Introduction:
A machine shop is a place where machining is done by skilled craftsmen to create parts by
using machine tools or cutting tools usually of metals, plastics or wood. Like every engineering
universities, our university possesses a well-established machine shop. The workshop offers
conventional machining processes for the practical, project and research purposes of the
undergraduate and postgraduate students of the institution, and all of this are done in the
Machine Shop. This shop provides a safe environment for the students under the guidance of
highly skilled craftsmen or technicians to assist students with the strong theoretical knowledge
they gain from the university and how to implement them in real. One of the most important
areas in engineering is machine shop and machine tools practices. This is done in the machine
shop of an institution.
The machine shop conducts practical sessions for engineering students, guides students in their
projects .It provides design assistance, repairs, equipment and machinery using a wide range
of materials, including steel, stainless steel, aluminum, plastics, wood etc. It allows hands-on
access to machines and equipment for undergraduate and graduate engineering students
involved in designing and fabrication of research equipment and class projects. It is also
available to engineering cub members that are involved in designing and fabrication of
competitive intercollegiate projects. The shop provides safety training and technical guidance
as well as machine operation instruction for the purpose of providing hands on experience
which seeks to balance and compliment the strong theoretical education here at RUET. It serves
engineering students from the ME faculty, mostly the IPE and ME department students.
Our machine shop has almost every kind of machines that an engineering student should learn
about. We first attained a good knowledge on those machines then later on got the sessional
classes in the machine shop. We learnt how each machines works, their main parts, how to
operate them, what to do and what not to. And then we used these knowledge to build a project
of our own in every sessional class, by each respective machines. We were firmly guided by
our assigned teachers and the craftsmen in the lab. It is really important to get the firsthand idea
of these machines, so as an industrial engineer if we see the workers in the floor are struggling
with any of the machines, we’ll be able to know what’s really happening there. It also gives
us the ability to control the machine on our own, and to learn the machine firsthand. The safety
policies, the machine shop policies, the manuals of the machines were all well introduced to us
by our respective teachers and craftsmen.
Various production processes like drilling, milling, shaping, finishing etc. are run out in here.
The machine typically include lathe machines, universal milling machines, vertical milling
machines, shaper machines, radial drill machines, machining centers, grinders etc. Machines
and machine tools combined do these machining processes. A machine tool is a machine for
shaping or machining metal or other rigid materials, usually by cutting, boring, grinding,
shearing, or other forms of deformation. Machine tools employ some sort of tool that does the
cutting or shaping. We had a thoroughly designed course to understand the machines and
machine tools used in the shop and the machining procedures. Machine tools are essential in
the development and manufacture of anything that are useful to man.
Importance of Safety in Machine Shop:
A machine shop is a hazardous place containing cutting tools and various machines capable of
causing serious injuries, burns, blindness, disfigurement, amputation or death. It should be the
goal of both management and employees in a machine shop to control hazards in this dangerous
workplace and make safety their most important goal. A serious workplace injury or death
changes lives forever – for families, friends, communities, and coworkers too. Human loss and
suffering is immeasurable. Injuries and illnesses can provoke major crises for the families in
which they occur. Safety improves employee commitment, loyalty to the institution. Safety
improves quality, because a safe workplace tends to be a more efficient one, free of debris and
tangles of cords. In other cases, it’s a matter of focus. By working in a clean, efficient
environment, workers are able to reduce distractions and truly focus on the quality of what they
do. The results? Better products that create customer loyalty Improved safety training and
awareness can help save lives and reduce injury. Financial loss and property damage will also
happen if safety is not ensured. In a machine shop, one simple mistake can have serious
consequences. Machines are loud and dangerous; some emit toxic fumes or lack shielding to
prevent splashing or leaking. Machines throw off sharp chips, metallic dust, splinters and
shavings. Some machinery is poorly designed, dangerous, lacks safety features and may not
shut down quickly. Antiquated machinery should be replaced and maintenance schedules
enforced. Identifying hazards and poorly planned procedures that endanger workers is the first
step towards improving safety. Employees working in the shop play a role in identifying and
correcting work place hazards. Work-site injuries should be reviewed as well as “near-misses."
Steps involved in each job should be analyzed to determine what went wrong, what triggered
an incident and identify the consequence. Regular reviews will encourage employees to
become aware of shop hazards and participate in developing safety procedures.
The Occupational Safety and Health Act of 1970 required employers to provide a workplace
that’s free of hazards and to comply with occupational safety and health standards. Congress
created OSHA (Occupational Health and Safety Administration) to enforce standards, provide
information, training and assistance to employers and workers. In 1985, the Hazard
Communication Standard Act established the rights of workers to know the dangers presented
by hazardous chemicals that they may be exposed to. This goes the same for the machine shop
in the very institution.
All new employees must be trained in safe operation of machinery. No craftsmen should ever
fill-in or take over work with a machine unless he knows how to operate it, observing safety
precautions. If assignments are changed, new procedures implemented or different machines
installed, all workers require training.
With a good and developed machine shop, there will be a better productivity, better service or
quality of the product, and a better institutional reputation. But more importantly, the students
and the employees will be safe. Establishing good safety practices including training, education
and the appropriate safety supplies begins with the employer’s commitment to safety. Safety
transforms an institution and its employees into a team of people with a common goal. It is a
win for everybody.
Because employees are not just a number, but they are the persons who make the real
difference.
Machine Shop Safety Rules
Key points and supporting information:
1. State of Mind. Do not operate power tools when you are ill, taking strong medications,
fatigued or consuming alcoholic drinks. Do not smoke while working with tools.
2. Wear proper clothing for the type of work being done. Do not wear loose-fitting clothes
or jewelry that can get caught in moving parts. Do not roll up long sleeves. Do not wear highly
flammable clothes. Do not wear sandals, open-toed or canvas shoes. Wearing safety- toed shoes
is preferable for protection of feet and toes.
3. Remove all jewelry, including rings, necklaces, bracelets and watches that could get
caught in tooling before starting work.
4. Safety Glasses must be worn at all times in the shop. Some operations may require
additional eye protection or other personal protective equipment
5. Protect your eyes, face, head, and scalp. At a minimum, wear industrial-quality safety
glasses with side shields. Add a face shield or wear impact resistant goggles if flying particles
are expected during the machining process.
6. Hair. Pull back long hair in a band and tuck it under your shirt collar or a cap to keep it
from getting caught in tools. Long beards must also be contained.
7. Avoid distractions. Keep your mind on your work. Talking or listening to the radio
while running machinery can lead to accidents. Stop working and turn off the power tool you
are working with if distracted by something or someone. Never look away from your work
when operating a power tool.
8. Keep the work area clean. Keep the floor free of scraps and oil. Cluttered work areas
invite accidents. Keeping workshop and storage spaces clean and dry can help prevent many
accidents. Sparks can ignite scraps, sawdust and solvents. Water can conduct electricity. Do
not stand in water, on damp floors or in the rain when working with electrical tools. Keep hands
and tools dry.
9. Food and Drink are only permitted in designated areas.
10. Aisles, exits and access to emergency equipment must be kept clear at all times.
11. Cell phones. mp3 players and other personal electronic devices must not be used with
working at any machine. Loud music is prohibited
12. Use Safety Shoe. Safety Shoe is a durable boot or shoe that has a protective
reinforcement in the toe which protects the foot from falling objects or compression, usually
combined with a mid-sole plate to protect against punctures from below.
13. Fires. Shop fires can be any, or all, of three fire classes: Class A, ordinary combustibles;
Class B, combustible liquids; and Class C, fires in live electrical equipment. To eliminate the
need for extinguishers for all three classes, install at least one 20-pound ABC Class
extinguisher in a convenient location, and possibly more, depending on the size of the shop.
14. Work only at operating speed. Do not use a power tool before it has reached operating
speed or while it is coming to a stop. Never force a tool by applying too much pressure. Let
each tool work at its own speed without forcing it. Once a power tool has been turned off, allow
it to coast to a stop. Never force an object into moving parts to stop a machine.
15. Keep tools clean and in good repair. Always clean up power tools before putting them
away. Avoid using tools that are or appear to be in disrepair. Use power tools only for their
intended functions.
16. Repairing and Cleaning Power Tools. Always turn off and unplug a power tool before
(1) adjusting, oiling, cleaning or repairing it; (2) attaching an accessory; or (3) changing bits,
blades or grinding wheels. Unplug or lockout tools when not in use. Unplug tools by pulling
directly on the plug. Jerking on the cord can cause damage to the tool. Do not leave tools,
hardware and other materials out when not in use. Before making adjustments or changing bits
or cutters, disconnect the power cord to avoid accidentally touching the switch and possible
injury when the tool starts.
17. Compressed Air Used for Cleaning. OSHA regulates the use of compressed air for
cleaning in 29 CFR 1910.242(b) as follows:
• Employees shall not use compressed air for cleaning themselves or their clothing.
• The operator shall not direct compressed air at nearby employees.
• Compressed air used for cleaning work areas, such as work benches, table saws, and
drill presses, shall not exceed 30 psi at the outlet, statically or dynamically, and shall be
permitted only with effective chip guarding or personal protective equipment (as described in
section 1910.133) to protect the operator and other employees from flying debris.
18. Hazardous materials. Take extra care when working with hazardous materials. Due to
the extreme fire hazard, machining or grinding of magnesium is prohibited in any Machine
Shop. Handle fiberglass with care. Its particles can irritate the skin, eyes and respiratory system.
When soldering, remember that lead solder is toxic. The work area should be ventilated or you
should wear the appropriate respirator if you have been properly trained to do so.
19. Storage. Develop a system of racks, bins and tool panels to make it easy to find the
right tool or materials quickly. Don't store tools, supplies or spare parts in the aisle or on the
floor where they become tripping hazards. Keep other flammable materials away from heaters
and welding areas to prevent fire. Grease, oil, paint and solvents should be stored in a closed
metal container, preferably in metal cabinets. Gasoline or other fuels should never be stored
inside the shop. Supplies and equipment should be stored in an area designed specifically for
them.
20. Keep guards in place – Safety guards cannot provide the intended protection if they are
not in place and in proper working order.
21. Do not leave a machine running unattended. Make sure all moving parts have come to
a complete stop before you leave the work area or make minor adjustments. In many cases
adjustments and repairs require locking and blocking of energy, including stored energy, before
proceeding.
22. Ventilation. No welding, cutting or brazing may occur in the shop. Move equipment to
the welding table located under the awning in the courtyard. Avoid operating power tools in
locations where sparks could ignite flammable vapors. Keep the shop well ventilated and
flammable materials properly stored.
Table 01: Safety rules followed in machine shop of different universities
SL
Safety rules BUET RUET KUET CUET
No.
1 State of Mind √ √ √ √
Wear proper clothing for
2 the type of work being √ × √ ×
done
3 Remove all jewelry × × × ×
4 Safety Glasses √ √ √ √
Protect your eyes, face,
5
head, and scalp × × × ×
6 Hair × × × ×
7 Avoid distractions × × × ×
8 Keep the work area clean × × × √
9 Food and Drink × × × ×
Aisles, exits and access
10 √ √ √ √
to emergency equipment
11 Cell phones × × × ×
12 Safety Shoe × × √ ×
13 Fires × × √ √
Work only at operating
14 √ √ √ √
speed
Keep tools clean and in
15 √ √ √ √
good repair
Repairing and Cleaning
16 √ √ √ √
Power Tools
Compressed Air Used for
17 √ × × √
Cleaning
18 Hazardous materials × × × ×
19 Storage √ √ √ √
20 Keep guards in place √ √ √ √
Do not leave a machine
21 √ √ √ √
running unattended
22 Ventilation √ √ √ √
Figure 01: Machine Shop in BUET
Figure 02: Machine Shop in RUET
Figure 03: Machine Shop in KUET
Figure 04: Machine Shop in CUET
Hazard Identification and Risk Assessment for Machine Shop of RUET:
Table 02: Value of A for HIRA analysis
A
Number of people affected
1-5 People 3
6-10 People 4
>10 People 5
Table 03: Value of B for HIRA analysis
B
Fetal/Total Noticeable
Permanent Temporary Physical
Likelihood permanent and requiring
disability disability discomfort
disability first Aid
Certain
200 150 100 40 10
(Very likely)
Quite
Possible 150 100 70 20 5
(Likely)
Unusual but
possible 100 50 30 10 2
(Unlikely)
Remote
50 20 5 2 1
(Very likely)
Improbable 5 2.5 1.5 1 0.5
Table 04: Value of C for HIRA analysis
C
Frequency of Activity
Duration of
Shift Daily Weekly Monthly >1 Month
exposure
<30 min 4 3 2 1.5 1
30 min – 2
6 5 4 3 2
hours
2 - 4 hours 8 6 5 4 3
>4 hours 10 8 7 6 4
Table 05: HIRA for lathe machine
HIRA for Lathe Machine
Activity Hazard A B C RPN=A*B*C S/NS
Machine Startup Electric Shock 3 5 2 30 NS
Tool Change Cut Injury 3 2 4 24 NS
Finger
3 2.5 4 30 NS
Workpiece Entanglement
Adjustment
Fall Hazard 3 5 4 60 NS
Chips Injury 4 20 7 560 S
Metal Cutting
Cut Injury 4 70 7 1960 S
Finger
3 2.5 7 52.5 NS
Carriage Entanglement
Movement Cloth
3 1 7 21 NS
Entanglement
Tailstock Cloth
3 1 4 12 NS
Movement Entanglement
Cut Injury 3 70 7 1470 S
Finger
Applying Coolant 3 2.5 7 52.5 NS
Entanglement
Chips Injury 3 20 7 420 S
Respiratory
Floor Cleaning 3 2.5 4 30 NS
Problem
Machine
Electric Shock 3 5 2 30 NS
Shutdown
Table 06: HIRA for shaper machine
HIRA for Shaper Machine
Activity Hazard A B C RPN=A*B*C S/NS
Machine Startup Electric Shock 3 5 2 30 NS
Finger
3 2.5 2 15 NS
Entanglement
Speed Change
Head Injury 3 100 2 600 S
Head Injury 3 100 7 2100 S
Machine Cloth
3 5 7 105 NS
Inspection Entanglement
Hand Injury 3 50 7 1050 S
Finger
Feed Change 3 2 2 12 NS
Entanglement
Chip Injury 4 20 7 560 S
Metal Cutting Cut Injury 4 70 7 1960 S
Eye Injury 4 70 7 1960 S
Respiratory
Floor Cleaning 3 2.5 4 30 NS
Problem
Machine
Electric Shock 3 5 2 30 NS
Shutdown
Table 07: HIRA for drill machine
HIRA for Drill Machine
Activity Hazard A B C RPN=A*B*C S/NS
Machine Startup Electric Shock 3 5 2 30 NS
Cut Injury 3 2 4 24 NS
Tool Change
Burn Injury 3 2 4 24 NS
Workpiece Finger Entanglement 3 2.5 4 30 NS
Adjustment Fall Hazard 3 5 4 60 NS
Chips Injury 4 20 7 560 S
Metal Cutting
Cut Injury 4 70 7 1960 S
Adjusting Spindle Finger Entanglement 3 2.5 7 52.5 NS
Speed Cloth Entanglement 3 1 7 21 NS
Floor Cleaning Respiratory Problem 3 1 4 12 NS
Cut Injury 3 70 7 1470 S
Applying Coolant Finger Entanglement 3 2.5 7 52.5 NS
Chips Injury 4 20 7 560 S
Cloth And Hair
Machine Running 3 20 7 420 S
Entanglement
Cut Injury 4 70 7 1960 S
Workpiece Drilling
Eye Injury 3 70 7 1470 S
Clamping Hand Injury 3 20 7 420 S
Machine Switch Off Electric Shock 3 5 3 45 NS
Feed Giving Eye Injury 3 20 4 240 S
Recommendations:
Proper clothing is not taken at our machine shop. Due to not following this, accident may occur.
For this we can take thick layer apron. Jewelries are not removed in our shop. This may also
occur accident. Any protecting equipment for eyes, faces, head, hair are not taken in our shop.
For this why another cloth should be provided. Also, the work areas are not kept clean in our
shop. This may also occur accidents such as slipping. So, after every operation each work area
should be cleaned. Safety shoes are not used. This may hurt in our feet. So, shoes should be
provided. Pneumatic system should be started for cleaning the machine.
In our lathe machine some significant risks are appeared such as chips injury. When we work
in front of lathe machine chips are thrown to body that may hamper our hands, legs, eyes. For
this why we recommend an extra metal cover to protect body from chips. The design was given
there. Also, in lathe machine during cutting operation temperature may rise high that can occur
expansion of cutting tools and jobs. In this case an automatic spray system can be used as
cutting fluid (coolant).
In shaper machine some significant risks were also marked such as head injury at the time of
machine inspection and speed changing, hand injury at the time of machine inspection, chip
injury by throwing the chips to body, eye injury in metal cutting. In this case safety goggles,
apron, mask, extra cloth and another external metallic cover mounted on shaper machine can
be used. This may protect the users most.
In drilling machine also, some significant risks are enlisted such as hand injury by drill bit,
thermal expansion of cutting tools and jobs, chips injury. In this case attention is must. Also,
the users have to wear hand gloves, safety goggles, apron, external cooling system and an
external metal sheet for protect the body from chips.
Some other recommendations we found that could be useful are:
1. Making sure the constant availability of fire extinguisher in the machine shop.
2. Using safer and more modern safety shoes.
3. Ensuring use of compressed air or other non-hazardous techniques for cleaning
4. Using caps or helmets or other safety measures like this to prevent head injuries
A few design recommendations are given for some machines to prevent more significant
risks associated with those machines:
Figure 05: Design of a lathe machine with a protective shield
Figure 06: Design of a drill head and spindle of a drill machine with a protective shield
Conclusion:
Safety is emerging as a priority and a core value of many academic institutions and of
individual laboratories. A strong, positive safety culture is more beneficial than a compliance-
only culture. If laboratory safety is an unquestioned core value and operational priority for the
institution, then safety will never be traded for research productivity. Universities often do not
provide sufficient incentives to promote a strong, positive safety culture. In some cases, they
may create barriers or disincentives. There is a lack of clarity and consistency about safety roles
and responsibilities across the university, particularly among faculty, researchers, and
environmental health and safety personnel. For reducing this critical problem, we must come
up with some initiatives. We have work on the safety of machine shop of our university and
compare with other universities such as BUET, CUET, KUET. We have introduced some
safety rules for grinding, milling, shaper machine. We have also discussed HIRA analysis for
safety of machine shop.
The Lab-HIRA approach uses adapted versions of the ubiquitous What-If and HAZOP
techniques to meet the needs of the research laboratory environment as well the requirement of
providing a reliable risk assessment. The advantage of the Lab-HIRA approach is that it
encourages the research group to consider less obvious ways in which a deviation may occur,
even though they may seem unlikely at first consideration. The result is that there is a good
chance of identifying potential failures and problems that had not previously been encountered
with this activity. It true for any hazard identification and analysis that, despite the best efforts
of the risk assessment team, not all upsets or hazards may have been identified. However, it is
also true that in virtually all thorough HIRA’s hazards will be identified and consequently some
type of risk reduction will need to be undertaken. It is the responsibility of the synthesis owner
and the supervisor to determine the adequacy of the hazard identification and risk analysis of
their synthesis.
