Advanced Photon Source

Shop Safety Study Guide P. 1

Shop Safety
This study guide will cover Shop Safety that is applicable to APS in-house safety guidelines and/or most machine shops in industry today. This study guide has been designed to directly represent the questions that will be found within all the open book machine specific written assessments, the Safety specific written assessment, and as an aid for the machine specific handson usability assessments. Answering the questions found at the end of this study guide will enable the user to successfully pass the hands-on usability and open book written assessments. All questions at the end of the study guide relate strictly to safety issues. The questions are of situations, general practices, common sense, and some are machine specific.

There are two absolute needs for any user of any machine shop machinery: 1. Knowledge of all safety guidelines. 2. Working knowledge of the specific machine. APS User Machine Shop Rules and Safety Guide-lines can be found in

APS Policies and Procedures for User Shop Access User Shop Orientation, which includes the User Shop Rules. The Accident Prevention Manual for Industrial Operations text National Safety Council (available from the APS Floor Coordinator). In the machine specific study guides. MANUF_1450 198 040 SUMMER 2003 Machine Shop Safety Management (available from the APS Floor Coordinator).

Use the above as reference material for study purposes.

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Shop Safety Study Guide P. 2

APS User Shop Safety

In an effort to create a safe working environment, safety rules and procedures must be adhered to. In the following section those safety items listed are APS specific and OSHA standards. Many times common sense will tell you, if it looks dangerous, dont do it! General Shop area safety measures include: Wear a face shield over safety glasses when using abrasive saws or grinders. Always maintain awareness of activity around you. Never wear gloves when working with equipment that has exposed moving/rotating parts. Deburr material before and after machining operations. Keep aisles clear and walk in aisles to the extent possible. Utilize chip guards at all times. Use exhaust trunks/rotoclone systems to capture mist/dust from grinding operations.

APS User machine shop safety measures include: Your are responsible for maintaining your work area in a safe and reasonable condition. Shields or splashguards will be used on machines where cutting oils or coolants are used. Never adjust coolant hoses while machines are running The work area floor should be kept dry and clear of refuse at all times. Use spill-control absorbent immediately to control leakage or spills. Use brushes to brush off chips and shavings from machines; do not use your bare hands or an air hose.

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Shop Safety Study Guide P. 3

You must be aware of the various machine controls (start button, stop button, speed-change control) for each machine you are authorized to operate. Machine controls must be accessible and unobstructed at all times during operation of any machine. General APS User Shop Rules Shop door must be propped open when working in the shop. Wear ANSI-approved safety eyewear with side shields whenever in the machine shop. Do not leave machines running unattended. Use only brushes, vacuum tools, or other special tools to clean debris from work prices and machines. Do not use compressed air to blow chips and dust from work where a brush can be used for the task. Use vises and clamps to hold work pieces as appropriate. Do not manually adjust work pieces or attempt to measure a work piece while the machine is running. Do not wear jewelry or loose fitting clothing while operating machinery. Remove neckties and roll up shirtsleeves to above the elbow. Restrain (i.e., cover or tie back) long hair that could get caught in moving parts. Proper machine guards must be in place on machine tools such as drill presses, lathes, grinders, sanders, and saws while these tools are being used. Do not remove or circumvent any machine guarding. Do not use solvents to clean your hands. Treat even minor cuts or scratches as causing potential infection.

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Shop Safety Study Guide P. 4

General Shop-Safety Tips Do not use the grinding wheels on the pedestal grinder to grind nonferrous materials (e.g., aluminum, brass, plastics, or wood). Compressed air shall not be used for cleaning clothing.

Never eat or drink in the machine shop. Practice Test

The following questions have been designed to directly represent the questions that will be found on the open book shop safety and machine specific written assessments and as an aid for the hands-on machine specific usability assessments. 1. 2. 3. Never force a grinder wheel onto the machines mounting hole. True True False False While drilling a hole, never hold work piece with your hands. For best eye protection when grinding, always: A. Use the grinders glass eye shield B. Use the grinders glass eye shield and wear goggles C. Use the grinders glass eye shield and wear a face shield D. Either B or C 4. 5. Machine shields should be in place before actual machining takes place. True False Wear safety glasses, goggles, or a face shield when performing grinding operations, even though the machine is fitted with eye shields. True 6. 7. 8. True True False False False Use vises or clamps to hold work piece. Use only brushes, vacuums or special tools for machine clean up. Machine safety guards are not required to be in place during some machining operations. True False

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Shop Safety Study Guide P. 5

9.

Always keep hands at a safe distance from moving machine parts. True False

10. It is not necessary to wear ANSI-approved safety eyewear upon entering the machine shop. True 11. 12. 13. True True False False False Always use vises or clamps to hold work pieces while machining. Always prop the machine shop door open upon entering shop. Serious injury can result from a work piece that becomes loose and spins during a drilling operation in a drill press. True 14. 15. 16. 17. True True True False False False False It is not necessary to remove sharp edges from machined part. Never attempt to measure a part on a lathe while the spindle is turning. It is permissible to leave the chuck key in the chuck while drilling a hole. If it is really cold in the shop it is OK not to roll up your shirtsleeves before beginning to use any machine shop machinery. True 18. 19. True False False Treat any small cuts or skin punctures as potentially infections. Be thoroughly familiar with the placement of the machines stop switch or lever. True 20. 21. True True False False False Never activate the rapid traverse while any cutter is making a cut. It is not necessary to keep the floor around your machine clear of chips.

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Shop Safety Study Guide P. 6

22.

Proper machine guards must be in place on machine tools such as drill presses, lathes, grinders, sanders, and saws while these tools are being used. True False

23. To avoid vibration while turning a long piece in a lathe, the work piece ________. A. can be supported with your hand B. does not need to be supported. C. Should be supported with a live center. 24. The countersink can be used to enlarge the end of hole for a flat-head screw. True False 25. When reaming, the speed of the drill press should be: A. 1/3 of that used for drilling B. The same as the speed used for drilling C. Twice the speed of the drill D. As slow as possible 26. The work area should be cleaned up before leaving the shop. True True 28. 29. True False False False 27. Never wear jewelry or loose clothing while operating machine. You should maintain awareness of activity in your surrounding area. Never stand directly in front of a grinding wheel whenever a grinder is started. True 30. True False False Do not turn on a grinder if the grinder wheel looks damaged.

31. Machine shields should be in place before actual machining takes place. True False

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Shop Safety Study Guide P. 7

32. Safety takes precedence before work. True True False False 33. Always debur all materials before and after machining. 34. Which of the following can cause serious injuries ___________? A. Materials with sharp edges B. Materials stored in racks above head level C. Potential tripping hazards D. Equipment with moving parts E. None of the above F. All of the above 35 It is OK to wear gloves when working with equipment that has exposed moving/rotating parts so you can keep your hands clean. True True True True True True False False False False False False

36. Always turn on the exhaust trunks/systems before any grinding operation. 37. The shop door should be propped open upon entering the shop. 38. Treat even minor cuts or scratches as causing potential infection. 39. All machine users must be authorized to operate specific shop machines. 40. Do not use solvents to clean your hands. 41. It is OK to wear jewelry or loose clothing while operating machine if you are very careful. True True True False False False 42. Use air hoses for a fast and quick machine clean up. 43. Always clean up the work area before leaving the shop.

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Shop Safety Study Guide P. 8 Study Guide Answer Sheet

1. True 2. True 3. D 4. True 5. True 6. True 7. True 8. False 9. True 10. False 11. True 12. True 13. True 14. False 15. True 16. False 17. False 18. True 19. True 20. True 21. False 22. True

23.

24. False 25. A 26. True 27. True 28. True 29. True 30. True 31. True 32. True 33. True 34. F 35. False 36. True 37. True 38. True 39. True 40. True 41. False 42. False 43. True

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