ME 22/L – Workshop Theory and Practice Module 1 – Safety Rules and Regulations

ME 22/L

WORKSHOP THEORY AND PRACTICE

MODULE 1

SAFETY RULES AND REGULATIONS

Prepared by:

Engr. Beberth J. Samillan

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Beberth J. Samillan 1
ME 22/L – Workshop Theory and Practice Module 1 – Safety Rules and Regulations

Module 1

SAFETY RULES AND REGULATIONS

OVERVIEW
Welcome to Workshop Theory and Practice!
This module covers the fundamental safety rules and regulations inherent in every workshops.
Make every safety rules and regulations a part of you when inside the shop because your limb or even
your life depend on it. Study these carefully and be on the alert to apply them. Make safety a way of life!

Learning Objectives
Upon completion of this module, you must be able to:
1. Apply safety rules and regulations.

LESSON PROPER

GENERAL SHOP SAFETY

All tools are dangerous if used improperly or carelessly. Working safely is the first thing the user or
operator should learn because the safe way is the correct way. A person learning to operate machine
tools must first learn the safety regulations and precautions for each tool or machine. Most accidents are
caused by not following prescribed procedures. Develop safe work habits rather than suffer the
consequences of an accident. Most of the safety practices mentioned in this module are general in nature.

EYE PROTECTION
Using eye protection in the machine shop is the most important safety rule of all. Metal chips and shavings
can fly at great speeds and distances and cause serious eye injury. Safety glasses must be worn when
working with hand-cutting tools, since most hand-cutting tools are made of hardened steel and can break
or shatter when used improperly. There are many different types of safety glasses available in the supply
system; however, the ones that offer the best protection are the safety glasses with side shields. Safety
goggles should be worn over prescription glasses.

HAZARDOUS NOISE PROTECTION

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ME 22/L – Workshop Theory and Practice Module 1 – Safety Rules and Regulations

Noise hazards are very common in the machine shop. High intensity noise can cause permanent loss
of hearing. Although noise hazards cannot always be eliminated, hearing loss is avoidable with ear
muffs, ear plugs, or both.

FOOT PROTECTION
The floor in a machine shop is often covered with razor-sharp metal chips, and heavy stock may be
dropped on the feet. Therefore, safety shoes or a solid leather shoe must be worn at all times.

GRINDING DUST AND HAZARDOUS FUMES

Grinding dust from abrasive wheels is made up of extremely fine particles of the metal and the wheel.
Some grinding machines are equipped with a vacuum dust collector. When operating a grinder without
a vacuum, wear an approved respirator to avoid inhaling the dust. Whenever possible, use coolant
when grinding. This will aid in dust control. Grinding dust can be very dangerous to your health,
especially beryllium or parts used in nuclear systems. These materials require careful control of
grinding dust. Metals such as zinc give off toxic fumes when heated above their boiling point. Inhaling
these fumes may cause temporary sickness, or death. The fumes produced from lead and mercury are
very harmful, as their effect is cumulative in the body and can cause irreversible damage. When unsure
of the materials being machined, it is advisable to wear a respirator.

PROPER LIFTING PROCEDURES

Using improper lifting procedures may result in a permanent back injury. Back injury can be avoided if
the correct lifting procedures are followed. When lifting heavy or large objects, get some assistance or
use a hoist or forklift. Objects within your ability can be lifted safely as long as the following procedures
are followed: Keep your back straight. Squat down, bending at the knees. Use the leg muscles to do
the work and lift slowly. Do not bend over the load as this will put excessive strain on your spine. Carry
the object where it is comfortable, and pay close attention to where you are walking and objects around
you. When placing the object back on the floor, use the same procedures as when it was lifted.

ELECTRICAL SAFETY
Exposure to electrical hazard will be minimal unless the operator becomes involved with machine
repair. The machine operator is mostly concerned with the on and off switch on the machine tool.
However, if adjustments or repairs must be made, the power source should be disconnected. If the
machine tool is wired permanently, the circuit breaker should be switched off and tagged with an
appropriate warning statement. Most often the power source will not be disconnected for routine
adjustment such as changing machine speeds. However, if a speed change involves a belt change,
make sure that no other person is likely to turn on the machine while the operator’s hands are in
contact with belts and pulleys.

SAFETY RULES FOR MACHINE TOOLS

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ME 22/L – Workshop Theory and Practice Module 1 – Safety Rules and Regulations

Since different cutting tools and machining procedures are used on various machine tools, the safety
precautions for each may vary. The following are general safety rules for any machine tool:

• Gears, pulleys, belts, couplings, ends of shafts having keyways, and other revolving or
reciprocating parts should be guarded to a height of 6 feet above the floor. The guards should
be removed only for repairing or adjusting the machine and must be replaced before operating
it.

• Safety setscrews should be used in collars and on all revolving or reciprocating members of the
machine tool or its equipment.

• Do not operate any machine tool without proper lighting.

• Never attempt to operate any machine tool until you fully understand how it works and know
how to stop it quickly.

• Never wear loose or torn clothing and secure long hair. Ties should be removed and shirt
sleeves should be rolled up above the elbow.

• Gloves should never be worn when operating machinery except when absolutely necessary.

• Always stop the machine before cleaning it or taking measurements of the workpiece.

• Do not lubricate a machine while it is in motion. Injury to the operator and damage to the
machine may result from this practice.

• Never remove metal chips, turnings, or shavings with your hands. If the shavings are long, stop
the machine and break them with pliers or a bent rod, and then brush chips off the machine.
Remove cast-iron chips, which break into small pieces, with a brush. Never wipe away chips
when the machine is operating.

• Always wear safety glasses or goggles while operating machine tools. Also, wear respiratory
protection if operation creates hazardous dust. All persons in the area where power tools are
being operated should also wear safety eye protection and respirators as needed.

• Know where tire extinguishers are located in the shop area and how to use them.

• Never wear jewelry while working around machine tools. Rings, watches, or bracelets maybe
caught in a revolving part which could result in the hand being pulled into the machine.

• Avoid horseplay. Tools are very sharp and machines are made of hard steel. An accidental slip
or fall may cause a serious injury.

• Never use compressed air without a safety nozzle to clean machines or clothing. It will blow
sharp, dangerous metal chips a long distance.

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ME 22/L – Workshop Theory and Practice Module 1 – Safety Rules and Regulations

• Keep the floor around machines free of tools, stock, oil, grease, and metal chips. Tripping over
metal on the floor, especially round bars, can cause dangerous falls. Wipe up all oil, grease, and
cutting fluid spills on the floor as soon as possible to prevent a fall. Metal chips are very sharp
and can easily become embedded in the soles of shoes, making them very slippery, especially
when walking on a concrete floor.

• Never place tools or other materials on the machine table. Cluttering up a machine with tools or
materials creates unsafe working conditions. Use a bench or table near the machine for this
purpose.

• Always use a rag when handling sharp cutters such as milling cutters and end mills.

• Do not expose power tools to rain or use in damp or wet.

• Remove adjusting keys and wrenches. Form a habit of locations checking to see that keys and
wrenches are removed from tools before turning them on.

• Always secure the workpiece. Use clamps or a vise. It is safer than using your hands, and it
frees both hands to

• Do not operate any machine tool while under the influence of drugs, alcohol, or any medication
that could cause drowsiness.

• Do not abuse electrical cords. Never carry a tool by its cord or yank it to disconnect it from a
receptacle. Keep electrical cords away from heat, oil, and sharp edges. Have damaged or worn
power cords and strain relievers repaired or replaced immediately.

Workshop Safety Rules

➢ Only those students assigned by the teacher may work in the shop.

➢ Operation of power tools and other potentially dangerous shop work, may only be done under
my supervision.

➢ Safety glasses must be worn at all times while working with tools. Other protective equipment
must be worn as directed by the Instructor.

➢ You may not use any power tool until you have been trained in safe operation techniques by a
Workshop Supervisor.

➢ Disconnect power before making adjustments to power tools. Do not service energized
equipment. Take appropriate steps to prevent release of dusts or noxious fumes.

➢ Take appropriate fire prevention precautions when your work generates heat or sparks, or
involves open flames or flammable liquids.

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ME 22/L – Workshop Theory and Practice Module 1 – Safety Rules and Regulations

➢ Do not remove machine guards.

➢ Keep shop clean and tidy. When not in use, store tools, equipment, and supplies properly.
Cleanup after you complete your work.

ASSESSMENT:
Answer the following questions and write your answer on a short bond paper. To be submitted next
meeting.
1. Why are persons under the influence of drugs, alcohol, or any medication that could cause
drowsiness should not be permitted to operate any machine tool?
2. Why is it not advisable to operate a machine tool without proper lighting?
3. Explain the reason why you should never wear loose or torn clothing and your long hair should
be secured.
4. Explain why you should wear safety goggles when operating machine specially when
performing grinding operations.
5. Explain why you should never remove metal chips, turnings, or shavings with your hands.

REFERENCES:
1. Carleton Safety Manual
(https://apps.carleton.edu/machinesafety/rules/)
2. Machining handbook chapter 1, Detroit machine tools
https://smithy.com/machining-handbook/chapter-1

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Beberth J. Samillan 6