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MME 1203

WORKSHOP TECHNOLOGY
Section2

Sharifah Imihezri Syed Shaharuddin


shaimihezri@iium.edu.my
Ext.3465
Lecturer Room, Level 3, E0 Building
(go left from lift)

Week 1
INTRODUCTION

Class Rules and Regulations


Be

on time for your class


Never sign in for your colleagues for
whatever reason this is classified as
cheating both parties will be punished
Use proper attire as suggested by the
IIUM.

Content
a)
b)
c)

d)
e)
f)
g)
h)

Introductory remarks
Taaruf
Workshop Requirements
Attire
Rules & Regulation
Relevance
Safety
Closing remarks
Assignment # 1
Q&A

Introductory Remarks

Foundation course extremely crucial for:


Exposure to general workshop practices
Boosting self-confidence
Need serious attention
Learning opportunity not to be wasted
Not to be taken lightly people fail in this
subject!!!!
Theory classes, practical classes, work-pieces,
reports & final test required

Taaruf (1)
Lecturers
Technicians

- workshop tour
Demonstrators - during practical
sessions

Taaruf (2)

Workshop Coordinator
Senior Technical Assistant
Bro. Mohd Faisal Mohd. Room

Technicians

Bro. Mohd Faisal Mohd. Room - Measurement


Bro. Ramle Ariffin Milling
Bro. Eddy Norhadi - Benchwork
Bro. Adanan Mat Arshat Welding /
Sheet Metal
Bro. Mohd. Shukor Mohd Noh
Turning
Bro. Mohd. Nazrani Mokhtar
Pattern Shop /
Heat Treatment
Bro. Nazrani and Bro. Eddy
Casting
Bro. Azhar Mohd. Nor
Storekeeper

Workshop Requirements

Attire

Green workshop jacket RM50.00 from Kulliyyah


Office Student Affairs (OSCENT)
Proper SAFETY shoes ~ no sandal
No entry shall be given to those without proper
attires

Rules & regulations

General safety practices


Instructions given by Workshop Staff, lecturers,
assistant lecturers
Safety signs
Note: Be humble for the sake of knowledge

Workshop Relevance
Exposure

practices

For own use


For demonstrators ~ RM 5/hr
For final year project
For research (RAs) ~ RM500/mth

Actual

to general workshop

working life

Maintenance & assembly, simple machining,


purchasing activities
Sampling of products to check on your operator..
Designing new products.

Course Outline (1)

Course Code: MME1203


Course Title: Workshop Technology
Credit Hour: 2 credits
Contact Hour: 4 ( 1 hour theory & 3 hours practical

Course Synopsis
Safety practices in engineering workshops;
measurement and measuring tools; introduction
to theory and practices of machining processes:
turning, milling, drilling, grinding; introduction to
theory and practices of fabrication processes:
benchworking, woodworking, moulding and
casting, welding, metal forming, and heattreatment operations.

Course Outline (2)


Week

Topic

Introduction

Turning processes, lathe machines, tool


angles, turning operations, cutting
parameters

Welding processes, oxyacetylene


welding, cutting torches, arc welding,
accessories

Milling processes, milling machines,


milling cutters, cutting parameters

Measurement, direct measuring


equipment, in-direct measuring
equipment, calipers, micrometers

Course Outline (3)


Week
6

Topic
Drilling processes, drilling machines,
drills,
tool-holding, reamers,
countersinking,
counter-boring,
bench-work, hacksaws,
chisels,
files, taps

Foundry processes, pattern making,


foundry sands, molding processes,
cores, melting furnaces

Heat treatment, material classifications,


iron-carbon diagram, annealing,
quenching, normalizing, stress relieving

Grinding processes, grinding machines,


grinding wheels, grinding parameters

Course Outline (4)


Week
10

Topic
Sheet metal processes, blank
development, hand shearing tools,
mechanical shears, forming tools,
soldering brazing

11

Wood working, types of wood, carpentry


tools, wood joints, carpentry tools

12
13

Revision week
End of semester test

Note: Due to scheduling constraints, classes shall not be always in


the above sequence.

Course Outline (5)


Assessment:
1. Projects (work specimens)
workpieces]
2. Reports & assignments
[individual]
3. Quizzes
3. End of semester test
test]

- 40 % [7
- 15 %
- 15 %
- 30 % [written

References:
1. Workshop Manual see Bro. Faisal
2. Kibbe, R.R., et al, Machine Tool Practice, Prentice Hall,
6th Edition, 1999
3. Kalpakjian, S., Manufacturing Processes for Engineering
Material, Addison Wesley, 1997

Overview (1)

Overview (2)

Operational Issues (1)


Submission

of reports:

Reports must be submitted one week after the


associated practical session(s) completed.
Submission is at the beginning of the
experimental work
Write your name & matric number on every page
of your report.
Staple your reports properly.
ZERO marksTwo reports deemed copied from
each other shall receive .
Marks shall be deducted for late submission.

Operational Issues (2)


Working

after office hours

Students are advised to plan their time properly to


avoid the need to work after working hours.
Plan your time & work properly to avoid rush
jobs - safety
In the event that you require to do so, permission
must be obtained using the official form:
Signature of the accompanying technician(s)
Signature of Workshop Coordinator

Operational Issues (3)


Working

after office hours

Minimum number of students working at any


time in one particular area two (2)
Maximum working time is 10:00 pm (in a big
group)

SAFETY

Content
a)
b)
c)
d)
e)
f)

Relevance
Definition
Dos & Donts
Illustrations
Operational Issues
Q&A

Relevance (1)
Address

two of the most prominent


safety issues:
Developing a good safety attitude in
you
Providing introductory safety training
the importance of safety in the
Kulliyyah

Relevance (2)
OSHA Legislation
LAWS OF MALAYSIA - Act 514
OCCUPATIONAL SAFETY AND HEALTH ACT
1994
An Act to make further provisions for securing the safety,
health and welfare of persons at work, for protecting others
against risks to safety or health in connection with the
activities of persons at work, to establish the National Council
for Occupational Safety and Health and for matters connected
therewith.

Definition

Human/machine/workplace interaction
Maximizes quality and efficiency of work
Maximizes human values such as safety,
satisfaction, comfort, learning

These two normally conflict the need for


juggling skill

Safety - judgment of the acceptability of


danger (hazard & risk) where
Hazard injury producer
Risk probability that an injury will occur
85 % of accidents caused by human: training
is extremely important to recognize hazard
& to work safely

Dos & Donts (1)

Occupational Safety & Health Act 1994


Control of Industrial Major Accident
Hazards Regulations 1995
Control of occupational hazards
1. Elimination
2. Substitution
3. Isolation
4. Engineering controls
5. Personal protective equipment (PPE)

Dos & Donts (2)

Dos and Donts to prevent accidents:

Wear proper attire

i.e., workshop jacket & proper shoes. Loose clothing,


finger rings and other accessories are some possible
sources of accident.

Footwear must be worn all the time to


prevent injury molten aluminum, hot metal
chips, slip
Be attentive while you are in the workshop.

Dos & Donts (3)

Dos and Donts to prevent accidents:

Do not run in the workshop. Be calm but


serious.
Pay attention to details. Always think before
you carry out any step.
Do not start any machine before obtaining
instructions from your instructor.
Make sure you understand your machine &
the procedures before you start working.
Check your vicinity. Ensure the floor is clean
& clear from oils, obstructions and debris.

Dos & Donts (4)

Dos and Donts to prevent accidents

Locate the Emergency button or foot pedal.


In the event of any accident, switch off the
machine using the Emergency button.
Never let anyone handle the starting switch
for you.
Ensure work-pieces are properly clamped or
secured to the machine. Remove any loose
parts such as chuck key, vice handle, etc.
flying chuck key (faint) & flying work-piece
Always wear goggles where fine chips are
produced bloated eye.

Dos & Donts (5)

Dos and Donts to prevent accidents:

Use machine guards all the time.


When you are operating any machine, stand
at a proper distance.
Do not use hand(s) or finger(s) to stop moving
or rotating machines or parts of machines
legs between rollers
Do not set the tools when the machine is
running. You may break the tool and worse
still, you may injure yourself.
Never handle machines or work-pieces during
running. Stop the machine first.

Dos & Donts (6)

Dos and Donts to prevent accidents:

Do not distract a person while he or she is


operating a machine. Wait till he or she
completes the operation & stop the machine
before doing so Do not be playful NO
PRACTICAL JOKES
Do not use hands to clear metal chips 600
~ 700OC (chip-tool interface)
Do not take measurement while machine or
work-piece is moving
Do not blow chips, dust from vices, etc. lest
they may get into your eyes.

Dos & Donts (7)

Dos and Donts to prevent accidents:

When facing with problems or uncertainty,


stop the machine & get clarification and help.
Stop any machine before leaving it. Never
leave any machine running unattended.
Beware of high temperatures associated with
metal chips, welding, heat treatment &
casting activities
Beware of high voltages. Ensure all
machines are properly earthed. Do not
interfere with electrical equipment or
connections.

DOS & DONTS (8)

Dos and Donts to prevent accidents:

Protect your eyes from bright lights & ears from


loud sounds
Plan your time properly. Working under
unnecessary pressure may lead to accidents
Grinding tools must be set up by experienced
personnel. Grinding tools rotate at great
circumferential speed
Damaged grinding tools & wheels must not be
used
Do not run any machining exceeding the maximum
allowable speeds
Beware of sharp or ragged edges

Dos & Donts (9)


Dos and Donts to prevent accidents
Report any injury, cut or scratch, no matter how
trivial it may be to your instructor
Clean the tools, cutters, machines & surrounding
area from debris, metal chips, oils, grease &
coolants whenever necessary and after
completing your work
Clean working + good order = safety
Return all tools to store or original cabinet
Never handle heavy objects unaided.
The above list is not exhaustive. Good
understanding, calmness and common sense
prevail.

Illustrations (1)

Illustrations (2)

MATERIAL SAFETY DATA SHEET


1. What is the material, and what are its
hazards?
2. What should I do if a problem occurs?
3. What precautions should I take when
working with this material?
4. Is there anything else I should know
about this substance?

Illustrations (3)
ELECTRICAL SAFETY

Slips, trips, and falls


account for more
workplace injuries
annually than any other
accident category.
Many of these injuries
can be disabling, or even

Illustrations (4)
Danger of working with
machinery
Minimizing risks by proper
installation and use of
safety guards and devices.
The risk of accidents from
powered machinery is so
great OSHA estimates that
lack of machine guarding is
the second most frequent
safety violation in industry
today.

Illustrations (5)
Industrial Ergonomics
Physiology of the body
Parts of the body most
effected
Eye strain
Preventative measures
Correct use of office
equipment
Exercises and stress release

Illustrations (6)
Material Handling
Back
Safety

ILLUSTRATIONS (7)
Prevent workplace accidents by paying attention
to safety housekeeping considerations.
Good safety housekeeping can significantly
reduce accidents and injuries in any type of work
environment.
By developing good safety habits / by being
aware of their work environment and any hazards
associated with it, employees can help to create a
much safer workplace.
Safety awareness
Handling rubbish and excess materials
Keeping aisles and stairways clean
Using ropes and electric cords
Dealing with hazardous chemicals

ILLUSTRATIONS (8)
Authorization for welding
operations
Sparking and fire risk
Guards and protective barriers
Hazardous fumes and
ventilation
Proper welding safety
procedures
The use of respirators
Eye protection (welding
helmets,
filters, glasses and goggles)

Illustrations (9)
Many eye problems are caused
by not paying attention to the
work or by not wearing the
appropriate protective
equipment.
Eye Safety

Hearing Safety

Our eyes are really very fragile,


and statistics show that eye
injuries occur frequently in the
workplace.
Selecting and using appropriate
personal protective equipment
would prevent short and longterm effects of eye and hearing

Illustrations (10)
Matching the tool to the
job
Importance of state of
mind
Good safety practices
Personal protective
equipment
Most common cause of
Tool care and
workplace injuries today is
maintenance
due to employees not using
personal protective
equipment (PPE) as they
work.
How to properly use PPE
Matching equipment to the
hazard

Illustrations (11)

Illustrations (12)
Compressed gas is used for many
things - refrigeration, welding,
heating, and a number of other
functions.
Compressed gas can be dangerous,
and employees who work with them
need to know how to handle them
Associated hazards
properly.

Moving and transporting


cylinders safely
Positioning cylinders
properly
Proper hook-up
procedures
Safe storage practices

Illustrations (13)
Workplace fires cause hundreds of millions
of dollars in damage and result in
numerous employee injuries, many of
which are fatal.
Work practices can contribute to the risk
of fire.
Common causes of workplace fires
Importance of good housekeeping
Other fire prevention measures
Various types of fire extinguishers
Using fire extinguishers
Evacuation and other employee s/

Illustrations (14)
Over 90% of crane-related accidents are caused
by human error, and that they are the key to
preventing these incidents.
Crane-related accidents can often be deadly,
due to the cumbersome and heavy loads that
are lifted.
A small miscalculation, or a brief moment of
inattention, and tragedy could strike.
Physical and mental preparation
Equipment inspection
Hazard assessment
Overhead cranes
General and operational safety devices
Crane operations

ILLUSTRATIONS (16)
Knowing basic first aid can often limit the severity
of any type of injury, or even prevent a death.
Not a day goes by without some type of injury
occurring. It can be as serious as a chemical burn,
or as minor as a small cut.
Any injury can be painful and affect an employee's
work performance, as well as their life off the job.
Cuts and bleeding
Muscle pulls and sprains
Burns
Broken bones
Shock
Artificial respiration and CPR

Illustrations (17)

Illustrations (18)
Full cooperation with any inquiry.
Focus to determine the cause of an accident
Goal to prevent similar accidents from
happening
Root-cause analysis
Importance of investigative interviews
Reporting near misses
Warning signs in accident prevention

Illustrations (19)

Illustrations (20)
How small changes in lifestyles can produce
big benefits.
Good wellness and fitness can significantly
help to improve safety records.
Accidents and injuries occur less frequently
with those who are healthier and in better
shape.
The importance of attitude
Blood pressure and other stress related
conditions
Nutrition and weight control
Drug and alcohol use

Operational Issues (1)


Working

after office hours

Plan your time properly to avoid the need


to work after working hours.
Plan your time & work properly to avoid
rush jobs - safety
In the event that you require to do so,
permission must be obtained using the
official form:

Signature of the accompanying technician(s)


Signature of Workshop Coordinator

Operational Issues (2)


Working

after office hours

Minimum number of students working at


any time in one particular area two (2)
Maximum working time is 10:00 pm (in a
big group)

CLOSING REMARKS
Lack of efforts: lectures not attended,
assignments not properly done, textbook not
referred,
Time management
English language
Communication

ASSIGNMENT NO. 1
To prepare a report containing the
following points:
1. Engineering Workshop ground floor layout
2. Workshop Organizational chart
3. Machine functions
4. Observations on housekeeping, safety, signs,
SOPs, layout with comments on possible
improvements.
5. Conclusions from Introductory session &
Workshop Tour

THE END

Lets have a tour to


the workshop