Hand & Power Tool Safety

Transcription

1 Hand & Power Tool Safety FA C I L I TAT O R S G U I D E

2 What s Inside Facilitator s Guidelines a Overview b Getting Started d Presentation Guidelines f Lesson Plan h Frequently Asked Questions 1 Introduction 2 Preparing To Work 4 Choosing The Right Tool 7 Using Tools Safely 14 Summary 15 Quiz 18 Quiz Answers 2005 Summit Training Source Inc. All rights reserved. No part of this book may be reproduced in any form or by any means without written permission from Summit Training Source Inc. If you wish to purchase additional copies, please call our office at

3 Overview Everyday, tools help us build and repair a variety of things. Some tools are more powerful and dangerous than others, but any tool can cause you harm if not used properly. Unfortunately, potential hazards are often forgotten or disregarded making work environments where hand and power tools are used unsafe for employees and bystanders. But by learning how to handle tools correctly, and wearing the correct personal protective equipment, you can help ensure a safe work environment for everyone. Summit Training Source, Inc. a

4 Getting Started Training Materials Collect all of the necessary materials and supplies before training begins. Here are some suggested materials and supplies: A training location that is free of distractions, has good lighting, and a comfortable temperature. Desks and chairs arranged so that everyone will be able to see the viewing screen, the facilitator, and each other. The video, a VCR, and a TV with a remote. Make sure the video is rewound. An employee handbook and pen/pencil for each trainee. Each handbook includes a quiz at the back, which can be used to test comprehension and document training. Other supplies and equipment you may need - blackboard chalk, paper, handouts, transparencies, overhead projector, markers, notepads, etc. Additional information, such as a copy of the regulation or other reference tools. b Summit Training Source, Inc.

5 Preparation A successful presentation requires preparation and planning. Give yourself several days before the training session to get organized. Locate and schedule the training site as soon as possible. Notify trainees of the training date and time, the training schedule, and proper dress. Obtain all necessary equipment and supplies. Make sure you know how to operate the TV, VCR, and other equipment. Check to ensure that all equipment is working properly. Replace or repair any damaged equipment. Review all training materials, including the Facilitator s Guide, handouts, and any other reference materials. Prepare your presentation, including a lesson plan or outline of the training. Include the training goals and objectives. Some presentation guidelines are included on the next page. A sample lesson plan has been included on page f of this Facilitator s Guide. A day or so before conducting the training session, you may want to have participants take the quiz as a pre-test. The results of this test can help you determine weak areas to focus on during the training session. Preview the videotape. Note any key points you want to expand upon in your training. Summit Training Source, Inc. c

6 Presentation Guidelines How you present the training course can have a great impact on learning. By following these simple presentation guidelines and keeping your objectives in mind, you can effectively and efficiently get the most out of your training session. Organize Training Time Efficiently In today s busy work climate it can be difficult to find the time needed for training, so it is important to be organized and wellprepared when you schedule training sessions. Whether you use Summit s suggested lesson plan or not, it is important to have a lesson plan prepared that you can implement comfortably. This ensures that time spent in training is productive and beneficial for everyone. Stress the Purpose and Goals of Training Training needs to be goal-oriented. State the purpose of training in a clear, specific manner - whether it s to reduce injuries, increase production, improve quality, improve working conditions, etc. Review the goals and objectives of the training so trainees know what is expected of them. Capture Their Attention Training needs to be interesting and compelling to hold trainees attention. To help motivate learners, give them specific evidence that their effort makes a difference and provide feedback on their progress. Also, remember that the first experience with a new subject usually forms a lasting impression on the learner. By making that experience a positive one, you can help ensure your audience retains the information learned. d Summit Training Source, Inc.

7 Make New Learning Experiences Pleasant For some adults, past experiences with education were unpleasant and not helpful. Adults learn best when they feel comfortable. By making the learning environment open and friendly, you can help adults feel secure in their new learning experience. Offer support and feedback as often as possible, and be ready to provide extra attention to those who may require it. Ask If There are any Questions When most adults learn new information that conflicts with what they already know, they are less likely to integrate those new ideas. It is very important to make sure participants fully understand the training and do not have any unresolved questions. Provide for a question and answer period so participants can resolve those questions and/or answer questions throughout the training session. Summit Training Source, Inc. e

8 Lesson Plan As a qualified trainer, your job is to effectively communicate a great deal of information in a well-organized manner. By preparing a lesson plan, you can ensure that each minute of the training session is productive. Summit has provided a suggested lesson plan for your use. 1. Program Objective This guide reviews hand and power tool safety. In it, we will cover: Preparing to work Choosing the right tool Using tools safely 2. Show the Video: Hand and Power Tool Safety 3. Discussion and Demonstration To help relate the training to your site, you may wish to incorporate your own discussion topics and exercises. Key issues you might consider include: Where can I find the manufacturer s instructions for the tools I use at the work site? What are the procedures to be followed if a tool is damaged or found defective? What procedures are to be followed in the event of an injury? f Summit Training Source, Inc.

9 4. Use Handbooks to Reinforce Training The handbooks increase comprehension and reinforce the information learned in the video program by explaining the main points and expanding on the original material. For increased employee information retention, go over one section at a time and stop to answer questions. The quiz at the back of the Facilitator s Guide is provided to document employee training. Answers to the quiz are provided on a separate page. 5. Questions and Answers Provide for a Q&A session to answer any questions. It may be necessary to review some of the material when providing answers. The employee handbook, equipment manuals, and other reference tools may be helpful. Summit Training Source, Inc. g

10 Frequently Asked Questions What type of precautions can I take to ensure my safety when using hand and power tools? Make sure the area you will be working in is well-lit and the area is free of clutter and debris. When using hand and power tools be sure to dress appropriately and wear the appropriate PPE for the tool and task you will be performing. Before using the tool, inspect it for any damage or defects. Refer to the manufacturer s instructions for details on how to use the tool properly. Choose the right tool for the task and don t try to get by with the wrong tool just because it s handy. When using power tools, make sure guards are in place and that a GFCI is used for damp or wet areas. Clean the tools after the job is complete and store them appropriately. By following these guidelines you can help reduce the risk of injury when working with hand and power tools. On a daily basis I use a box cutter. What safety precautions should I be aware of to ensure my safety? As with any bladed tool, be sure the blade is sharp before using it. You can check the sharpness of the blade by testing it on a piece of scrap material. When using a box cutter or knife try to make your cut away from the body in case the blade should slip. Also, try to secure small pieces that need to be cut to ensure they will not slide as you are cutting. When you are finished with your cut, be sure to retract the blade. This will prevent injuries when carrying the tool or when someone else goes to retrieve the tool. h Summit Training Source, Inc.

11 Introduction The pyramids of Egypt. One of the seven wonders of the Ancient World. Built by skilled craftsmen using bronze and stone tools that we easily recognize as the forerunners of the hand and power tools used today. From these early times, tools have evolved continuously becoming lighter, faster and safer allowing us to build our modern, high-performance world. In this handbook we will discuss: Preparing to work Choosing the right tool Using tools safely Because tools are such a routine part of our everyday lives, it s easy to forget how dangerous they can be. Electric and pneumatic power tools can make performing a task easier and more efficient, while minimizing wear and stress on the body. But the same thing that makes power tools so useful their motor-driven energy and speed -- can also create potential hazards for you. While injuries from manually powered hand tools are often less serious than injuries from power tools, hand tool injuries occur more frequently and include eye loss, fractures, punctures, cuts and bruises. Most hand and power tool hazards can be traced to either using a tool improperly or poor maintenance. But by remembering the risks and following basic safety procedures while in the shop or out on the job, accidents can be avoided. Summit Training Source, Inc. 1

12 Preparing To Work The first step in working safely with hand and power tools is to maintain a safe work environment. Make sure the lighting in the area where you ll be working is adequate. Cluttered work areas invite accidents -- tools left on the floor can become trip hazards, while tools scattered on a bench or ledge can fall off and injure someone. Store tools in a dry, secure location when not in use. To prevent accidental slips, keep floors as clean and dry as possible. When working with hand and power tools dress appropriately. Before using power tools, tie back hair that is shoulder length or longer and avoid wearing jewelry or loose clothing that can catch in rotating parts. The personal protective equipment you ll need to wear depends on the type of tools you will be working with. Each hand or power tool you use may require specific personal protective equipment that you should be aware of. For example, cutting, grinding, chipping and sanding are a few of the tasks that can produce flying objects or dust, and safety glasses with side shields or safety goggles are a must. If an activity generates fine or toxic dusts, check your company s written Respiratory Protection Program to determine the respirator or dust mask you will need to wear. 2 Summit Training Source, Inc.

13 When using power tools, hearing protection such as earplugs or earmuffs must be worn if noise levels reach 85 decibels or more, averaged over an 8-hour time period. In most situations, work shoes or boots with sturdy leather uppers and non-skid soles are appropriate. Choosing footwear with a reinforced toe provides additional protection against dropped equipment, while a non-conductive sole provides additional protection against hazardous electricity. Wearing the appropriate gloves can protect from splinters and minor cuts, and reduce the impact of vibration. But, when working with some power tools such as drills or saws, gloves themselves can become a hazard and should not be worn. If you have any questions about the type of personal protective equipment you ll need for the tools you use, ask your supervisor. Summit Training Source, Inc. 3

14 Choosing The Right Tool Always follow the manufacturer s instructions for the proper use and maintenance of hand and power tools. When selecting blades, bits, cutters, grinding wheels or other attachments for power tools, the manufacturer s recommendations provide the best guide. Remember that each tool is designed to do only certain jobs. For example, never substitute a screwdriver for another type of tool, just because the screwdriver is handy. Using a screwdriver as a chisel or pry bar can easily cause it to break or chip, exposing you or a nearby coworker to injury. Pliers are a versatile tool, but do not use them in place of a wrench - - plier jaws are flexible and nonlocking, making it difficult to turn tight nuts and bolts without slipping. Choosing the right tool for each task isn t just a smart safety decision it is another way of improving productivity while turning out higher quality work. Before using any tool inspect its condition to make sure it can function safely. If the handle on a tool such as a hammer or an axe is loose, splintered or cracked, the head of the tool may fly off and strike you or a coworker. Instead of taping the handle or attempting to get by have the handle replaced before using the tool. 4 Summit Training Source, Inc.

15 Discard wrenches that have cracked, sprung or worn jaws they can easily slip and cause an injury. With repeated use, impact tools such as chisels and wedges can develop mushroomed heads when used in that condition, they can shatter on impact, sending sharp fragments flying. To work safely, recondition or replace these tools as necessary. Inspect the body of electric tools for cracks or other damage. Check that power cords are not frayed, and that plugs do not have loose or broken prongs. Whether the tool s power switch can be locked in the on position, or automatically shuts power off when the trigger is released, the switch should operate freely without sticking. Replace drill or router bits that are dull or bent, and saw blades with teeth that are dull, chipped or missing. Before mounting an abrasive wheel test it for cracks by gently tapping it with a light, nonmetallic instrument. If, instead of a clear metallic tone, it sounds cracked or dead, do not use it -- the wheel could fly apart in operation. Key Point To work safely, recondition or replace impact tools such as chisels and wedges with mushroomed heads as necessary. Summit Training Source, Inc. 5

16 Choosing The Right Tool continued Many power tools have safety guards to prevent contact with potential hazards such as rotating parts, blades, pinch points, flying particles, or sparks. Before using a power tool, check that the appropriate guards are in place and working properly. A circular saw, for example, has two guards. The upper guard is fixed; the lower guard retracts while making a cut. To protect the operator from contact with the moving blade, the lower guard automatically returns to the covering position when the tool is withdrawn. Before plugging the saw in, always make sure that the lower guard works freely, and clear away any wood chips or sawdust that could prevent the guard from closing. 6 Summit Training Source, Inc.

17 Using Tools Safely Every hand and power tool has built-in design limitations overloading a tool by pushing it beyond its range of safe operation can damage the tool and cause injury. For this reason, it s important to operate all tools according to the manufacturer s instructions. To prevent accidental start-ups, run the extension cord to the work site before connecting it to a power tool, and, before plugging in a tool, always make sure the power switch is in the off position. When carrying a plugged-in tool, remember to keep your finger off the start switch. To avoid creating a trip hazard or causing damage to electrical cords, keep them off of pathways or, when this is not possible, place a rollover protector over the cord. tools to the work location using a bucket or bag that s secured to a rope. This leaves both hands free so that you can maintain three points of contact with the ladder for safer climbing. Only use tools around live electrical systems if you are qualified to do so. Choose pliers, screwdrivers or wire cutters that have an insulated grip, and check that the protective covering is free of cracks or holes. Carrying screwdrivers, chisels, punches or other sharp-edged tools in your pocket could cause a serious injury if you trip use a toolbelt, a cart, or a toolbox instead. A knife should be carried in a sheath or holder, placed over the hip rather than on the front part of the belt. When climbing a ladder, carry your tools on a toolbelt, or hoist the Summit Training Source, Inc. 7

18 Using Tools Safely continued cutting or striking activity, and direct the tool away from aisle areas and other employees working nearby. If working around flammable gases, highly volatile liquids, or other explosive substances only use power tools that have been specially designed to be explosion proof. Even metal hand tools can produce sparks that could be an ignition source. Where a flammable or explosive hazard exists, use sparkresistant hand tools made of nonferrous materials. When working with pneumatic tools, the most common danger is getting struck by one of the tool s attachments or by a fastener shot from the tool such as a staple or nail. To prevent this, first, always check that the tool you will be using is securely fastened to the air hose and any attachment is secured to the tool. Whether a tool contains a fastener or not, never point it at yourself or anyone else. Be aware that many pneumatic tools have a trigger that is easily activated to stay safe, keep your finger off the trigger until you are ready to begin working. When using hand or power tools, make sure your hands are free of oil and grease to prevent slipping. Before using a power saw, inspect the material to be cut for nails, staples, or other objects that could create potential hazards if struck by a rotating blade. Take note of your surroundings before beginning any 8 Summit Training Source, Inc.

19 Maintain good balance while using power tools by distributing your weight equally on both feet, and do not overreach. Wait for the tool to achieve operating speed before beginning work. Once started, keep up a steady, even pressure, but never force the tool. Letting the tool do the work allows the bit or saw blade to cut smoothly. To stay safe when using knives, box cutters or power saws, always make sure the blade you are using is sharp. To test a tool s sharpness never run your finger along the edge test on a piece of scrap material instead. Dull tools are dangerous because they require greater effort and increase the chance of a slip or a kickback. When using knives and box cutters, cut in the direction away from your body. While this may feel unnatural at first, it will prevent injuries if the blade catches or slips. When a cutting task is completed, retract the blade on a box cutter or utility knife to help ensure that no one gets hurt while carrying the tool or retrieving it from storage. Before using such tools as saws, screwdrivers or files, secure small workpieces on a flat surface or in a vice. Never hold the material in your hand while you are working on it if the tool slips it could cause a serious cut or puncture wound. Before drilling, always clamp smaller workpieces to prevent them from moving. An unsecured object can become a flying projectile if a drill catches or binds. Summit Training Source, Inc. 9

20 Using Tools Safely continued Do not push tools beyond their capacity. Never hammer on a wrench, for instance, or use an extension, such as a pipe, to improve leverage. Instead, select a wrench with a longer handle and use penetrating oil to help loosen stuck nuts and bolts. Avoid forcing a power tool by applying excessive pressure this can overheat the tool and reduce operator control. If at any time you experience unusual vibration, noise, sparking or other indications that a power tool is malfunctioning, stop work immediately and have the tool checked by a qualified individual. To protect yourself and coworkers from electrical shock or burns, be sure power tools have either a three-wire cord with a grounding prong, or are double insulated. Double insulated tools have an internal layer of protective insulation completely isolating the tool s external housing. To check if a tool is double insulated, look for the Underwriters Lab seal and a double insulation designation. To further protect against electrical injury, always unplug tools when not in use, before servicing and cleaning, and when changing accessories. When unplugging a tool, grasp the plug instead of yanking the cord. To maintain a cord s physical integrity, never carry an electric tool by its cord, and keep cords away from heat, oil, and sharp edges. 10 Summit Training Source, Inc.

21 Remember that water is an excellent conductor of electricity and can create a dangerous path between you and an electric power source for that reason, never use a power tool while standing in water. When working with a power tool outdoors or in a damp environment, plug it into a GFCI-protected outlet. A GFCI, or ground fault circuit interrupter, monitors imbalances in the flow of electricity if current does not follow its intended path, the GFCI can quickly cut power before it travels through you and causes serious shock and injury. Before changing pneumatic tools or attachments, or making an adjustment, always turn off the air pressure and vent the line unless the hose has a quick disconnect coupling that makes these precautions unnecessary. Do not kink the hose to stop airflow. When a task is completed, wait for the tool to come to a complete stop before setting it down. Summit Training Source, Inc. 11

22 Using Tools Safely continued If not handled carefully, compressed air can be extremely dangerous. A blast of compressed air is powerful enough to drive dirt, grease or air into the body causing injury or death. For this reason, never point a compressed air gun at anyone or use compressed air to clean your clothing. If using compressed air to clean equipment, make sure the pressure is reduced to less than 30 pounds per square inch, and use a chip guard to protect against flying debris. Pneumatic tools should only be attached to a compressed air supply system never to lines supplying breathing air or any type of gas as this is extremely hazardous. Before working with a pneumatic tool, check couplings and fittings and set the air pressure according to the manufacturer s specifications. 12 Summit Training Source, Inc.

23 Housekeeping may seem like a simple or boring task, but removing excess sawdust, grime, moisture and other debris from your tools after each use will help keep them working properly. To prevent accidents, as well as loss or damage to your tools, when you are finished with a task have a specific location to store each tool. Heavy-headed tools, such as sledgehammers, should be stored with the heavy end down. Store cutting tools by covering or retracting blades, so that they can t cause injuries to someone reaching into a toolbox or drawer. To store a pneumatic hose, begin by carefully coiling it. Avoid putting kinks in the hose by hanging it over a broad support, instead of a hook, nail, or angle iron. Summit Training Source, Inc. 13

24 Summary Without hand and power tools many of the tasks we routinely perform would be much more difficult or impossible. When we use tools everyday, however, it becomes all too easy to underestimate the hazards. To minimize your risk of injury, remember these safety principles every time you use a hand or power tool: Keep all tools in good condition with regular maintenance. Choose the right tool for the job. Examine each tool before use and do not use damaged tools. Wear the correct personal protective equipment for the tool and environment. Operate tools according to the manufacturers instructions. If you have any questions about the hand and power tools you use, ask your supervisor. We ve come a long way since the first tools, and our awareness of how to stay safe in the workplace has also advanced. To prevent accidents or injuries from slowing you down, follow safe work practices every time you pick up a hand or power tool. 14 Summit Training Source, Inc.

25 Quiz To review your knowledge of Hand and Power Tool Safety, answer the questions below. Your Name Date 1. What type of personal protective equipment may be required for someone working with hand and power tools? Select all that apply. a. Safety glasses with side shields b. Safety goggles c. Leather footwear with non-skid soles d. Loose clothing 2. Gloves must always be worn when using power tools such as drills or saws. a. True b. False 3. The manufacturer s instructions provide the best guide for the proper use and maintenance of hand and power tools and recommendations for attachments. a. True b. False 4. When should a tool be inspected? a. Only when it begins to give you problems or breaks b. Before each use c. Only every 5 years d. Only every other year 5. What type of things should be checked when inspecting an electric tool? Select all that apply. a. Check for frayed power cords b. Loose plugs or broken prongs c. Check the body of the tool for cracks or other damage d. The power switch Summit Training Source, Inc. 15

26 Quiz continued 6. A power tool with a missing guard is just as safe to use as a tool that has its guard in place. a. True b. False 7. Screwdrivers, chisels, punches, or other sharp-edged tools should always be carried in your pocket. a. True b. False 8. What kind of tools should be used when working around flammable gases, highly volatile liquids, or other explosive substances? a. Normal, everyday power tools b. Explosion proof and/or spark-resistant tools c. Metal hand tools d. Never use any type of a tool near these types of materials 9. When working with pneumatic tools, it is fine to point the tool at yourself or someone else as long as it has a fastener. a. True b. False 10. How should you test a tool s sharpness? a. Run your finger along the edge b. Ask someone else to run their finger along the edge c. Test on a piece of scrap material d. There is no way to test this safely 11. Small work pieces should be secured before beginning work to prevent the material from slipping and injuring you. a. True b. False 12. When working with a power tool outdoors or in a damp environment, where should the cord be plugged into? a. A non-waterproof extension cord b. A GFCI c. A outlet without a grounding plug d. All of the above 16 Summit Training Source, Inc.

27 13. If using compressed air to clean equipment, what should the pressure be set to? a. Less than 30 pounds per square inch b. Less than 60 pounds per square inch c. More than 30 pounds per square inch d. More than 60 pounds per square inch 14. What is the proper way to care for a tool after a task is completed? Select all that apply. a. Remove excess debris from your tools b. Store it in a specific location c. Hang the tool by the cord d. All of the above 15. A pneumatic hose should always be hung on a nail or hook. a. True b. False Summit Training Source, Inc. 17

28 Quiz Answers 1. a Safety glasses with side shields b Safety goggles c Leather footwear with non-skid soles 2. b False 3. a True 4. b Before each use 5. a Check for frayed power cords b Loose plugs or broken prongs c The body of the tool for cracks or other damage d The power switch 6. b False 7. b False 8. b Explosion proof and/or spark-resistant tools 9. b False 10. c Test on a piece of scrap material 11. a True 12. b a GFCI 13. a Less than 30 pounds per square inch 14. a Remove excess debris from your tools b Store it in a specific location 15. b False 18 Summit Training Source, Inc.

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