Laboratory Machine Shop

Guidelines and Suggestions

If you plan to set up a machine shop facility in your laboratory, there are several issues one needs to think about before purchasing machinery and clearing floor space. Specifically, one needs to review both the safety and maintenance issues that go hand in hand with having machine tools.

The following outline covers basic machine shop safety and maintenance. These should be considered to be the minimum safety requirements. From this list one can customize the shop safety program appropriate for your laboratory.

Safety

1. All personnel that will use the machine tools must either take a class in Machine Tool Operation or, through their prior experience, be able to prove their proficiency to the Shop Instructor.
2. The area directly surrounding the Machine Tools must be marked off (yellow floor tape or paint).
3. All personnel in the shop area must wear eye protection at all times.
4. Hearing protection (ear plugs) should be readily available to shop users
5. A first aid kit must be placed in the shop, and a lab member should be assigned to keep it well stocked.
6. An oil spill kit should be purchased and placed in an accessible spot with an assigned lab responsible for its contents.
7. A fire extinguisher must be readily available.
8. Basic Safety rules must be followed at all times. Among theses are:
   • (a) Long hair must be tied back at all times
   • (b) No sandals or opened toed shoes are permitted in the work area
   • (c) If lifting heavy objects you are required to wear steel toe safety shoes
   • (d) Any oil spilled on the floor must be immediately cleaned up
   • (e) Loose fitting clothing must be tucked in or tied up
   • (f) Neckties must be removed
   • (g) Bracelets and other loose jewelry must be removed prior to using the shop.
   • (h) No horseplay around the machines is permitted. Machine tools can be dangerous.
9. No person should work alone. In certain situations people may establish a buddy system where people located in other parts of the building are responsible for checking to see that the shop user is safe at all times. A possible implementation might involve the purchase a good set of two-way radios. The “buddy” could then call the user every 15 minutes or so to check on his safety. If the “buddy” does not get a response, he/she would then immediately go to the shop area to check on the shop user. As part of this system, a sign-in sheet could be placed in the shop that the users would fill in to indicate when they entered and left the area, and name and location of their buddy.
10. The shop area must be kept clean. It is impossible to maintain a safe work environment if tools, stock and last weeks coffee are lying about the equipment. A lab member should be put in charge of the shops cleanliness.
11. Practice common sense. If your gut tells you not to setup a part in a certain way in a machine, don’t do it. Most shop accidents are a result of lack of knowledge, not carelessness. If you have any doubt, consult the professional machinist (Stan Cotreau in the physics machine shop).

Maintenance

Maintenance of the machine tools is key to safe operation. Each week a lab member should be elected to lubricate the equipment. If the proper lubrication regimen is not known, consult Stan Cotreau in the physics machine shop. He will gladly to instruct you as to what needs to be done.

Cutting tools, such as drill bits, end mills, and lathe turning tools should be inspected and sharpened as required on a weekly basis. A sheet should be placed in the shop so the shop users record which drills, tool bits, end mills, etc. are either broken or in need of sharpening or repair.

Milling machines should have the alignment checked on a monthly basis

If you do not know how to check machine alignment, consult Stan.

The machinery must be cleaned after each usage. Dirty machine tools tend to need repair and alignment more frequently than clean ones. It is the responsibility of the shop user to clean up after himself/herself. Chips and debris must be swept up and properly disposed. One must clean the machine tools so they are in the same condition as when one began to work. All hand and measuring tools must be returned to their proper storage site. All unused stock must be placed back in proper storage. If your lab has a belt driven milling machine the belt should be inspected for wear every month.

Measuring tools should be kept in good working order. They should be stored in a clean space, away from the chips and oil of the cutting environment. Measuring tools should have their “zero” checked prior to each use. If you do not know how to “zero” a micrometer or dial caliper, ask Stan.

A machine shop is, by nature, a dangerous place. All machinery has the potential to cause you harm if it is used incorrectly or not inspected periodically. Please remember that it is always a bad idea to run dangerous equipment if you are over tired or not feeling well. Never operate the equipment if you are under the influence of alcohol or cold medication that makes you drowsy. Focus is very important.

Accidents in the shop happen very quickly and most always there isn’t any warning before a problem occurs. The shop guidelines listed above, if put into use, will allow one to work safely and independently in a small machine shop. It is a good idea to have Stan come in and align/inspect your equipment annually. Remember, above all else it is important to work safely!

Submitted by Stan Cotreau
Created: November 5, 2003
Last Updated: November 5, 2003