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OCCUPATIONAL SAFETY AND HEALTH
Instructions for labor protection for machine operators during metalworking. Full document
Occupational Safety and Health / Standard instructions for labor protection Safe Operation 1. General requirements for labor protection 1.1. Persons who have passed a medical examination, been trained in safe work methods and have a certificate for the right to work on the machine are allowed to work on metal-cutting machines, as well as:
1.2. It is allowed to work only on machines to which you are authorized and to perform only the work assigned by the master. 1.3. Do not allow persons unrelated to the assigned work to enter your workplace. Do not transfer the machine to anyone without the master’s permission, even for a short time. 1.4. Do not lean on the machine during operation, do not allow others to do so. 1.5. Do not work on a faulty machine, do not repair the machine yourself. 1.6. It is forbidden to work on the machine with gloves or mittens. 1.7. To avoid accidents and dirt and chips getting into the machine mechanisms, it is prohibited to blow air from a hose onto the surface being processed. 1.8. The weight and overall dimensions of the workpiece must correspond to the machine’s passport data. 1.9. Install and remove heavy parts and accessories (weighing more than 16 kg) only with the help of lifting mechanisms. 1.10. Use lifting mechanisms only after undergoing special training and knowledge testing. 1.11. The machine operator must use the following personal protective equipment: cotton overalls, leather boots, goggles. 1.12. The operator must know:
1.13. The machine operator must:
1.14. The machine operator is prohibited from:
1.15. While working, the machine operator may be exposed to the following hazardous factors:
1.16. Eat only in canteens, buffets or specially designated rooms. 1.17. For violation of the requirements of these instructions, the machine operator is responsible in accordance with current legislation. 1.18. The machine operator has the right not to follow the instructions of the administration if they contradict the safety requirements of this instruction. 2. Labor protection requirements before starting work 2.1. The machine operator must make sure that the machine, all tools and equipment are in good working order, and wear the required special clothing and safety shoes. Clothes should be tucked in so that there are no loose ends, and cuffs should be fastened. 2.2. It is prohibited to work on machines without personal protective equipment (goggles). 2.3. Use only serviceable tools and devices and use them strictly for their intended purpose. 2.4. Prepare a hook for removing chips, keys and other tools. Do not use a hook or loop. 2.5. Check when the machine is idling: a) serviceability of controls (mechanisms of the main movement of feeding, starting, stopping movement); b) serviceability of the lubrication and cooling system; c) the locking of the on and off levers is in good working order (make sure that the possibility of spontaneous switching from idle to power is excluded). 2.6. Check the serviceability of the tool received from the warehouse. 2.7. Do not wash your hands in oil, emulsion, kerosene and do not wipe them with ends contaminated with shavings. 2.8. Before each start-up of the machine, make sure that starting up the machine does not endanger anyone. 2.9. Adjust the local lighting of the machine so that the working area is sufficiently illuminated and the light does not blind the eyes. 2.10. Whenever there is a power outage, turn off the machine immediately. 2.11. Do not cool the cutting tool with wet rags or brushes. 2.12. Do not allow oil to splash on the floor. To protect against splashes, install shields. 3. Labor protection requirements during work 3.1. Follow the instructions for servicing and caring for machines set out in the machine manual, as well as the requirements of the warning tables available on the machine. 3.2. Install and remove cutting tools, as well as take measurements only after the machine has completely stopped. 3.3. Do not work without a casing covering the change gears. 3.4. Beware of the wrench falling off, place the wrench on the nut correctly, and do not jerk the nut. 3.5. While the machine is operating, do not pick up or feed any objects through the operating machine, do not tighten bolts and nuts and other connecting parts of the machine. Safety requirements when working on lathes 3.6. Be careful not to wind the chips around the workpiece or cutter and do not direct the curling chips towards yourself. 3.7. Monitor the timely removal of chips from the workplace. Check the correct installation of the product before starting the machine. 3.8. The workpiece must be securely secured in the chuck or centers. It is prohibited to brake the chuck or faceplate by hand to speed up the machine stop. 3.9. When processing parts in centers, you need to carefully monitor the condition of the centers and lubricate them in a timely manner. 3.10. Fastening devices (chuck, faceplate, etc.) must be installed on the machine so as to exclude the possibility of self-unscrewing or tearing them off the spindle during operation and during reverse rotation of the spindle. 3.11. Clamping devices (back center, chuck, etc.) of lathes must provide quick and reliable fastening of the part. 3.12. Fastening devices (chuck, faceplate) should not have protruding parts or unsealed open recesses on the outer forming surfaces. In exceptional cases, the cartridge and faceplates with protruding parts must be protected. 3.13. Steady rests should be used for turning long pieces. 3.14. When processing metals that produce spiral chips, tools and devices must be used to crush the chips during the cutting process. 3.5. When polishing and filing products on machines, methods and devices must be used to ensure the safe performance of these operations. 3.16. It is necessary to clean workpieces on machines with an emery cloth only with the help of appropriate devices. 3.17. Installing and removing chucks or a faceplate is permitted only after the machine has completely stopped. 3.18. To install the cutter, it is allowed to use only special supports, the area of which is equal to the entire supporting part of the cutter. 3.19. The clamp for securing the workpiece in the centers must have a hidden clamping bolt that cannot catch the worker’s sleeve or injure his hand. 3.20. It is necessary to periodically check that the tailstock is securely fastened and prevent it from moving or vibrating. If the product rotates in the direction of screwing the chuck, you need to carefully monitor the position of the chuck and secure it in a timely manner. 3.21. When securing the product in the chuck, the set screw must be in a vertical position, and not in an inclined position, in which the chuck can turn and use a key to press the turner’s hands to the machine bed. 3.22. When manually processing parts with a file on a lathe, the cutouts or slots on the surface of the part must be sealed with inserts. 3.23. When processing bar metal, the end of the bar protruding from the spindle must be protected. 3.24. You cannot turn on the self-propelled gun until the cutter comes into contact with the part. To avoid breaking the cutter, it should be brought to the workpiece slowly and carefully. 3.25. Before you begin manual processing of the part (scraping, cleaning and grinding) on a lathe, you should move the support to the side at a safe distance. 3.26. Before stopping the machine, the cutter must be moved away from the workpiece. 3.27. Cleaning, lubricating and wiping down machines, changing parts or cutting tools, removing chips from under the machine should be done only after the machine has completely stopped; moving away from the machine is also allowed only after it has completely stopped. Safety requirements when working with thread-turning machines: 3.28.Install and secure the cut nuts correctly and securely so that the possibility of them flying out is excluded and the technological process is not disrupted during operation of the machine. 3.29 Make sure that the vice and clamps are in good working order and that the notch of the jaws is not worked. 3.30. The table must be smooth, without potholes, and the grooves and slots must not be worked out. 3.31. To fasten taps, do not use chucks or devices with protruding, unguarded parts. 3.32. When installing a tap in a chuck or spindle, stop the machine. 3.33. Do not hold the part with your hands during operation. 3.34. Bring the caliper with the clamped bolt to the dies slowly and, if the latter do not take the end of the bolt, move the caliper back and tell the installer about the need to install the dies correctly. 3.35.When cutting long bolts, carefully monitor their tightening and use supporting posts. 3.36. It is forbidden to measure the thread with gauges during the rotation of the product or dies. 3.37. When working on automatic lathes:
Working on turret lathes 3.38. Securely and rigidly fix the workpiece on the machine. 3.39. Before installing the chuck or faceplate on the machine and before removing it, wipe off any oil, since a lubricated chuck can easily slip out of your hands and cause injury. 3.40. After securing the part, do not allow the jaws to protrude from the chuck or faceplate beyond their outer diameter. 3.41. If the jaws protrude, replace the chuck or install special guards. 3.42. When processing bar material, the end of the bar protruding from the spindle must be protected along its entire length. 3.43. After fixing the part in the chuck, be sure to remove the socket wrench. 3.44. To install the cut, use only special spacers that are even along the length of the entire supporting plane of the cutter. Attach the cutter so that its overhang is minimal and does not exceed more than 1,5 times the height of the cutter holder. 3.45. Do not leave tools in the turret that are not used to process the part. 3.46. When installing, removing and measuring a part in a chuck or collet, leave the retracted turret head so that the mandrels with the cutting tool are not on the same axis with the workpiece. 3.47. Be careful not to hit the cutting tool when turning the turret. 3.48. Do not throw or feed the bar being processed into the spindle by hand while the machine is operating. 3.49. Do not brake the machine by pressing your hand on the workpiece or rotating parts of the machine. 3.50. While the machine is operating, do not open or remove guards and safety devices. 3.51. Move the turret and the support with the tool to a safe distance when changing the support, installing and removing parts and tools. 3.52. Do not measure the workpiece while the machine is running. The part can only be measured after the clutch is turned off. 3.53. Manual processing of the part: cleaning, grinding, eliminating runout should be done with the caliper and turret retracted. 3.54. When processing brittle materials that produce flying chips, as well as when crushing steel chips during processing, use protective devices. Work on a milling machine 3.55 Install the workpiece correctly and securely so that during the operation of the machine the possibility of it flying out or any other disruption to the technological process is excluded 3.56. Fix the part in places as close as possible to the surface to be treated. 3.57. When using pneumatic, hydraulic and electromagnetic devices to secure parts, carefully protect air or liquid supply tubes, as well as electrical wiring, from mechanical damage. 3.58. The part is fed to the cutter when the latter receives working rotation. 3.59. When changing the workpiece or measuring it, move the cutter to a safe distance and stop the spindle rotation. 3.60. Before removing the part from the vice or presser feet, stop the machine and move the cutting tool away so as not to injure your hand on the cutting edges. 3.61. Cut the cutter into the part gradually, turn on the mechanical feed until the part comes into contact with the cutter. When feeding manually, avoid sudden increases in cutting speed and depth. 3.62. When milling, do not put your hands into the danger zone of rotation of the cutter. 3.63. Before stopping the cutter, check the reliability and strength of fastening of the teeth or carbide plates. The latter should not have crumbled places, cracks, or burns. 3.64. If the cutting edges are dull or chipped, replace the cutter. 3.65. Make sure there is a cutter guard and work only with a guarded cutter. In the case where there is no fencing of the work area, it is necessary to work in safety glasses. 3.66. When processing viscous metals, use milling cutters with chip breakers. 3.67. When knocking the cutter out of the spindle, do not support it with an unprotected hand; use an elastic pad for this. 3.68. Near a rotating cutter, you can remove chips only with a basting tool with a handle at least 250 mm long. 3.69. Secure the milling mandrel or cutter only with a key, turning on the overdrive so that the spindle does not turn. 3.70. When installing and removing milling cutters, beware of injuries from the cutting edges. 3.71. When installing the tool shank into the spindle hole, make sure that it fits tightly without play. 3.72. Secure the milling mandrel or cutter in the spindle with a wrench only after turning on the gearbox to avoid turning the spindle. 3.73. Clamping and pressing the cutter with a key on the mandrel by turning on the electric motor is prohibited. 3.74. When removing an adapter sleeve, mandrel or cutter from the spindle, use a special drift and place a wooden pad on the machine table. 3.75. Do not stand on or walk over the moving table of the milling machine until the machine has come to a complete stop. 3.76. Do not slow down the machine by pressing on the parts, your hand may get under the cutter. 3.77. When high-speed milling, use guards and devices to catch and remove chips 3.78. Stop the machine, turn off the feed, then move the cutter away from the workpiece and turn off the rotation of the cutter. Work on boring machines 3.79. Securely and rigidly fix the part on the machine, regardless of its size. 3.80. When fastening parts, use bolts with high nuts. 3.80. If a machine cliche is installed while processing one part another, you need to be especially careful and careful. 3.81. The fastening of the part should be carried out in places with solid supports. 3.82. When installing and aligning parts on the machine, level the parts using safe jacks or wedges. 3.83. After removing the part from the machine, remove all bolts from the grooves and put them in the designated place. 3.84. Rigidly and firmly fasten the cutting tool. 3.85. Install the tool with the spindle turned off. 3.86. Apply the cutting tool to the part gradually without impact. When feeding manually, avoid sudden changes in feed speed and depth of cut. 3.87. When working with a flying caliper, install stops and use mechanically fed calipers. 3.88. If the tool becomes dull or the carbide inserts chip, change the tool. 3.89. When changing a tool, knock out the tool only with a wedge specifically designed for this purpose. 3.90. Select the wedge securing the tool shank so that the ends are flush, i.e. did not protrude from the spindle. 3.91. It is prohibited to fasten the tool with pins and home-made devices, since when rotating they can catch clothing, coming out of the spindle. 3.92. When installing cutters, wrap open cutting parts with rags. 3.93. Do not allow the heads of the clamping bolts or wedges to protrude above the surface of the mandrel. 3.94. During rapid feeds, be careful not to be caught or hit by the handwheels and handles of the boring machine lead screws. 3.95. When boring, do not approach the spindle to observe the progress of machining. 3.96. When installing and removing boring heads of large mass, place wooden pads under them on the table. 3.97. Before attaching the workpiece to them, securely fasten portable tables, plates, squares to the plate. Work on cutting machines 3.98.Check the serviceability of the saw blade. It is prohibited to work with a faulty disk. 3.98. Check the correct operation of the auto-locking start and feed of the saw with the workpiece clamp. 3.99. Do not clamp the workpiece while the disc is rotating. 3.100. Before bringing the saw to the workpiece, make sure that the saw is securely fastened. 3.101. At the beginning of cutting, move the disc towards the workpiece carefully, smoothly, without impacts. 3.102. It is prohibited to correct the position of the cooling system tube while the disk is rotating. Avoid splashing oil and coolants. 3.103. It is forbidden to stand in the plane of rotation of the disk during the operation of the machine. 3.104. It is forbidden to support the cut end of the workpiece with your hands. 3.105. It is forbidden to push chips out of the disc segments on the move. 3.106. Immediately stop the machine if chipped teeth are detected or the disk becomes dull to change it Work on broaching machines 3.107. Check that the tool holder is working properly. 3.108. Check the presence and serviceability of a guard in the form of a bracket on vertical broaching machines to catch the broach if it falls out of the chuck. 3.109. Check the presence and serviceability on the horizontal broaching machine of a protective device for the broach fastening mechanism, which reliably protects the worker from flying out of an accidentally broken tool; these devices should also prevent the possibility of hands getting into the danger zone. 3.110. Install parts on the machine and remove them from the machine only when the clamping device and cutting tool are in their original condition. 3.111. Clean cutting tools, fixtures and workpieces with special brushes and only when the cutting tool and fixture are in their original position. 3.112. It is prohibited to clean and adjust the cutting tool of the device and the workpieces while the machine is operating. 3.113. When working with long broaches on horizontal broaching machines, use a moving steady rest with a sliding broach guard. 3.114. Two workers are prohibited from working on a two-column vertical broaching machine. The worker must know that when the machine is operating, one slider is in its initial position at the top, the other at the bottom. 3.115. Installation and removal of broaches weighing more than 16 kg should only be done using lifting mechanisms. Work on planers 3.116. Check the presence and serviceability of the fencing of the working area of the maximum exit of the slider from the frame on cross-planing machines. 3.116. Check the presence and serviceability of guards in the area where the table extends beyond the frame dimensions of longitudinal planing machines. 3.117. Move the table or slide as far as possible from the support when installing the workpiece on the machine and removing it from the machine. 3.118. Clamp the workpiece to the machine securely and firmly. 3.119. Installation and fastening of the workpiece, fixtures and tools should be done with the machine completely stopped. 3.120. On the move of the machine, do not check the sharpness and serviceability of the cutter with your hand. 3.121. Fastening is carried out with special fasteners. 3.122. Set the stops so that they perceive the cutting forces. 3.123. Check the correct installation of the part on small machines by moving the table or slide manually, on large machines using a scale ruler. 3.124. It is forbidden to tilt the cutter with your hands during the idling of the machine. 3.125. Do not allow people to enter or enter dangerous areas yourself unless the electric motor is turned off and a poster is posted warning about the danger of turning on the table. Work on slotting machines 3.126. Check the serviceability of the tool head. 3.127. When installing the cutter, check that it is sharpened correctly and that there are no cracks or breaks on it. 3.128. Reliably and rigidly fasten the workpieces to the machine table. Fastening is carried out using special fasteners. 3.129. Set the stops so that they perceive the cutting forces. 3.130. When chiselling against the stop and securing the part, make sure that there is sufficient exit for the cutter and chips. 3.131. Adjustment and fastening of the travel limiter cams should be carried out only after turning off the machine and stopping the movement of its parts. Work on gear cutting machines 3.132. Reliably and firmly fasten the workpieces to the machine and rigidly fasten the cutting tool. 3.133. When fastening the part, use special fastening devices and safe handles. 3.134. When milling and shaving, do not put your hands into the dangerous zone of rotation of the cutter or shaver. 3.135. Do not allow the mandrel for cutters, cutters and gears to run out when cutting a profile. 3.136. Check the gears with an indicator for runout only after the rotating tool has stopped. 3.137. On gear shaping machines, when removing the workpiece, remove the support only when the machine is completely stopped with the shaper in its original position. 3.138. Do not open or remove protective and safety devices while the machine is operating. Work on gear grinding machines 3.139. Do not install an untested grinding wheel on the machine. 3.140. Before starting work, the grinding wheel installed on the machine must be subjected to short-term idle rotation at operating speed with a diameter of 150-400 mm for 2 minutes, with a diameter of 400 mm for 5 minutes. A protective cover is required. 3.141. Check for wheel runout. The spindle runout must comply with the technical specifications for this machine. 3.142. Check for visible cracks and nicks on the abrasive wheel. 3.143. Tighten loose nuts, locknuts, bolts, wedges and check how the corresponding bolt connections of the machine are secured. 3.144. Protect the grinding wheel from impacts and shocks. 3.145. When working, apply the grinding wheel to the part or the part to the wheel smoothly, without jerking or sharp pressure. 3.146. Do not touch the moving workpiece or the grinding wheel until they have come to a complete stop. 3.147. When working with special grinding wheels, make sure that the clamping flange on the side surface does not touch the workpiece. 3.148. Make sure that the wheel wears evenly across the entire width of the working surface. 3.149. If a grinding wheel intended for wet grinding has been running dry, then when switching to work with cooling, you should allow the wheel to pre-cool and only then start working with coolant. 3.150. When working with cooling, the liquid must wash over the entire surface of the grinding wheel and be drained in a timely manner so that the wheel remains immersed in the liquid. 3.151. When finished working with coolant, turn off the liquid supply. 3.152. Each gear grinding machine or group of machines on which work is carried out with grinding wheels of different diameters must have a table posted in a visible place indicating the permissible operating peripheral speed of the grinding wheels used and the rotation speed per minute of the machine spindle. 3.153. On machines operating at high speeds with speeds over 40 m/s, the protective cover must have a color different from that of the machine. 3.154. On special machines or devices intended for dressing or turning grinding wheels, protective devices must be installed to protect the worker from flying particles of the grinding wheel and dressing tool, as well as dust suction devices. 3.155. Abrasive tools, as well as rotating spindle ends and fasteners, must be protected with protective guards. 3.156. The feed of a tool or device for dressing an abrasive wheel, as a rule, must be mechanical. 3.157. Tools should only be installed on a grinding machine by a specially trained worker or service technician who constantly works on this machine. 3.158. Dress the abrasive wheel only with special devices: a cutter with stars or disks, abrasive wheels or bars, as well as a diamond embedded in a metal frame. 3.159. When dressing the grinding wheel, do not press the device with your body, stand slightly to the side relative to the rotation of the wheel. 3.160. While the machine is operating, guards and safety devices must not be removed or opened. 3.161. It is strictly forbidden to work with the side surface of an abrasive wheel if the wheel is not intended for this work. Work on drilling machines 3.162. During operation, do not lean close to the spindle and cutting tool. 3.162. Install the workpiece correctly and securely so that the possibility of flying out during work is excluded. 3.163. Do not use chucks and fixtures with protruding locking screws and bolts when working. If there are protruding parts, they must be protected. 3.164. The workpieces, vices and fixtures must be firmly and securely fastened to the table. 3.165. The vise must be in good condition and the notch of the jaws must be unfinished. 3.166. Installation of parts on the machine and removal from the machine is carried out in the case when the spindle with the cutting tool is in its original position. 3.167. When installing the tool, carefully monitor the reliability and strength of their fastenings and correct alignment. Install the tool when the machine is completely stopped. 3.168. When changing tools, lower the spindle. Changing tools while the machine is running is only allowed if there is a special quick-change chuck. 3.169. Do not use tools with worn taper shanks. 3.170. If the tool jams, the drill shank, tap or other tool breaks, turn off the machine. 3.171. It is prohibited to hold the part being drilled with your hands. Small parts, if suitable fastening devices are not available, can be held with a hand vice, pliers or parallel-nose pliers only with the permission of the master. 3.172. It is prohibited to drill thin plates, strips or other similar parts without securing them with special tools. 3.173. Monitor the serviceability and strength of fastening the load to the counterweight cable 3.174. When drilling brittle metals, if the machine does not have chip guards, use safety glasses. 3.175. Remove chips when the machine is stopped. 3.176. When changing a chuck or drill, use a wooden drift. 3.177. Do not stop the machine when it is turned off by pressing your hand on the spindle or chuck. 3.178. Apply the cutting tool to the workpiece smoothly and gradually. 3.179. When manually feeding the drill and when drilling through passage or small drills, do not press the lever too hard. When feeding automatically, do not allow feeds exceeding the norms specified in the passport. 3.180. Before stopping the machine, be sure to move the tool away from the workpiece. 4. Labor protection requirements in emergency situations 4.1. If a machine malfunction occurs, the grounding is broken or other malfunctions that can lead to an emergency, the machine operator must: a) suspend further operation of the machine until the malfunction is eliminated; b) notify the work manager and the person responsible for the good condition of the machine. 4.2. If the machine catches fire due to short circuit currents, it is necessary to de-energize the machine and use a carbon dioxide fire extinguisher to extinguish the fire. 4.3. If any accident occurs with you or your friend, immediately send the victim to the medical center and notify the foreman. 5. Labor protection requirements at the end of work 5.1. Turn off the machine, clean the workplace. 5.2. Report any malfunctions to the master.
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