MODULE I

GENERAL MACHINE SHOP SAFETY

PRACTICES AND METROLOGY

Lesson 1. Occupational Health and

Safety Practices

Lesson 2. Practice Total Preventive

Maintenance (TPM) and 5's

Lesson 3. Ratio, Proportion, and

Measurement

Lesson 4. Metrology: Measurement

Instruments & Tools
 MODULE 1

GENERAL MACHINE SHOP SAFETY PRACTICES AND METROLOGY

 INTRODUCTION

There are virtually endless practical examples of how accurate

measurements are vital in ensuring our safety, ranging from the compatibility
of electrical and mechanical equipment .
Machine shops contain many potential hazards, but with proper
training, knowledge, common sense, and caution, you can avoid these
dangers. You must remember that human flesh is no match for machines
powered by several horsepowers and designed to rapidly remove large
volumes of metal. In addition to machine hazards, there are chemical,
electrical, fire, and environmental hazards. The material in this chapter
cannot cover every potential hazard and circumstance, but it will get you
started in the right direction. Additional safety precautions associated with
specific machines appear in relevant chapters.

LEARNING OUTCOMES

After studying the module, you should be able to:

1. Practice Occupational Health and Safety Practices

2. Practice Total Preventive Maintenance (TPM) and 5'S
3. Perform Four Fundamental Operations
4. Convert English to Metric Measurement and Vice Versa
5. Perform Basic Ratio and Proportion, Area and Volume Calculation
6. Perform Metrology: Measurement Instruments & Tools

 DIRECTIONS/ MODULE ORGANIZER

There are four (4) lessons in the module. Read each lesson carefully
then answer the exercises/activities to find out how much you have
benefited from it. Work on these exercises carefully and submit your output
to your instructor thru FB Google classroom (MEFC 103).

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Lesson 1
Occupational Health And
 Safety Practices

Occupational Safety and Health Standards (OSHS) are mandatory rules

and standards set and enforced to eliminate or reduce occupational safety
and health hazards in the workplace. OSH Standards aim to provide at least
the minimum acceptable degree of protection that must be granted to every
worker in relation to dangers of injury, sickness, or death that may arise
because of his or her occupation. The provision of OSHS by the government is
an exercise of police power, to promote the welfare and well-being of
workers.

The OSHS requires every company to keep and maintain its workplace free
from work hazards that are likely to cause physical harm to the workers or
damage to property. The following must be provided;
• Appropriate seats, lighting, and ventilation.
• Adequate passageways, exits, and firefighting equipment
• Separate toilet facilities and lockers for men and women.
• Appropriate safety clothing like protective gear, masks, helmets,
safety boots, coats, or goggles.
• Medicines, medical supplies, or first-aid kits.
• Free medical and dental services and facilities.

IDENTIFY HAZARDS AND RISKS

Identify Workplace Hazards

Every workplace should have a system in place to identify, assess and
control the hazards.

What is a hazard?
• A condition or changing set of circumstances that presents a potential
for injury illness or property damage.
• A hazard is anything or a situation with the potential to cause harm.

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What Is A Risk?
• Risk is the potential or inherent characteristics of an activity, condition,
or circumstances that can produce adverse or harmful consequences.
• A risk is a combination of the likelihood of actual harm from the hazard
and the consequences of that harm.
• Risk is a combination of the extent of the hazard and the amount of
exposure to the hazard.
RISK = [HAZARD] x [EXPOSURE]

What Is A Safety Hazard?

• Safety hazards include any force that is strong enough to cause injury in
an accident.
• Safety hazards occur most often when adequate workplace safety
standards are not met.
What Is An Occupational Health Hazard?
An occupational health hazard is any material or condition that can cause
occupational injury and/or illness. Health hazards can cause immediate and
serious effects or slow and gradual injury. Some occupational health
hazards include:
• chemicals (acid, solvents, paint)
• biological hazards (bacteria, virus, dust, and molds)
• physical agents (electrical currents, heat, light, noise, radiation.
• Ergonomic hazards (poor workstation designs)
• Other stress agents (violence, abuse, harassment)

ENVIRONMENTAL HAZARDS

1. Physical Hazards. Hazards are due to the transfer of energy between an

object and a worker.
• Excessive noise
• Inadequate illumination
• Extreme temperature
• Extreme pressure

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 • Vibration
• Radiation
• Inadequate ventilation
• Cluttered area
• Ignorance or carelessness of the worker

2. Chemical Hazards. These hazards arise from inhaling chemical agents in

the form of vapor gases, dust, fumes, mist, or skin contact with these
materials.
• Mist Fine particles of a liquid float in the air
• Gases- substances in a gaseous state but are always airborne at room
temperature.
• Vapor- results when substances that are liquid at room temperature
evaporate.
• Dust- solid harmful substances are ground, cut, or crushed by
mechanical actions.
• Fumes- gas is condensed in air, chemically changed, and becomes
fine solid particles that float in the air.

Four Possible Routes of Entry of Chemical Hazards

• Inhalation- breathing in toxins is the most common and dangerous
route.
• Ingestion- toxins enter through the gastrointestinal tract.
• Absorption- toxins pass through the skin into the bloodstream.
• Injection- toxics may be injected into the body (needles, etc.)- the
least common, yet most direct route of entry

3. Biological Hazards. Hazards caused by living organisms which include

insects, molds, fungi, viruses, and bacterial contamination; from defects
in sanitation and housekeeping procedures, such as in the provision of potable
water, removal of industrial wastes and sewage, food handling, and personal
cleanliness.

Agents of Biological Hazards

• Bacteria – simple, one-celled organisms that may or may not be
harmful.

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 • Viruses – organisms that depend on a host cell for development or
reproduction
• Fungi – may be small or large parasitic organisms growing in a
living or dead plant or animal
• Rickettsia – rod-shaped microorganisms that are smaller than
bacteria and depend on a host for development or reproduction.
Microorganisms transmitted by fleas, ticks, and lice

Common Health Problems from Biological Hazards

• Tuberculosis (TB)
• Tetanus
• Viral Hepatitis
Diseases caused by a virus
• Upper Respiratory Tract Infection
• Hepatitis B Infection
• Acquired Immunodeficiency Syndrome (AIDS)
• Rabies

4. Ergonomic Hazards. Hazards are commonly seen in the workplace, which

is improperly designed tools or work areas, improper lifting or reaching, poor
visual conditions, or repeated motions in an awkward position that may be
responsible for fatigue, stress, and strain and may lead to accidents in the
occupational environment. Ergonomics is the study of designing equipment
and devices that fit the workers.

Effects of Ergonomic Hazards

• low productivity
• high rate of errors
• material wastage and equipment
Health Problems caused by Ergonomics
• musculoskeletal problems
• vascular problems
• visual problems
• hearing problems

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 • skin problem
• psychological problems

What is the best way to control hazards in the workplace?

Three main steps can be taken to control hazards.

• Eliminate the hazards posed by equipment and work processes
(i.e. redesign work stations, switch chemicals used in work, etc.).
• If eliminating the hazard is not possible, control the hazard to
reduce the risk to Workers
(i.e. install machine guards or better ventilation systems, etc.).
• If controlling the hazards is not effective, protect the workers from
risk with the use of tools and protective equipment, and proper
safety training.

How to identify workplace hazards?

Workplaces should have a process through which employees can

quickly and easily report hazards to both the Health and Safety.
Representative and the supervisor A wide range of methods can be us
ed for identifying hazards in the workplace and these can include:
• injury and illness records (reviewing workers compensation data and sick l
eave records)
• workplace inspections (walk through surveys usually carried out by the
Health and Safety Representative with the supervisor)
• investigating workplace incidents and near hits reports (in some cases the
re may be more than one hazard contributing to an incident)
• feedback from employees (they can often provide valuable information
about hazards because they have “hands-on” experience in their
work area)
• keeping up to date with information (such as manuals that come with
equipment, information sheets on chemicals [Material Safety Data Sheets
–MSDSs], articles in the print media, the Internet)

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 CONTROL HAZARDS AND RISKS

Safety Regulations:

Safety regulation means the guidelines provided to avoid every type

of the inappropriate action and utilize or work with full safety and to its full
extent.

Clean Air Act: Republic Act No. 8749 also known as the Philippine Clean Air
Act of 1999.

Declaration of Principles (Section 2):

• The State shall protect and advance the right of the people to a
balanced and healthful ecology in accord with the rhythm and harmony
of nature.
• The State shall promote and protect the global environment to attain
sustainable development while recognizing the primary responsibility of
local government units to deal with environmental problems.
• The State recognizes that the responsibility of cleaning the habitat and
the environment is primarily area-based.
• The State also recognizes the principle that “polluters must pay”.
• Finally, the State recognizes that a clean and healthy environment is for
the good of all
and should, therefore, be the concern of all.

SAFETY PROCEDURES OF MACHINE SHOP

GENERAL SAFETY TIPS

• Safety glasses with side shields must be worn at all times.
• Do not wear loose clothing, loose neckwear, or exposed jewelry while
operating machinery.
• Do not work alone in the Student shop. (Implement the "buddy" system
if possible)
• Pull back and secure long hair. (Use hair net or ball cap)

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 • Do not wear thin fabric shoes, sandals, open-toed shoes, and high-
heeled shoes.
• A machinist's apron tied in a quick-release manner should be worn.
• Always keep hands and other body parts a safe distance away from
moving machine parts, workpieces, and cutters.
• Use hand tools for their designed purposes only.
• Report defective machinery, equipment, or hand tools to the
supervisor.

SAFETY GUIDELINES:

1. Be sure that all machines have effective and properly working guards
and covers, and that they are always in place when machines are
operating.
2. Replace guards immediately after any repairs.
3. Do not attempt to oil, clean, adjust, or repair any machine while it is
running. Stop the machine and lock the power switch in the "OFF"
position.
4. Do not operate any machine unless authorized to do so by the instructor
or under the instructor's supervision.
5. Do not set up or operate machinery when an instructor is not in the
shop.
6. Even after the power is off, do not leave the machine until it has
stopped running. Someone else may not notice that it is still in motion
and be injured. Do not leave a machine until it has come to a complete
stop.
7. Do not try to stop the machine with your hands or body.
8. Check tools before use to assure they are safe to use.
9. Always see that work and cutting tools on any machine are clamped
securely before starting to work.
10. All setscrews should be of the flush or recessed type. If they are not,
move with caution when near them. Projecting setscrews are very
dangerous because they may catch on sleeves or clothing.
11. Only one person should operate the machine or switches.

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 12. Concentrate on the work and do not talk unnecessarily while operating
the machine.
13. Do not talk to others when they are operating a machine. A distraction
may lead to an injury.
14. Do not walk behind people operating a machine; you may bump them
by accident or startle them and cause an accident.
15. Always remove gloves before turning on or operating any machine. If
material is rough or sharp and gloves must be worn, place or handle
material with the machine turned off.
16. Do not leave tools or work on the table of a machine even if the
machine is not running. Tools or work may fall off and cause toe or foot
injury.
17. Use a brush to remove short, discontinuous types of chips--not hands,
fingers, or rags.
18. Use a pair of pliers to remove chips, especially the long, stringy type.
19. Never handle chips with your hands or fingers. Chips are extremely
sharp and can easily cause cuts.
20. Stop the machine tool to make speed and feed changes that require
the shifting of a gear lever.

STUDENT/FACULTY SHOP RULES

1. SAFETY

Safety Glasses:
Safety glasses must be worn when using machine tools (mill, lathe, drill,
etc.) and when using manual tools made of high tensile steel such as taps.
High tensile steel will shatter and send chips flying.

Clothing:
Rotating spindles can catch clothes, hair, gloves, and jewelry.
When using machines with rotating spindles, do not wear long sleeves, pull
back long hair (but do not braid), and remove the jewelry and anything else
that could get caught in the spindle. Do NOT wear gloves.

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Long sleeves, long hair, or jewelry can get caught in the spindle and pull
you right into the spindle. Do not braid your hair because if your braided
hair gets caught, all your hair gets pulled towards the spindle instead of just
a few hairs. Sandals are not allowed in the machine shop.

Hearing Protection:
Use ear protection if you are using a loud machine.

Buddy system:
Never machine alone. There must always be someone nearby in case you get
hurt.

2. TRAINING
a. Do not operate a machine until you have been trained. Other qualified
users can give training. Read the machine's Operator Manual and/or
Technical manual before operating the machine.
b. Do not disturb someone while they are using a machine. Wait until they
have finished machining. Machining is very dangerous and can require
concentration. If you interrupt somebody they could make a mistake that
leads to an accident.

3. LIGHTING
DC lamps must always be turned on when using any rotating machines. The
main fluorescent lights in the machine shop run off the 110 V, 60 Hz electrical
supply and effectively strobe at 60 or 120 Hz. Machines that rotate at
harmonics of 60 Hz will appear to be stationary. For this reason, all rotating
machines in the shop have a DC lamp beside them. Use the lamps! Otherwise,
you might try to reach for a spindle that looks stationary but is rotating.

4. CLEANUP

• Tools must be put away. You are not the only user of the shop. You will
waste other peoples’ time if you don't put tools away in the correct place.
• Clean up! When you finish using a machine, clean the machine thoroughly.
The coolant should be wiped off and all the chips cleared. If appropriate,
lubricate the machine. Leaving machines dirty is rude to the next user and

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 is also bad for the machines. Coolant and chips can get into the moving
parts of the machine and cause rust and wear.
• Do not use high-pressure air to clean machines. High-pressure air can push
chips into the moving parts of the machinery where the chips will wear
the machine.
• Return all tools, fasteners, and materials to their proper location when
you finish work or at the end of the day. Do not leave tools out overnight.
• If you are last to leave, check that everything is in order. If necessary,
sweep the floor and put anything left out away.
5. MACHINE USE

Most machines have rules posted beside them. Read them.

• Coolant: cutting fluid must be used during all cutting, machining, turning,
tapping, and drilling operations to promote proper chip removal and
prolong tool life.
• Printed circuit boards (PCBs) should not be cut on the band saw. PCBs are
made from fiberglass, which dulls the cutting blade very quickly. PCB dust
is toxic. You can cut PCBs with shears or with a hacksaw.
• Precision instruments (micrometers, rulers, etc.) should never come into
contact with each other or with any other surface of equal or greater
hardness. i.e. Never put a micrometer on a metal surface. Precision
instruments are ground very carefully. Any scratches on their surface make
them less accurate and can make them useless.
• Tool and machine damage must be reported. If you break a tap, drill, or
end mill, order more if they are needed.
6. FOOD
No food in the shop. Drinks must be in containers with non-spill lids.

PERSONAL PROTECTIVE EQUIPMENT

Proper Use of Personal Protective Equipment

The primary approach in any safety effort is to maintain or change

the physical environment so that accidents would not occur, as shown in

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Fig.1.1.1. However, it is necessary for economic reasons or in temporary or
changing conditions to safeguard personnel by equipping them individually
with specialized personal protective equipment (PPE). Although the use of
PPE is an important consideration in the development of a safety and health
program, it should not be used permanently for maintaining a safe and
healthy work environment. In general, government regulations list the use
of PPE as a case of last resort. Analyzing accident situations is done to
determine whether PPE can prevent a recurrence. When work conditions
cannot be made more safely PPE is necessary.

Safety glasses must be Long and loose hair must

worn at all times in work be contained or
areas.
Appropriate protective restrained.
Coveralls, protective
footwear with substantial clothing, or a workshop
uppers must be worn. apron is encouraged.
Rings and jewelry must Gloves must not be worn
not be worn. when operating this
machinery.
Fig. 1.1.1 Safety Operational Procedures

PROPER TRAINING
To obtain the worker’s complete compliance with the requirements to wear
the PPE, the following factors must be considered:
• the extent to which the person who must wear the equipment
understand its necessity
• the ease and comfort with which it can be worn with a minimum of
interference with normal procedures
• the available economic, social, and disciplinary sanctions which can
be used to influence the attitudes of the workers

HEAD PROTECTION

Safety hats should be inspected before their use.

Inspect suspension systems that show evidence of materials cracking, tearing,
fraying, or other signs of deterioration. Suspension should provide a minimum

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clearance of 1 to 1.25 inches between the top of the worker’s head and the
inside crown of the hat.
▪ Check any signs of cracks of perforations of brim or shell, deformation of
shell, or evidence or exposure to excessive heat, chemicals, or radiation.
▪ Remove any accumulation of conductive material on or inside the shell
that cannot be removed before use.
Objects should not be placed inside the safety hat between the shell and the
suspension device. This space is designed so an impact will not transmit to
the head of the worker.
Safety hats should be kept free of abrasions, scrapes, and nicks and should
not be deliberately dropped, thrown, or otherwise abused because they will
lose their protective qualities.
EYE AND FACE PROTECTION
Eye protectors must meet the minimum requirements:
• Provide adequate protection against the particular
hazards for which they are designed
• Be reasonably comfortable when worn under the
designated conditions
• Be durable.
• Be capable of being disinfected.
• Be kept clean and in good repair
• Design, construction, testing, and use
of eye and face protection must be in
accordance with ANZI Z8.1-1989. The fitting of goggles and safety
spectacles should be performed by someone skilled in the procedure.
Prescribed safety spectacles should be fitted only by a qualified optical
person. Safety spectacles require special frames.

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EAR PROTECTION

The prevention of excessive

noise exposure is the only way
to avoid hearing damage.
Engineering and
administrative control must be
used if the sound levels are
exceeded. If such controls fail
to reduce the sound levels
within the level specified,
personal hearing protection
must be used. Molded earplugs should be individually fitted by a professional.

FOOT AND LEG PROTECTION

For the protection of feet and legs from falling or rolling objects, sharp
objects, molten metal, hot surfaces, and wet slippery surfaces, workers
should use appropriate foot guards, safety shoes, boots, and leggings.
Never wear open-toed footwear while working with hot metal or welding
apparatus.

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  LEARNING ACTIVITY

ACTIVITY 1
Title:

SOP/PPE of General Machine Shop

Performance Objectives:
It is a requirement of this Unit you complete SOP/PPE Rules as advised by your
Instructor.
You must submit documentation, suitable evidence, or other relevant proof of
completion of the project by the agreed date.
The student will need to complete an SOP and PPE of the General Machine Shop.

Supplies:
• Bond paper
• Pen
• Folder

Equipment:

• Laptop
• Printer

Steps/Procedure:
• List of all SOP equipment in General Machine Shop
• List of all PPE in MSP
• Layout design for every SOP/PPE equipment in Machine Shop.

Performance Criteria:
Quality and Accuracy Speed Care and Use Total
workmanship (30%) (30%) of tools (10%) (100%)
(30%)

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Lesson 2

 Practice Total Preventive

Maintenance (Tpm) And 5's

1. GOALS OF TOTAL PREVENTIVE MAINTENANCE

Total Preventive Maintenance is considered as the medical science of

machines. Total Preventive Maintenance (TPM) is a maintenance program that
involves a newly defined concept for maintaining plants and equipment.
The goal of the TPM program is to markedly increase production while, at the
same time, increasing employee morale and job satisfaction, as shown in Fig.
1.2.1

Fig. 1.2.1 Goals of TPM

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2. TOTAL PREVENTIVE MAINTENANCE BASIC APPROACH

TPM Approach: Changing Way We Do Things

Fig. 1.2.3 Traditional VS TPM Practices

TPM BASIC CONCEPTS:

• From the traditional “I Operate, You Fix Syndrome” to operators should

take care of Basic Equipment Condition through cleaning, lubricating &
bolting. Fig. 1.2.3 shows the traditional versus the TPM practices.
• It will all start by Initially Cleaning Your Equipment
- Maintenance teaches operators on their machines
- Cleaning becomes Inspection
- Inspection reveals abnormalities
- Abnormalities are being revealed and restored
- Teams think of ways to prevent recurrence of the problem
restoration, improvement can produce positive effects and lead to
pride in the workplace.

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3. PRINCIPLES OF 5'S

TPM STARTS WITH 5S.

Problems cannot be seen when the workplace is unorganized. Cleaning and
Organizing the Workplace helps the team to uncover Problems. Making
problems visible is the first step of Improvement. Figure 1.2.4 shows the 5’S
Principles.

Fig. 1.2.4 5’S

PRINCIPLES of 5'S

1. SEIRI - SORT OUT :

This means sorting and organizing the
items as critical, important,
frequently used items, useless, or
items that are not needed as of now.
Unwanted items can be salvaged.
Critical items should be kept for use
nearby and items that are not be used
Fig. 1.2.5 Sorting Tools

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in near future should be stored someplace. For this step, the worth of the
item should be decided based on utility and not cost. As a result of this step,
the search time is reduced (see Fig. 1.2.5).

2. SEITON - SYSTEMATIZE :
The concept here is that "Each item
has a place and only one place". The
items should be placed back after
usage at the same place. To identify
items easily, nameplates and colored
tags have to be used. Vertical racks
can be used for this purpose, and
heavy items occupy the bottom
position in the racks (see Fig. 1.2.6).
Fig. 1.2.6. Systematize

3. SEISO – SWEEP / CLEAN:

This involves CLEANING the
workplace free of burrs, grease, oil,
waste, scrap, etc. No, loosely
hanging wires or oil leakage from
machines (see Fig. 1.2.7).
Fig. 1.2.7 Cleaning Lathe Machine

4. SEIKETSU - STANDARDIZATION :
Employees have to discuss together and decide on standards for keeping the
workplace / Machines/pathways neat and clean. This standard is
implemented for the whole organization and is tested/inspected randomly.

5. SHITSUKE - SELF DISCIPLINE :

Considering 5S as a way of life and bring about self-discipline among the
employees of the organization. This includes wearing badges, following work
procedures, punctuality, dedication to the organization, etc.

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4. HOUSEKEEPING PROCEDURES

1. SPACE: which spaces will receive this level of housekeeping (e.g. storage
areas, work areas, exhibit areas, etc.)?
2. ACTIVITIES: state what procedures will take place in which areas, for
example, collections areas versus public spaces. In public areas, you may
want to discuss trash removal, dusting, and vacuuming. In addition, in
collections areas, you may want to add cleaning the inside of cabinets,
exhibit cases, shelving, etc.
3. METHODS: state what methods will be used to perform housekeeping
activities. For example, vacuum cleaners should be used with caution,
taking care to avoid running into the furniture.
4. SCHEDULING: developing a housekeeping schedule and task list allows
staff an extra opportunity to closely and regularly inspect collection areas.
How often will activities take place? Activities can be divided up by daily,
weekly, monthly, bi-monthly, quarterly, and annually.
See Fig 1.2.8.

TOTAL PRODUCTIVE MAINTENANCE

Fig. 1.2.8 Housekeeping Schedule

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 LEARNING ACTIVITY

I. ESSAY: Answer the following question in your own words. (10pts/each)

1. What are the goals of the TPM?

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
___________________________________________________________

2. How can you apply your TPM in your machine shop area?

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
___________________________________________________________

3. What are the principles of 5'S?

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
___________________________________________________________

4. How do you practice your 5’S in your workplace?

____________________________________________________________
____________________________________________________________
____________________________________________________________
____________________________________________________________
___________________________________________________________

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II. Make a Housekeeping Checklist

Activity 2
Title:

Prepare a Housekeeping Checklist

Performance Objectives:
After reading Lesson 2 using the Blank Template, YOU MUST be able to prepare a
Housekeeping Checklist for chosen area/areas.
Supplies:
1. Blank Template # 1
2. Inventory of Tools and Equipment
3. Pencil/Pen
4. Bond Paper

Equipment:

1. Laptop/PC
2. Printer

Steps/Procedure:

1. Prepare all your reference materials and laptop/PC

2. Identify the area or location you have chosen.
3. Fill up all items in Blank Template # 1.
4. Tick the box corresponding to each given inspection area.
5. Call your facilitator (Guardian) who will guide you and check your work
after doing this activity.

Performance Criteria:
Quality and Accuracy Speed Safety/PPE Total
workmanship (30%) (30%) (10%) (100%)
(30%)

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III. Make a workshop housekeeping schedule.

WORKSHOP HOUSEKEEPING SCHEDULE

DAILY TASK YES NO

WEEKLY TASK YES NO

MONTHLY TASK YES NO

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