Instruction on labor protection for the adjuster and operator of CNC machines

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Instructions on labor protection for the adjuster and operator of CNC machines. Full document

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General requirements for labor protection

1.1. This instruction has been developed in accordance with the "Intersectoral Rules for OT in the cold working of metals" POTRM-006-97 is intended for persons performing metal processing on CNC metal-cutting machines.

1.2. Persons who have passed a medical examination, introductory briefing, on-the-job training, training in safe working methods and methods, and who have passed the exam with the assignment of a qualification category are allowed to perform the metal processing process on CNC machines.

1.3. OSH training and training in safe working practices and methods are mandatory for all employees and newcomers to work, including for persons who have a break from work for 3 months and persons undergoing industrial practice.

1.4. Repeated briefing at the workplace is carried out with each employee individually at least every 3 months.

1.5. Unscheduled briefing is carried out when changing the rules for labor protection, the technological process, replacing and upgrading equipment, fixtures and tools, raw materials; violations of labor protection requirements by employees that have led or may lead to injury, accident, fire, explosion.

1.6. Unscheduled briefing is carried out individually or with a group of workers of the same profession in the amount of primary briefing at the workplace.

1.7. On the territory of the plant and in the workshops, follow these rules:

walk on sidewalks and paths specially designed for pedestrian traffic, and where there are none, on the carriageway, keeping to the left;
be attentive to the signals of moving vehicles and do not run across the path in front of it;
do not walk on railroad tracks;
do not crawl under standing platforms and wagons;
do not accelerate workshop transport carts and do not ride on them;
use only the established passages, do not climb over conveyors, conveyors;
if people work at a height, pass this place at a safe distance, as any object may fall from a height;
do not stand or walk under a lifted load or in its immediate vicinity;
do not look at electric welding with unprotected eyes, remember that pain in the eyes may not appear immediately, but after a few hours;
beware of gas poisoning, do not be near acetylene machines and other devices where gas can be released;
do not touch electrical wires or other current-carrying parts, do not try to fix the malfunction of electrical wires or electrical equipment yourself, call an electrician for this purpose;
do not turn on or turn off (except in emergency cases) machines, machines and mechanisms, the work on which is not entrusted to you by the foreman or the head of the workshop;
it is forbidden to ride electric cars, tractor trailers, sit on the sides of cars, the steps of cars;
do not open the doors of electrical panels and other electrical equipment;
do not lift the load beyond the allowable limits.

Remember that it is allowed to lift a load weighing no more than:

female adolescents - 7 kg;
male adolescents - 16 kg;
men - 30 kg;
women aged 18 years and older: lifting and moving weights when alternating with other work (up to 2 times per hour) - 10 kg;
lifting and moving weights constantly during a work shift - 7 kg;
the value of the dynamic work performed during each hour of the work shift should not exceed 1750 kGm from the working surface;
from the floor - 875 kgm.

The mass of the lifted and moved cargo includes the mass of tare and packaging.

1.8. Do only the work that is entrusted to you by the master and provided that you know the safe ways to do it.

1.9. Work on machines only of those systems that you have studied and for independent work on which you are admitted.

1.10. If you notice violations of labor protection rules by other workers, warn them about the need to comply with OT requirements and inform the foreman.

1.11. Work only in serviceable, neatly tucked overalls and change the protective equipment provided for by the Model Industry Standards for this profession. To perform work, the adjuster and operator of CNC machines are issued the following means of individual protection:

costume;
leather boots;
goggles;
respirator (when processing dust-forming and glass-containing materials).

1.12. Make sure that the floor around the equipment is level and non-slip, if it is covered with oil, emulsion, request that it be sprinkled with sawdust or do it yourself. Then sweep the floor with a brush, or remove the sawdust with a dustpan or shovel in a specially designed container for collecting industrial waste.

1.13. Do not work on faulty equipment, as well as in the absence or malfunction of: barriers, interlocks, ground wires.

1.14. Do not follow the order of the master, if it contradicts the rules of labor protection and can lead to an accident, inform the head of the workshop about this.

1.15. Hazardous production factors when working on CNC machines:

danger of clothing being caught by rotating parts of the machine or cutting tool; monotonous noise of working machines;
danger of cuts to hands with an open rotating tool in case of violation of the rules for operating the machine;
danger of injury from flying chips when working without a fence and personal protective equipment;
danger of electric shock.

To preserve the health of an employee, the maximum allowable concentration (MPC) and the maximum allowable level (MPL) of physical factors that are most characteristic at the workplace of an employee of this profession:

noise (equivalent sound level) 80db;
illumination of the working surface 400 lx;
air temperature:
summer 18-27°C
winter 17-23°C
dust content 6,0 mg/m3;

1.16. For fire safety purposes, keep your work area clean. Smoke only in a designated area. Put used rags in a special box.

1.17. About every accident with you or your comrade, immediately notify the master and contact the health center.

1.18. The adjuster and operator of CNC machines must know:

operating instructions for CNC machines (machine passport);
instructions on fire safety measures;
instructions for providing first aid to victims;
OT instructions for those working at the plant;
rules of internal labor regulations;
when working with PMG: safety instructions for persons associated with work on small load-lifting mechanisms controlled from the floor.

To work on lifting mechanisms controlled from the floor, by order of the workshop, persons who have been trained and instructed, followed by testing their skills in managing these mechanisms, are allowed.

1.19. Follow the "Rules of internal labor regulations", fire safety, observe the regime of work and rest.

1.20. Observe personal hygiene measures:

do not wash your hands in oil, emulsion, kerosene;
do not dry your hands with the ends contaminated with shavings;
do not eat at the machine;
do not store personal clothing in the workplace.

1.21. The requirements of this manual are mandatory. Failure to comply with these requirements is considered as a violation of labor and production discipline.

1.22. Follow the instructions for labor protection, this way you will protect yourself and others from an accident.

2. Labor protection requirements before starting work

2.1. Before starting work, you must:

put on work clothes, which must be fastened with all buttons;
fasten or tie the cuffs of the sleeves;
remove long hair under a headdress;
put on personal protective equipment (goggles, headphones). It is forbidden to work in light open shoes, as well as with rolled up sleeves.

2.2. Before starting work, carefully study the equipment passport, inspect the machine fixture, necessary tools, keys, chip removal hook, determine their serviceability and readiness for use.

2.3. Accept the machine from the shifter: the workplace must be clean, ask the shifter or foreman about the problems with the machine during the previous shift and what measures were taken to eliminate them.

2.4. Adjust local lighting so that the work area is adequately lit so that the light does not blind your eyes. Wipe the fittings and the electric lamp with a dry rag before turning on the lamp. It is forbidden to use local lighting powered by a voltage network above 50 V.

2.5. Passages, places at the machine equipment should be free from tools, parts and consumables. Equipment, blanks, finished parts and production waste should be on special racks, tables, in containers.

2.6. To work while sitting, the workplace must have a chair (seat) with adjustable height and backrest. Near the machine on the floor there must be serviceable wooden gratings (flooring) for the entire length of the working area and a width of at least 0,6 m.

2.7. Check for availability and serviceability:

governing bodies;
fencing of hazardous areas, current-carrying parts of electrical equipment (starters, knife switches, transformers, etc.) Folding, sliding and removable fences must be kept from spontaneous movement;
grounding devices;
safety devices for protection against chips, coolants, hoses supplying coolant must be solid and must be placed so that their contact with the cutting tool and moving parts of the machine is excluded;
inspect the rubbing surfaces of the machine, if necessary, lubricate them with oil from an oil can;
tool holders;
cutting (no cracks, breaks, fastening strength of hard alloy plates or ceramic plates, etc.), measuring, fastening tools and fixtures;
foot grate and the condition of the floor in the workplace.

2.8. Check the operation of the CNC device and the machine itself using a test program, make sure that coolant is supplied, check the operation of the limit stops.

2.9. With the machine idling, check:

serviceability of controls;
serviceability of fixing the switching and switching levers (make sure that the possibility of spontaneous switching from idling to working is excluded);
there is no binding or excessive slack in the moving parts of the machine, especially in the spindle and table guides.
operation of interlocks, stops, limit switches;
serviceability of the lubrication and cooling system.

2.10. Multi-operation machines with a turret, as well as machines equipped with tool magazines and automatic tool change systems, must have protective devices that protect against injury by the tool.

2.11. The cutting tool must be properly sharpened, shanks and seats must not be damaged or deformed.

2.12. Do not turn on the machine without grounding.

2.13. Report a malfunction of the machine immediately to the foreman or foreman, and do not start work without his instructions.

3. Labor protection requirements during work

3.1. Be careful not to distract yourself and do not distract others from work.

3.2. Make sure there are no foreign objects on the machine

3.3. Work on machines, in the absence or malfunction:

grounding devices, stops, controls;
screens and fences that protect workers from flying chips and metal particles;
blocking devices of the machine;
protective fences.

3.4. It is not allowed to work on machines in mittens or gloves, as well as with bandaged fingers without fingertips. Before installing the part in the fixture, it is necessary to wipe the surface of the fixing devices.

3.5. The mass and overall dimensions of the workpiece must not exceed the requirements of the machine passport.

3.6. Stack workpieces and machined parts steadily on racks or tables: the height of the stacks should not exceed - 1 m.

3.7. Install and remove heavy parts and attachments (weighing more than 30 kg) using lifting mechanisms only. Do not exceed the load specified for lifting equipment. Work in accordance with the "OT Instruction for Persons Associated with Work on Small Floor Operated Lifting Machines". Remember that persons who have been trained and instructed with subsequent testing of skills in managing these mechanisms are allowed to work on load-lifting mechanisms controlled from the floor, by order of the workshop.

3.8. Install the cutting tool in the working positions of the turret, inspect for the absence of chips, cracks in the cutting edges.

3.9. After installing the cutting tool, test the machine in idle operation in manual mode at various speeds, then start the machine according to the program at idle.

3.10. During automatic tool change, it is forbidden to be in the working area of the manipulator.

3.11. Manual verification of the dimensions of the workpieces and removal of parts for inspection should be carried out only with the mechanisms for rotating or moving workpieces, tools, and fixtures turned off.

3.12. Do not allow chips to accumulate on the cutting tool and mandrel, use a special hook or brush for this.

3.13. Do not cool the cutting tool with wet rags or brushes.

3.14. Do not transmit or receive anything through the machine while it is running.

3.15. Be sure to stop the machine and turn off the motor when:

leaving the machine even for a short time;
temporary cessation of work;
interruption in the supply of electricity;
cleaning, lubricating, cleaning the machine;
detection of a malfunction in equipment, tools, fixtures, grounding elements, protective fences, blocking devices, stops.
adjusting the coolant tube;
installation, measurement and removal of parts;
checking and cleaning the cutting edge of the cutting tool.

3.16. When working with oil-based coolants, use ointment for preventive lubrication of hands as recommended by medical institutions, and a respirator when working with glass-textile and dust-forming materials.

3.17. When sharpening a tool (or other object) on an emery machine, follow the requirements in accordance with the "OT Instructions for Working on Grinding Machines", do not raise the protective screen, and in the absence of it, wear glasses. Remember that the gap between the circle and the handpiece should not be more than 3 mm.

3.18. Forbidden

open and remove guards and safety devices during machine operation;
remove chips from the machine with bare hands or compressed air;
work on machines in gloves;
eat at work.

4. Labor protection requirements in emergency situations

4.1. In the event of a sudden breakdown of the machine, fixture, cutting tool, immediately turn off the machine and disconnect it from power.

4.2. When working on metal-cutting machines or power tools with a complete or partial interruption of the power supply, turn off the machine, power tool. Resume work after troubleshooting.

4.3. If the fuses at the electrical equipment of the machine or power tool burn out, inform the foreman or shop mechanic about this.

4.4. If voltage is detected on the metal parts of the machine (feeling of current), the electric motor is running in two phases (buzzing), the ground wire is broken - immediately stop the machine, inform the foreman about the malfunction of the electrical equipment and do not start work without his instructions.

4.5. In case of fire:

de-energize the machine;
turn off the ventilation;
call the fire brigade;
immediately notify all workers and the foreman about the fire.

Proceed to extinguish the fire with primary fire extinguishing equipment.

Remember that fired electrical equipment must be extinguished with carbon dioxide, powder fire extinguishers, as well as sand, flared oil, kerosene - with an OXO-10 fire extinguisher.

4.6. In the event of a power outage:

stop working;
de-energize the machine;
inform the master;
resume operation when power is supplied.

4.7. In the event of an accident, first release the victim from the traumatic factor. Then report to the master. When providing first aid to the victim, use the "Instructions on the provision of first aid to victims" No. 149.

ATTENTION! When releasing the victim from the action of electric current, make sure that you yourself do not come into contact with the current-carrying part and under the voltage of the step. Why do you need to use a wooden stick, board or dry clothes wrapped around your hand.

5. Labor protection requirements at the end of work

5.1. Switch off and disconnect the machine

5.2. Tidy up your workspace. Remove chips and metal dust from the machine only with a brush and a hook.

5.3. Remove the parts and blanks in a special container and put them in the designated place.

5.4. Turn off local lighting.

5.5. Collect oiled rags in a specially designed box

5.6. Take off your work clothes, put them in the place intended for them.

5.7. Wash your face and hands with warm soapy water.

5.8. Report all comments to the master.

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