Information Sheet No.

1A
Shop Safety
Objectives

After completing this unit, you will be able to:

1. Recognize safe and unsafe work practices in a shop

2. Perform your job in a manner that is safe for you and other workers

Introduction

“SAFETY FIRST” is the first and the most important rule that every
student of the machine trade should learn and observe. This rule
means that above all, the student machinist should consider the
safety of himself and of everybody in the shop.

 Safe working habits are acquired by keeping in mind

his own safety and that of others and by practicing safe
working habits at all times.

 Rules and regulations, mechanical guards and devices

placed around machinery, posters and lectures are not
enough for safe working. The student machinist should
take intelligent precautions in doing his work.

“ACCIDENT”

In the school-shop point of view, is defines as any mishap that causes injury to the body
or a member of the body.

ACCIDENTS ARE COMMONLY CAUSES BY THE

FOLLOWING:
1.) Hurry. As the saying goes, “haste makes waste”,
so is true with the one who wants to finish his job
earlier by holding his work by hand instead of
clamping it to the machine while machining it.
2.) Hand or machine tools. The latter is more
common, depending upon the nature of the
machine.
3.) Handling of rough or sharp materials.
4.) Electric hazards due to damaged installations.

Although the above are the direct causes of accidents, yet a deeper
analysis will prove that accidents primarily stem from three common individuals faults:
ignorance, negligence and carelessness. Safe working depends upon the operator’s knowledge
of his machine, plus consciousness and the constant application of the safety rules.
 PRECAUTIONS AND SAFE PRACTICES FOR THE MACHINE SHOP

The following precautions and safe practices are recommended by the National Safety Council.
They should be learned by every student machinist.

GENERAL SAFETY PRECAUTIONS

• Be sure that all machines have effective and properly working guards that are always in
place when machines are operating.
• Replace guards immediately after any repair.
• Do not attempt to oil, clean, adjust, or repair any machine while it is running. Stop the
machine and lock the power in the “Off” position.
• Do not operate any machine unless authorized to do so by the instructor, or under his
supervision.
• Even after the power is off, do not leave the machine until it has stopped running.
Someone else may not notice that it is still running and be injured.
• Do not try to shop the machine with your hands or body.
• Always see that the work and the cutting tools on any machine are securely clamped
before starting.
• Keep the floor clear of metal chips or curls and waste pieces. Put them in the container
provided for such things. Scraps are tripping hazards, and chips or curls may cut
through a shoe and injure the foot.
• Do not operate any machine when the instructor is not in the shop.
• All setscrews should be flush or recess-type. If they are not, move with caution when
near them. Projecting setscrews are very dangerous because they may catch on sleeves
of clothing.
• Get help for handling long or heavy pieces of material. Follow safe lifting practices – lift
with your leg muscles, not with your back. If you do not know how to lift safely, ask
your teacher to show you.
• When working with another student, only one should operate machine or switches.
• Do not lean against the machines.
• Do not run in the shop; there is no “fooling around” in the shop. Don’t be a “wise guy”.
• Concentrate on the work and do not talk unnecessarily while operating the machine.
• Don’t talk to others when they are operating a machine.
• Get first aid for ANY injury.
• Be sure you have sufficient light to see clearly. Check with the instructor if you do not
have enough

PROPER LIFTING TECHNIQUE

 Squat down, bending your knees, but be sure to

keep your back straight

 Grasp the material securely and use your leg

muscles to raise the load. Keep your back
straight; bending the back puts an excessive
strain on it

 Lower the material to the floor by bending the knees.

CLOTHING AND SAFETY EQUIPMENT

• Always wear safety glasses, goggles, or face shields designed for the type of work when
operating the machine.
• Wear clothing suited for the job. Wear shoes with thick soles – safety shoes if heavy
work is being done.
• Do not wear rings, watches, bracelets, or other jewelry that could get caught in moving
machinery.
• Do not wear neckties or loose or torn clothing of any kind.
• Wear shirts with short sleeves. Roll long sleeves above the elbows.
• Always remove gloves before turning on or operating any machine. If material is rough
or sharp hand gloves must be worn.

HOUSEKEEPING

• Keep floors free of oil, grease, or any other liquid. Clean spilled liquids immediately;
they are slipping hazards.
• Aisles should be clear at all times to avoid tripping or other accidents.
• Store materials in such a way that they can not become tripping hazards.
• Do not leave tools or work on the table of a machine even if the machine is not running.
Tools or work may fall off and cause toe or foot injury.
• Put tools away when not in use.
• Place all scraps in scrap boxes.

SCREW DRIVERS

• Select screw drivers to fit the screw head being used.

• Keep screw driver handles smooth.
• Do not use hammer on a screw driver handle.
• Avoid holding work in the hand when using a screw driver on it, as it may slip and cause
stab wounds.
• Never grind a screw driver to a chisel edge.

WRENCHES

• Discard wrenches that are spread.

• Select open-end wrenches to fit the job.
• Where possible, avoid using an adjustable or monkey wrench.
• If a wrench has become burred, grind off the rough spots to avoid cutting hands.
• It is generally safer to pull a wrench toward yourself than to push it away from you.
• Be sure that your knuckles will clear obstructions when the wrench turns.

FILES

• Always use a file with a handle.

• When filing in a lathe, learn to file left-handed.
• Keep your file and your hand clear off the chuck jaws or dog.
• Do not use a file as a pry bar.
• If filing in a lathe, do not use a pad cloth or waste under the thumb on the end of the
file.
• Keep a firm grip on the file at all times.
• Do not blow filings so they can go into anyone’s eyes
HACKSAW

• Use the correct blade for the job.

• See that the blade is correctly secured in the frame.
• When the saw breaks through the work, ease up on the pressure so that the hand will
not strike the work or vise.
• Be sure the work is held securely in the vise.
• Do not force cut.

TAPS AND DIES

• Be sure the work is firmly mounted in the vise.

• Secure the proper size of the tap wrench.
• Avoid cutting the hands of a broke tap end.
• If a broken tap is removed by using a punch and hammer, wear goggles.
• If a long thread is cut with a hand die, keep the arms and hands clear of the sharp
thread coming through the die.

HAMMER

• Hammers that are chipped should be discarded.

• Never use a hammer that has a loose handle
 Information Sheet No.1B
5’S of Good Housekeeping
Introduction

PROBLEMS COMMONLY ENCOUNTERED AT YOUR WORKPLACE

o High absenteeism
o High turnover
o Demotivated employees
o Disordered/ cluttered environment
o Mistakes/errors
 The solution to all these problems is 5S.

HOUSEKEEPING TECHNIQUE
PRODUCTIVITY AND SAFETY
Enhancement Technique

In order to achieve high levels of quality, safety, and productivity, workers must have a
conducive working environment. That is the idea behind 5s.

WHAT IS 5S?
 Developed by the Japanese
 Housekeeping System
 Helps Create a Better Working Environment and a Consistently High Quality Process

THE 5S PRINCIPLES
 SEIRI – Organisation/Sort out
 SEITON – Orderliness/Systemize
 SEISO – The Cleaning/Shining
 SEIKETSU – STANDARDIZE
 SHITSUKE - Sustain/Discipline

DISCOVERY OF 5S
 Thirty years ago researchers started studying the secret of success of Japanese
manufacturing companies
 5S turned out to be the most impressive "secret"
 The factories were so well organized that abnormal situations were readily apparent
 Equipments were so clean and well maintained that any problem such as a loose bolt
or leaking oil could be easily seen
 This passion of cleanliness and orderliness became a hallmark of Japanese
organizations

ADVANTAGES OF 5S
If tools and materials are conveniently located in uncluttered work areas:
 Operators spend less time looking for items
 This leads to higher workstation efficiency, a fundamental goal in mass production
 A clean and tidy workplace leads to greater well being and increased motivation
 Company image improves
 Health and Safety is ensured
 Machine maintenance
 Quality
 Productivity
 Lean Manufacturing
 Results in a place easier to manage
  Smooth working  NO OBSTRUCTION
 No deviation, no problems b/c everyone knows where the things are supposed to be
 Time saving
 Quick retrieval
 Accidents & mistakes minimized
 Increases space
 Creates workplace ownership
 FOUNDATION OF ALL QC TOOLS
-continuous quality improvement
-Lean manufacturing
-Kindergarten of quality tools & techniques
 VISUAL MANAGEMENT SYSTEM
-Visual control to see the abnormalities
-simple signals that provide an understanding of the condition (normal/ abnormal)
-a look at the process reveals its direction (right/wrong)

LEAN PRODUCTION
 The latest incarnation of JIT
 Based on Toyota Production System.
 Waste elimination
 Widely used in automotive manufacturing & other repetitive mfg.

It’s the
elimination of
waste Everywhere
– while adding
customer value…
It’s a mindset & commitment to achieve a totally waste-free operation
that’s focused on your customer’s success… achieved by simplifying and continuously
improving all processes.

From the operations perspective

Lean production cuts costs & inventories rapidly to free cash, which is critical. It also
supports growth by improving productivity & quality, reducing lead times, and freeing huge
amounts of resources.

For example, lean production frees office and plant space and increases capacity so
companies can:
1. Add product lines
2. In-source component production
3. Increase output of existing products without acquiring new facilities.
KINDERGARTEN OF ALL THE QC TOOLS

 5s is the starting point of all the QC tools

 Could be said as the pre- requisite of all QC tools

METHODOLOGY OF 5S

1. ORGANISATION (SEIRI)
 Decide what you need
 Remove unnecessary clutter
 All tools, gauges, materials, classified and then stored
 Remove items which are broken, unusable or only occasionally used
RED TAG TECHNIQUE
o Give staff red labels
o Ask staff to go through every item in the work place
o Ask if needed & those that are needed in what quantity
o Not needed red tag it
o Store in the red tag area

For wavering items

 Place the suspected items in the red tag area for one week
 Allow the staff to reevaluate the needed items
 At the end of week those who need items should be returned

ORGANISATION

PRIORITY FREQUENCY OF USE HOW TO USE

Less than once per year Throw away

Low Once per year Store away from the workplace
Once per month
Ave Store together but offline
Once per week
High Once Per Day Locate at the workplace

2. ORDERLINESS (SEITON)
Once you have eliminated all the unneeded items, now turn to the left over items.

Organise layout of tools and equipment

– Designated locations
– Use tapes and labels
– Ensure everything is available as it is needed and at the “point of use”

Workplace Checkpoints:-
– Positions of aisles and storage places clearly marked?
– Tools classified and stored by frequency of use?
– Pallets stacked correctly?
– Safety equipment easily accessible?
– Floors in good condition?

3. SEISO (CLEAN/SHINE)
 Create a spotless workplace
 Identify and eliminate causes of dirt and grime – remove the need to clean
 Sweep, dust, polish and paint
  Divide areas into zones
 Define responsibilities for cleaning
 Tools and equipment must be owned by an individual
 Focus on removing the need to clean

4. SEIKETSU (STANDARDISE)
 Generate a maintenance system for the first three
 Develop procedures, schedules, practices
 Continue to assess the use and disposal of items
 Regularly audit using checklists and measures of housekeeping
 Real challenge is to keep it clean

5. SHITSUKE (SUSTAIN / DISCIPLINE)

 Means inoculate courtesy & good habits
 Driving force behind all 5S
 Deming’s point number 1: Constancy of purpose
 Make it a way of life
 Part of health and safety
 Involve the whole workforce
 Develop and keep good habits

LITMUS TEST FOR 5S

o 30 second rule
o One must locate the item with in 30 second if 5s is properly implemented
o Also applies to the electronic records retrieval

WHAT YOU HAVE COME ACROSS AT THE END OF DAY

Followings can be harnessed from the 5S

1. Neat & clean workplace

2. Smooth working
3. No obstruction
4. Safety increases
5. Productivity improves
6. Quality improves
7. Wastage decrease
8. Machine maintenance
9. Visual control system
10. Employees motivated
11. Workstations become spacious