NATIONAL INSTITUTE OF TECHNOLOGY

KURUKSHETRA
INTRODUCTIO
N TO
ENGINEERING
PracticeS &
INDUSTRIAL
SAFETY
BY : SACHIN
KANSAL
INTRODUCTION
 Manufacturing is the backbone of any industrialized
nation
 All future engineers must know the basic requirements

of workshop activities in term of

Man
Machine
Material
Methods,
Money
other infrastructure facilities
ENGINEERING/ WORKSHOPS
PRACTICES
Engineering/Workshops Practices is the study to
imparting the basic working knowledge of the different
 Engineering materials
 Tools & equipments
 Manufacturing processes,
 Basic concepts of electromechanical controls of

machine tools
 Production criteria’s
ENGINEERING/ WORKSHOPS
PRACTICES

 Characteristics and uses of various testing instruments

 Measuring or inspecting devices for checking

components or products

manufactured in various manufacturing shops in an

industrial environment
ENGINEERING/ WORKSHOPS
PRACTICES
It also describes and demonstrates the use of
 Different hand tools (measuring, marking, holding and

supporting tools, cutting etc.)

 Equipments & machinery
 Various methods of manufacturing

that facilitate shaping or forming the different existing

raw materials into suitable usable forms.
MANUFACTURING PROCESS
It is that part of the production process which is
directly concerned with the change of form or
dimensions of the part being produced

 Primary Shaping Processes

 Secondary or Machining Processes

 Metal Forming Processes

 Joining Processes
MANUFACTURING PROCESS
 Primary Shaping Processes
 (1) Casting
 (2) Powder metallurgy
 (3) Plastic technology
 (4) Gas cutting,
 (5) Bending and
 (6) Forging.
MANUFACTURING PROCESS
 Secondary or Machining Processes
 (1) Turning
 (2) Threading
 (3) Knurling
 (4) Milling
 (5) Drilling
 (6) Boring
 (7) Planning
 (8) Shaping
MANUFACTURING PROCESS
 (9) Slotting
 (10) Sawing
 (11) Broaching
 (12) Hobbing
 (13) Grinding
 (14) Gear cutting
 (15) Thread cutting
 (16) Unconventional machining processes namely machining with
Numerical Control (NC) machines tools or Computer Numerical
Control (CNC) machines tools using ECM, LBM, AJM, USM
setups etc.
MANUFACTURING PROCESS
 Metal Forming Processes
Hot working Processes
(1) Forging
(2) Rolling
(3) Hot spinning
(4) Extrusion
(5) Hot drawing
(6) Hot spinning.
Cold working processes
(1) Cold forging,
MANUFACTURING PROCESS
(2) Cold rolling
(3) Cold heading
(4) Cold drawing
(5) Wire drawing
(6) Stretch forming
(7) Sheet metal working processes such as piercing,
punching, lancing, notching, coining, squeezing, deep
drawing, bending etc.
MANUFACTURING PROCESS
 Joining Processes
(1) Welding (plastic or fusion)
(2) Brazing
(3) Soldering
(4) Riveting
(5) Screwing,
(6) Press fitting
Many others like Sintering, Adhesive bonding, Shrink,
Explosive welding, Diffusion welding, Keys and cotters
joints, Coupling , Nut and bolt joints.
MANUFACTURING PROCESS
 Surface Finishing Processes
(1) Honing
(2) Lapping
(3) Super finishing
(4) Belt grinding
(5) Polishing
(6) Tumbling
(7) Organic finishes
MANUFACTURING PROCESS
(8) Sanding
(9) deburring
(10) Electroplating
Many more like Buffing, Metal spraying, Painting,
Inorganic coating, Anodizing, Sheradising, Parkerizing,
Galvanizing, Plastic coating, Metallic coating, Anodizing
and Sand blasting..
SIGNIFICANCE OF
INDUSTRIAL SAFETY
 Industrial accidents causes a great loss to both the
Employer & Employee,

 Cost of compensation
 Cost of medical-aid
 Cost of training a new worker
 Cost of the lost time
 Cost of investigation
 Cost to the Govt. in terms of factory inspectors, &
public health services
 Cost of spoilage of materials
 Cost of the damage of machinery
 Cost of cost of wages payble during injury
 Cost of loss of morale; &
 Cost of loss to the worker and his family
WHAT IS INDUSTRIAL SAFETY
 Industrial safety is primarily a management activity
which is concerned with
 Reducing
 Controlling
 Eliminating hazards from the industries

or industrial units.
OBJECTIVES OF INDUSTRIAL
SAFETY
 Industrial safety are needed in order to:
(1) Check all the possible chances of accidents for preventing
loss of life and permanent disability of any industrial
employee, any damage to machine and material as it leads to
the loss to the whole establishment.
(2) Eliminate accidents causing work stoppage and production
loss.
(3) Prevent accidents in industry by reducing any hazard to
minimum.
(4) Reduce workman’s compensation, insurance rate and all
the cost of accidents.
OBJECTIVES OF INDUSTRIAL
SAFETY
(5) Educate all members regarding the safety principles to
avoid accidents in industry.
(6) Achieve better morale of the industrial employees.
(7) Have better human relations within the industry.
(8)Increase production means to a higher standard of living.
CAUSES OF INDUSTRIAL
ACCIDENTS
 1. Unsafe conditions
a. The job itself
b. Work schedules
c. Psychological conditions
d. Machinery & Equipment
 2. Unsafe Acts
 3. Miscellaneous Causes
MEASURES TO ENSURE INDUSTRIAL SAFETY

 1. Safety Policy
 2. Safety Committee
 3. Safety Engineering
 a. Guarding of machinery
 b. Material handling equipment
 c. Safety devices
 d. Ergonomics
 e. Plan maintenance
 f. General house keeping
 4. Safety Education & Training
 5. Role of Government
COMMON SAFTY METHODS
The common methods of safety are as follows:
1. Safety by construction or design.
2. Safety by position.
3. Safety by using fixed guards.
4. Safety by using interlock guards.
5. Safety by using automatic guards.
6. Safety by using trip guards.
7. Safety by using distance guards.
8. Safety by workplace layout and proper working
conditions.
COMMON SAFTY METHODS
9. Safety by proper material handling.
10. Safety by using personal protective
devices.
General Safety Precautions while
Working in a Workshop
(1) One should not leave the machine ON even
after the power is OFF and until it has stopped
running completely. Someone else may not notice
that the machine is still in motion and be injured.
(2)Operator should not talk to other industrial
persons when he is operating a machine.
(3) One should not oil, clean, adjust or repair any
machine while it is running. Stop the machine and
lock the power switch in the OFF position.
General Safety Precautions while
Working in a Workshop
(4)One should not operate any machine unless
authorized to do so by the authorize person in the
shop.
(5)Always check that work and cutting tools on any
machine are clamped securely before starting
(6)The floor should be kept clean and clear of metal
chips or curls and waste pieces. Put them in the
container provided for such things. Scraps and chips or
curls may cut through a shoe and injure the foot
General Safety Precautions while
Working in a Workshop
(7) Defective guards must be replaced or repaired
immediately.
(8) One should not operate any machinery when the
supervisor or instructor is not in the shop
(9)All set screws should be of flush or recessed type.
Projecting set screws are very dangerous because they catch
on sleeves or clothing.
(10)One should not try to stop the machine with hands or
body
(11) Only trained operator should operate machine or
switches as far as possible.
General Safety Precautions while
Working in a Workshop
(12) Always take help for handling long or heavy pieces of
material.
(13)Always follow safe lifting practices
(14) No one should run in the shop at work time.
(15) Always keep your body and clothes away from moving
machine parts. Get first aid immediately for any injury.
(16) Never talk to anyone while operating the machine, nor
allow anyone to come near you or the machine.
(17)Stop the machine before making measurements or
adjustments.
General Safety Precautions while
Working in a Workshop
(18) Operator should concentrate on the work and must not
talk unnecessarily while operating the machine
(19) Never wear necktie, loose sweater, wristwatch, bangles,
rings, and loose fitting clothing while working in workshop.
(20) Always wear overcoat or apron.
(21) Stop machines before attempting to clean it.
(22) Make sure that all guards are in their place before
starting to operate a machine.
(23) Do not attempt to operate a machine until you have
received operating instructions.
(24) Be thoroughly familiar with the ‘stop’ button and any
emergency stop buttons provided on the machines.
General Safety Precautions while
Working in a Workshop
 (25) Remove burrs, chips and other unwanted materials as soon as
possible. They can cause serious cuts.
 (26)Do not leave loose rags on machines.
 (27) Wash your hands thoroughly after working to remove oils, abrasive
particles, cutting fluid, etc.
 (28)Report all injuries to the foreman, howsoever small. Cuts and burns
should be treated immediately.
 (29) Keep the work area clean.
 (30)Keep your mind on the job, be alert, and be ready for any
emergency.
 (31) Always work in proper lighting.
 (32)One should not lean against the machines.