OCTE toolSAFE

TMJ Manufacturing Technology

Milling Machine
Safety Lesson
Video QR code
Writer: John Hobbins
(to be inserted)
Doc version
(version Y/M/D date 160430
i.e.150630):

Specific Tool or Process: Milling a Block Square and Parallel – Milling

Machine

Main Applicable Course: Manufacturing TMJ20

Additional Applicable Courses: TMJ3M, TMJ3C, TMJ3E, TMR3M

Safety Instruction Type

Whole class preparation Demo at course start
lesson x
Small group demo x Just in Time (JIT) demo x
Individual demo if/where Assessment Review x
needed e.g. IEP Students x (using exemplars)
Student presentation Assessment demo
Students repeat demo x Demo Assessed exemplar x
Squaring and Parallel
Block Operation

This resource was produced

by the Ontario Council for Technological Education (OCTE)
It may be used in its entirety, in part, or adapted

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Assessment Procedure

Prior Assessment and Preparation Assignments

 Milling Machine Overview Assignment
 Safety Reading chapter and review questions (page 529)
 Vertical and Horizontal Milling Machine review questions (page 466)
 Speeds, Feeds and Depth of Cut Chapter and Review Question (page 473)
 Machining a Block Square and Parallel Test (as per student workbook (page
106)
 Basic Measurement and Micrometers Chapter (page 60-80)
 Machining a Block Square and Parallel, chapter and questions 5-10, (page 497)

Assessment and Evaluation Task

Machining a Block to be square and parallel on 6 sides

 Machine rough and finish surfaces in preparation for specified component shape
and predetermined size
 Rubric as A&E tool - see “Dice Project” Appendix A

Assessments and Evaluations

 Appendix D: Vertical mill Safety Quiz
 Appendix E: General Safety Quiz
 Appendix F: General Rules Quiz

Associated Documents

Appendice Appendix A: Milling Machine “Dice” Project

s to this Appendix B: Vertical Milling Machine Safety Poster
lesson Appendix C: Assessment Rubric
Appendix D: Vertical mill Safety Quiz
Appendix E: General Safety Quiz
Appendix F: General Rules Quiz
Appendix G: Record of Safety Training
Appendix H: Horizontal Milling Machine 1 Poster
Appendix I: Horizontal Milling Machine 2 Poster
Appendix J: Squaring Blocks On Milling Machine Safety Passport

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OCTE OCTE SAFEdoc

SafeDOC http://www.octelab.com/content/safedoc-manufacturing
General Safety Rules - page 77, 78, 79
Vertical & Horizontal Mill Safety – page 58, 59, 60
Vertical Mill Safety – page 93
Safety Passports – pages 97,98,99
Record of Safety Training - page 103

Other
Ministry Curriculum documents - Technological Education, 2009
http://www.edu.gov.on.ca/eng/curriculum/secondary/teched910curr09.pdf

Other Referenced – Textbook, and Student Workbook

Reference  Technology of Machine Tools, by Steve F Krar, Arthur R Gill, Peter
Docs Smid
 Machining a Block Square and Parallel (page 486)

Illustrations and diagrams

 Reference “Technology of Machine Tools” textbook and student
review and test workbook , 6th edition, Krar, Gill and Smid
Assessment docs
 Student Review & Test workbook assessments

Video URL’s
 “How to square up stock on the milling machine”
https://www.youtube.com/watch?v=igfqYZPdQ78

 “Squaring stock on a mill”

https://www.youtube.com/watch?v=XdEM77NDejE

 “End Mill selection and use on a milling machine”

https://www.youtube.com/watch?v=HfIaISnqHOk

 “Face Milling on a milling machine”

https://www.youtube.com/watch?v=9OsNUi_o6C4

 “Cutting Speed and RPM”

https://www.youtube.com/watch?v=gIUS_0xfeGg

OSHA – Machine Guarding

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9836

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Milling Machine Safety - OSHA

http://www.ccohs.ca/oshanswers/safety_haz/metalworking/millingmachines.html

General Metal Machine Safety

http://www.ccohs.ca/oshanswers/safety_haz/metalworking/general.html

Milling Machine Visuals

https://www.google.ca/search?
q=safety+on+a+vertical+milling+machine&biw=1398&bih=767&tbm=isch&tbo=u
&source=univ&sa=X&ei=ulaVVZyONIGoyATRtoq4Dw&ved=0CBwQsAQ&dpr=1

Guarding Examples for Milling Machines

http://rockfordsystems.com/online/safeguarding/mill-safety-shields-guards.cfm

Cutting Fluids - section “B” The Basics of Metal Working Fluids

https://www.osha.gov/SLTC/metalworkingfluids/metalworkingfluids_manual.html

WHMIS MSDS – if using metal cutting fluids during the turning process,
please reference the related MSDS sheets and WHMIS Labels
See Safedocs page 66

Canadian Centre for Occupational Health and Safety

http://www.ccohs.ca/oshanswers/safety_haz/welding/

Ministry of Labour
http://www.labour.gov.on.ca/english/index.php

Ontario College of Trades (OCT)

http://www.collegeoftrades.ca/

Passport to Safety
www.passporttosafety.com

Live Safe! Work Smart! Grade 9/10 and Grade 11/12

http://www.livesafeworksmart.net

Ontario School Boards Insurance Exchange

http://www.osbie.on.ca

Workplace Safety and Insurance Board

http://www.wsib.on.ca

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Hazard Table
Standard Tool Hazards Biological Hazards
Sharp objects, cuts X Food contamination
Knives/sharp tool procedures X Food temperature handling
Set up adjustments, lock procedures X Sharps/cutting tools handling X
Machine guarding X Exposure to sunlight/ultraviolet light
High speed moving elements Exposure to blood products
Pinch points X Exposure to mold, mildew
Sharp noise Temperature extremes X
Constant noise Insect bites/plant/animal hazards
Drop hazards Emergency contamination proc.
Kickback hazards
Heavy material hazards Chemical Hazards
Use of recycled products/materials WHMIS identification X
Dust/debris hazards Exposure to dangerous gases/fumes
Spill hazards Exposure to dangerous liquids
Emergency stop procedures X Exposure to solvents X
Exposure to pesticides/herbicides
Glassware handling
Emergency chemical procedures
Fire/Burn Hazards
Flammable material hazards Electrical hazards
Hot processes Electrical shock
Sparks Electrical sparks
Explosion hazards Electrical burns
Noxious gases/fumes Short circuits
Emergency fire procedures Wire/cord/cable inspection
Electrical connection inspection
Power cables/bars handling
Ergonomic hazards Emergency power shutoff procedures
Heavy lifting
Awkward lifting Site hazards
Heavy or extreme force Confined spaces
Constant heavy force Working from heights
Vibration Slip/trip/fall hazards
Posture, body placement X Hazardous location of others
Repetitive stress injuries Vertical Mill Tool Change Hazard X
Working with helpers
Emergency injury procedures
Safe disposal and Cleanup Other hazards (specify)
Material scrap disposal X Work-piece held short – pinch points X
Chemical disposal Long Work-piece, deflection/pressure
Biological materials disposal Carriage collision with chuck face
Tool cleanup procedures X Avoid razor sharp & hot cuttings X
Sharp Cutting tool hazard X
Hold length of Tool – keep short X

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Personal Protective Equipment

PPE Required Suggested Details
Eye, Face, Head Protection
Safety glasses X
Face shields X
Welding helmets/goggles
Hard hats

Hearing Protection
Ear plugs X
Ear muffs

Hand protection
Work gloves
Disposal gloves
Chemical resistant gloves
Knife shields

Respiration Protection
Dust masks
Surgical masks
Respirator (describe type) X Cutting oil fumes

Body Protection
Foot protection X Hard shoes, steel toes
Arm shields
Leg shields
Bibs
Coveralls X Where available
Welding jackets
Hot/Cold temperature protection

Fall Arrest X Protect against falling

when changing tool if on
steps for vertical mill
Fire protection

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Lesson Preparation Procedures

Formal lesson to be delivered in classroom with all students preparing them for the
“Rough and Finish Turning a Diameter” operation followed by a teacher demo lesson on
metal lathe.

Demo lesson – (best performed in small groups, consider one to one for students
with IEP)
- requires safety glasses
- ventilation and/or mask for cutting fluid fumes (if desired)
- cutting tool selection and inspection for functional purpose and sharpness
- have files and emery paper on hand for deburring
- acquire work-piece of appropriate size for the project
- use of all guarding
- brush for clearing cuttings
- work-piece prepared by sawing to +.06-.1”
- ensure work area is clutter free
- have cutting oil and related MSDS on hand and associated clean up materials

Look Fors (Possible Risk Factor from Safety Passport Form 3)

- ensure no loose clothing or jewellery
- tie long hair back
- awareness of hard stop to stop carriage from hitting revolving chuck
- wrenches, chuck keys, and allen keys are removed from machine and work-
holding devices
- work-piece, tool holder and cutting tool is securely fastened
- cutting tool is of appropriate length for the task
- awareness of sharp edges and/or burrs on work-piece
- work-piece is moved clear of stopped cutter when measuring, installing and/or
removing from vise
- guarding is in place to protect self and others from flying cuttings

Step by Step: Performing the Demo Lesson

Objective
 Set up and safely operate a milling machine using cutting tools to perform
roughing and finish cutting operations on a work-piece machined to a specified
size

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Preparations
 Ensure machine is free of clutter and in safe working order including guards

 Operators must wear safety glasses, and appropriate apron or coveralls if

available

 Ensure a brush is nearby for debris removal and clean up

 Tools and work-piece, and work holding devices have been set up properly and
secured

 Recommended machine speeds and feeds have been calculated and set

 Student has referenced the “Possible Risk Factors” specific to the milling
machine just prior to operating (see Safety Passport Form 3)

 Student is aware of standing position relative to direction of cutting removal

 Student is aware of accessing the E-stop, and has tested it’s functionality

Procedure
Note:
 Work-pieces may require a rough milling operation prior to completing the finish
milling operation

 Whenever possible, the rough work piece size should allow for a two cut
operation: one roughing and one finishing cut

 It is important to employ a round bar (when needed) to help seat the work-piece
squarely against the solid jaw of the vise

 The largest surface should be face milled first

 It is important that dirt and burrs be removed from the work, vise, and parallels,
since they can cause inaccurate work and an unstable and/or loose work-piece

Rough and Finish Milling*

Machining Side 1
1. Clean the vise and parallels thoroughly, and remove all burrs from the work-
piece

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2. Set the work-piece in the vise centre with the largest surface (side 1) facing
up (see fig. 62-10)

3. Place short paper feelers under each corner between the parallels and the
work. This will indicate if the work-piece is sitting down onto the parallels

4. Use a round bar between the work-piece and the moveable jaw to help force
irregular shaped work-pieces squarely against the solid jaw and tighten the
vise securely

5. Tap the work-piece with a soft-faced hammer until all paper feelers are tight

6. Mount a cutter into the machine spindle

7. Set the machine for the proper speed for the size of cutter and the material
being machined

8. Start the machine and raise the table until the cutter just touches near the
right-hand end of side 1

9. Move the work clear of the cutter

10. Raise the table about .030” and machine side 1 using a steady feed rate

11. STOP the revolving cutter, and take the work-piece out of the vise and
remove all burrs from the edges with a file

Machining Side 2
12. Thoroughly clean the vise, work and parallels

13. Place the work on parallels, if necessary, with side 1 against the solid jaw and
side 2 upward (see fig. 62-11)

14. Place short paper feelers under each corner between the parallels and the
work

15. Place a round bar between side 4 and the movable jaw approximately in the
center of the work-piece

16. Tighten the vise securely and tap the work down until the paper feelers are
tight

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17. Follow steps 8 to 11 and machine side 2 marking each machined side with a
marker identifying number of the side machined

Machining Side 3
18. Clean the vise, work and parallels thoroughly

19. Place side 1 against the solid vise jaw, with side 2 resting on parallels if
necessary (see fig. 62-12)

20. Position the parallel to the left so the work-piece extends just beyond the
parallel about .25”

21. Place short paper feelers under each end or corner between the parallels and
the work

22. Place a round bar between side 4 and the movable jaw, making sure the that
the round bar is in the center of the amount of work held inside the vise

23. Tighten the vise securely and tap the work down until the paper feelers are
tight

24. Start the machine and raise the table until the cutter just touches near the
right-hand end of side 3

25. Move the work clear of the cutter and raise the table about .010”

26. Take a trial cut about ¼” long, stop the machine, and measure the width of
the work (see fig. 62-13)

27. Raise the table the required amount and machine side 3 to the correct width

28. STOP the revolving cutter and remove the work and file off all burrs

Machining Side 4
29. Clean the vise, work, and parallels thoroughly

30. Place side 1 down on the parallels with side 4 up and tighten the vise
securely (see fig. 62-14)

31. Place short paper feelers under each corner between the parallels and work
(fig. 62-14)

32. Tighten the vise securely

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33. Tap the work down until the paper feelers are tight

34. Follow steps 24 to 27 and machine side 4 to the correct thickness

Machining Side 5
35. Set the work in the center of the vise with one of the ends (side 5 or 6) up and
tighten the vise lightly

36. Hold a square down firmly on the accurate surface of the vise and bring the
blade of the square into light contact with the side of the work

37. Tap the work until its edge is aligned with the blade of the square ensuring an
accurate right angle cut (see fig. 62-15)

38. Tighten the vise securely and recheck the square-ness of the side

39. Take a cut machining the end square (see fig. 62-16)

40. Remove the burrs from the end of the machined surface

Machining Side 6
41. Clean the vise and set the machined end on paper feelers in the bottom of the
vise or on parallels

42. Tighten the vise securely and tap the work down until the paper feelers are
tight

43. Take a trial cut from the end until the surface cleans up

44. Measure the size of the work-piece

45. Raise the table the required amount and machine the work to size. You may
need to take a roughing cut leaving a finish cut of about .010”

46. Raise the table the required amount and machine the work to finish size

47. Follow proper clean up procedures

*Referenced from Technology of Machine Tools, by Steve F Krar, Arthur R Gill, Peter
Smid “Machining a Block Square and Parallel” - page 486

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Emergencies

Before procedure, ensure students understand potential hazards and their mitigation.

Students must be trained to be aware of potential hazards, how to deal with

emergencies, locations of safety equipment such as fire extinguishers, first aid kits and
safety exits. Teachers must ensure safety equipment is up to date and ready.

Any injury, no matter how seemingly insignificant, must be reported to the instructor.
Instructors must make reports as per Board and OSBIE requirements.

Ensure proper understanding of machine operations and functions with respect to

Vertical and/or Horizontal Milling machine operation and E-stop access. In the event the
machine needs to be shut off quickly, knowing the location and accessibility of the E-
stop and spindle brake is critical in minimizing injuries

Fire
1. Warn instructor & other students. Stop machine operation and hit shop E-stop as
applicable. Instructor must direct students away from the danger and toward fire
exit, ensuring fire alarm is activated, and use fire extinguisher if warranted.
2. Burns must be treated right away, with water or preferably burn cream. Cover
wound and bring student to administration.
3. Any injury must be reported as per Board and OSBIE requirements.

Cuts/Scratches/Slicing
1. Student must stop operation, tell students close by to watch over equipment, tell
instructor, then proceed to wash out the cut/scrape. Disinfectant and bandages
should be brought in from the first aid kit and cut dressed.
2. Inspect and assess the reason for the cut and inspect the tools and work pieces
involved. Clean any blood, skin in the area with disinfectant. Instructors must
approve of continuing operation and warn all students about the incident and
instruct how to avoid future events.
3. Any injuries must be reported as per Board and OSBIE requirements.

Lifting strain
1. Stop procedure immediately. Safely lower weight.
2. Assist person, ensure they cannot fall.
3. Assist in moving person to comfortable position or location only when safe to do
so.
4. Get someone to notify administration immediately.
5. Any injury must be reported as per Board and OSBIE requirements.

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Electrical Shock
1. Students must be trained to notice signs of electrical shock. Person undergoing
shock must not be touched until power removed remotely.
2. Clear the area; shut off power at fuse panel or e-stop. Unplug equipment only
when power is off.
3. Get someone to notify administration immediately.
4. If shock is severe or prolonged:
a. Begin CPR if the person shows no signs of circulation, such as breathing,
coughing or movement.
b. Keep person warm.
5. Cover any burned areas with a sterile gauze bandage.
6. Leave scene as is for inspectors.
7. Any injury must be reported as per Board and OSBIE requirements.

Cleanup Procedures

 When milling procedures are completed, the operator is required to place all tools
and related equipment away in their proper locations

 The mill must be brushed clear of all cuttings, wiped across the table, and have
all tools removed from the spindle

 *special emphasis is directed to ensuring wrenches are removed from the

drawbar after tool holder removal

Assessing Safety Knowledge

Before students operate the milling machine for the intended operation, they must have:
 Passed the milling machine safety test
 Passed the mill operation test and demonstration (checklist & sign-off)
 Attended the teacher rough and surface machining finish demo

Machining a Block to be square and parallel on 6 sides

 Machine rough and finish surfaces in preparation for specified component shape
and predetermined size
 Rubric as A&E tool - see “Dice Project” Appendix A

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Assessments and Evaluations

 Appendix D: Vertical mill Safety Quiz
 Appendix E: General Safety Quiz
 Appendix F: General Rules Quiz

IEP’s and Accommodations

Students with IEP’s can be supported by:
 Taking steps to support students as specifically referenced in their IEP
 Teacher and student one to one demo instead of small group
 Allocating extra time to complete the task

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Appendix A

Milling Machine “Dice” Project

TMJ20, TMJ3E, TMR3M, TMM3M
(part layout, setting part zero, milling, drilling and tapping)

Student Name(s) ,

Project Scope
The objective of this project is to provide a practical means for students to demonstrate key
competencies at performing operations on the milling machine – vertical or horizontal. Students
will create a basic dice design, layout dice, machine it square and accurately locate and drill a
series of holes. The operations will be performed following the completion of related theory to
support their knowledge and understanding about the tasks on the milling machine. It is
important that students have completed all required assignments, tests, and attended teacher
demonstrations/lessons that are involved in this project.

Steps to complete the project:

1. Saw cut the rough size of work-piece on band saw leaving enough material to
square the block, and to machine a rough and finish milling cut on all 6 sides
2. Follow procedures to machine a “block square and parallel” from the teacher
demonstration and lesson. Ensure that the block is of consistent size on all sides
and is square across adjacent sides
3. Layout hole locations for the dice patterns on all six sides of the block
4. Follow the milling machine “drilling” teacher demonstration and lesson to develop
an understanding of machine use, work-piece set up and safe drilling procedures
5. On the side with the "one dot", drill & tap to accept an eyebolt of a specific size.
(see teacher for specific size of thread)
6. Finish by filing to remove all burrs, sand and polish

Important Safety Considerations for this project

- Wear safety glasses at all time
- Ensure no loose clothing or jewellery and tie long hair back
- Always ensure Work-piece, vise, tool holder, cutting tool(s) and spindle/quill are securely
fastened
- Wrenches and keys must be removed from machine revolving devices prior to turning on
machine
- Guarding is employed to guard against injury from flying cuttings and potential broken
tool bits, drills or work-pieces that may become dis-lodged from its holding device
- Keep hands well clear of revolving parts and never attempt to grab the spindle/tool until
it has come to a complete stop
- It is important to ensure that drills, tools, and cutters are sharp, in good condition and
held short for rigidity

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- Ensure a brush is nearby for debris removal and clean up

- Awareness of sharp edges and/or burrs on work-pieces resulting from machining and
drilling holes and using files, emery paper and de-burring tools to remove the sharp
edges
- It is important to be aware of reducing the downward feed of the spindle/drill through
the bottom of the work-piece when drilling holes to prevent the drill from grabbing the
work-piece
- Move your work-piece well clear of the stopped cutter when measuring, installing
and/or removing from vise

Required Prior Review and Assessment

Students must complete related chapter work for these topics - submit questions
and answers to the teacher for evaluation. Students must complete the requirements
of the Safety Passport for the Milling Machine before operating the machine.

Related Theory - Text: "Technology of Machine Tools"

Basic Layout (pg. 140-149, questions 1-17) Measurement (pg. 71-79, questions
1-7)
Milling Machine (482-496, questions 1-17) Drilling & Hand Tapping (pg. 324-331,
questions 1-12)

Milling Machine Safety Quiz and Drilling Hints review page

Throughout Project:

 Wear appropriate safety glasses.

 Ensure that the milling machine has a start/stop button within easy reach of the
operator.

 Ensure that the work piece and cutter are mounted securely before taking a cut.

 Check that work is mounted squarely.

 Mount work in a vise that is bolted or held magnetically to the table. Use proper
hand tools to make adjustments. Refer to Hand Tools for more information.

 Hold milling cutters with a cloth to avoid being cut when handling them.

 Move table as far as possible from cutter while setting up work to avoid injuring
your hands.

 Mill the largest surface first.

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 Keep hands, brushes and rags away from the revolving milling cutter.

 Use a vacuum, brush or rake to remove cuttings only after the cutters have
stopped moving.

 Change cutting compounds periodically.

 Keep cutters sharpened correctly and in good condition.

 Keep working surface clear of scraps, tools and materials.

 Remove cutting tools from spindle when cleaning the machine.

 Keep floor around the milling machine free of oil and grease.

 Use lifting equipment when appropriate to move heavy work to or from milling
machines. Refer to Materials Handling for more information.

 Make sure the power is off before changing cutters.

 Always stay at the machine when it is in operation.

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Appendix B

Vertical Milling Machine

1. Wear Personal Protective Equipment (P.P.E) such as safety glasses, safety goggles,
face shields, proper clothing as appropriate. No loose clothing, long hair, or jewelry is
allowed in the shop.

2. Be aware of the position of the on/off switches and emergency STOP button.

3. Keep work area clean and free of oil, grease and debris.

4. Make sure spindle, beds and control handles are working properly before operating.

5. Ensure work holding device is mounted securely to the table.

6. Ensure work piece and cutter are mounted securely before starting motor and making
a cut.

7. To avoid injury, move the machine table as far as possible away from the cutter when
setting up or measuring work.

8. Do not attempt to setup or measure work piece until the cutter is completely stopped.
Keep hands away from moving parts.

9. When setting up or removing a milling cutter from its holder, proper precautions should
be taken to avoid injury.

10. Ensure all tool bits are sharp and undamaged. Show your instructor any problems
with tooling before operating the milling machine.

1. Make sure you have proper speeds and feeds for the type of material being machined.
When in doubt, ask the instructor.

2. When the machine comes to a complete stop, remove cut material and chips with a
brush.

3. Turn milling machine off immediately if it does not sound correct or there is excessive
vibration.

AT ALL TIMES – IF IN DOUBT, SEE YOUR INSTRUCTOR

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Appendix C:

Assessment Rubric
Level One Level Two Level Three Level four %
Score
Layout Basic layout was Good evidence of Evidence of some All six sides were
evident showing following proper precision accurately laid out with
Procedures two or more sides layout procedures measurement using accurate hole positions and
with holes drill with four sides Vernier caliper as depth of holes were /10
close to within drilled showing holes were consistent on all sides. Dice
1/32” of their pre- consistent hole accurately showed evidence of
determined depth and location. positioned to precision measurement
position Evidence of good within .02” on all using height gage and
measurement sides. centre punch resulting in
technique using a accurately following precise
scale layout using layout and
proper setting of part zero
Locating part Evidence showed More than two Very good evidence Significant evidence
part being sides showed hole of using machine demonstrating high
zero positioned using locations were accessories to accuracy locating all holes
basic within 1/16” of their accurately drill 4 or on all six sides. Holes were
measurement to intended location. more sides showing within .005” of their
position some hole locations within intended locations. /10
holes close to .01” of intended
their intended location
location
Rough & Evidence of Good evidence of Very good evidence Excellent demonstration of
satisfactory rough rough and finish of the roughing and rough and finish milling
Finish Milling and finish milling milling on more finishing milling operation competencies to
a Block operation on than 4 sides. More operations to square machine a block square /20
more than 3 than three sides all sides accurately and parallel on all sides.
Square and sides. At least were square and and within .015” in Each paired sides were
Parallel two paired sides accurate in size to accuracy within .01” accuracy and
were square and less than .02” perfectly square.
accurate to within
.025”
Drilling Some evidence Good evidence of Very good evidence Excellent demonstration of
that student employing proper demonstrating a a very strong ability to carry
understood procedures to drill strong ability to out drilling procedures with
drilling holes on the follow machine outstanding results of holes /20
procedures on milling machine procedures for on all sides
the milling drilling
machine.
Finishing Finished with little Good overall finish Very good finish and Outstanding finish; highly
attention to with no sharp nicely polished polished with zero sharp
polishing and edges. project with no edges. Excellent evidence
deb-burring. Recommended sharp edges. Very of using recommended
Recommended speeds and feeds good evidence of speeds and feeds.
speeds and feeds were used. recommended /10
were not fully speeds and feeds.
employed.
Safety Basic application Good application Very good Excellent application of all
of safety related of almost all safety application of all safety related precautions,
precautions, and related safety related and sequences of steps to
sequences of precautions, and precautions, and ensure safe operation of
steps to ensure sequences of sequences of steps machine and tooling.
safety operation steps to ensure to ensure safety Including demonstrated /30
of machine and safety operation of operation of referencing of MSDS,
tooling. machine and machine and Speeds and Feeds,

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tooling. tooling. Very good specification attention to

attention to safety in task related safety “Look
all aspects of fors” and the safety of self
performing tasks and others
Comments

/100
Total

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Appendix D:

VERTICAL MILL SAFETY QUIZ

Name:_______________________________

Date:________________

1. Always wear ____________________ when operating a vertical milling machine.

2. Ensure _______________ and _______________ are mounted securely before

starting motor and making a cut.

3. Remove chips and cut off material with a _______________ when the machine comes
to a complete ___________________.

4. Work areas need to be clean and free of ______________________.

5. When setting up or removing a _____________________________ from its holder

proper precaution should be taken to avoid getting injured.

6. Keep __________________________ away from revolving parts.

7. One person only should __________________________ a machine at any time.

8. Never___________ or_________________ work until cutter is completely stopped.

WORD BANK:
cutter, adjust, brush, milling cutter, hands, safety glasses, stop, work piece, operate, debris,
measure

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Appendix E

GENERAL SAFETY QUIZ

Name:_______________________________

Date:________________

The following are True or False questions. Write T for true or F for False for each question.

1. If you are uncertain about something in the shop, it is okay to ask a peer.

2. If the fire alarm sounds, continue working until told to stop.

3. Shop equipment needs to be cleaned only at the end of the period each day.

4. It is okay to bring a drink into the shop as long as none of the equipment is running

5. Any adjustments to a machine must be made with the power off.

6. It is okay to talk to a person while they are using a piece of equipment, as long as
you do not distract them.

7. It is okay to use a flat screwdriver to scrape some old paint off of a piece of metal.

8. The first aid kit can be stored in the school main office so no one steals the
contents.

9. A class “D” fire extinguisher is a must in a manufacturing shop.

10. Once you have passed the safety test/quiz on a piece of equipment you may use
the equipment any time without permission

11. Minor injuries need not be reported.

12. If a machine does not work, report it to the instructor.

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13. All guards must be in place and properly working before using the equipment

14. A safety zone is an area where shop rules do not apply.

15. As long as no one is using the equipment after you, leave it running until you need
it again.

16. Safety equipment is necessary only when power is on.

17. A safety zone is an area where shop rules do not apply.

18. Long hair must be tied back before using any power tool.

19. Before working in a construction shop you should know where the emergency
exits are.

20. Any adjustments to a machine must be made with the power off.

Answer Key
1. F 2. T 3. F 4. F 5. F
6. F 7. F 8. F 9. F 10. F
11. T 12. T 13. F 14. T 15. F
16. F 17. F 18. T 19. T 20. T

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Appendix F

GENERAL SAFETY RULES QUIZ

Name:_______________________________

Date:________________

Write the rule that relates to the following statements:

1. Using the proper tool for the job.

2. How to carry tools.

3. Electrical cords and plugs.

4. Portable tools when not in use.

5. Securing your work.

6. Safety guards.

7. Moving parts on equipment.

8. How many persons operate machines at one time, what do partners do.

9. Make sure it is completely stopped before leaving.

10. Broken or damaged tools.

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Appendix G
Record of Safety Training

Student: Class:

Over the course of the semester or term(s) you will receive direct instruction in the safe and
appropriate use of the all the equipment, tools, materials, and facilities required to complete
your classroom activities. Instruction consists of a combination of demonstration and written and
verbal instruction. A satisfactory mark on a safety quiz following the instruction demonstrates
the acquisition of sufficient knowledge to use and access the relevant equipment and materials.
Your ongoing demonstration of safe practice is assessed in the project marking. Your teacher
will put the date and sign-off beside each topic in acknowledgement of your attendance at the
discussion or demonstration.

STUDENTS MAY NOT USE ANY EQUIPMENT, TOOL, OR FACILITY UNTIL:

 his or her training has been signed off by the teacher
 he or she has received a satisfactory mark on the related safety quiz.

Topic Date Teacher’s Signature

Computer Resources and the Internet
 Acceptable Use Policy
 Safety on the Internet
 Computer Ergonomics
Patient or Client Care
 Safe use of chemical treatments
 Use of personal protective equipment
(PPE) for patient/client
 Safe and proper handling of patient or
client

Facility Care
 Proper cleaning and setup procedures
 Maintaining safe working environment
 Use of personal protective equipment
(PPE) for self
 Proper sanitation and sterilization
procedures
 Safe and proper disposal of
consumables and hazardous materials

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Appendix H

Horizontal Milling Machine 1

1. Wear Personal Protective Equipment (P.P.E.) such as safety glasses, safety

googles, and face shields. No loose clothing, long hair or jewellery is allowed
in the shop.

2. Operate the milling machine only after you have received instruction and
permission from instructor.

3. Be aware of the position of the on/off switches and emergency STOP button .

4. Keep work area clean and free of oil, grease and debris.

5. Make sure spindle, beds and control handles are working properly before
operating.

6. Ensure work holding device is mounted securely to the table.

7. Ensure work piece and cutter are mounted securely before starting motor and
making a cut.

8. To avoid injury when setting up or measuring work, move the machine table as
far as possible away from the cutter.

9. Do not attempt to setup or measure a work piece until the cutter is completely
stopped. Keep hands away from revolving parts.

10. When setting up or removing a milling cutter from its holder or arbor, ensure
proper procedures are followed in order to avoid injury.

AT ALL TIMES – IF IN DOUBT, SEE YOUR INSTRUCTOR

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Appendix I

Horizontal Milling Machine 2

11. When setting up a cutter on the horizontal milling machine, always make sure
that the cutter is properly keyed to the arbor

12. When assembling or disassembling a tool on the arbor with an over-arm

support, always leave the support in place when loosening or tightening the
arbor nut.

13. Tighten the arbor nut with a wrench. Never use a hammer to strike the wrench
when tightening the nut.

14. Ensure all tool bits are sharp and not damaged. Show your instructor any
problems with the tooling.

15. Do not operate the milling machine until you have established proper speeds,
stops, and tool depths.

16. Make sure you have proper speeds and feeds for the type of material, tooling
and the operation to be performed.

17. Be sure to have firm footing when operating the milling machine.

18. When the machine comes to a complete stop, remove cut off material and
chips with a brush. Never use your hands to clear cut materials.

19. Turn milling machine off immediately if it does not sound correct or if there is
excessive vibration.

AT ALL TIMES – IF IN DOUBT, SEE YOUR INSTRUCTOR

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Appendix J: Safety Passport Form 3

Squaring Blocks on Milling Machine

General Conditions
 Mill is functional, all tools are in good condition (sharp, not damaged etc.)
 Student has completed all prior Safety assignments and assessments
 Student has attended demo lesson
 Student is informed of how to access and engage lathe E-Stop
 Student understands to use available guarding to protect self and others
 Proper setting of machine speeds and feeds for the cutter and material being used

Personal Protective Equipment

 Safety glasses
 Long hair tied back
 No loose clothing or jewellery
 Venting and/or respirator mask is available
 MSDS available if cutting fluids are used

Possible Risk Factor

 Work-piece, tool holder and cutting tool is securely fastened
 Wrenches and keys are removed from machine revolving devices prior to turning on milling
machine
 Cutting tool is of appropriate length for the job (hold short for ragidity)
 Irregular shaped work-pieces are secured using a round bar pushing the work-piece squarely
against the solid jaw
 Removal of sharp edges and/or burrs on work-piece during each removal and installation into
the vise
 Guarding is employed to guard against injury from flying cuttings and potential broken tool bits
or work-pieces that may become dis-lodged from the vise
 Ensure machine spindle quill is securely tightened and locked to prevent being pulled down into
the work-piece causing possible injury
 If Automatic feed is used, start cutter rotation and feed from a distance well clear of the work-
piece to prevent sudden and unexpected impact

 The student has been trained on this equipment and procedure.

 The student understands the required personal protective equipment to operate this equipment
and perform this procedure.
 The student is aware of the possible risk factors

Student signature ________________________________

Teachers signature ________________________________

Date of training ________________________________

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