TITLE:

ES&H Manual

 

DOCUMENT ID:

6121Appendix T1

Safe Operation of Machine Tools

 

 

1.0            Purpose

 

Machine tools are inherently risky. Jefferson Lab has determined that use of a machine tool carries an unmitigated Risk Code 3. To reduce the risk to an acceptable level an Operational Safety Procedure (OSP) is written for each machine tool and read by operators prior to use.

 

This appendix provides the safety rules applicable to operating machine tools at Jefferson Lab.  It is based on Occupational Safety and Health Administration (OSHA) regulations and American National Standards Institute (ANSI) standards.  Operator’s Manuals also provide valuable information and are used in preparation of OSPs and training.

 

2.0            Scope

 

This document outlines the responsibilities and process steps for safe operation of machine tools. 

 

Portable hand tools, which include manually powered tools, portable power tools, and powder actuated fastening tools, are discussed in ES&H Manual Chapter 6120 Appendix T1 Portable Hand Tool Safe Practices.

 

The process steps for this procedure are performed in coordination with ES&H Manual Chapter 6121 Machine Tools.

 

3.0            Responsibilities

NOTE:           Management authority may be delegated at the discretion of the responsible manager.

 

3.1              Operators

·         Only use machine tools which you are currently trained and authorized to use, in the manner in which they were intended.

·         Use required PPE (See ES&H Manual Chapter 6620 Personal Protective Equipment Program and ES&H Manual Chapter 6640 Hearing Conservation.  Seek assistance with hazard awareness from Industrial Hygiene).

 

NOTE:  Wear appropriate clothing when operating machine tools.  Do not wear jewelry, neck wear, loose clothing, long hair, or other items that can get caught in the machine.

 

·         Ensure that the machine tool is in proper working order and guards are in place before operating. Do not make any temporary or make-shift repairs to machine tools.

·         Ensure that the proper tool, blade, or attachment is being used for both the machine tool and material being worked on.

 

3.2              Maintenance Personnel

·         Ensure that you are qualified and knowledgeable of the machine tool operation prior to beginning any maintenance work.

·         If it is necessary to terminate power to the machine tool use ES&H Manual Chapter 6110 Lock, Tag, Try (LTT) Program.  Blocks, chocks, and other physical devices may also be required to prevent unexpected movement.

·         Refer to the Manufacturer’s Operations Manual for minimum requirements and guidance.

 

3.3              Machine Shop Manager or Operator’s Supervisor

·         Establish and maintain:

o   A program for qualifying operators on each machine tool under your authority.

o   An effective preventive maintenance program for each machine tool – minimal requirements are those recommended by the manufacturer.  (Ensure that machine lubricants are properly stored, handled, and disposed of in accordance with the Material Safety Data Sheet (MSDS) (See ES&H Manual Chapter 6610 Chemical Hygiene.)

o   Equipment-specific administrative control procedures for each piece of machinery.  (See ES&H Manual Chapter 6111 Administrative Control Using Locks and Tags.)

o   Adequate clearance around machine tools (See 29 CFR 1910 Subpart N).

·         Ensure that operators are authorized and appropriately trained to use machine tools.

·         Enforce the use of required personal protective equipment (PPE).  (See ES&H Manual Chapter 6620 Personal Protective Equipment Program and ES&H Manual Chapter 6640 Hearing Conservation.  Seek assistance with hazard awareness from Industrial Hygiene.)

·         Ensure that each machine tool has proper guards in place (See 29 CFR 1910 Subpart O).

·         Do not allow any temporary or make-shift repairs to machine tools.

·         Ensure an Operational Safety Procedure (OSP) is maintained for each machine tool in accordance with ES&H Manual Chapter 3310 Operational Safety Procedure Program.

·         Ensure that machine tools are properly maintained.

·         Ensure that safety signs are posted in the vicinity of machine tools and at shop entrances.

 

3.4              Associate Directors and Department Managers

·         Ensure that machine tool controls and authorization practices, under your authority, are maintained.  (Refer to ES&H Manual Chapter 6121 Appendix T1 Safe Operation of Machine Tools for guidance.)

 

4.0            Process Steps

 

4.1              Develop an Operational Safety Procedures (OSPs)

 

An OSP is developed for each machine tool in accordance with ES&H Manual Chapter 3310 Appendix T1 Operational Safety Procedure (OSP) and Temporary OSP Procedure.

 

 

The list of safety concerns addressed in the OSP includes:

 

·         Selection and installation of the appropriate attachments and/or tools (ex: drill bits, blades, grinding wheel, etc.).

·         Adequate clearance requirements.

·         Use and function of guards.

·         Limits of machine operations.

·         Emergency “Shut-down/Restart” procedures.

·         Inspection and maintenance requirements.

·         Selection and use of appropriate PPE.  This includes push sticks, or other implements required to reduce risk to the operator.

·         Containment, handling, and storage of cutting fluids and bulk lubricants, when applicable.

 

The OSP is reviewed and signed in accordance with ES&H Manual Chapter 3310 Appendix T1 Operational Safety Procedure (OSP) and Temporary OSP Procedure.

 

4.2              Train Operators

 

·         Attend specialized training as required by Machine Owner.

·         Read/sign the appropriate OSP for the machine tool.

·         Demonstrate performance to a competent and trained operator.

·         Receive management authorization.

 

4.3              Inspect Machines

 

Machine tools are inspected prior to use. Any inadequacies are reported to the supervisor/owner of the equipment for determination.

 

Look for:

·         Housekeeping (both the equipment and work area)

·         Appropriate stability

·         Power cord condition

·         Condition of blade or work tool

·         Condition and functionality of guards

·         Check chuck tightness on lathes and drill presses

·         Check tightness of necessary bolts on milling machine

 

If machine deficiencies are detected, shut the equipment down, tag it out of service in accordance with ES&H Manual Chapter 6111 Administrative Control using Locks and Tags, and do not use it until it is repaired, tested, and approved for service.

 

5.0            References

 

·         OSHA Regulation 29 CFR 1910 Subpart N, Material Handling and Storage

·         OSHA Regulation 29 CFR 1910 Subpart O, Machinery and Machine Guarding

 

6.0            Revision Summary

 

Revision 0.3 – 08/19/14 – Updated TechPOC from N.Walker to B.Manzlak

Revision 0.2 – 04/23/13 – Added link to Machine Shop OSP Templates.

Revision 0.1 – 09/28/12 – Periodic Review. Clarification made to responsibilities only.

Revision 0 – 09/21/09 – This is original content.

 

 

ISSUING AUTHORITY

TECHNICAL POINT-OF-CONTACT

APPROVAL DATE

REVIEW  DATE

REV.

ESH&Q Division

Bert Manzlak

09/21/09

09/28/15

0.3

This document is controlled as an on line file.  It may be printed but the print copy is not a controlled document.  It is the user’s responsibility to ensure that the document is the same revision as the current on line file.  This copy was printed on 8/19/2014.