MACHINE SHOP SAFETY PLAN - Southern Illinois University

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MACHINE SHOP SAFETY PLANINTRODUCTIONIn the academic teaching and research environment, machine shops pose a unique set ofchallenges in terms of risks to users. The current safety protocols established by the Center forEnvironmental Health and Safety do not specifically address these risks or associated hazards.The purpose of this Machine Shop Safety Plan is to provide guidance to all students andemployees in the (Name of work unit) at Southern Illinois University(SIU) Carbondale who work with machining tools and equipment in order to ensure a safe andproductive work environment.The Dean (or supervisor, responsible party, etc.) will designate and authorize an individual theMachine Shop Safety Administrator (MSSA). The MSSA will have thorough knowledge of propermachine operation and safe working procedures. The MSSA will manage all activities thatimpact machine shop safety, including user training, proper use of personal protectiveequipment, project set up, removal of unsafe machines from service, posting of appropriatesignage at work areas, and approval of users in the shop. After a user has gone through basicsafety training and training of a specific piece of equipment or machinery, the MSSA willapprove individuals to use specific equipment, and maintain records of the training. The MSSAwill have the authority to determine who is allowed into the shop. The MSSA will also serve asa liaison to the Center for Environmental Health and Safety.EMERGENCY PROCEDUREImmediately contact 9-1-1 via SIU landline or 453-3771 via cellphone to get the Department ofPublic Safety (DPS).*If a 911 is dialed via cellphone, you will get the state police*Next, report the incident to the MSSA and complete the “Report of Injury/Incident/HazardForm” on the Center for Environmental Health & Safety (CEHS) website(http://cehs.siu.edu/occupational health/forms.html)FILESA binder will be kept in the machine shops with the following information: Machine Shop Safety PlanRecords of TrainingAnnual Inspection Forms

Students will be issued a card that shows their training. Students will be required to have thiscard on them when they are working in the machine shop.STUDENT RESPONSIBILITY Must use the buddy system when working in the shopMust complete the general training and arrange with the MSSA for machine specifictraining before using any machine.Must observe all shop safety rulesMust report all injuries to the MSSA, regardless of seriousness.Must promptly report unsafe conditions, actions or near-miss incidents to the MSSASHOP EQUIPMENT HAZARD CLASSIFICATION MATRIX (APPENDIX A)A hazard analysis of the most common types of equipment used in the (Namework unit) has been completed. This analysis has resulted in various pieces of shop equipmentbeing placed into one of three hazard categories: low, medium, or high. The type of equipmentpresent within a given shop will therefore determine the corresponding hazard category.The matrix located in Appendix A of this document details a number of shop requirementsassociated with each hazard category. These requirements have been established in order toprovide a safe working environment within University shops. The points within the tableinclude the following: The three hazard levels (low, medium, and high) are noted at the top of the matrix.The “general design” category contains a basic explanation of the size and power ofshop equipment categorized in each hazard level.The “common examples” category is a listing of the common equipment types that fitthe criteria for each hazard level.GENERAL SAFETY TRAININGRefer to Appendix CMACHINE AND EQUIPMENT TRAININGThe following information is provided as a guide for the minimum safety training that shall beprovided to personnel prior to authorized use of any machining tools or pieces of equipment.An authorized user must score 100% on the General Safety Training prior to testing on any ofthe machinery or equipment. An authorized user must score 100% on a safety test in order touse any individual piece of machinery or equipment.

NOTE: Machine shop personnel have been asked to provide a list of basic safety tips for eachpiece of machinery in their shop.FAILURE TO FOLLOW MACHINE SAFETY PROTOCOLS First time failure to observe all safety procedures will result in a warning.Second time failure to observe all safety procedures will result in a loss of access to themachine shop.Access can only be reinstated with a petition to and approval by the Dean andDepartment Chairs (or supervisor, responsible party, etc.).DEFINITIONSAdequate Facility – a facility which provides satisfactory clearance, power, light and ventilationAuthorized User – an employee or student who has received both general machine shop safetytraining and specific machine tool and equipment training administered by the appropriatemachine shop personnelBuddy System – a system designed to protect and assist the user in case of injury. During offhours when the machine shop is unsupervised, a “buddy” would be present so that, in theevent of an injury, emergency assistance is not delayed.Guard – an enclosure designed to restrain pieces of abrasive wheels, wheel pulley assemblies,or other moving parts or working stock, and to protect the employee in the event of breakageor accidental contact with the moving part.Machine Shop – a facility which may contain at least one of the following pieces of equipment:drill press, lathe, band saw, table saw, mill, grinder buffer, shear, metal punch, jointer, portablepower tools, swing arm saw, radial arm saw, planer, slitter, roll-form machine, cold header,multi-slide machines, drum sanders, belt sanders, splicers and alligator sheers.Machine Shop Safety Administrator – person designated to maintain the safety of the machineshop.REFERENCEThis guide is adapted from the best practices outline for the Shop Safety Policy of ColumbiaUniversity, the Occupational Safety and Environmental Health guidelines for Machine ShopSafety for Academic Departments used at the University of Michigan and the Machine ShopSafety Program at Pennsylvania State University.

Appendix A is attached separately.

Appendix BGeneral Shop InformationShop Personnel:1. The MSSA is2. MSSA contact information (phone and office number)3. The shop supervisor is3. Shop supervisor contact Information is4. Additional contact names and information (If Applicable):Emergencies:1. From landline call 9-1-1 or via cell phone call 453-3771 Calling 9-1-1 from cell phone will get you the state police.2. Location of the shop phone(s) (if available) are as follows:Injury:Life threatening (large cut, uncontrollable bleeding, amputation, head injury, etc.) call 9-1-1from landline or 453-3771 from cell phone.Non-Life threatening (small cut, burn, scrape, contusion, etc.) contact MSSA and seek medicaltreatment (if needed).Emergency Equipment Location:1. Fire extinguisher(s)2. First aid kit(s)3. Eyewash/ShowerDocumentation and Reporting Requirements:In the event of emergencies and/or injury, a “Report of Injury/Incident/Hazard Form” must becompleted (http://cehs.siu.edu/occupational health/forms.html).

Appendix CGeneral Shop Safety TrainingThis document must be reviewed by all authorized users who utilize machine shops. Theseauthorized users will participate in a test and must score 100% in order to have access to theshop. Never use a machine if you are not trained. You must pass a basic safety test andspecific training on the machine you intend to use.Never be too shy to seek help. Always ask if you are unsure about the safe operation ofa tool or piece of equipment, or need refresher training.Never work without proper eye protection. Safety glasses with side shields must beworn at all time. Eye protection must be labeled with the ANSI Z87 designation.o Individuals that wear prescription glasses must 1) use googles that can fitcomfortably over there corrective eyeglasses without disturbing the alignment ofthe eyeglasses OR 2) use goggles that incorporate corrective lenses mountedbehind protective lenses.Protect your feet. At a minimum, closed-toed shoes that cover the entire foot must beworn. Do not wear thin fabric shoes, sandals, open toed shoes or high heeled shoes.Tools, chips, and fixtures are sharp and often hot.Remove or secure anything you are wearing that might get caught in moving machinery.Do not wear loose clothing, loose neckwear, lanyards, or exposed jewelry whileoperating machinery. Long sleeves on shirts should be rolled up above the elbows. Pullback and secure long hair.Never wear gloves when using rotating equipment. Gloves can become entangled inrotating machine parts and cause serious injury.Never work alone in the machine shop. Use the buddy system.Never use a machine or equipment when impaired - be sober and smart. This includesprescription drugs.Loose objects can become flying particles. Remove all loose items (wrenches, chucks,rags, etc.) from machinery before starting.Keep your work area clean and dry. Dispose of all debris and waste materials by placingthem in the appropriate containers (e.g. oily rags in approved metal containers, trash intrash can). Remove chips, oil and obstacles that can cause someone to slip or trip. Shopequipment and/or materials must be placed in the proper storage location.Machines must be turned off when cleaning debris.Never lean on your machine. Stand away when the machine is running.

Appendix C: ContinuedGeneral Shop Safety Training Never remove safety guards from equipment. You must ensure that all safety guardsare in place before using equipment.Always keep hands and other body parts a safe distance away from moving machineparts, work pieces, and cutters.Report defective machinery, equipment or hand tools immediately to the MSSA.Machinery and equipment must only be serviced by the MSSA.Foods and drinks are only allowed in designated areas.Horseplay within shop areas is strictly forbidden.The majority of the equipment in this shop requires further instruction from the MSSA beforeyou are you are allowed to operate the equipment.Anyone who 1) disregards the shop rules OR 2) works unsafely will have their shop privilegessuspended.I have read the “General Shop Information” and the “General Shop Safety Training” documentsand understand that I must follow all the above safety rules when working in this machine shopand not operate any equipment until I have complete the General Safety gnature:Recordkeeping information: MSSA must keep a copyA copy must remain in the machine shop that the student/employee uses.A copy must also be provided to the student/employee.

Appendix DEquipment Specific Safety TrainingThis form documents that an individual has been trained to operate certain shop equipment.The procedure is as follows:1. The trainer must be the MSSA for the (Name of work unit) at SIU.2. The trainee must go through General Shop Safety Training before Equipment SpecificTraining can take place.3. The trainer must provide an overview of the equipment and hands-on training, whichmust include the following: How to properly use the machine, including a description and identificationof the hazards associated with the machine; Proper personal protective equipment (PPE) to use, while using the machine; How to use the safeguards and why, including how they provide protectionand the hazards for which they are intended; Under what circumstances safeguards can be removed, and by whom (inmost cases, repair or maintenance personnel only); and What to do (e.g., contact MSSA) if a safeguard is damaged, missing or unableto provide adequate protection.This training certification is permanent unless any of the following occur:1. Changes in the workplace render previous training obsolete.2. Changes in the type of shop equipment used render previous training obsolete.3. The operator has been observed using the equipment in an unsafe manner.4. The operator has been involved in an accident or near miss.

Appendix D: ContinuedTool Specific Safety Training-“Proof of Training”Initial and date all of the shop equipment that the individual has been trained on and in ispermitted to operate.ToolAngle GrindersBand Saw (Standing)Belt/Disc Sander(standing)Bench GrinderChop/Miter SawsCircular SawDrill Press (BenchTop)Drill Press (standing)Enclosed CNCMachineHorizontal Band SawHydraulic/MechanicalPower PressJointerLaser cuttingLarger than 3/8” drills(cordless and corded)LathesManual BrakeManual ShearMilling Machines(Bench Top)Milling Machine(Standing)Trainer’s DateInitialsToolNail Gun (all types)Open CNC millPlanerPlastic injection moldingPower Press BrakePower ShearRadial Arm SawReciprocating Saw(cordless or corded)Robot (Fully Enclosed)Robot (not fullyenclosed)RoutersShaper/moulderSurface grinderTable SawVertical Band SawWater Jet ��sInitialsDate

Appendix D: ContinuedTool Specific Safety Training-“Proof of ign:Recordkeeping information: MSSA must keep a copy A copy must remain in the machine shop that the student/employee uses. A copy must also be provided to the student/employee.

Appendix EMachine Guarding Reference GuideThe following are general guidelines regarding machine guarding. In many casesthere are more than one way to achieve proper machine guarding. This is notintended to be an all-inclusive list of shop equipment.Consult with the MSSA, equipment manufacturer and/or CEHS for additionalmachine guarding information.Guarding Requirements for All Shop EquipmentThe following points must be adequately guarded on all types of shopequipment:Unguarded Point of operationGuardedo Area where the machineperforms work. (An examplewould be where a saw blademeets the material being cut). Power transmission devices:o Elements of mechanical systemthat transmits energy.(Examples would includeflywheels, belt, chains and pulleys). Other moving parts:o Other parts of the machine that move when the machine is in cycle.Tongue GuardsBench Grinder Guarding Requirementso Adjustable tongue guard ¼” from wheel.o Adjustable work rest 1/8” from wheel.o Bench grinder needs to be secured towork surface.o The required guarding for a wire brushattachment is a tongue guard. (A toolrest is not recommended in this situation).Work RestOptional Eye Shield

Appendix E Safe Work Practiceso Grinding wheel must be dressed to prevent a ridge from forming.o Perform a ring test before mounting an abrasive wheel. The abrasive wheel must not be used if a dull sound isnoted.o If the grinding wheel is cracked, do not use it because it couldshatter.Grinder DresserToolBand Saw Guarding Requirementso Adjustable guard. Set the guard as close as possibleto the stock.Blade GuardMilling Machine Guarding Requirementso Point of operation guard.Point of operationguardBelt/Disc Sander Guarding Requirementso Fixed guards at pinch and nip points.Fixed Guards

Appendix EAngle GrindersGuarding requirementsA fixed guard must be on the grindingwheel enclosing one-half or 180 of thegrinding wheel.Table Saw Guarding RequirementsThere are three guards needed on atable saw: a wood spreading guard,anti-kickback guard and aself-adjusting guard over the blade.Safe Work PracticesA push stick must be used whenthe stock being cut is small.The top of the teeth of the tablesaw blade shall not extend ¼”above the material being cut.Saw Stop – Table SawGuarding RequirementsThe guarding requirements for a“Saw Stop” table saw are thesame as those for a standard table guardSaw Stop Table Saw

Appendix ERadial Arm Saw Self-adjusting guardGuarding Requirementso A self-adjusting guard below the bladeSafe Work Practiceso The radial are saw must be returnedto the original position after a cut isfinished.o Saw should only be used for crosscutting. A table saw is a better tool for rippingJointer (manual) Guarding Requirementso Self-adjusting blade guard. Safe Work Practiceso If the wood stock is small, use a push stickto feed the stock.Self-adjusting blade guardPlaner/Moulder (Automatic) Guarding Requirementso Cutter heads must be completely enclosed, except for the opening needed tofeed the stock into the tool.Completely enclosed

Appendix ECircular Saw Self-adjusting blade guardGuarding Requirementso Self-adjusting blade guard.Safe Work Practiceso If the saw cut is stopped before the cut isfinished, the saw must be turned off beforebeing removed. If thesaw is pulled out before stopping, kickback couldoccur.Routers Guarding Requirementso Self-adjusting guard above cutting bit on benchversion. Fixed guard on hand held version.Self-adjusting blade guardWelding and Brazing PPEOxygen Acetylene Torcho Fire resistance clothing Coat Pantso Welding helmet or tinted face shield Tinted number depends on what typeof welding or torch is being used. If face shield is used, safety glasses arerequired.o Leather gloves Heat resistanto Respiratory Protection (site specific)Safety Work Practiceso Oxygen and acetylene cylinders must be secured to a cart by using a chain orwebbing strap.

o If a cylinder does not have a regulatorattached, it must be capped.o Inspect work area for any combustibles.Stick WeldingChop/Miter saws Guarding Requirementso Both saws must have self-adjustingChop Saw-selfadjusting guardblade guards. Safe Work Practiceso Only use the recommended blade based on size andrevolutions per minute (RPM)Miter Saw –self adjustingguardReciprocating Saw Guarding Requirementso Must be equipped with hand/finger guard.Hand/finger guardJig Saw Guarding Requirementso Upper portion of the blade, above the tool rest,must be guarded.Blade guard

Appendix EBlade guardScroll Saw Guarding Requirementso Blade guardPower Press Brake Guarding RequirementsNote: There are many different methods whichcan be used to effectively guard this equipment.They are listed below. The best means of guardingwill depend on how the press brake is used.o Moveable barrier guardso Fixed guardso Presence-sensing deviceso Pull back deviceso Restraint deviceso Two-hand trip devicesThis press is equippedwith a properly designedtwo-hand controlPower Shear Guarding Requirementso Adjustable guardAdjustable guard

Appendix EPower Press (Mechanical and Hydraulic)(Part Revolution and Full Revolution) Guarding Requirementso Note: Depending on the size and type of powerpress a variety of guarding methods are available.The following are examples of such methods.Contact the equipment manufacturerfor consultation. Point of operation guard Pull back device Restraint device Gate type guards (A and B types) Two-hand trip Two-hand control Presence-sensing deviceSafe Work Practiceso Operators must never place their hands in thedie area (point of operation) while performingnormal production operations.o Hand tools designed for freeing or removing work orscrap pieces from the die must be used.o OSHA has a specific standard on Mechanical PowerPresses. (CFR 1910.217 – Mechanical Power Presses)Hydraulic Power PressLathe (Automatic and Manual) (Wood and Metal) Guarding Requirementso A guard over the chuck.o For lathes used for turning long stock, a guardover top of the stock.Safe Work Practiceso Tie back hair and no loose clothing so it doesn’tget caught on the spinning chuck.After making adjustments to the machine, remove theMechanical Power Press

chuck key.Drill Press Guarding Requirementso Chuck guardSafe Work Practiceso Small material being cut shall beclamped to prevent any spinning.o The drill press machine must besecured so it will not “walk”.Milling Machine Guarding Requirementso Adjustable or permanent chip/coolant shieldSafe Work Practiceso Tie back hair and no loose clothing so it doesn’tget caught on the spinning chuck.o Do not allow large quantities of chips to accumulatearound the work piece or machine table.

Appendix ECompressed Air Tools Guarding requirementso Safety tips must be installed to relieveair pressure in the event the nozzle is“dead-ended”.o Air pressure must be less than 30 PSI when usingcompressed air for cleaning.Safe Work Practiceso Compressed air tools shall never be used toremove dirt from clothing or skin.Safety Tip

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.

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