TITLE:

ES&H Manual

 

DOCUMENT ID:

6121Appendix T1

Safe Operation of Machine Tools

 

 

Text Box: 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.

 

1.0            Purpose

 

This appendix provides the safety rules applicable to operating machine tools used at Jefferson Lab.

 

2.0            Scope

 

This document outlines the responsibilities and process steps for safe operation of machine tools.  Hand tools, which include natural sandstone wheels; and metal, wooden, cloth, or paper discs, etc. are discussed in ES&H Manual Chapter 6120 Hand Powered Tools.

 

3.0            Responsibilities

 

3.1              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).

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

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

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

 

3.2              Operators

·         Use only those machine tools on 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 and ES&H Manual Chapter 6640 Hearing Conservation.  Seek assistance with hazard awareness from the ESH&Q Division).

 

Text Box: 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 that 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.

 

3.3              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) Policy.  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.

 

4.0            Process Steps

 

4.1              Develop Operational Safety Procedures (OSPs)

The minimum safety concerns addressed in the OSP for the machine tool are:

·         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 by the appropriate ES&H Safety Professional, Division Safety Officer, Department Head, and area Safety Warden in accordance with ES&H Manual Chapter 3310 Operational Safety Procedure Program.

 

4.2              Training of 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.

 

Text Box: If safety 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.

 

4.3              Machine Inspection

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

 

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

 

 

 

ISSUING AUTHORITY

APPENDIX AUTHOR

APPROVAL DATE

EFFECTIVE DATE

EXPIRATION DATE

REV.

 

 

 

ESH&Q Division

Ned Walker

09/21/09

01/01/10

09/21/09

0

 

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 10/12/2009.