WHAT THE WHAT???
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(Table of Contents)
Introduction
/ Purpose of Archive [RETURN TO
T.O.C.]
For a change of pace, this section contains a collection of photos
demonstrating poor techniques, tooling, safety protocols, and the like. See if you can identify the issue(s) in each
photo before reading the captions. Please submit ideas for additional points here.
Drill Presses
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1.
Operator does not have the vise pressed against the drill press
column or clamped to the table. (That
particular vise does have a vee jaw for clamping cylindrical
workpieces, so that’s okay.)
2.
Operator is wearing gloves and does not have the part anywhere
close to securely clamped.
3.
Operator is touching chips with her bare hand(s).
4.
Operator is wearing gloves and long sleeves, but makes up for it
by not wearing eye protection.
5.
Gotcha! Operator
is safely operating the drill press using the following safety protocols:
a.
the operator is wearing safety glasses
b.
the operator has her hair tied up
c.
the operator is not wearing any loose clothing
d.
the operator is not wearing any jewelry on her hands
e.
the operator has the part securely clamped
f.
the operator has the drill bit aligned with the center hole in the
table
Milling Machines [RETURN TO T.O.C.]
1.
Operator is attempting to improperly
perform a tool change (quill is not raised or locked, tool is not completely over the
plastic table covers, collet is not correctly inserted into the spindle, not
using a rag to protect his hand, pressing the wrong button).
2.
Operator is performing cutting
operations before removing parallels from the vise. Mill is also in LO range.
3.
Operator is using the power
feed without their hand on the joystick.
4.
Operator did not return
calipers to their storage box.
Lathes
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1.
Operator left chuck key in chuck.
2.
Operator did not check HI / LO range before turning on lathe (it
is incorrectly set to LO range when facing/turning).
3.
Operator is reaching across/over the lathe chuck with their right
hand.
4.
Operator is rotating the
chuck/work backwards.
5.
Operator is operating power
feed without their hand on it.
6.
Operator is drilling without
the tailstock locked.
7.
Operator did not return
calipers to their storage box.
Fasteners
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1.
Some genius thought slotted screws would be a good idea. Come on, that’s always funny :).
2.
Another genius thought it would be a good idea to place fastener
threads in shear. Unfortunately, these
were on flywheels on commercial aircraft engines. The solution was (surprise!) a redesign that
used dowel pins to react the shear forces, which allowed the fasteners to do what
they do best: clamp. Click the
image for the full service bulletin report.
1.
Operator allowed read edge of blade to completely pass workpiece.
2.
Operator improperly clamped workpiece so the blade is presented
with a non-uniform C.S.A. as the cut is made.
3.
Operator does not have her long hair tied back and is wearing long
sleeves.
4.
Operator does not have a hand on the power feed.
5.
Gotcha! Operator
is safely operating the Roll-In using the following safety protocols:
a.
the operator
is wearing eye protection
b.
the part is
clamped properly (engaging the largest number of teeth)
c.
the operator
is not wearing loose clothing
d.
the operator
is not wearing loose jewelry
e.
the
operator’s hair is tied up / back
6.
Operator is not wearing safety glasses and is wearing a bracelet.
7.
Operator has her hand in the plane of the blade.
8.
Operator is wearing gloves.
9.
Gotcha. Operator
is safely operating the Do-All using the following safety protocols:
a.
the operator
is wearing safety glasses
b.
the operator
has her hair tied up
c.
the operator
is not wearing any loose clothing
d.
the operator
is not wearing any jewelry on her hands
e.
the
operator’s hand is not in the plane of the blade
Welding Shop [RETURN TO
T.O.C.]
1.
Operator is not wearing a welding helmet, welding jacket, or
welding gloves.
2.
Operator should never weld in close proximity to flammable chemicals/liquids
(like the acetone in the red-top bottle).
3.
Gotcha. Operator
is safely operating the welder using the following safety protocols:
a.
safety glasses
b.
welding mask
c.
welding jacket
d.
welding gloves
Sheetmetal Equipment [RETURN TO
T.O.C.]
1.
Operating a shear with two
people and failing to wear safety glasses.
2.
Not wearing gloves when
using non-powered sheetmetal equipment.
3.
Attempting to drill sheetmetal while holding it by hand and
wearing gloves when operating powered equipment.
4.
Using vise grips instead of
c-clamps to secure sheetmetal to the table for grinding.
5.
Mixing up order of
operation on sheetmetal equipment (punch holes, then
bend!).
Project Motors and Related [RETURN TO T.O.C.]
Control Boxes and
Electrical [RETURN TO T.O.C.]
Metrology
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1.
Operator is a little confused about proper caliper use :).
Miscellaneous
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1.
If you are going to do it, own it …
2.
Sometimes you just need a little more …
3.
Teamwork.
4.
New lightweight welding masks just hit the market …
5.
Barney’s boss told him he didn’t need a taller ladder…