A workshop is a room or building in which manual work or manufacturing is carried out. In any society, rules and regulations must be devised for the guidance and benefit of all concerned; the workshop is no exception. These rules are necessary to make the workshop a safe, efficient, and healthy place in which to work.
Workshop Environment and Conditions Affecting Safety
There are many different sets of conditions and circumstances affecting the safe layout of workshops. However, certain general points to consider are:
1. Gangways: Those parts of a workshop floor allocated for personnel movement should:
i. Be clearly marked with broad lines and labelled, preferably with light-coloured luminous paint.
ii. Be wide enough to ensure people using them are clear of machines and their operators.
iii. Allow clear access, by the shortest practicable route, to all exits.
iv. Be kept clean and free from obstruction.
2. Emergency Lighting: In the event of the main lighting system failing during the hours of darkness, an alternative system is essential. This should ideally consist of battery-operated lamps that automatically switch on when the mains power fails.
These lamps should be positioned to illuminate gangways, corridors, exits, and places where projecting objects can be hazardous. Regular testing of emergency lighting equipment is necessary, especially when emergencies are rare.
3. Suspended Weights: If heavy weights must be suspended for any length of time:
i. Get them down as soon as possible.
ii. Ensure that all lifting equipment is in first-class condition.
iii. Never stand underneath.
4. Dangerous Substances: Many workshops contain materials that are dangerous if improperly stored or handled. These may include deadly poisons like cyanide, highly inflammable liquids like petrol, explosive gases, or corrosive acids. These materials are safe if a few common-sense rules are followed:
i. Obey all handling and storage instructions issued by manufacturers and competent authorities.
ii. Never dispose of unwanted substances by burning them or pouring them into drains.
iii. Ensure dangerous substances do not come into contact with one another (e.g., oil and oxygen may explode when mixed).
iv. Always wear correct protective clothing and equipment.
v. Ensure adequate ventilation.
vi. Never investigate mysterious packages that appear to have lost their labels.
vii. “No Smoking” signs must be strictly observed.
5. Bars of Metal: Bars of metal that are incorrectly stored can be very dangerous. They should be stored horizontally in strongly built racks, with the shorter pieces on top so they are supported by, and parallel with, the longer bars.
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Workshop Cleanliness and Order
All tools, materials, etc., not immediately required for the job at hand should be put away or returned to the stores. Benches should be brushed, floors swept, machines cleaned, and swarf trays emptied regularly to prevent the accumulation of dirt and metal cuttings. Proper receptacles for swarf and rubbish disposal should also be provided.
Injuries and First Aid in the Workshop
All cuts and scratches, however slight, must be treated as soon as possible in a first-aid centre. Particles of foreign matter should be removed from the eyes immediately. Delaying these actions can lead to infections, loss of limbs, or blindness.
It may not be practical for everyone to be skilled in first aid, but workshop personnel should know certain fundamental responsibilities:
i. Read all safety notices displayed in the workshop concerning accident prevention and life-saving procedures.
ii. Know the location of first-aid boxes, fire blankets, and fire extinguishers.
iii. Be aware of those skilled in first aid and where they can be found.
iv. Know the procedure for calling an ambulance, with this information prominently displayed along with the location of the nearest telephone.
Care and Order in the Workshop
Good habits should be developed early in one’s career. These habits are invaluable and should remain throughout a career.
1. Tidiness: Habits of tidiness are no less important in the workshop than in any other aspect of life. The tidiness and order in one’s work method often reflect a worker’s reliability. Tidiness goes beyond keeping tools in their proper place; it implies order and cleanliness in such a way that work proceeds smoothly without effort.
A first-class mechanic should regard dirt or superfluous articles about his machine, tools, or work with concern. An orderly worker does not waste energy searching for tools or clearing unwanted items and will be more productive and fresher at the end of the day than a worker with untidy habits.
2. Care of Tools and Machines: From the start of a career, tools and machines play a crucial role in work, and as time progresses, they become more numerous and costly. Some tools may belong to the employer, and others to the worker. The employer’s equipment represents capital used to obtain output and profits, while the worker’s tools are essential for earning a living.
Proper care of tools and machines enhances their accuracy and lifespan. Tools like spanners and files should not be dropped on machined surfaces. Placing a board under tools stored on a machine bed will keep things tidy and prevent damage.
3. Use of Hammers: When a hammer is needed to loosen or tighten parts of a machine, a lead or copper hammer should be used to avoid bruising. If unavailable, a block of hard wood or soft metal should be used to prevent damage. Careless hammering can mutilate parts of machines, especially handles of vises and jigs, which are often damaged unnecessarily.
4. Grinding Tools: In every machine shop, a significant amount of capital is invested in cutting tools like drills and cutters. Although these tools may not appear valuable, they are costly and must be treated with respect. Over time, tools dull and require sharpening. Delaying re-sharpening can ruin tools.
Proper grinding techniques should be learned as tools can be spoiled by improper grinding just as easily as by neglect. Grinding tools generate heat, and water flow is necessary to carry heat away and prevent overheating. Grinding without sufficient water or intermittent splashes can cause sudden quenching, leading to cracks that may cause tool failure.
5. Tool Failure in Cutting: A common cause of tool failure is running the machine too fast, which causes overheating and deterioration of the cutting edge. Reducing speed and using plenty of cutting lubricant can prevent this. Cast iron does not require lubricant but can be machined more effectively if the first cut penetrates beneath the hard outer scale.
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Workshop Safety
Workshop safety is crucial, and work must always be done with everyone’s safety in mind. Five important safety areas are:
1. Personal Safety: Loose clothing, such as sweaters, jackets, ties, and jewellery, should be removed. Shirt tails and long hair must be tucked in. Sleeves should be rolled above the elbow, and aprons should be worn. Report all injuries, even minor ones, immediately.
2. Eye Protection: Eye protection is required when using power tools or working in environments where flying dust or particles are present.
3. Tool Safety: Tools should not be handled until safe and correct use has been demonstrated. Use the right tool for the right job, carry sharp tools with care, and always cut away from the body. Return tools to their proper place and avoid using damaged tools.
4. Housekeeping: Keeping the workshop clean is essential for safety. Sweep up scraps, avoid spilling oils or finishes, and keep aisles clear. Proper storage of materials, including shavings, dust, solvents, and rags, prevents fires.
5. Material Storage and Handling: Proper storage of materials prevents accidents and fire hazards.
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Frequently Asked Questions
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