TITLE:

ES&H Manual

 

DOCUMENT ID:

6121Appendix T1

Safe Operation of Machine Tools

 

 

1.0             Purpose

 

NOTE:  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 to a task qualified Jefferson Lab employee at the discretion of the responsible manager.

 

3.1              Machine Tool Operator

·         Only use a machine tool when:

1.      You are trained and qualified.

2.      You are authorized by your supervisor.

3.      You are authorized by the Machine Owner / Machine Shop Supervisor / Machine Tool Granting Authority.

4.      You have read, signed, and agreed to abide by the most current machine tool specific work control document; OSP.

·         If you cannot abide by the OSP, you must suspend the machine tool task and contact your supervisor and the OSP owner to seek resolution in accordance with ES&H Manual Chapter 3310 Appendix T1 Operational Safety Procedure (OSP) and Temporary Operational Safety Procedure (TOSP) Instructions.

·         Use required PPE (refer to ES&H Manual Chapter 6620 Personal Protective Equipment Program and ES&H Manual Chapter 6640 Hearing Conservation) and 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 working order and guards are in place and used as required for the operation being performed. 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              Machine Tool Operator Supervisor

·         Authorize individuals to use a specific machine tool for which they will be trained / qualified by the Machine Owner / Machine Shop Owner / Machine Tool Granting Authority.

·         Ensure that the individual was trained / qualified for a specific machine tool by the Machine Owner / Machine Shop Owner / Machine Tool Granting Authority.

·         Validate training / qualifying of a specific machine tool and that the Machine Tool Operator has signed the most current machine tool specific work control document.

·         If the individual has not been granted authorization for use of a specific machine tool contact and seek resolution with the specific Machine Shop Manager / Machine Owner / Machine Tool Granting Authority.

·         If the individual you supervise cannot abide by the OSP, the individual must suspend the machine tool task and contact her / his supervisor and the work control document owner to seek resolution in accordance with ES&H Manual Chapter 3310 Appendix T1 Operational Safety Procedure (OSP) and Temporary Operational Safety Procedure (TOSP) – Instructions.

 

3.3              Maintenance Personnel

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

·         If it becomes necessary to terminate power to the machine tool, refer to 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.

 

3.4              Machine Shop Manager /Machine Tool Owner / Machine Tool Granting Authority

·         Ensure and validate that an individual seeking to use a specific machine tool is authorized by their supervisor.

·         Establish and maintain a program for training / qualifying an individual on each specific machine tool under your authority.

·         Grant approval for use of a specific machine tool under your authority.

·         If the individual has not been granted authorization or their authorization is revoked for use of a specific machine tool, communicate with the individual’s supervisor and seek resolution and or an understanding of the matter.

·         Establish and maintain 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 Safety Data Sheet (SDS). Refer to ES&H Manual Chapter 6610 Chemical Hygiene.)

·         Establish and maintain adequate clearance around machine tools (see 29 CFR 1910 Subpart N).

·         Enforce the use of required personal protective equipment (PPE). Refer to 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 the machine tool is in working order and guards are in place and used as required for the operations being performed.

·         Do not allow any temporary or make-shift repairs to machine tools (see 29 CFR 1910 Subpart O).

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

 

3.5              Associate Directors and Department Managers

·         Ensure 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 Procedure (OSP)

 

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.

NOTE:  There is no specific OSHA standard for lathe chucks; however, there is a National Consensus Standard, ANSI B11.6-2001 (R2012) and it shall be used as a guideline for applying the general guarding requirements.

·         Limits of machine operations.

·         Emergency “Shut-down/Restart” procedures.

·         Inspection and maintenance requirements.

·         Selection and use of appropriate PPE, including 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 Machine Tool Operators

·         Attend training as required by the Machine Shop Manager / Machine Owner / Machine Tool Granting Authority.

·         Read, sign, and agree to abide by the most current, tool specific work control document; OSP.

 

4.3              Inspect Machines

 

Machine tools are inspected prior to use. Any inadequacies are reported to the Machine Tool Manager / Machine Tool Owner / Machine Tool Granting Authority 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

 

NOTE: 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

·         American National Standards Institute (ANSI) B 11 Series, Machinery Safety Series

 

6.0             Revision Summary

 

Revision 0.5 – 04/24/18 – Updated Responsibilities, Process Steps, and References for machine guarding per CATS# IA-2017-05-01-07, CATS# IA-2017-05-08-01, CATS# IA-2017-05-09-01

Revision 0.4 – 04/19/16 – Periodic Review; MSDS replaced with SDS per updated OSHA regulations

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 0.0 – 09/21/09 – This is original content

 

 

ISSUING AUTHORITY

TECHNICAL POINT-OF-CONTACT

APPROVAL DATE

REVIEW  DATE

REV.

ESH&Q Division

Bert Manzlak

04/24/18

04/24/23

0.5

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 5/16/2018.