The University of Zambia

School of Engineering
Department of Mechanical Engineering

MECHANICAL WORKSHOP TECHNOLOGY

ENG 2159

LECTURE 1 WORKSHOP SAFETY – ENGINEERING

MATERIALS

1
 GENERAL INFORMATION

Course: ENG 2159

Course Title: Mechanical Workshop

Technology

Lectures: 2 hours per week

Laboratory/Tutorial: 3 hours per week

Instructor: Dr. J. Phiri

Dr. S. Sichilalu
Tutor: TBA

2
Assessment

The course will be assessed in the following

manner:

Assignments/Quizes: 5%

Labs/projects: 15%

Tests: 20%

Final Exam: 60%

3
Attendance

• Attendance and participation in the lecture are

compulsory and will be considered in the grading.

• Students are expected to keep up with the

assigned reading and be prepared to answer
questions on these readings during lectures and
for the pop quizes.

4
 TIME TABLE

LECTURES

WEDNESDAY : 11:00 – 13:00

LABS/TUTORIALS

MON-THURSDAY: 14:00 – 17:00

5
Course Objective

The course objective is to impart workshop based knowledge to

students and introduce practical workshop skills such that upon
successful completion of the course, the students will be able to:

1. Describe workshop processes for metal and wood cutting and

related machine tool kinematic designs;

2. Conduct precision measurements associated with machined

products;

3. Operate basic machine tools and electrical workshop appliances;

4. Manufacture metal and wood products using the various workshop

machine tools and casting facilities;

5. Describe safety procedures and standards applicable to mechanical

and electrical workshops.
6
Course Content

A. Mechanical Workshop Technology

i) Workshop and Industrial safety

ii) Materials used in workshops

iii) Workshop secondary processes ( machining- milling, turning, drilling e.t.c)

iv) Workshop primary processes (casting )

v) Welding

vi) Engineering metrology

vii) Process planning

viii) Manufacturing project

7
B. Electrical Workshop Technology
i) Workshop, industrial and home safety
.

ii) Basic electrical components

.

iii) Electrical workshop practice

.

8
 Prescribed Books
• Mechanical Workshop Technology

i) Chapman W. A. J., 1972, Workshop Technology Part 1, 5th

Edition, Arnold, ISBN 0 7131 3287 6

ii) Chapman W. A. J., 1972, Workshop Technology Part 2, 5th

Edition, Arnold, ISBN 0 7131 3287 6

B. Principles of Electricity and Electronics II

•Ian McKenzie Smith, John Hiley and Keith Brown, 2005 Hughes
Electrical and Electronic/ Edward Hughes.- 9th Ed., Prentice Hall,
ISBN 0-13–114397-2

•Allan R. Hambley: 2008, Electrical Engineering: Principles and

Applications:International Edition, 4/E, Prentice Hall,ISBN-10
0132066920
9
Recommended Books

A. Mechanical Workshop Technology

i) Black S.C., Chiles V., Lissaman A.J. and Martin J.J., 1996,
Principles of Engineering Manufacture, 3rd Ed., Arnold, ISBN –

ii) Kalpakjian S., 1995, Manufacturing Engineering and

Technology, 3rd Ed., Addison-Wesley, ISBN -

10
LECTURE 1 – WORKSHOP SAFETY

11
Safety in the workshop!!
(All Technology Classes)
Because safety is #1

12
Assessing the situation:
Why assess a situation?

Before beginning any task in an Engineering Workshop,

particularly if it involves the use of tools or machinery,
it is very important to stop and think. Consider these
points:

• What are you going to do?

• How are you going to do it?

• What tools or equipment do you need to do it?

and most importantly,

• What safety procedures have to be put in place to

prevent accidents or injury?

By asking yourself these questions, you are assessing a

situation in order to minimise risk.

Workshop safety is an attitude of mind. 13

Workshop Safety
In the school workshop, students always use tools with sharp edges and operate
some dangerous machines for the project work.

Therefore, students must be very careful during working and observe all workshop
safety rules.
This presentation will explore:
◼ Safety Clothing
◼ Workshop Safety Hazards
◼ Safety Data Sheets and Labels
◼ Storage and Spills
15 of 24
Typical Workshop Safety Hazards
A number of accidents could
occur in a workshop:
◼ Fires and explosions.

◼ Chemical burns.

◼ Electric shocks.
◼ Physical injuries.

It is important to know what

action to take and how to
minimize accidents.

Next >
Basic Personal Protective Clothing
Personal protective clothing helps
minimize personal injury in the
event of an accident. Basic
protective clothing is:

◼ Overalls.

◼ Protective boots.

◼ Latex gloves.

If not overalls, clothing

must be well fitting and of
hard-wearing material.

Next >
Eye Protection
Eye damage can result from small
particles, sharp objects, liquids,
gases or intense light. Typical eye
protection is:
◼ Safety glasses.
◼ Safety (splash) goggles.
◼ Face shield.
◼ Welding helmet (mask).

Hazardous liquids in eyes must

be washed out with clean water
or eye wash.

Next
18 of 9 >
 Hand Protection
Hands may be injured in a
workshop by cuts, skin damage or
chemical burns. Gloves must be
worn to help prevent injuries:

◼ Latex gloves.

◼ Rubber gloves.

◼ Leather gloves.

Next
19 of 9 >
Ear and Respiratory Protection
Loud noises over long periods
can damage ears.

Ear defenders and earplugs

can protect ears.

Respiratory equipment is
required during some tasks,
or breathing difficulties,
headaches, dizziness or
sickness may occur.

Dust masks and respirators

are used.

Next
20 of 9 >
Lifting and Carrying
Bulky objects must be lifted and
carried correctly to prevent injury
(particularly to the back).

Ensure feet are close to object

keeping back straight.

Keep object as close to body as

possible when lifting. Lift from leg
muscles, back must be straight
all the time.

Proper protective shoes must be

worn.
Next
21 of 9 >
First Aid
Seek medical help after
an accident. First aid
station and first aid
representative available.

First aid station has minor

injury relief and eye wash.

First aid representative provides

basic assistance. Call professional
services for more serious accidents.

Next
22 of 9 >
Workshop Ventilation and Lighting
Workshop must be ventilated to
remove fumes.

Fans and exhaust extraction are

used for this purpose.

Good lighting essential to see work.

Portable lamps direct light to

work areas.

Next
23 of 9 >
Fire Exits and Assembly Points
Use designated fire exits to
evacuate building and meet at
assembly point.

Fire notices provide information.

Next
24 of 9 >
Hazardous Materials
Hazardous materials found in workshop.
Take precautions when handling.
Typical hazardous materials:
◼ Fuel.
◼ Battery acid (electrolyte).
◼ Engine oil.

◼ Engine coolant (antifreeze).

◼ Brake, transmission and

power steering fluid.
◼ Cleaning chemicals.
◼ Paints and thinners.

Next
25 of 9 >
Hazardous Materials
Hazardous materials found in workshop.
Take precautions when handling.
Typical hazardous materials:
◼ Fuel.
◼ Battery acid (electrolyte).
◼ Engine oil.

◼ Engine coolant (antifreeze).

◼ Brake, transmission and

power steering fluid.
◼ Cleaning chemicals.
◼ Paints and thinners.

Next
26 of 9 >
Material Safety Data Sheets
MSDS provides information about hazardous products.
Available in workshop.
MSDS information includes:
◼ What the product is.
◼ Manufacturer details.
◼ Product ingredients.
◼ Physical description.
◼ Potential health hazards.
◼ Conditions that could
increase hazard.
◼ How to safely handle it.
◼ What to do if exposed to it.
◼ What to do in the event of a spill. Next
27 of 9 >
Product Warning Labels
Hazardous materials container/
packaging has product warning
label including:
◼ What the product is.
◼ Manufacturer details.
◼ Hazard types.
◼ Potential health hazards.
◼ Protection.

Warning symbols indicate type

of hazard associated with a
material/chemical.

Next
28 of 9 >
Hazardous Material Health Symptoms
Hazardous material contact can cause
physical symptoms:
◼ Breathing difficulties.
◼ Irritation of the nose, throat
or lungs.
◼ Discomfort/headaches.
◼ Fatigue/weakness.
◼ Dizziness.
◼ Loss of consciousness.
◼ Restricted movement.
◼ Poor/blurred vision.

Seek medical attention immediately

if symptoms occur. Next
29 of 9 >
Dealing With Spillages
Fuel leaks, oil leaks, damaged/
dropped containers etc.

Clean up immediately, wear

appropriate clothing and do
not let into drain.

Use appropriate clean-up material

and dispose of properly.

Next
30 of 9 >
Disposal of Workshop Waste
Used engine/transmission oils,
coolant, fluids, used oil filters,
rags and used cleaning chemical.

Properly store in sealed

and labelled containers.

Some waste can be recycled, e.g.

recovered refrigerant. Other
waste must be disposed of
following strict regulations.
Next
31 of 9 >
Summary
You should now be aware of:

◼ Safety Clothing

◼ Workshop Safety Hazards

◼ Safety Data Sheets and Labels

◼ Storage and Spills

37
>
1.

Safety rules for student's outfit in the workshop.

i) Always wear protective clothing (an apron or overall)

ii） Wear hard leather shoes or safety shoes. Do not wear

sandals or rubber shoes﹔

iii） Roll up sleeves and take off your tie and watch﹔

iv） Tie up long hair.

33 of 9
2. Use suitable tools or machines for your work.

3. Enter the workshop only with the teacher's permission.

4. Do not use any tools or machines without the teacher's permission.

5. Never work alone in the workshop.

6. When carrying tools, point the sharp edge downwards.

7. A machine must always be operated by one student at a time.

8. Switch off the machine before adjusting or cleaning.

34
9. Do not run or play in the workshop.

10. When carrying large objects or tools, take great note of the surrounding.

11. Press the emergency button in case of accidents and inform the teacher
immediately.

12. Do not put tools or materials near the edge of the bench

35
13.
Do not leave any tools, materials or waste on the bench, machine
or floor after working.

36
37 of 9
14.
Always clean the bench, machine and floor after working and make sure
that there is no paint, oil, dirt or rubbish left behind.

38
15. No eating in the workshop.

39 of 31
16.
Inform the lecturer/technician of the damaged tool.

THANK YOU

40