Transcript Robert R. Shaw Center for S.T.E.A.M Basic Safety Training
Robert R. Shaw Center for S.T.E.A.M
Basic Safety Training
2015 Katy ISD, Katy, Texas
Basic Safety Training Outline
Introductions Safety Moment – RSC Orientation – Exits, Safety Features Expectations of Teams Using the RSC Safety Rules for Everybody Tools Provided in Each Team Bay Tools Provided by Teams Specific, Hands-on Training on Band Saw and Drill Press Training Your Team Members Q & A Closing
Introductions
Steve Adams – RSC Cordinator Phone: Cell: 832-216-2530; Office: 281-396-7670 Email: [email protected]
Mariam Manual – RSC Educational Specialist eMail: [email protected]
Steve Treese – Team 624 Safety Mentor 832-247-5200 [email protected]
Safety Moment: RSC Orientation
A = Emergency Exits B = Extinguishers
D C A F B
C = Fire Alarm Pull
G A C F B
D = AED
G G B F F B B F F B
E = Safety Shower/ Eyewash
G
F = First Aid Kit
B F B C A B F E B B F C A
G = Goggle Sanitizing
G G G G
Expectations of Teams Using RSC
Agreement to abide by Operating Guidelines
Comply with the KISD RSC Site Safety Rules
Train team members and mentors in safe use of tools
Maintain verifiable record of training
Conduct annual refresher training for all persons
Prevent damage to facilities and equipment
Maintain safety and security of facility users
Do not use tools that generate cuttings or debris on the central carpeted field – move to the bays to work
Safety Rules for Everybody
Adult supervision
KISD employee must be present in building
Two mentors required on site, one may be the KISD employee
No one-on-one student/adult work
No unsupervised student work
Building secured by KISD employee after work session
Safety glasses
Required in work bays
Required within 5 feet of field when in use (basically the carpet area)
Must meet OSHA Z-87
Side shields required (or compliant wrap-around glasses or goggles)
Normal glasses with side shields do NOT satisfy this requirement
Safety Rules for Everybody (continued)
Shoe requirements
Substantial, closed-toed shoes required in work areas
Required within 5 feet of central, carpeted field when in use
Prohibited: flip-flops, sandals, flats, “Crocs”, others
Sole of shoe must resist puncture
Other personal protective equipment (PPE)
Specific PPE required in areas defined by KISD and building administration
Individual teams may require additional PPE in their bays
Consider gloves when handling sharp materials
Open flames
No open flames in the building
Safety Rules for Everybody (continued)
Loose clothing, jewelry, and hair
Shall be kept out of the way when working with power tools
Do not wear long-sleeves or gloves when working with potentially entangling tools (e.g. mill, lathe, and drill press)
Tie back long hair; remove jewelry; roll up long sleeves
Training requirements
Proper training in safe use required to operate a power tool or the plasma cutter
Includes everyone working at the RSC (mentors and students)
Each team is expected to have key representatives trained by KISD (“train the trainer”)
Trained representatives can train others on their teams
Maintain records to show this requirement has been met
Team safety programs
Within their own bay, a team may have more strict safety requirements
Team requirements must be at least as strict as these rules
Safety Rules for Everybody (continued)
Housekeeping requirements
Keep areas clean and uncluttered
Keep emergency exits clear
Keep carpeted area clear of debris and cuttings
Chemicals and paint usage
No use of volatile or vapor emitting chemicals in the building
No spray painting in the building – OK out back with adult supervision
Proper PPE required when handling chemicals
Materials must be used in accordance with the manufacturers instructions
Have MSDSs (or SDSs) available for any chemicals used in your area
In the event of a spill, notify KISD representative and mentor
Behavior
No horseplay or rowdy behavior on the premises
Safety Rules for Everybody (continued)
Incident reporting requirements
Report any incident resulting in injury, fire, or damage to people, building, or equipment immediately
KISD representative and mentor
Includes minor first aid, like a band aid
Food and drinks
No food or drinks (except water) in the bays
Food is allowed around the central bay (not on the carpet) and outside the building (patios)
Be courteous to other users of the building
Safety Rules for Everybody (continued)
Visitors allowed with clearance by KISD representative
Same PPE and shoe restrictions apply
Visitor stickers required – generated by Raptor system
Visitors may not operate equipment
Use proper tools, in good condition, for each job
Team training in safety rules
Teams are required to ensure all team members and mentors know and comply with the safety rules.
If a team member from one team visits another team’s bay, they are expected to comply with the safety rules of the team they are visiting.
Tools Provided in Each Team Bay
Drill press – Jet 15” Floor Mounted, Model JDP-15MF
Band Saw – Jet 14” Vertical, Model J-8201K
Miscellaneous Hand Tools
Basic training provided for key team representatives on drill press and band saw (this class)
Each team is expected to provide equivalent training in the safe use of the drill press and band saw provided by KISD to all members of the team who will work in the RSC
Maintain a record of this training for auditing
Tools Provided by Teams
Each team is expected to provide additional tools as necessary and within the limitations of the safety rules (e.g. mills, lathes, other band saws or drill presses, etc.)
Each team is expected to provide necessary training in the safe use of these tools and maintain records of that training for auditing
Hands-on Training – Jet Band Saw
Description
Capacities
6 inches under guide
13.5 inches throat
Speeds, SFPM
Wood and Aluminum: 3300
Steels: 39, 57, 78, 107, 142, 196, 278 (pulley adj.)
Blade size: 3/8” x 0.025” x 93.5”
Weight: 171 lbs
Hands-on Training – Jet Band Saw
Parts Identification
Lower blade guide and support assembly Lower drive wheel
Hands-on Training – Jet Band Saw
Key Guidelines
Use the Operating Instructions and Parts Manual available online
Wear proper PPE – especially eye protection
Keep loose clothing, jewelry, and long hair away from saw
Do not wear gloves while cutting, but use them when changing blades
Keep hands away from blade
Use the rip fence and miter gauge when possible
For small pieces, use a pusher stick or paddles
Keep all doors closed in operation
Hands-on Training – Jet Band Saw
Key Guidelines (cont’d)
Do not start the saw with the blade in contact with work piece
Wait for saw to stop fully before removing cuttings
Disconnect saw from power before any maintenance
Lower saw blade guides to about ¼ - ½” above work piece
Set saw blade speed appropriately for material being cut:
Wood – 3000 FPM
Aluminum – 3000 FPM
(Normally should not have to change speed)
Steel (low carbon) – 160-165 FPM (down to 70 FPM for harder steels)
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Hands-on Training – Jet Band Saw
Making a Cut 10.
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Mark work piece to be cut Ensure you are wearing proper PPE, especially eye protection Clean off saw table Adjust height of blade guide Install rip fence or miter guide if needed Place work piece on table, not contacting blade Start the saw Push the work piece slowly through the saw along mark – use pushers if necessary – keep hands away from blade When through with cut, stop the saw Wait for it to come to a complete stop Remove work piece and cuttings – they will be hot! Watch for sharp edges
Hands-on Training – Jet Band Saw
Common Maintenance Activities and Adjustments
Adjusting blade tension and tracking Adjusting table angle and leveling Adjusting miter slot parallelism Adjusting blade speed (use table in manual) Changing saw blades (use gloves)
Adjusting blade guides
Hands-on Training – Jet Band Saw
Troubleshooting Common Problems
Excessive blade breakage: Material loose, incorrect speed or feed rate, teeth too coarse for material, incorrect blade tension, starting saw in contact with work piece, blade rubbing wheel flange (tracking), misaligned blade guides, cracking of blade weld Premature blade dulling: Blade teeth too coarse, blade speed too high, hard spots or scale on work piece, work-hardening of material (esp. stainless), insufficient blade tension, operating saw without pressure on work piece Bad cuts (out of square): Feeding too fast, guides out of adjustment, inadequate blade tension, dull blade, incorrect blade speed, loose blade guide assembly, loose blade guide bearing assembly, blade too far from wheel flanges, worn guide bearing Bad cuts (rough): Blade speed too high for feed rate, blade too coarse Blade twisting: Feeding too fast, blade tension too high Unusual blade wear on back or sides: Worn blade guides, blade guide bearings not adjusted, blade guide bracket loose Teeth missing or ripped from blade: Blade tooth pitch too coarse for material, feeding too slow or too fast, work piece vibrating, gullets loaded with chips Motor running too hot: Blade tension too high, drive belt tension too high, blade too coarse or too fine, speed reducer needs lubrication Excessive speed reducer noise or vibration: V-belt too tight Slamming or banging sound when cutting: Missing teeth, gullets loaded with chips
Hands-on Training – Jet Drill Press
Description
Swing: 15 inches
Spindle travel: 3-1/8 inches
Maximum chuck capacity: 5/8 inch
Maximum spindle to table distance: 29 inches
Table size: 16.5 x 13 inches
Speed range: 200-3630 RPM
Weight: 161 lbs
Hands-on Training – Jet Drill Press
Key Parts Identification
On/Off Switch Depth stop adjustment Work light switch Chuck Work table Pulley cover and pulleys Motor Downfeed handle Quill (chuck connects to quill) Crank lock (on opposite side) Table lock Table height crank handle Column Base Work light (under) Return spring
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Hands-on Training – Jet Drill Press
Drilling a Hole 10.
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Mark work piece to be drilled Use an auto-punch or transfer punch to mark the center of the hole Ensure you are wearing proper PPE, especially eye protection Locate the correct drill bit and tighten it in the chuck Adjust height (and angle if necessary) of the drill press table Tighten locks on table height and angle adjustments Align work piece mark with drill bit, using a piece of wood or spacer below piece to avoid drilling into table Secure work piece to the table (a machine vise is a good investment) Turn on drill press Drill hole to required depth, avoid drilling into the table or machine vise Pull drill out and stop motor Allow drill to stop completely before reaching for work piece – watch for sharp cuttings
Hands-on Training – Jet Drill Press
Maintenance and Adjustments
Refer to the Operating Instructions and Parts Manual available online Return spring adjustment Adjusting the depth stop gauge Changing spindle speeds (higher for wood, lower for metals) Replacing work light (underside of head) Lubrication – gear, rack, table height crank, spindle grooves, quill
Hands-on Training – Jet Drill Press
Troubleshooting Common Problems
Will not start: Unplugged, fuse blown or breaker tripped, cord damaged, bad starting capacitor Does not come up to speed: Extension cord too light or too long, low current Vibrates excessively: Uneven surface for base, bad belt Noisy operation: Incorrect belt tension, dry spindle, loose spindle pulley, loose motor pulley Work piece burns: Incorrect speed, chips not clearing hole or bit, dull bit, feeding too slowly Drill bit wanders: Dull bit, bent bit, bit or chuck not installed properly, work piece moving or vibrating, did not use auto-punch to mark hole location Wood splinters on underside: No backing board used Drill bit binds in work piece: Work piece pinching bit (moving), excessive feed rate, chuck jaws not tight, improper belt tension Excessive drill bit runout or wobble: Bent drill bit, worn spindle bearings, bit or chuck not installed properly Quill returns too slowly or too fast: Improper spring return tension Chuck or arbor does not stay in place: Dirt, grease, etc. on arbor, chuck, or spindle
Hands-on Training – Demonstrations
Identify the main parts of the drill press and band saw
Demonstrate use
Each person use the drill press and band saw
Training Your Team Members
Plan training for your team, including annual refreshers
Train your team members
Be sure you keep a record of who is trained
Have the record available in your bay
Online files available which include:
Copy of these presentation materials (Powerpoint)
Copy of suggested written test
Some example safety program materials
Copies of Operating Instructions and Parts Manuals