ME 1101 Workshop Engineering

2.Safety and accident prevention

R.M.R.C. Udayanandana, B.Sc.Eng. (Hons), P.G.Dip.

Assistant Lecturer

Email: rmrcu@yahoo.com

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 Causes of accidents
Almost two-thirds of small engineering
workshops accidents reported to be arise from
the movement of people, goods and vehicles
into, around and out of workshops.
Of these movement accidents:
about half involve lifting and moving goods, and
about half involve slips, trips and falls and hitting
stationary or moving plant and equipment.

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 Causes of accidents
Non-movement accidents usually arise from the
use of machinery; these account for between 10
and 15% of all accidents.
Electrical accidents are not uncommon and
frequently have the potential for more serious
injuries than those recorded.
The most common occupational diseases are
dermatitis, deafness, asthma and vibration white
finger, and back, hand, arm, shoulder and neck
problems.
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 workshop risks factors
movement of people, goods and vehicles around
the workshop, particularly manual handling
machinery safeguarding
hazardous substances, particularly metalworking
fluids, degreasing solvents, and dust or fume
from welding, brazing, soldering, coating and
painting
noise, and
vibration.

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Which machinist looks right for the job-and
more importantly for a career ?

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 Shop Clothing
NO LOOSE CLOTHING.

Ties, scarves, loose sleeves, etc. are prohibited.
NO GLOVES
REMOVE JEWELLARY
WEAR APPROPRIATE SHOES

No open-toed sandals. Wear shoes that give a sure footing.
If you are working with heavy objects, steel toes are
recommended.

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Shop Clothing

Loose clothing does get

caught in moving
machinery !

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 Shop Clothing

Two hot chips melted

onto this nylon cloth
while the center one
went completely
through to possibly
burn the person
within

Wear natural fiber clothes !

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No Accessories

Jewelry is
dangerous. It
catches on
machines and
chips and
conducts heat
and electricity

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 Clothes and Hair
Check your clothes and hair before you walk into the
shop. In particular;

IF YOU HAVE LONG HAIR OR A LONG BEARD, TIE IT
UP.

If your hair is caught in spinning machinery, it will be
pulled out if youre lucky. If youre unlucky, you will
be pulled into the machine.

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Hair

Hair does catch on

moving machinery

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 Safe Conduct in the Shop
Be aware whats going around you. For example, be
careful not to bump into someone while theyre cutting
with a machine
Concentrate on what youre doing. If you get tired,
leave.
Dont hurry. If you catch yourself rushing, slow down.
Dont rush speeds and feeds. Youll end up damaging
your part, the tools, and may be the machine itself.
Listen to the machine. If something doesnt sound right
turn the machine off.

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 Safe Conduct in the Shop
Dont let someone else talk you into doing
something dangerous.
Dont attempt to measure a part thats
moving.
Wear safety glasses when told to do so and
always when working in an area where light
illumination is likely to be a problem
Always wear the appropriate eye/clothes
protection when welding.
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Eye protection
Be a trend
setter-wear
safety glasses
even when
others dont.

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 Hearing Protection
Machine shops
can be noisy
places. Some
cutting
operations are
loud enough to
cause hearing
loss over time

Earplugs Earmuffs 15
 Machining
IF YOU DONT KNOW HOW TO DO SOMETHING, ASK!
BEFORE YOU START THE MACHINE
o Study the machine. Know which parts move, which are
stationary, and which are sharp.
o Double check that your work piece is securely held.
o Remove chuck keys and wrenches.
DO NOT LEAVE MACHINES RUNNING UNATTENDED!
CLEAN UP MACHINES AFTER YOU USE THEM!
o A dirty machine is unsafe and uncomfortable to work on.
o Do not use compressed air to blow machines clean. This
endangers peoples eyes and can force dirt into machine
bearings.
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 Handling Materials
Always use a machine if you can to lift heavy
loads.
Overhead cranes moving on rails
Fork lift trucks
Rolling lift tables
Portable jib cranes.

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Use your Legs (and Your Head) Not
Your Back

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Carrying Materials

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 Managing an Efficient workspace
The work area also a tool in itself and like all
tools, requires attention and proper care.
Advantages
Pride
Tasks go faster and have more reliable results.
Safety

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Managing an Efficient workspace

A lean show
board

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 Managing an Efficient workspace
There are various names for the science of
efficient work areas and environments.
The most common in modern manufacturing is
lean manufacturing.
The heart of lean manufacturing is the finding the
most efficient , logical way to organize and
manage work space.
It starts with people having exactly what they
need to do a job right where they need it and
eliminating clutter.
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 It also means returning tools to their place
throughout the shift not just at quitting time.
Lean people constantly control the space in
which they work.

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Machine accessories

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 Five kinds of shop chemicals
Lubricants
Coolants
Solvents/coatings
Cleaning products
Gasses (compressed and liquefied)

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 Lubricants
Special oils for hydrostatic bearings
Sliding lubricants and rolling action lubricants.
The sliding type oil is called way oil.
Way oil is thicker than spindle oil.
For bearings that rotate, spindle oil is the
correct lubricant.

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 Coolants
Make machining safer and faster
Todays coolants are water based
When used correctly, tools last longer,
productivity increases, and power is reduced.

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Coolants

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Electrical Safety
 Rules of Electricity
Electricity travels in a completed circuit
Electricity always travels in the path of
least resistance
Electricity tries to travel to ground

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 Electricity and People
A person usually offers a lesser resistance
for the electricity
The person forms a completed circuit when
touching the ground

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 Effects on the Human Body
1 mA: Can be felt by the body
2-10 mA: Minor shock, might result in a fall
10-25 mA: Loss of muscle control, may
not be able to let go of the current
25-75 mA: Painful, may lead to collapse
or death
75-300 mA: Last for 1/4 second, almost always
immediately fatal

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 Bodys Resistance
Skin offers most of the bodys
electrical resistance
Increased resistance
Thick and callused skin (foot or hand)
Dry skin
Decreased resistance
Thin skin (inner forearm)
Wet or sweaty skin
Broken or abraded skin (scratches)

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 Resistance Varies
Different levels of electrical resistance
for each person
Ranges from 500 ohms to many thousands
of ohms
The greater the bodys resistance, the less
chance of harm
A similar voltage shock can be minor to
one person and deadly to another

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 Additional Resistance
Gloves
Shoes
Mats

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 General Electrical Hazards
High-voltage overhead
power lines
Damaged insulation on wires
Digging or trenching near
buried lines
Broken switches or plugs
Overloaded circuits
Overheated appliances or tools
Static electricity
Flammable materials

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 Summary
Electricity will try to reach ground even if it
means going through a person
Even the small voltage from your home can
cause serious injury
Always inspect power tools and cords and do
not use them if damaged
Do not attempt to repair electrical equipment
unless trained and qualified

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