Engineering Programs at UNC Asheville



NC State Engineering Programs at UNC AshevilleMarch 242015This manual was developed by the Engineering Programs to ensure safe operation for users of their Design Studio.Design Studio Safety ManualContents TOC \o "1-3" \h \z \u Designated Design Studio Supervisor(s): PAGEREF _Toc384193409 \h 2Controlled Access To Design Studio: PAGEREF _Toc384193410 \h 2Safe Work Practices: PAGEREF _Toc384193411 \h 3Training PAGEREF _Toc384193412 \h 3Training Outline: PAGEREF _Toc384193413 \h 4Engineering Design Studio Standard Operating Procedures (SOPs) PAGEREF _Toc384193414 \h 4Welding PAGEREF _Toc384193415 \h 5Auditing and Inspections PAGEREF _Toc384193416 \h 7Training Certificates PAGEREF _Toc384193417 \h 7Machine/Equipment PAGEREF _Toc384193418 \h 7Eyewash PAGEREF _Toc384193419 \h 7Fire Extinguishers PAGEREF _Toc384193420 \h 7Mechatronics Design Studio Safety Manual PAGEREF _Toc384193421 \h 7Appendix A: NCSU/UNCA Design Studio Safety Orientation Training Certificate PAGEREF _Toc384193422 \h 8Appendix B: Standard Operation Procedures (SOPs) for machinery PAGEREF _Toc384193423 \h 1SOP: Band Saw PAGEREF _Toc384193424 \h 2SOP: Bench Grinder PAGEREF _Toc384193425 \h 4SOP: Belt/Disk Sander PAGEREF _Toc384193426 \h 2SOP: Chop Saw PAGEREF _Toc384193427 \h 4SOP: Drill Press PAGEREF _Toc384193428 \h 6SOP: Jig Saw PAGEREF _Toc384193429 \h 8SOP: Metal Lathe PAGEREF _Toc384193430 \h 10SOP: Milling Machine PAGEREF _Toc384193431 \h 12SOP: Miter Saw PAGEREF _Toc384193432 \h 14SOP: Sand Blaster PAGEREF _Toc384193433 \h 16SOP: Table Saw PAGEREF _Toc384193434 \h 18Designated Design Studio Supervisor(s):Design Studio Supervisors are responsible for the safe operations of the Engineering Program’s Design Studio. They have the authority to grant or deny access to the Design Studio over all Faculty, Staff and students. Design Studio Supervisors are responsible for user training and supervision.Controlled Access To Engineering Design Studio:Use of machines in the Engineering Program’s Design Studio is restricted to the Design Studio’s hours of operation when Design Studio Supervisors are present. Design Studio hours of operation for Spring Semester 2015:Monday1:00 - 5:00Tuesday1:00 - 5:00Wednesday1:00 - 5:00Thursday1:00 - 5:00Friday10:00-12:00For access outside of open hours, contact Design Studio Manager sjsander@unca.edu or 828 250 3836.Safe Work Practices/ Studio Orientation:The Engineering Design Studio in Rhoades Hall is available to support the research of faculty, staff, and students. Access to the Design Studio, tools and equipment will be granted on an individual basis, upon completion of the safety orientation by a Design Studio Supervisor. The privilege of access and use of the facilities requires that every user adheres to the safety regulations outlined in this document. Any violation of Design Studio rules may revoke that person’s access to the Design Studio until further notice. These guidelines ensure safe working conditions for you and those around you.1. The shop may only be used by those who have completed the shop safety orientation2. No one is to work in the shop alone.3. Always ask for assistance if you are unsure about a setup or operation.4. Only use equipment on which you have been trained, and only for its intended use. 5. Safety glasses are provided and must be worn at all times.6. Closed-heel, closed-toe shoes must be worn at all times. Leather Shoes or shoe covers must be worn in welding areas. 7. Long hair must be tied back, secured at all times. 8. No loose clothing, jewelry, or headphones allowed while using tools. 9. Hearing protection is provided and should be used at your discretion.10. Always report accidents, broken equipment, unsafe conditions to the supervisor.11. Never leave a running machine unattended.12. Always disconnect power when changing bits, blades, etc.13. Always remove wrenches, chuck keys, etc. before turning on a machine.14. No food or drink allowed in shop.15. Keep a clean work area, free of clutter and debris. Keep pathways clear.16. Gloves are available for moving material and hot work only. Do not use gloves when operating motorized equipment.17. The shop is to be used for university-related projects.18. Do not enter the shop under the influence of drugs or alcohol.19. Before leaving the shop, clean up your work area and replace all tools.TrainingDesign Studio training will be conducted on an individual basis by a Design Studio supervisor. No one will be allowed to use any of the machines in the Design Studio without being trained on the equipment first. Training records will be specific as to what machines the individual has been trained on. Training records will be kept on file in the Engineering Program’s Design Studio.Appendix ANCSU/UNCA Engineering Design Studio Training CertificateTraining Outline:Safety Manual: Location and contents of the safety manual will be discussed.Safe Work Practices: Safe work practices of the Design Studio will be reviewed.Machinery: Demonstrations for each piece of machinery will be conducted with emphasis on the machine’s function, safety mechanisms, PPE requirements and safe operating procedures. Training is based off of the Standard Operating Procedure for that piece of equipment.Welding: Demonstrations for welding will be conducted with emphasis on different welding techniques, safety mechanisms, PPE requirements and safe operating procedures. Welding will only be performed under strict Design Studio supervision by competent individuals. Otherwise welding will be done by a designated Design Studio Supervisor.Engineering Design Studio Standard Operating Procedures (SOPs)Every piece of equipment in the Engineering Program’s Design Studio has a written Standard Operating Procedure (SOP). SOPs should be referenced before each use of the machinery.Appendix B(SOPs) for MachineryWeldingWelding, soldering, and brazing are commonly known as “hot work”. Hot work presents increased potential for fire and explosion hazards, especially when performed in confined and enclosed spaces. You must be aware of these hazards to work safely and avoid accidents and injuries. All welding, brazing, and soldering operators must be trained on each piece of equipment they use. You must be trained by your supervisor or another qualified person before conducting any type of hot work. All training must be documented and kept on file. COMMON HAZARDSAir Contaminants Hot work produces air contaminants. The most common contaminants include metal fumes and gases. Hazardous fumes may be produced from heating toxic metals found in common alloys. Some examples are beryllium, cadmium and nickel. The fume particles created are small and can deposit deep in the lungs. The adverse health effects of overexposure to welding fumes and gases can range from systemic poisoning to respiratory tract irritations. These effects can be short or long term, depending on the level of exposure. Setting up an appropriate work environment and using the appropriate goggles, face shields, and/or respirators will protect you from contaminants. Radiation Both visible ultraviolet (UV) and infrared (IR) radiation are produced when welding and cutting. These types of radiation can cause skin damage (sunburn and cancer) and eye damage (welder’s flash, cataracts, and burns). You may not be aware of these injuries until after they occur since UV and IR radiation is not detectable by the senses. Appropriate clothing and filter lenses will protect you from radiation damage. Burns and FiresHot work can be a fire hazard. Burns, fires, or explosions can result from flames, arcs, molten metals, heated surfaces, or metal splatters. Sparks from welding operations have been known to travel as far as 35 feet horizontally from the welding sight. Be aware of fire hazards when welding and remember that you can cause fires or be burned when working. Unplug and place soldering irons or guns in holders or stands when not in use. Always assume that a soldering iron or gun is hot. Give equipment time to cool down before touching tongs and tips. A fire watch should be posted for at least 30 minutes after the welding operations have ceased to ensure that no fires will be started. Electrical ShocksEvery year welders die from electric shock. Electric shocks can occur when proper precautions are not taken. Equipment must meet Underwriters Laboratories (UL) code and be checked and serviced regularly. Servicing and installation must only be undertaken by a qualified licensed electrician. Never tamper with electrical supply circuits or systems. Welders are only responsible for making connections in the welding circuit and for setting external welding machine controls.Be aware of your work environment. Do not work in wet conditions or on noninsulated surfaces. Use wooden platforms and rubber mats for protection, especially in confined spaces. Always use fully insulated electrode holders and never touch an energized electrode when in contact with the work circuit. Remember, hot work increases the risk of electrocution due to the reduced skin resistance when sweating occurs. If you sweat profusely, stop working. Don’t touch electrodes or welding wire with your bare hands. And never place holders or welding guns under your armpits. For your protection, make sure all work areas are well ventilated. Use hoods or local exhaust ventilation (LEV) to minimize exposure to hazardous fumes, gases, and heat. Consider the safety of other workers around you. Use light filters and welding screens. And always have fire extinguishers readily available.Do not work around sources of ignition. Keep flammable chemicals in approved storage cabinets. Keep combustible material at least 35 feet (11 meters) away from hot work operations. If this is not possible, then make sure these items are properly shielded. Remember that walls, ceilings, and floors are also combustible. Shield these areas as necessary. Seal or guard any cracks and holes where hot sparks might fall.Always use appropriate guards when welding. Do not put fingers between tongs or linkages when spot welding. Make sure that guards are always in place, and follow Lock out/Tag out procedures when welding energized or powered equipment. Gas welding and cutting tasks pose a high level of fire and explosion hazards due to the flammability of the gas cylinders. Always use appropriate pressure and backflow prevention devices when using gas systems. Ignite torches with approved friction devices. Remember to close gas valves before removing regulators. Protect cylinders from hot metal and sparks by positioning them away from your point of operation. Always secure cylinders from falling over using cylinder racks or other means to secure the cylinder such as having the cylinders chained to the wall. Personal Protective Equipment (PPE) Requirements:Welding, soldering, or brazing without the proper personal protective (PPE) equipment is dangerous and unhealthy. Because hot work involves an open electric arc or flame, the risk of burns is significant. To prevent burns, you must wear the proper PPE, such as heavy leather gloves and protective long sleeve jackets. Additionally, the brightness of the weld area can lead to a condition called arc eye, in which ultraviolet light causes inflammation of the cornea and can burn the retinas of the eyes. Goggles and welding helmets with dark face plates prevent this exposure. To protect bystanders, translucent welding screens can be placed around the welding area. These curtains, made of a polyvinyl chloride plastic film, shield nearby workers from exposure to the UV light from the electric arc, but should not be used to replace the filter glass used in helmets.Auditing and InspectionsTraining CertificatesTraining certificates will be kept on file in the Engineering Program’s Design Studio. Design Studio Supervisors will review safe work practices for the Design Studio to Design Studio users at the beginning of each semester.Machine/EquipmentMachines will be visually inspected at the start of each day by Design Studio Supervisors and prior to use by the machine operator. A documented equipment maintenance/inspection log will be maintained for each machine. Eyewash Eyewash stations will be activated on a weekly basis by Design Studio Supervisors to ensure operation and to flush the plumbing lines. Eyewashes will be kept clear from debris and have a sign posted identifying their location.Fire ExtinguishersFire Extinguishers will be visually inspected on an annual basis to ensure that servicing has been completed and that they are securely mounted to the wall. Fire extinguishers should be kept clear from debris.Engineering Program Design Studio Safety ManualThe Engineering Program’s Safety Program and Manual will be evaluated on an annual basis by Design Studio supervisors to ensure that all hazards are accounted for and that the manual has been updated with new hazards that have been introduced into the Design Studio.Appendix A: NCSU/UNCA Engineering Design Studio Training CertificateI have completed the Engineering Design Studio’s Safety Orientation and agree to do my best to ensure safe working conditions for myself and others in the Design Studio. I understand that failure to do so may result in loss of access to the Design Studio and equipment. The Safety Orientation includes the following:Location of Safety Manual Location of Safety Equipment Safe Work Practices/Orientation SignatureDateApproved:Design Studio SupervisorDateI , have been trained on and understand the following safety practices and procedures implemented for working in the Design Studio and I have been trained on the following machine Standard Operating Procedures (SOPs).Date CertifiedDesign Studio Supervisor SignatureBand Saw _____________________________________________Bench Grinder _____________________________________________Belt/Disk Sander _____________________________________________Chop Saw _____________________________________________Drill Press _____________________________________________Jig Saw _____________________________________________Metal Lathe _____________________________________________Milling Machine _____________________________________________Miter Saw _____________________________________________Sand Blaster _____________________________________________Table Saw _____________________________________________I have been trained to safely use the welding equipment and am considered by the Design Studio supervisor as a competent welder.Design Studio Supervisor Signature and Date:Appendix B: Standard Operation Procedures (SOPs) for machineryNever Leave a Running Machine Unattended Appendix B includes Standard Operating Procedures (SOPs) for the following machines:Band SawBench Grinder Belt/Disk Sander Chop Saw Drill Press Jig Saw Metal Lathe Milling Machine Miter Saw Sand Blaster Table Saw SOP: Band SawNever Leave a Running Machine Unattended PPE Requirements:Safety glassesPre-Inspection:Ensure that the machine has been unplugged before making any adjustments.Check the blade tension and tracking before starting.The teeth of the band saw blade should point down toward the table.The blade should be 1/32” from the rear roller bearing.The blade alignment tracking should be at the center of the wheel.Use of Band Saw:Keep your hands away from the path of the blade.Make sure that the upper and lower wheel guard doors are closed when running the machine.Keep the blade guard and guide only 1/4” above your stock.To control the stock, use push sticks, or other safety device when cutting short stock.Use a “V” block when cutting cylindrical stock.Cut at a moderate feed rate into the blade. Do not force a cut. Forcing a cut can result in kickback.Cut relief cuts prior to cutting long or tight curves. The relief cuts will free the blade of the tension.If you need to back out of a cut, cut the machine off first, wait for the blade to stop and then back out.If a blade breaks, shut the machine off and stand clear until everything stops.When shutting the band saw off, wait until the blade comes to a complete stop by itself.Maintenance/Inspection LogBand SawDATEACTION ITEMSIGNATURE/INITIALSSOP: Bench GrinderNever Leave a Running Machine Unattended PPE Requirements:Safety Glasses Face ShieldLeather gloves for handling hot metalsLong sleeve shirtPre-Inspection:Ensure that the machine has been unplugged before making any adjustments.Adjust wheel guards to be close to the grinding disc.Do not fit a grinding disc that has been damaged or is wet.Be sure blotters and wheel flanges are used to mount the grinding wheels onto the shaft of the grinder.Tool rests should be adjusted close to the wheels and thoroughly tightened in place so they cannot shift position while in use.Use of Bench Grinder:Stand to one side of the wheel when turning on power.Ensure your work piece is firmly secured and supported.Keep fingers, hands and power cord clear of the disk.Allow the grinder to reach operating speed, then apply load gradually.When grinding, use the face of the wheel only.Maintain a constant pace to avoid uneven surfaces.Maintain complete control. Always operate with both hands and maintain proper and steady footing.Do not apply excessive force.Be aware of flying hot sparks. Shut off power when finished and remove guards. Maintenance/Inspection LogBench GrinderDATEACTION ITEMSIGNATURE/INITIALSSOP: Belt/Disk SanderNever Leave a Running Machine Unattended PPE Requirements:Safety Glasses/gogglesPre-Inspection:Ensure that the machine has been unplugged before making any adjustments.Inspect the sandpaper disk to ensure that it is not dull or loose. Notify the instructor if it is.The rest should be adjusted so that it is no more than 1/8” from the disk/belt.Use of Belt/Disk Sander:Always sand on the downward motion side of the disc/belt. Attempt to place your work against the rest on the disc and belt sanders and hold the work securely.Keep fingers away from the abrasive surface on the sander.Avoid pressure against the disc. Stock that is 1” or smaller in length should not be sanded using this machine.Maintenance/Inspection LogBelt/Disk SanderDATEACTION ITEMSIGNATURE/INITIALSSOP: Chop SawNever Leave a Running Machine UnattendedPPE Requirements:Safety glassesFace shieldPre-Inspection:Ensure that the machine has been unplugged before making any adjustments.Check and tighten the blade and the blade-attachment mechanism.Ensure that the blade and its related washers and fasteners are correctly positioned and secured on the saw's arbor.All guards must be in place and operating. If a guard seems slow to return to its normal position or hangs up, adjust it or repair it immediately. Use only the recommended RPM and sizes of blades.Use of Chop Saw:To avoid losing control or placing hands in the blade path, hold or clamp all material securely against the fence when cutting. Do not perform operations freehand.Hands and fingers must be kept clear of the path in which the blade travels.Clean the lower guard frequently to help visibility and movement.Do not re-cut small pieces of material. Long material should be supported at the same height as the saw table.After completing a cut, release the trigger switch and allow the blade to come to a complete stop, and then raise the blade from the work piece. Maintenance/Inspection LogChop SawDATEACTION ITEMSIGNATURE/INITIALSSOP: Drill PressNever Leave a Running Machine Unattended PPE Requirements:Safety glassesPre-Inspection:Ensure that the machine has been unplugged before making any adjustments.Use only properly sharpened drill bits, sockets and chucks that are in good condition. All belts and pulleys must be guarded. If frayed belts or pulleys are observed, inform the Design Studio Supervisor so that the machine can be taken out of service.The drill bit should be mounted the full depth and in the center of the chuck.Position the table and adjust the feed stroke eliminating the possibility of the bit striking the table.Use of Drill Press:All stock must be properly secured with a vise or clamps. If the stock material slips in the vise or clamp, the machine must be shut down. Do not attempt to hold the work to make necessary adjustments while the machine is running.Use the appropriate bit for the stock being machined. Bits with feed screw or extremely long bits should not be used.Use the correct speed and drill for the type of stock being machined.Feed the bit smoothly into the work. If the hole being drilled is deep, withdraw the bit frequently to remove shavings on the bit.Never attempt to remove a broken bit with a center punch or hammer.When an operator has finished working on the drill press, turn the power off and wait for the machine to come to a complete stop.Clean metal shavings from the machine using a brush, not your hands.Maintenance/Inspection LogDrill PressDATEACTION ITEMSIGNATURE/INITIALSSOP: Jig SawNever Leave a Running Machine Unattended PPE Requirements:Safety glassesPre-Inspection:Ensure that the machine has been unplugged before making any adjustments.Make sure the blade is intact and suits the material to be cut.Plan a sawing strategy to minimize backing the blade out.Use of Jig Saw:Ensure the material is secure and well supported.Allow the machine to reach full speed before starting a cut. Always saw at a moderate rate.Keep hands away from the blade.Take care when cutting curves to ensure that the blade does not twist or bind. Drill small holes if necessary to aid blade movement.If the blade binds, turn off the machine immediately. Free the blade and inspect if for damage.Keep the machine free from accumulating saw dust.Maintenance/Inspection LogJig SawDATEACTION ITEMSIGNATURE/INITIALSSOP: Metal LatheNever Leave a Running Machine Unattended Supervision RequiredPPE Requirements:Safety glassesPre-Inspection:Ensure that the machine has been unplugged before making any adjustments.All belts and pulleys must be guarded. If frayed belts or pulleys are observed, the lathe must be taken out of service and the belts or pulleys replaced.All stock must be properly secured in the lathe chuck or mounted prior to the machining process taking place. Use the correct sized clamp or vise for the stock being machined.Turn the chuck or faceplate by hand to ensure there is no binding or danger of the work striking any part of the lathe.Only properly sharpened drill bits and cutting tools in good condition should be used. Dull drill bits and chipped or broken cutting tools must be removed from service.Use of Metal Lathe:Select turning speed carefully. Large diameter stock must be turned at a very low speed. Always use the lowest speed to rough out the stock prior to final machining. The correct speed and feed for the specific material and cutting tool must be used. Stop the machine before making adjustments or measurements. Do not remove chips from the table or stock by hand. Use a brush or other tool to properly remove chips or shavings from the table or stock.When an operator has finished working on the lathe, and before leaving the lathe for any reason, the power must be shut off and the machine must come to a complete stop.Maintenance/Inspection LogMetal LatheDATEACTION ITEMSIGNATURE/INITIALSSOP: Milling MachineNever Leave a Running Machine Unattended Supervision RequiredPPE Requirements:Safety glassesPre-Inspection:Ensure that the machine has been unplugged before making any adjustments.Ensure all guards are in place.Securely fasten all cutting tools in the machine spindle with the appropriate accessory.Use of Milling Machine:Work pieces and stock must be rigidly fastened to the mill bed with clamps, a vise, or special fixtures.Make sure the cutting tool is clear of the work piece before starting the machine.Keep hands away from moving cutting tools.Use appropriate speeds and feeds for the type and size of cutter being used and the material being machined.Do not make measurements of the stock while the milling machine is powered.Do not allow large quantities of chips to accumulate around the work piece or machine table. After stopping the machine, use a brush or rag to remove all excess chips from the mill bed and stock.Maintenance/Inspection LogMilling MachineDATEACTION ITEMSIGNATURE/INITIALSSOP: Miter SawNever Leave a Running Machine Unattended PPE Requirements:Safety glassesPre-Inspection:Ensure that the machine has been unplugged before making any adjustments.Make sure all guards are in place and operating correctly.Ensure the blade rotates in the correct direction and that the teeth at the bottom of the blade are pointing to the rear of the miter saw.Ensure the blade moves freely and the kerf plate is in good condition.Use of Miter Saw:All materials should be inspected for defects such as warps, knots and foreign objects.Hold the stock firmly against the fence and the table keeping your fingers at least 150 mm (6”) away from the blade. Allow the blade to reach full operating speed before letting the blade enter into the stock. Be aware that the saw moves up or down slightly upon start-up and stopping. Return carriage (cutter head) to its full rear position after each cross-cut. If the blade begins to bind while cutting stop immediately.When finished, turn off the miter saw and wait for the blade to come to a complete stop before retracting from the work piece.Maintenance/Inspection LogMiter SawDATEACTION ITEMSIGNATURE/INITIALSSOP: Sand BlasterNever Leave a Running Machine Unattended PPE Requirements:Safety glassesPre-Inspection:Ensure that the machine has been unplugged before making any adjustments.Ensure gloves are in good condition.Check and tighten sand hose clamps and check other fittings for leaks and wear.Check for loose or worn hose and fittings.Use of Sand Blaster:Prior to adding abrasive, fully pressurize the unit to check all hose and pipe fittings for tightness.Check for air leaks and tighten as necessary. Turn the sandblaster on and off several times to become familiar with the operation.Add abrasive and start to sandblast.Maintenance/Inspection LogSand BlasterDATEACTION ITEMSIGNATURE/INITIALSSOP: Table SawNever Leave a Running Machine Unattended PPE Requirements:Safety glassesPre-Inspection:Ensure that the machine has been unplugged before making any adjustments.Check the blade for chips or cracks and make sure it is the correct type of blade for the cut to be made.Ensure the blade is adjusted to the appropriate height.Ensure the saw teeth are sharp so they will cut. Dull teeth are more likely to cause a kickback.Ensure all guards are in place and attached securely.Use of Table Saw:Keep hands away from the saw blade. Use saw blade at high speed when entering or removing material from a cut.Never force a piece of material through the saw, as a “kick-back” of the material could result.Always be watchful for blade-pinching situations.Always use splitter and anti-kickback fingers when ripping.Always hold the work firmly against the miter gage or fence.Always use a push stick for ripping narrow stock.Move the rip fence out of the way when cross cutting.Never run the stock between the fence and molding cutter head when cutting molding. Shut off power and clean the saw before you leave it.Maintenance/Inspection LogTable SawDATEACTION ITEMSIGNATURE/INITIALS ................
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