Machine Shop Safety For Academic Departments

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Machine Shop Safety for Academic DepartmentsGuidelineRevision Date: 09/21/18Applies To: All University academic departments. Employees and non-employees who actively work inmachine shops, laboratories and other University facilities with machining tools and machiningequipment are covered under this guideline.Table of ContentsMachine Shop Safety for Academic Departments Guideline Statement .2Related Machine Shop Safety for Academic Departments Guideline Documents . 2Additional Resources .2Unit-Specific Machine Shop Safety Policy Development .2Potential Hazards .2Training Requirements .3Developing a Basic Machine Shop Safety Training Program . 3Proficiency Testing .4Recordkeeping . 4Re-Training . 4Emergency Response Training . 4Shop Access .5Buddy System. 5Establish Hours of Operation . 5Shop Inspections .5Recordkeeping .5Machine Tool and Equipment Servicing .5Machine Shop Safety Signage and Postings .5EHS Door Sign. 6Project Review .6Appendix A: Reference Regulations .7Appendix B: Responsibility .8Deans, Directors and Department Heads . 8Machine Shop Responsible Person (Responsible Person) . 8Machine Shop Monitors . 9Authorized Machine Tool Users. 9EHS . 10Attachment 1: Machine Shop Forms and Machine-Specific Checklists .11Glossary of Terms .12Machine ShopBack to Table of ContentsPage 1 of 13Revision Date: 09/21/18

Machine Shop Safety for Academic Departments Guideline StatementThe purpose of the Machine Shop Safety Guideline is to provide a University Standard for safety andadministrative controls for individuals who work with machining tools and equipment. This guideline isderived from government regulations, the Academic Laboratory and Research Safety Policy and bestpractices from research studies.It provides guidance for safe handling of machines and how to develop a shop-specific policy addressingtraining and oversight for specific pieces of equipment, room, and equipment access requirements,general rules and responsibilities of shop users and a process for student project review (if applicable).Post the shop-specific policy in the shop (for review or reference) or its location noted.Related Machine Shop Safety for Academic Departments Guideline DocumentsEHS Guideline, Lock-out/Tag-out - Control of Hazardous Energy SourcesEHS Guideline, Personal Protective Equipment, GeneralAdditional ResourcesAll reference guidelines, regulations, and other documents are available in Appendix A of this document.For information about machine shop personnel responsibilities, see Appendix B of this document.Unit-Specific Machine Shop Safety Policy DevelopmentEach shop must develop a policy regarding training requirements and oversight necessary for specificpieces of equipment, room and equipment access requirements, general rules and responsibilities ofshop users and a process for student project review (if applicable). This policy should be posted withinthe shop (for review or reference) or its location noted. A template is provided for an AcademicMachine Shop Safety Policy that can be modified to the specific shop’s requirements.The Classification Matrix for Academic Machine Shop Equipment document can be used as generalguidance for development of the unit-specific shop policy. This can be implemented in a mannerthatbest suits the individual department/unit’s needs, but the Responsible Person must establish clearrequirements for access to the equipment and/or shop as well as providing for a means to restrictunauthorized users from using equipment that they have not been trained to operate.Potential HazardsA machine shop contains the same hazards as one experiences in a laboratory, such as, but not limitedto the following hazards:POTENTIAL HAZARDPhysicalElectricalFireChemicalMachine ShopEXAMPLESInjuries from compressed gas, flying debris, noise,pinching, cutting, and falling.Fire and shockFlammable chemicals and sparksToxic liquids, fumes, gas, and dustBack to Table of ContentsPage 2 of 13Revision Date: 09/21/18

Training RequirementsOnly authorized machine tool users as defined by this Guideline are permitted to operate machiningtools in U-M facilities. To become an authorized machine tool user, individuals must complete thefollowing training prior to using the machinery and associated equipment:PERSONNELMachine Shop Responsible Person(Responsible Person)Machine Shop Monitor (Monitor)Authorized Machine Tool UsersTRAINING REQUIREDMachine Shop ResponsiblePerson (My LINC IHS070w)Machine Shop ResponsiblePerson (My LINC IHS070w) Basic machine shop safety Specific machine tool andequipmentPROVIDED BYEHSEHSResponsible Person orMonitorDeveloping a Basic Machine Shop Safety Training ProgramThe Responsible Person or Monitor must train the authorized machine tool users. The ResponsiblePerson or Monitor must have thorough knowledge about and experience with the following topics: How the individual machining tools and equipment operateThe safety hazards associated with the machining tools and equipmentSpecific actions to take in case of an emergencyThe training should include the following topics at a minimum. Unit-specific Machine Shop PolicyHazard Communication (online)Use of personal protective equipment (PPE)Applicable prohibitions (e.g., loose clothing, hair, gloves and jewelry, etc.)Guard use/positioningMachining tool and bit maintenanceHand tool and facility safetyMachine shop general safety rules and equipment specific guidelines should also be included in thebasic training program.o General Shop Dresso General Shop Safety Ruleso Lathe Safety Guidelineso Mill Safety Guidelineso Drill Press Safety Guidelineso Bench or Pedestal Grinder Safety Guidelineso Planer Safety Guidelineso Band Saw Safety Guidelineso Table Saw Safety GuidelinesMachine ShopBack to Table of ContentsPage 3 of 13Revision Date: 09/21/18

Shop equipment will require Tool Specific Training, which should include instruction and hands-ondemonstration of the following topics: Refer to the document Classification Matrix for AcademicMachine Shop Equipment for guidance about the length and type of training for specific machines. Description and identification of the hazards associated with a particular machine;Proper safety precautions when working with a particular machine;Limitations of the tools/equipment/materials and when and what not to use;Safeguards, protection they provide, and ensuring their presence before using a machine;What to do if a damaged guard, missing part, unusual noise, etc., is noticed.How to use the emergency buttons and other measures, when necessary.Maintenance (as applicable) and cleaning procedures.Proficiency TestingBased on the unit-specific Machine Shop Policy, certain tools or machines may also require proficiencytesting prior to being deemed an “authorized machine tool user.” Proficiency determinations may beevaluated through completion of a shop project or through extensive hands-on training/oversight asdetermined by the Responsible Person.RecordkeepingIndividual departments must maintain training records on authorized machine tool users. Trainingrecords must include the specific machining tool or other equipment the individual was trained on, dateof training, U-M ID number and the signature of trainee and trainer.The Machine Shop Usage Agreement and Training Documentation Form is an example of a form that canbe used to document both the Basic Machine Shop Safety Training and Tool Specific Training for anindividual user.This training information shall be posted in the designated machine shop, other machine tool user area,or maintained in a central location.Individuals will be classified as "Authorized Machine Tool Users" upon completion of training anddocumented departmental training records. The Responsible Person will determine what method ofidentification will be used to distinguish between authorized users and those who have not beenauthorized.Re-TrainingRe-training shall be provided if there is a change in job assignment, change in machine tool orequipment use, or additional jobs present new hazard(s). Re-training may also occur if the ResponsiblePerson/Monitor or EHS determines that it is necessary.Emergency Response TrainingFirst Aid training is recommended, but is not a requirement, for the Responsible Person/Monitor. At aminimum, a stocked first aid kit should be available in or near the shop area.Each shop’s Responsible Person/Monitor are also encouraged to obtain Fire Extinguisher training bycontacting EHS’s Fire Safety Service (EHS-FSS) group at (734) 615-6764.Machine ShopBack to Table of ContentsPage 4 of 13Revision Date: 09/21/18

Shop AccessAll University students and employees, i.e., professors, researchers, must have received formal machineshop safety training and be a designated "Authorized Machine Tool User" prior to access and use ofmachining tools and machining equipment in machine shops and other University facilities.Buddy SystemIn accordance with this Guideline, the designated Responsible Person shall implement a mandatory"buddy" system for all Authorized Machine Tool Users while working in machine shops, laboratories, orother University facilities that have machining tools or equipment.Establish Hours of OperationEmployee and student use of machine shops and facilities with machining tools and equipment shall belimited to established hours of operation. Using machining tools and equipment beyond establishedworking hours and during weekends by Authorized Machine Tool Users is prohibited unless thedesignated Responsible Person has issued prior written approval.Departments are strongly encouraged to limit after-hours usage of power equipment after midnight dueto increased fatigue factors associated with late night working.Shop InspectionsIn addition to normal oversight and review of the shop area on a continual basis, the Responsible Personshall conduct annual machine tool, associated equipment, and facility safety inspections. Inspectioncriteria shall be based on manufacturer’s recommendations and in accordance with state safetyregulations listed in the reference regulation section of this document. To aid in the inspection process,use the machine shop safety Self Inspection Checklist Survey.All machine tools and equipment that are in violation of applicable safety standards, EHS Guidelines orunsafe in any manner shall be removed from service and locked out until properly repaired or replaced.RecordkeepingDocumentation of these inspections shall be maintained by the department and be made available toEHS upon request.Machine Tool and Equipment ServicingIndividual departments must have a formal Lock-out/Tag-out procedure established prior to servicing orrepairing any piece of machinery or equipment in a machine shop or other University facility.The Lock-out/Tag-out procedure shall be formulated in compliance with the EHS Guideline, Lockout/Tag-out - Control of Hazardous Energy Sources.Machine Shop Safety Signage and PostingsAt a minimum, applicable and appropriate safety signs, tags, stickers and other postings shall beprovided, installed and maintained in all areas where a person or equipment operator might be, orwould likely be, injured if not alerted to the hazard. Free safety posters, stickers, and cards are availableonline through MIOSHA and free Machine Safeguarding Placards online through Lovegreen MachineSafety website. Machine safeguarding placards are also available from EHS.Machine ShopBack to Table of ContentsPage 5 of 13Revision Date: 09/21/18

Consideration should also be given to using signs and labels based on the American National StandardsInstitute's (ANSI) Z535.4 Standard for Product Safety Signs and Labels or ISO 3864, both which specifythe use of symbols which have the ability to communicate hazards across language barriers.EHS Door SignThe posting of an informational door sign on the outside of each entrance to a shop is also stronglyencouraged. The use of a U-M door sign is an important part of emergency response. Emergencyresponders use these signs to determine the primary hazards in the room and the emergency contactperson. The sign would include current emergency contact information including contact names, officelocation, and work and home phone numbers. To obtain a door sign, complete the online Shops/StudiosRequest Form on EHS’s Forms webpage equestform/) or contact EHS at (734) 647-1143.Project ReviewAnother element to consider incorporating into a shop’s safety program is the use of a Project ReviewForm. This form can be used by shop’s Responsible Persons and Monitors to review and sign off onstudent's and other machine user’s projects and ideally would include project description, anticipatedmachines, tools, materials, etc., potential safety concerns, and safety measures to be taken to addressthe concerns.Machine ShopBack to Table of ContentsPage 6 of 13Revision Date: 09/21/18

Appendix A: Reference Regulations University of Michigan Standard Practice Guide (SPG 605.1)Hand Tools Institute, "Guide to Hand Tools" manualMIOSHA General Industry:o Part 1. General Provisionso Part1A. Abrasive Wheelso Part 7. Guards for Power Transmissiono Part 11. Polishing, Buffing and Abradingo Part12. Welding and Cuttingo Part 26. Metalworking Machineryo Part 27. Woodworking Machineryo Part 33. Personal Protective Equipmento Part 38. Hand and Portable Powered ToolsOSHA:oooSafeguarding Equipment and Protecting Employees from AmputationsGuide to Protecting Workers from Woodworking HazardsMachine Guarding e-ToolMachine ShopBack to Table of ContentsPage 7 of 13Revision Date: 09/21/18

Appendix B: ResponsibilityEveryone working at the University of Michigan has the right to expect a safe and healthy workenvironment. They also have a responsibility to help assure a safe and healthy environment forthemselves and others. These responsibilities are detailed in the University of Michigan AcademicLaboratory and Research Safety Policy, issued jointly by the Department of Environment, Health &Safety (EHS) and the Office of Research Ethics & Compliance (UMOR). Please click on the Policy link toview role specific responsibilities including but not limited to the following categories: All faculty, staff, other employees and studentsGraduate Student Research Assistants/TraineesPost-Doctoral Trainee/FellowLaboratory Director (Faculty/Lab Manager/SupervisorDepartment ChairFacility Managers/Department Managers/Key Administrators/Chief Department AdministratorsUnit (School/College/Department) Safety CoordinatorsDeans, Directors and Department Heads Ensure that machine shops are located in adequate facilities to allow for safe operation and layoutof equipment.Designate and authorize an individual who has thorough knowledge of proper machine operationand safe working procedures as the Responsible Person.Implement a unit-specific Machine Shop Safety Policy that incorporates all of the quality elements ofthe University Standard provided in this guideline.Actively support and enforce their unit-specific Machine Shop Safety Policy.Ensure an environment where supervisors and other personnel are encouraged to follow thisGuideline.Inform the Department of Environment, Health & Safety (EHS) of the designated ResponsiblePerson.Machine Shop Responsible Person (Responsible Person) Prepare and implement a unit-specific Machine Shop Safety Policy.Manage and enforce all aspects of the unit-specific Machine Shop Safety Policy and activities thatimpact machine shop safety. Examples of these activities include user training, proper use ofpersonal protective equipment (PPE), project review, removal of unsafe machines from service,posting of appropriate signage at work areas, access controls, and approval of users.Designate individuals with the appropriate training and experience to function as Monitors toprovide oversight and training as necessary to support the Machine Shop Safety Policy.Complete EHS’s Machine Shop Responsible Person Training Program and ensure that all designatedMonitors complete the training as well. Go to EHS’s My LINC training website and log-in, in order toaccess this training module (IHS070w).Train and credential all machine tool users in the proper and safe machining tool and equipmentuse.Maintain training documentation on all authorized machine tool users.Limit access to tools, equipment and the shop. Individuals using machining tools and equipmentbeyond established working hours and during weekends shall be prohibited unless prior writtenMachine ShopBack to Table of ContentsPage 8 of 13Revision Date: 09/21/18

approval is given by the Responsible Person and use complies with the “buddy system” part of thissection.Conduct self-inspections and preventative maintenance (PM) of machining tools, equipment andfacilities at a minimum of once a year and in accordance with manufacturer’s recommendations.Maintain documentation of inspections and the preventative maintenance performed.Develop a Lock-out/Tag-out (

Machine Shop Safety for Academic Departments Guideline Statement . The purpose of the Machine Shop Safety Guideline is to provide a University Standard for safety and administrative controls for individuals who work with machining tools and equipment. This guideline is derived from government regulations, the

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This guide is adapted from the best practices outline for the Shop Safety Policy of Columbia University, the Occupational Safety and Environmental Health guidelines for Machine Shop Safety for Academic Departments used at the University of Michigan and the Machine Shop Safety Program at Pennsylvania State University.