This document provides an outline for the WT4603 Wood Processing Safety & Practice module. It details the module assessment breakdown, coursework requirements including a table project and risk assessments, and the lab and lecture schedule. The lab sessions will provide exposure to machines like the surface planer, thicknesser, bandsaw, and teach safety procedures for operating them. Students must complete various assessments and attend all labs to pass the module.

2. Lecturer: Mr. Joe Lyster

3. joseph.lyster@ul.ie

4. Department of Design & Manufacturing Technology

6. Teaching Assistant: Michael Crehan

8. Courses Involved:

9. LM094 Materials & Architectural Technology

10. LM067 Wood Science & Technology

11. Lecture Times

12. Monday9-11am in FB-028 (Foundation Building)

13. Lecture Notes

14. Available @ www.slideshare.net/WT4603WT4603 Department of Design & Manufacturing Technology

15. WT4603 Module Outline The aim of WT4603 is wood processing safety and best practice. This is a core module and a requirement for second year teaching practice (TP). Department of Design & Manufacturing Technology

17. 35% Laboratory Work:

18. Table Manufacture 20%

19. A3 Process Booklet 15%

20. 25% Term Assignments:

21. Risk Assessments 15%

22. Information posters 10%

23. 35% Written Exam (Terminal)

24. 5% Lecture Worksheets

25. Machines Practical Exam (Pass / Fail Basis)

26. Lab Booklet (Pass / Fail Basis)

27. Note:

28. Students must pass allassessment elements to obtain a pass in the module.

29. Students that fail the practical machines exam will automatically fail the entire module.Department of Design & Manufacturing Technology

30. WT4603 Coursework Marking Scheme Department of Design & Manufacturing Technology

32. Laboratory Work:

33. Table project

34. Lab Booklet

35. Term Assignments:

36. Risk Assessments

37. Information Poster

38. Lecture Work:

39. WorksheetsDepartment of Design & Manufacturing Technology

41. Purpose of the table project is to reflect your use of woodworking machinery through wood processing safety and best practice

42. Project enables you to purposely process material to construct an artefact (table) from a raw plank state in the most efficient and safe manner possible

43. Use of the surface planer, thicknesser, rip saw, mortiser, bandsaw, panel saw as part of this project

44. Produce appropriate cutting lists, plans and procedures with the awareness of material processing waste, which is an important element for the sustainable use of material and procurement of bulk raw plank material for class projects

45. Develop hand skills in preparation for teaching practice by producing a series of hand-crafted joints to construct the table

46. Develop your awareness of machine safety through risk assessment procedures including aspects such as hazard identification and risk magnitude. This is a critical aspect regarding the safe operation of any second level technology classroom.Department of Design & Manufacturing Technology

49. The purpose of the lab book is to record your in lab exposure to wood processing safety and best practice.

50. It is advised that you complete the lab book during your lab time as it intends to capture your initial exposure to using wood processing machinery

51. You will not be permitted to the lab without your lab book

52. Lab book can be purchased from snap printing at a cost of €6.Department of Design & Manufacturing Technology

54. Risk Assessments

55. Create an A3 booklet to include the following:

57. Information PosterCreate an appropriately designed A2 laminated poster on an assigned machine. Must be accompanied by a user information sheet You must also develop a work activity sheet that addresses machine safety and best practice to reinforce operant knowledge, understanding and safety culture All assigned machine lists, as discussed in both cases above, can be viewed in the lab. Department of Design & Manufacturing Technology

59. Each week you will be given an activity sheet to be completed during the lecture.

60. The aim of the lecture worksheets is to reinforce wood processing safety and best practice.

61. The worksheet will prepare you in advance of activities taking place in forthcoming labs.

62. It will provide you with a theoretical understanding of wood processing safety and best practice that will strengthen your knowledge and understanding in preparation for labs.

63. The worksheets will also involve reflection on the use of machinery in previous labsDepartment of Design & Manufacturing Technology

64. Module Outline WT4603 Timetable: Department of Design & Manufacturing Technology

65. Lecture Content – 24hrs WT4603 Introduction + Labs W2 Machine Provision + Labs W3 Risk Assessment + Labs W4 PPE + Labs 4 W5 Planing Machines + Labs W6 Circular saws + Labs W7 Material Management & Sustainable Use + W8 Labs + (Machines Exam Prep.) Bandsaw + Labs W9 + (Machines Exam Prep.) Morticer +Labs W10 Routers + Labs W11 Other Machines and Equipment + Labs W12 Dust, Noise, Manual Handling Department of Design & Manufacturing Technology

67. Labs will take place in SR2058 & SR2047.

68. Lab coat and safety glasses are a prerequisite to gaining entry to the lab.

69. You must have your lab booklet during all labs.

70. Groups are divided and timetabled

71. Labs will begin on Week 2

72. Labs are mandatory – 100% attendance

73. Absence in the case of illness must be explained with a doctors note.

74. Other reasons must be explained to the lecture/TA.Department of Design & Manufacturing Technology

76. Labs begin on the hour and finish at 10 minutes before the hour, e.g. 9:00am to 10:50am

77. Late arrivals will not be permitted to join the lab session.

78. Lab Rules and Requirements:

79. Report for lab on time

80. White lab coat

81. Safety glasses

82. Students must sign the attendance sheet

83. Students will be assigned a work bench

84. I.D. cards to be submitted to T.A. for locker keys

85. Students must follow instructions of T.A.

86. Students under the influence of alcohol will not be permitted.Department of Design & Manufacturing Technology

88. Students have a responsibility for the care of the tools in their locker

89. At thee beginning and end of the lab students must:

90. Check tools list and condition

91. Report to T.A. if any tools are missing

92. Report to T.A. if tools are damaged

93. At the end of each lab session:

94. Benches must be brushed down

95. Bench hooks returned to the underneath of each bench.

96. Vices must be in the closed position.

97. The floor area is swept and/or all waste material is removed from the ground area.

98. Wood waste and paper waste to be segregated.

99. If stools are used during a lab session, they must be removed from the floor and placed on top of the bench.

100. I.D. cards will only be returned to students when they have complied with these regulations.Department of Design & Manufacturing Technology

102. Safety glasses must be worn at the appropriate times as laid out by the T.A. in charge.

103. Students must report damage to tools and equipment to the T.A. in charge.

104. Students must immediately report any personal injury (nicks, cuts etc.) to the T.A. in charge.

105. Failure to comply with safety regulations will result in removal from the lab session.

106. Any malicious damage to University property or equipment will result in removal from the lab and University disciplinary procedures will be put in place.WT4603 Department of Design & Manufacturing Technology

108. 2B Pencil

109. Max 3M Measuring Tape

110. 150mm Steel Rule

111. Masking Tape

112. Lab Book (Available from Snap Printing on 07/09/2011 (Wednesday))

113. Failure to present this equipment at the beginning of the lab will result in you not being able to participate in the lab

114. You must bring all equipment & PPE to all labsWT4603 Department of Design & Manufacturing Technology

115. WT4603 Department of Design & Manufacturing Technology

116. WT4603 WT4603 Department of Design & Manufacturing Technology

117. WT4603 Week2: Lab 1 & 2 Table Department of Design & Manufacturing Technology

118. WT4603 Week 2: Lab 1 & 2 Machine Exposure: Surface Planer Planer Thicknesser Bandsaw Material Process – Component A: Each student will receive an unprocessed plank of red deal measuring 750 x 245 x 50 (mm) Aim of week 2 labs is to square the material to a clean workable condition of required dimension. 242 740 Department of Design & Manufacturing Technology

119. WT4603 Surface Planer Department of Design & Manufacturing Technology

120. WT4603 1 9 8 2 7 3 4 6 5 Surface Planer 10 11 12 Department of Design & Manufacturing Technology

122. Note infeed and outfeed table.

123. Square to infeed using right angle square.

124. Use red lock handles to open and adjust fence.

125. Lock gently when fence is perpendicular to infeed table.Infeed Table Department of Design & Manufacturing Technology

127. Maximum recommended material removal is 1-2mm/pass

128. Dept stop to be set at 2mm

129. Open infeed lock handle

130. Turn wheel to left to drop table to 2mm

131. Lower you drop, the more the planer cutting block is exposed

132. Close infeed lock handle when required dept is achieved.

133. * Do not adjust outfeed table level, this is for maintenance purposes only*Department of Design & Manufacturing Technology

135. Width of material + 10mm is recommended

136. This results in 10mm blade exposure - Safety

137. Adjust lock handle to wind in or out guide fence

138. Lock in appropriate position242 + 10 Department of Design & Manufacturing Technology

140. Guard set for face edge = handle flat – no blade exposureDepartment of Design & Manufacturing Technology

142. Cupping

143. Bowing

144. Twist

145. Knots

146. Loose grain

147. Example - if material is bowed, set the bowed face to the surface planer table surface and process. Material should never be run through hump side down.Department of Design & Manufacturing Technology

149. Select appropriate face side and face edge based on inspection

150. Preliminary surface marking using an ‘X’ with no less than a HB pencil

151. Ensure extraction gate valve is open and extraction is on

152. Proceed to plane material – face side and face edge only!Gate Valve locate on extractor pipe just above surface planer X X Department of Design & Manufacturing Technology

154. Hand positionsDept of Hand Dept of Hand Ensure Guard Guide is in a vertical position to plane face side Department of Design & Manufacturing Technology

155. WT4603 Department of Design & Manufacturing Technology

156. WT4603 Note Hand Positions in relation to material Department of Design & Manufacturing Technology

158. Hand positionDept of Hand Dept of Hand Ensure Guard Guide is in a horizontal position to plane face edge Department of Design & Manufacturing Technology

159. WT4603 Note Hand Positions in relation to material Split second blade Exposure Blade guard flat onto table Department of Design & Manufacturing Technology

160. WT4603 Thicknesser Department of Design & Manufacturing Technology

161. WT4603 1 2 3 4 Thicknesser Department of Design & Manufacturing Technology

162. WT4603 Lab sequence – Thicknesser Step 1: Unlock twist release stop mechanism Press green button to start Allow machine to build up, this can be determined by noise consistency When noise is consistent flip delta switch to on position Feed rate, i.e. Speed at which material is passed, is set. Adjust table height as required Feed material as directed Delta Switch Stop/Start Twist Release Stop Display Panel Thicknesser Bed Adjustment Control Feed Rate Control Department of Design & Manufacturing Technology

163. WT4603 Bandsaw Department of Design & Manufacturing Technology

164. WT4603 The bandsaw Department of Design & Manufacturing Technology

165. See you all next week! Next week: Machine Provision Risk assessment Week 3 ripsaw labs WT4603 Department of Design & Manufacturing Technology