Manufacturing Processes Study Guide
All Machines
You must always wear safety glasses when in the shop.
Never have someone else turn on the machine for you. You must turn them on by yourself.
The floor and machine should be clean and free of scraps before you begin working.
In order to cut cylindrical stock you must use a holding devise.
Never force the blade through the material.
Never talk to and or stand close to the person operating a machine.
Wait till the machine you are using comes to a complete stop before leaving the machine.
Never use a machine without the proper guard in place.
Never saw or joint material containing nails, and or paint.
Never start cutting until the machine reaches full speed.
Never have the blade contacting the material when turning the machine on.
Never wear gloves while operating any of the machines.
When plugging in or unplugging any of the machines, always hold the cord by the plug,
Never work on a machine that is plugged in. Always make sure it is unplugged before working on it.
Never wear flip flops, jewelry or loose fitting clothing.
You must take off your ID before operating any machines.
Radial Arm Saw
You should always hold the material with your left hand and the saw with your right hand.
You must always hold the wood tightly against the fence in a stationary position.
Never place your hands closer then 6” from the path of the blade while making a cut.
Never start the motor while the blade is touching the Material.
You must always pull the saw slowly through the material to make a cut, never push the saw away from you while making a cut.
Never leave scraps, tools, and or other materials on the table while making a cut.
Never make adjustments to the saw while it is running.
Never try to stop the machine by forcing a piece of material against the blade.
You must wait for the saw to stop rotating before returning it to the rear of the table.
Never leave the saw extended at the front of the table, always return the saw to the rear of the table.
The teeth on the bottom of the blade should always be pointing to the rear of the machine.
If a piece of material is too long to support on your own you should ask someone to help support it.
You should never cut more than one piece of material at the same time.
Rough cross cutting is the only operation that can be performed on the Radial Arm Saw.
Jointer
You should only cut a 1/16” from the edge of hardwood stock, never cut deeper then 1/16”.
You should always stand next to the infeed table, never in line with the table while jointing the edge of a board.
You should always feed the material through the machine slowly, never push the material through the jointer fast, and never joint the end grain of a board.
Never feed the material through the jointer from the rear-outfeed table.
Never joint a board that is less than 8” long.
Your hands must be at least three inches from the cutter head at all time. They should never pass over top of the cutter head.
Never make adjustments to the machine while it is running, adjustment should only be made with the machine turned off.
If you are going to joint a long board ask the instructor for help to support it.
When jointing the edge of material, your hands should always be behind the stock pushing it from the infeed table.
The purpose of adjusting the fence is to Joint a bevel, allow all parts of the blade to be used and to make sure the fence is square.
Be careful that you do not run any material that might have nails, screw, or loose knots in it.
Table Saw
Never remove sawed off scraps from the machine with your fingers while it is running
When replacing the blade the teeth at the top should always be pointing toward the direction from which the material is to be feed.
All adjustments should be made on the machine when it is turned off.
The blade should be adjusted so that the gullets of the blade are just above the material being cut. Ends up being roughly 1/4”.
Never saw warped or twisted material.
Never Free hand saw on the table saw always use the fence or miter gauge.
You should always use a push stick when ripping material narrower than 2”.
Never stand directly in line with the saw blade.
Never talk with others while the saw is running.
When cutting dados, grooves, and interlocking joints make sure the correct blade is on the machine.
Never make a cut without first jointing one edge.
When ripping long material push the material all the way through to the floor or with the help of someone on the outfeed side.
You should never remove the blade guard to make a cut unless first getting the Instructors permission.
Band Saw
The guard and guide should be a maximum of 1/4” above material
The blade should be a 1/16” ahead of the thrust bearing when not cutting.
The teeth on the band saw should point in a downward direction
On tight curves or long cuts, relief cuts should be made so that you do not have to back out of a cut.
The band saw is the only saw that you can free hand saw on using one hand to guide the work and the other to push the work into the saw.
Never make adjustments to the machine or push scraps away with your hands while the machine is running.
If the band saw blade where to break or come off of the guides you should turn off the machine immediately, step back form the machine and tell the instructor.
You must always keep your fingers at least 2” from the blade.
Cut slowly so you don’t put excess stress on the blade.
If you need to back out of long cuts first stop the machine and wait for it to come to a comlete stop.
Cylindrical stock may only be cut when using a V-block.
Miter Saw
Hold the blade all the way down after finishing a cut until the blade stops rotating and then return to the upright position
Make sure the material is held firmly against the fence and table before making a cut.
Your hands should never be within 6” from the blade when the machine is running.
You should never rip stock on the miter saw.
Always start the miter saw with the blade in the upright position.
Make sure that the table is locked before making a cut.
Never cross your hands over to hold material while making a cut.
Never hold the guard up while making a cut.
The teeth on the miter saw should point away from you at the bottom of the blade.
All pieces need to be at least 8” long to be cut on the miter saw.
Only cut one piece of material at a time.
If you need more than one piece the same length, set a stop block.
Make all adjustments before starting the blade.
Drill Press
You should ease up on the feed pressure just before the drill begins to break through the material.
When drilling large holes make sure you drill a pilot hole first.
The long end of the work should be to the left of the operator.
The speed of the machine should only be adjusted while the machine is running.
The chuck key should be kept on the table when not being used.
Never clear chips away from the spindle with your hands.
Never reach around a rotating bit wait until the bit comes to a stop.
Never use a dull drill bit.
The speed of the drill press should be set to the correct operating speed for the material being drilled.
Never try to stop the material if it gets caught in the drill bit.
The chuck should always be tightened with the chuck key and not by hand.
On deep cuts you need to back out from time to time to prevent the bit from clogging up.
Sanders
All material should be held flat on the table when sanding.
Use the appropriate throat plate with the appropriate drum.
Only one person should use the spindle sander at a time even though the table goes all the way around it.
Never use a sander that has a small rip in the belt or disk.
Always sand on the downward stroke on the disc sander never on the upward stroke.
You should always move the material back and forth while sanding never leave it in the same position.
Make sure you keep your fingers at least 3 inches away from the abrasive material while sanding.
Never sand more than a 1/8” of material off to get the correct dimension.
Make sure you stop sanding before your finish point on the belt sander.
Never remove any of the guards while sanding.
Router
When using hand routers the work needs to be held firmly in a vise, in a clamp, or on a routing mat while routing.
Never use a router bit that is not sharp
Never start the router with the cutter touching the work
Check the switch to see that it is in the off position before plugging in the router
Always hold on to the router with both hands; never hold on to the router with only one hand
Never router any other material except for wood
Always check and make sure the router isn’t going to hit the table, clamp, vise, etc
Make sure that the bit is tight in the router before using it
Never use a drill bit in the router
Always router in a counterclockwise direction on the outside of material
Always router in a clockwise direction on the inside of material
Always practice on a scrap piece of wood first before routering your project
Make several light cuts rather that one heavy one on large cuts
Power Nailer
Never carry the nailer or stapler with your finger on the trigger
Never operate the nailer or stapler with the work-contacting element removed
Never nail directly above another nail or close to the edge of a workpiece
When loading the nailer or stapler make sure the air supply is disconnected
When making adjustments to the nailer make sure the air supply is disconnected
Always disconnect the air supply from the nailer when it is not being used
The nailer and stapler should be lubricated each day before being used
Never point the nailer or stapler at someone whether it is connected or disconnected
Never hold the trigger down and let the contacting element fire the nailer when depressed
Always make sure that the correct nails are being used in the nailers
Your hands should be at least 4” from where you are nailing
When nailing you should always nail at a 90° angle. Never nail at any other angle other than a 90° angle