACTIVITY RULES/SAFETY MEASURES

i Management in workshop  Customers are to drop their vehicles at the

car park/pickup area.
 Customers are not allowed to drive their
vehicles within the workshop.
 Serviced/repaired vehicles are to be moved
to the customer car park/pickup area by an
employee.

ii Work Areas  The vehicle route is marked out from the

route of service personnel and pedestrian.

iii Planning for pedestrian traffic  They should be designated customer

parking bays
 A sign that reads “No unauthorized access”
should be in place at all entry points of the
workshop.
iv Vehicle Handling (Driving)  Employees are to drive vehicles within their
licence and competency.
 Earth moving equipment and farm vehicles
are to be moved to the designated repair
areas from the vehicle drop off areas by
licensed operators with appropriate
experience.

v Preventing vehicles from moving Vehicles in the workshop are prevented from
moving using atleast three methods:

 The vehicle keys are removed from the

ignition.
 The hand brake is to be engaged.
 Vehicles are raised on a pillar hoist with all
wheels off the ground.
 The vehicle’s wheels are chocked on both
sides of the vehicle’s wheel with
serviceable purpose-built chocks.

vi Slip and trip prevention  All leads are stored out of the ways e.g.
retractable reels.
 Power and pneumatic outlets are located
close to the service area.

 Spill on the workshop floor are covered

with absorbent material and immediately
cleaned up.
 Potentially slippery surfaces are coated
with non-slip coatings.

vii Vehicle payload stability  Vehicle is unloaded or load is reduced to

safe level before the start of brake servicing
or tyre changing.

viii Availability of the lifting  Manual handling aids are made available to
equipment for the lifting and technical staff while undertaking repair or
management of heavy objects servicing work.

ix Communication with isolated  Constant communication with technical

worker/s staffs working in isolated areas should be
maintained by the supervisor.
 Emergency/panic alarm must be made
available in such places.
1.1.2 When Working with Vehicles on the Roadside:

The hazards include: high speed traffic, poor visibility and weather conditions, loose, soft or
sloping ground conditions. Employees may be struck by a passing vehicle or crushed by the
vehicle moving off jack. The rules and control measures below apply to all vehicles.

Figure 1.2a: Low risk workshop: Visible warning signs for approaching drivers

Figure 1.2b: Low risk workshop: Highly visible vest and warning lights
Table 1.2: When Working with Vehicles on the Roadside
TASK / ACTIVITY RULES/SAFETY MEASURES

i Traffic control at the site of the  Service personnel are to be competent in risk
broken-down vehicle assessment and traffic control at the scene of
a broken down vehicle.
 The control measure may include:

 Calling the police or other appropriate

authorities e.g. Road safety officials.

 Arranging for the towing of the vehicle to a

safe work area before the commencement of
repair work.

 Putting in place prominent warning signs

and lights for approaching drivers, some
meters away from the broken-down vehicle.

 Traffic lane could be close to protect

personnel and the broken-down vehicle.

 Traffic controller with appropriate

equipment warns approaching drivers of the
traffic danger ahead.

ii Work area lighting and visibility  Worksite area and vehicle must be
adequately lit using auxiliary lighting
systems if required.
 High visibility vest appropriate to day or
night must be worn by personnel at
worksite.
 A combination of warning lights and signs
must be prominently displayed to warn
motorists of the activities going on at the
site.

iii All other rules that are applicable

in the workshop apply here too.

1.1.3 When Working with Lifting Equipment:

Hazards: Failure of lifting equipment causing crushing injuries and/or fatalities. Control
measures to ensure safety are to be taken.
Figure 1.3a: Low risk workshop activity: Operating instruction prominently in display.

Figure 1.3b: Low risk workshop activity: Trolley jack and axle stands must be used at all
times.

Table 1.3: When Working with Lifting Equipment

TASK / ACTIVITY RULES/SAFETY MEASURES

i Vehicle hoists  Hoist inspections are to be undertaken to the

manufacturer’s standard.
 Pre-operation inspections are to be done daily.

 Routine inspection and maintenance are to be

done at least every three (3) months.
 Comprehensive annual inspections are to be
conducted.
  Results of all inspections, servicing and
maintenance are to be recorded in a log book and
made available to users and maintenance or
inspection personnel.
 All servicing and maintenance are to be carried
out by qualified and competent persons.
 Operating and maintenance instruction plates are
to be prominently displayed on hoists.
 Safe working loads are to be prominently
displayed on equipment.
 The moving parts of the hoist or its loads should
have a minimum clearance of 600 mm to any
fixed structure or other equipment that moves.
 Electrical hoists and wiring are to be tested
according to AS/NZS 3000 Australian wiring
rules.
 The hoist controls are meant to be in good
conditions, properly positioned and clearly
marked for safe operation.
 Dropper bar should be fitted to in-ground
hydraulic ram type hoist to prevent hoist
lowering to less than 760 mm.
 All hoist-safety devices must be operational.
 All hoist operators must be properly trained in
the correct use and inspection of the vehicle
hoist.

ii Hydraulic jacks and trolley Same as vehicle hoist inspection.

jacks use.

iii Vehicle ramps and stands  Vehicle ramps and stands are to be marked with
rated capacities.
 Inspections of the vehicle ramp and stands are to
be undertaken.
 Pre-operation inspections are to be done daily.
 Routine inspection and maintenance are to be
done at least once every 3 months.

 Annual inspections are to be conducted.

 The results of all inspections, servicing and
maintenance are to be recorded in a log book and
 made available to people using the equipment.
 Vehicles on ramps are to be secured in such a
way to prevent movement.

iv Tag out/lock out system  All hoists, trolley jack, stands and ramps that are
found to be unsafe are immediately removed
from service.
 Tag out/lock out system are to be put in place to
ensure faulty equipment are not used until they
are made safe.