Prototype Shop Safety Orientation

Report
MIT LL Beaver Works Center
BEAVER WORKS
PROTOTYPING WORKSHOP
SAFETY TRAINING & ORIENTATION
David Allaby – Facility Manager
Lisa Kelley – Business Manager
Topics
• Beaver Works Prototyping Workshop Description
• Emergency Evacuation
• Prototyping Workshop Access
• Prototyping Workshop Safety Policies
• Personal Safety Policies
• General Shop Safety Guidelines
BW Prototyping Workshop Orientation - 2
Beaver Works Prototyping Workshop
• Beaver Works Prototyping Workshop is an unclassified work
space that contains multiple pieces of equipment
Drill Press
Mill
Band Saw
Sanding Table
Lathe
Brake
Shear
Notcher
3D Printer
Laser Cutter
• Do-it-yourself approach to your project
• Facility Manager to help/train on equipment
BW Prototyping Workshop Orientation - 3
Evacuation & Muster Plan / Telephone Locations
• Evacuation Routes/Muster Location
– Refer to map below (a map is posted on the Main Entrance as well)
– In case of evacuation please muster in the Quad Area outside
Main Street
Prototype Shop
Research Area
Class Rooms
= Exit
= Telephone
BW Prototyping Workshop Orientation - 4
= Fire Extinguishers
Beaver Works Safety Policy/Training
EMERGENCY SAFETY PROCEDURES
• Fire extinguisher locations
– Main Entrance, straight back to the windows center
– Research Area, next to eye wash station
– Small Class Room, inside door on the wall side
– Prototyping Workshop, Chemical work group room in the center back of the room
• Emergencies – Dial 100
• MIT Police – Dial 31212
• 5 telephone locations (4 in the General Research Area, 1 in
Prototyping Workshop. Locations shown on map in previous slide.)
– Facility Manager’s office
– Office #2
– VPN room
– In General Research area, located along the windows
– Prototyping Workshop – on the table to the right when you walk in
We are in the process of adding two additional telephones in the Prototyping Workshop.
BW Prototyping Workshop Orientation - 5
Prototyping Workshop Access
• Prototyping Workshop Access Policy
1.
Potential users must already have Access to General Research Laboratory
2.
Potential users must attend this Prototyping Workshop Orientation
3.
Users of industrial machining equipment must receive machine- specific training
and evaluation by Facility Manager prior to being granted access. This will include
going through the “Flashlight Program” if not already qualified in the Prototyping
Workshop on machine-specific equipment
4.
Approved users will be allowed to access the Prototyping Workshop in groups of
2 or more approved/trained users 24/7 when industrial machining equipment is in
use. After hours, an authorized/trained graduate student must be present in the
workshop per MIT policy
5.
The number allowed in the Prototyping Workshop: Min 2 – Max 10
6.
The Facility Manager will grant key access to specific industrial machining
equipment when he determines that a user(s) is capable of using that specific
equipment while abiding by all the safety policies and procedures. Keys cannot be
given to other users without the permission of the Facility Manager
7.
The Facility Manager can deny access if the policies and procedures are not
followed
BW Prototyping Workshop Orientation - 6
Prototyping Workshop Safety Policy
• See Beaver Works Safety Policy (SP) BW001 for general rules
• Prototyping Workshop rules
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Personal Protective Equipment (PPE) is required (safety glasses, gloves)
Must sign in and pick up a “Panic” button that is to be worn at all times in the workshop
Guarding required to be utilized
No cell phones, Ipods or headphones
Safety glasses must be worn at all times
Wear ear protection when necessary
Long hair must be pulled back
No jewelry can be worn – including rings and watches
No loose clothing – including ties
Badges must be removed and placed in a designated location
Must wear appropriate shoes (flat and toes must be covered)
Gloves must be worn when necessary (never around equipment with rotating parts)
Never work alone – the Prototyping Workshop uses the 2-person rule
Never leave a machine running unattended
Never use a rag near moving machinery
Never use damaged machinery or tools – report any issues to the Facility Manager
No food or drinks
Dial x100 in case of Emergency
BW Prototyping Workshop Orientation - 7
General Shop Safety Guidelines
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Safety Rules around Machines
Machine Guarding
Machine Installation
Personal Protective Equipment
Shop Housekeeping
Fire Prevention
Lockout/Tagout
Compressed Air Safety
Abrasive Grinding
General Machine Safety
BW Prototyping Workshop Orientation - 8
Safety Rules around Machines
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Only operate a machine that you have been properly trained to
use
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Dress Safety – wear tucked in short-sleeved shirts and noncuffed pants. Long sleeves, gloves, neckties, scarves, badge
lanyards, and jewelry can get caught in moving parts. Tie long
hair back and use a hair net or hat
BW Prototyping Workshop Orientation - 9
Safety Rules around Machines
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Concentrate on what you’re doing and stay aware of what’s
going on around you
Perform another task if you’re tired and having trouble
focusing
Take your time. Rushing will only increase your chances of
being injured or causing damage to the machine
BW Prototyping Workshop Orientation - 10
Safety Rules around Machines
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Never leave a running machine unattended
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Let the machine stop completely by itself – never use your
hands or a makeshift device to slow it down
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Clean the machine when you have finished using it. A dirty
machine is unsafe and uncomfortable to work on. Also,
maintain good housekeeping in the shop
BW Prototyping Workshop Orientation - 11
Safety Rules around Machines
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Never lean on a machine for support
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Do not run or joke around or near
machinery
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NO working alone in machine shops
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No cell phones, Ipods or headphones
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NO eating or drinking in work areas; and
most importantly,
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Use machine safety guards at all times.
BW Prototyping Workshop Orientation - 12
Concept of Machine Guarding
HAZARD
MACHINE
GUARD
YOU
The concept of machine guarding is to PREVENT you from
coming in contact with hazards.
BW Prototyping Workshop Orientation - 13
Machine Guarding
Helps Protect Workers from incurring:
• Cuts
• Fractures
• Electric shock
• Chemical exposure
• Eye injuries
• Skin burns; and,
• Amputation or loss of the use of an appendage
BW Prototyping Workshop Orientation - 14
Sources of Machine Hazards
• Shear points - edges of two objects are moved closely enough
together to cut a soft material
• Pinch points - two rotating objects move together and at least
one of them moves in a circle
• Wrap points - rotating shafts
• Crush points - two objects come together. One of the objects
may be stationary
• Free wheels or fly wheels - parts continue to spin after the power
is shut off
• Springs - under compression will expand with great force when
released, and springs that are stretched will contract rapidly
when released
• Hydraulic systems - fluid under very high pressure
BW Prototyping Workshop Orientation - 15
Common Machine Hazards
Crush point
Pinch point
Shear point
Wrap point
BW Prototyping Workshop Orientation - 16
Machine Guards
• Covers and Plates – most common safeguard to prevent access
to hazard
• Interlocks – shuts down the equipment if a cover is opened
• Emergency Stops – located near the operator to shut off
machine
• Lockout Procedures – locking out equipment to prevent
accidents; equipment may still be energized
BW Prototyping Workshop Orientation - 17
Common Machine Guards
Guard doors on CNC Mill
Belt guard on lathe
Blade guard on miter saw
Guard on abrasive wheel grinder
BW Prototyping Workshop Orientation - 18
Machine Installations
• Readily accessible “lockout” points are required to be installed
and labeled at or very near the equipment
• Services (pipes) shall be labeled
BW Prototyping Workshop Orientation - 19
Personal Protective Equipment
Hand Protection
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Never reach into energized or running machinery
To remove chips, use a brush
To remove ribbon, use pliers
DO NOT feel for burrs
If you drop something, let it go
To change belt positions, throw disconnect
To dress a tool, use a fixture or handle-mounted device
For hot parts, use ALUMINIZED or Nomex gloves (asbestos
gloves are no longer allowed)
• For chemicals, use impermeable gloves such as nitrile or
neoprene
• When handling sharp tools, scrap or stock, use cut resistant
gloves such as Kevlar. NEVER wear gloves when running a
machine with rotating parts!
BW Prototyping Workshop Orientation - 20
Personal Protective Equipment
Eye and Face Protection
• Safety glasses with side shields meeting “ANSI Z87” certification
are required to be worn when working with any machine shop
machinery – some areas require safety glasses to be worn upon
entering the area
• Replace defective eyewear immediately (scratched lenses, broken
frame, etc.)
• When grinding, safety glasses AND face shield are required
• When welding, special ultraviolet (UV) welding helmets are
required
BW Prototyping Workshop Orientation - 21
Personal Protective Equipment
Clothing and Foot Protection
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Wear only short sleeve or tight sleeve shirts
DO NOT WEAR loose fitting clothing
DO NOT WEAR jewelry on hands and arms
DO NOT WEAR neck jewelry, badge lanyards or ties outside your
shirt
• Do NOT Wear open toe shoes
• Keep long hair tied back or under hair net or hat
BW Prototyping Workshop Orientation - 22
Shop Housekeeping
• Keep aisles clear of furniture, equipment, and debris
• Keep access clear to EXITS, fire extinguishers, eye
wash/showers units
• DO NOT allow scrap to accumulate on or around machines
• DO NOT allow coolant or oil to accumulate on floor
BW Prototyping Workshop Orientation - 23
Fire Prevention
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Avoid grinding or sparks near flammable or combustible liquids
Do not allow oily materials to accumulate
Keep metal turnings in a dry, covered, metal container (drum)
Keep access to fire extinguishers clear
CLASS D Fire Extinguisher is used for combustible metal fires
(e.g. magnesium)
• Notify the Facility Manager if fire extinguishers are damaged or
empty
BW Prototyping Workshop Orientation - 24
Compressed Air Safety
• Use only OSHA-Approved guns/nozzles that limit air pressure to
30 psi
• DO NOT modify guns/nozzles
• DO NOT put tape on gun nozzle
• Brush away or vacuum chips before blowing chips
• Wear safety glasses
• Report leaking hoses to your supervisor
• DO NOT blow off body or clothes with compressed air. Cuts can
be blown open, causing severe injury and
infections. Eyes can only withstand 4 psi
before severe permanent damage occurs
BW Prototyping Workshop Orientation - 25
Abrasive Grinding
• Wear safety glasses AND face shield when grinding
• The grinder shall be secured (bolted) to the work surface
and electrically grounded
• Ensure the tongue guard (top) is within 1/4” of the grinding
wheel
• Ensure that the work rest is within 1/8” of wheel
• The maximum RPM rating of the wheel must be compatible
with the RPM of the grinder motor
• Keep end-plates in place
• “Ring test” grinding wheels before use
• Never grind on the side of the wheel
BW Prototyping Workshop Orientation - 26
Machine Safety
• All machines contain hazards from rotating parts, belts, pulleys,
high voltage electricity, noise and compressed air
• When using manual and/or CNC machines, basic safety
precautions must always be followed to reduce the risk of
personal injury and mechanical damage
• Specific safety issues will be discussed during all training
BW Prototyping Workshop Orientation - 27
Machine Safety
• Only authorized personnel can work on a machine
• Check for damaged parts and tools before operating the machine.
Remove damaged tools from service
• Some tools have RPM limits. DO NOT exceed these limits
• Wear eye protection
• Do not operate the machine unless the guards are in place. This
includes the doors. Door interlocks should function properly
• The Emergency Stop Button is for emergencies
• Door(s) to the machine should be closed when machine
is running. Never bypass door interlocks!
Emergency Stop
Button
BW Prototyping Workshop Orientation - 28
Your Role and Responsibilities
• Users
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Complete general and work area-specific training
Sign in to shop and pick up a “Panic” button before proceeding
Be familiar with all machines you are using
Only use machines you are trained on
Promptly report chemical exposures, accidents, incidents, and
near misses to the Facility Manager
Seek help at MIT Medical Department if injured at Beaver Works
Clean up facility after each use
No food or drink in the Prototyping Workshop
No cell phones, Ipods or headphones
Know where to find the first aid kits, fire extinguishers and
telephones
BW Prototyping Workshop Orientation - 29
Conclusion
• Safety is the #1 priority and will be incorporated into all aspects of
training and using equipment and tools at the Beaver Works Center
• A two-man rule is always in effect when using the machines in the
Prototyping Workshop
• Contact the Facility Manager with any questions
BW Prototyping Workshop Orientation - 30
Beaver Works User Agreement
Prototype Shop
Beaver Works is a do-it-yourself open laboratory space consisting of the following:
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Prototyping Workshop
Rapid Prototyping Area (Laser Cutter/3D Printer)
Software Development Area
Electronics Area
Systems Development Area
The Beaver Works Center serves as a single convenient, comprehensive, and open laboratory
designed to foster innovation, collaboration, and creative problem solving. This area is
available to students and staff for development, preprogram idea or concept validation, and
unstructured curiosity driven prototyping. Each of the areas within Beaver Works is equipped
with tools and equipment that provide the maximum utility to those students and staff looking
to train, explore and/or prototype.
As a student / staff member and potential user of Beaver Works, I
Name
agree on
Date
to attend all required safety orientations and to abide by all
safety rules and regulations present to me by the Facility Manager. By signing this document,
I also understand the potential hazards associated with the equipment within the Beaver
Works facility and that by following the Safety Procedures and regulations I will be allowed to
use the facility. Failure to follow the Beaver Works rules and regulations may result in my loss
of access to the lab as determined by the Facility Manager.
Signature:
Date
Facility Manger:
Date
BW Prototyping Workshop Orientation - 31

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