Hand Power Tools

HAND & POWER TOOLS

POLICY & PURPOSE

It is Zoetis Union City policy to ensure that colleagues who use hand and power tools are aware of the hazards and are properly trained in their use to avoid injury. Everyone is familiar with common, everyday tools, but should not take them for granted.

The purpose of this plan is to prevent the occurrence of workplace injuries associated with the improper use of hand or power tools.

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Avoid Tool Injuries

AVOID TOOL INJURIES

Crushed hands and arms, severed fingers, blindness - the list of possible machine-related injuries is as long as it is horrifying. There seems to be as many hazards created by moving machine parts as there are types of machines. And, commonly used portable tools also cause serious injuries. Even hand tools cause injuries. Too frequently, tool use causes serious eye injuries, lacerations, fractures, burns, and minor scrapes, cuts or bruises.

In addition, most machines and power tools are powered by electricity. Electrical hazards are equally harmful.

General Tool Safety Rules

GENERAL TOOL SAFETY RULES

Injuries can be prevented by keeping tools in good condition, using the right tool for the job, using the tool properly, and wearing required personal protective equipment.

Keep your work area well lit, clean and dry
Stand where you have firm footing and good balance while you use any tools.
Arrange the work and use portable tools so that the tool will move away from your hands and body if it slips.
Make sure that the material you are working on is held securely - use clamps or a vise if you need to.
Use the right tool for the job. Don't force a small tool to do heavy-duty work.
Regularly inspect tools, cords, and accessories. Repair or replace problem equipment immediately.
Never use a dull blade or cutting edge
Keep electric cables and cords clean and free from kinks. Never carry a tool by its cord.
Use all guards and safety devices (i.e.: three-pronged plugs, double-insulated tools, and safety switches) that are designed to be used with the equipment.
Dress right. Never wear clothing or jewelry that could become entangled in machinery or power tools.
Use protective equipment when necessary. This might include safety glasses, hearing protection, and dust mask.
Make adjustments and accessory changes when machinery is turned off and unplugged.
Concentrate - don't take your eyes off your work or talk to anyone as you use tools.
Maintain your tools. Keep them sharp, oiled and stored in a safe dry place.
Install or repair equipment only if you're qualified. A faulty job may cause fires or seriously injury you or other workers.

Good tool habits soon become second nature. Follow the tool safety guidelines at your workplace and the equipment you operate will serve you efficiently and safely.

Dangers of Hand Tools

DANGERS OF HAND TOOLS

Hand tools are tools that are powered manually. Hand tools include anything from axes to wrenches. The greatest hazards posed by hand tools result from misuse and improper maintenance. Some examples include the following:

If a chisel is used as a screwdriver, the tip of the chisel may break and fly off, hitting the user or other employees.
If a wooden 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 the user or other employees.
If the jaws of a wrench are sprung, the wrench might slip.
If impact tools such as chisels, wedges, or drift pins have mushroomed heads, the heads might shatter on impact, sending sharp fragments flying toward the user or other employees.

The employer is responsible for the safe condition of tools and equipment used by colleagues. Employers shall not issue or permit the use of unsafe hand tools. Colleagues should be trained in the proper use and handling of tools and equipment.

Colleagues, when using saw blades, knives, or other tools, should direct the tools away from aisle areas and away from other colleagues working in close proximity.
Knives and scissors must be sharp; dull tools can cause more hazards than sharp ones.
Cracked saw blades must be removed from service.
Wrenches must not be used when jaws are sprung to the point that slippage occurs.
Impact tools such as drift pins, wedges, and chisels must be kept free of mushroomed heads.
The wooden handles of tools must not be splintered.
Iron or steel hand tools may produce sparks that can be an ignition source around flammable substances. Where this hazard exists, spark-resistant tools made of non-ferrous materials should be used where flammable gases, highly volatile liquids, and other explosive substances are stored or used.

Dangers of Power Tools

DANGERS OF POWER TOOLS

Power tool injuries account for as many as 400,000 emergency room visits each year.

The use of tools enables us to work much more productively, but hand and power tools can expose colleagues to flying objects like sparks and metal and wood splinters, electrical shock, and sharp blades and loud noises.

As tool users, colleagues have a primary role in safety. Colleagues must have clear, established safety protocols for working with each unique piece of equipment and colleagues must follow those procedures when using tools, while relying on training to operate equipment safely.

First, colleagues must dress for the job by removing loose clothing or articles that could get caught in a tool’s moving parts, including jewelry when necessary. They must also wear appropriate personal protective equipment (PPE) when required; even with hand tools the job or the tool will often require specific personal protective equipment. PPE only works if you wear it.

Other basic safety precautions include:

Using the right tool for the job—a wrench is not a hammer.
Following manufacturer instructions—don’t by-pass safety features.
Never carrying a power tool by its cord.
Never yanking a cord or hose to disconnect it from the power source.
When appropriate, secure work with a clamp or vise to keep it from slipping.
Be careful to keep footing and balance stable when working with dangerous tools.
Be aware of the other people around you and keep them at a safe distance.

Misuse occurs when a tool is used for a job other than its intended purpose and can lead to tool failure. Never force or modify a tool to get the job done.

When tools aren’t properly maintained, they can present a hazard. For example, tools with dull blades do not perform as intended and cause more injuries than sharp tools.

And when iron or steel tools are used in the presence of flammable substances, sparks can fly, causing an ignition hazard.

While many power tools are now battery powered or work through compressed air via pneumatic pumps, the risk of electric shock remains a major hazard commonly resulting in accidents when working with power tools. Here are some steps to take for working with electric power tools safely:

For electric tools, keep floors dry and clean to avoid slipping while working with or around dangerous tools.
Keep cords from presenting a tripping hazard.
Examine tools and cords for damage before use.
Use tools that are double-insulated or have a three-pronged cord and are plugged into a grounded receptacle.
Do not use electric tools in wet conditions unless they are approved for that use.
Do not exceed the design limitation of the tool.
Use a ground fault circuit interrupter (GFCI) or an assured grounding program.
Use appropriate PPE.

Since the primary hazard of pneumatic tools relates to parts of the tool not being connected securely, safety measures require that you verify that tools are fastened securely before use.

Here are some steps you can take to work with pneumatic tools safely:

Never point a compressed air gun at anyone or press one against yourself or anyone else.
When you are finished using the tool, make sure that the pressure is released before you break the hose connections.
Use a safety clip or retainer to prevent attachments from being ejected during operation, and use a chip guard when using high-pressure compressed air for cleaning. Be sure to limit the nozzle pressure to 30 pounds per square inch.
Always wear eye protection—head and face protection is recommended along with ear protection when working with noisy tools.
Use screens to protect nearby workers from flying fragments and never store a loaded air gun or leave it unattended.

Training

TRAINING

Colleagues using powered tools and working in the Machine Shop are expected to be competent in using a powered tool or machine. If not trained, the supervisor or manager will arrange for training and document the training on an Zoetis Union City training log. The workplace supervisor may also coordinate with the Safety Officer if outside expertise is necessary to train workers.

Training records must be kept. At a minimum, the following subjects must be covered:

Hazard recognition
Proper use and application for all tools
Operating instructions
Safety precautions
Guarding
Safety switches and emergency shut-offs
General safety rules and precautions

Manufacturer representatives may be able to provide specialized training on the safe and proper use of their equipment. OSHA also publishes guidelines for safe operation of power tools and machines that are recommended for training workers.

Program Requirements

PROGRAM REQUIREMENTS

Machine Shop Power Tools and Equipment

The machine shop fabricates parts for assembly equipment and only select workers have access to the shop. Any machine or power tool with moving parts that cut, grind, and drill present inherent risks. Tools used in our machine shops in the fabrication of assembly machines and equipment used to manufacture products include, but are not limited to:

Milling Machine
Lathes
Drill Press
Grinders
Buffers

General Power Tool Safety Requirements

General Safety Requirements for Power Tools

It is common for these workers to work in the shop alone, so the following safety considerations must be followed when working on machines and using powered tools.

Appropriate personal protective equipment includes safety goggles, hearing protection, and work gloves to protect against projectiles, metal shards, loud sounds, and sharp edges, respectively.
Workplace floors shall be kept as clean and dry as possible to prevent accidental slips with or around machines where lubricants and oils are commonly used.
Shards of metal and plastics produced by lathes, drill presses, and grinders should be collected by a vacuum device and not blown off machines using compressed air.
Power tools should be fitted with guards and emergency shut-off switches.
The following types of power sources must be evaluated, because each has inherent hazards associated with them.

o    Electric
o    Pneumatic
o    Liquid fuel
o    Hydraulic

Safe Work Practices

Colleagues are expected to follow the safety precautions outlined in this section when working with machines or tools:

Colleagues use only tools with which they have experience, or on which they have been trained.
Tools are used only on secure and stable work surfaces. Work is secured with a vise or clamps if necessary.
Colleagues using tools stand on a clean, dry surface to prevent slipping.
Work areas are well-lighted.
Do not work in awkward positions when using tools.
Air hoses and electric cables used in elevated locations are securely fastened to a substantial anchorage at or near the working level, and are fastened no more than 15 feet from the working end.
Carry tools by the handle; never carry a tool by the cord or hose.
Never yank the cord or the hose from its receptacle.
Keep cords and hoses away from heat, oil, and sharp edges.
Disconnect tools when not using them, before servicing and cleaning them, and when changing accessories such as blades, bits, and cutters.
Keep all people not involved with the work at a safe distance from the work area.
Secure work with clamps or a vise, freeing both hands to operate the tool. This is especially important on the drill press where thin pieces of sheet can become entrapped by the drill bit, and spin out of control of the operator.
Keep fingers off of the switch or ON button while carrying a plugged-in tool.
Maintain tools with care, keeping them sharp and clean for best performance.
Follow instructions in the user’s manual for lubricating and changing accessories.
Be sure to keep good footing and maintain good balance when operating power tools.
Wear proper apparel for the task, and avoid wearing loose clothing, ties, or jewelry that can become caught in moving parts.
Remove all damaged tools from use and tag them: “Do Not Use.”

Machine Guarding

Guards

The exposed moving parts of power tools are designed with safeguards, to prevent contact with the moving parts. Belts, gears, shafts, pulleys, sprockets, spindles, drums, flywheels, chains, or other reciprocating, rotating, or moving parts of equipment must be guarded, or colleagues sufficiently protected to prevent the operator and others from contact with the following:

Point of operation
Pinch points where clothing or the body may be caught
Rotating parts
Flying chips and sparks

Safety guards must never be removed or altered for convenience or against manufacturer recommendations. Point of operation guards shall be properly set up, adjusted and maintained in safe and efficient working condition that will prevent the operator's hand from entering the point of operation. Colleagues are responsible for checking machine guards before use to ensure safe operation. If machines without safety guards are equipped with guard mounts, the shop supervisor is responsible for checking the manufacturer’s recommendations, and replace missing parts where applicable.

Electric Tools

Colleagues using electric hand tools must be aware of several dangers. The most serious hazard is electrical burns and shocks. All machines and electrically activated tools must have a three-wire cord with a ground, plugged into a grounded receptacle. Three-wire cords contain two current carrying conductors and a grounding conductor. A three-pronged adapter should be used to accommodate a two-pronged plug to provide a grounded circuit.

Colleagues are required to operate electric tools within manufacturer specification. Basic safe work practices with electric powered tools include the following:

Use gloves and appropriate safety footwear when using electric tools.
Store electric tools in a dry place when not in use.
Do not use electric tools in damp or wet locations unless they are approved for that purpose.
Keep work areas well lighted when operating electric tools.
Ensure that cords from electric tools do not present a tripping hazard.

Ground-fault circuit interrupters should be used; when they are not available use an assured equipment grounding conductor program (AEGCP) to protect workers who use electric tools.

Tool Inspections

Tools must be inspected daily before use and kept clean and in good repair when not in use. Any colleague who finds defects in a tool or machine may take it out of service. Damaged, defective, or worn tools must be tagged with a prominent warning and removed from service until repaired. Colleagues are responsible for contacting the work area supervisor to inform them of the disabled tool or machine. Basic inspections include the following.

Check blades, bits, and other cutting parts to determine if they are sharp, worn, or cracked.
Operating parts are in good operating condition.

Controls & Switches

Hand-Held Power Tools Operating Controls and Switches

The following must be equipped with a constant-pressure switch or control that shuts off the power when pressure is released:

Drills
Tappers
Fastener drivers
Horizontal, vertical, and angle grinders
Disc sanders with discs greater than 2 inches (5.08 centimeters)
Belt sanders
Reciprocating saws

These tools also may be equipped with a “lock-on” control, if it allows the worker to also shut off the control in a single motion using the same finger or fingers. It is recommended that the constant-pressure control switch be regarded as the preferred activation device for these types of tools in order that when pressure is released, the tool stops.

Abrasive Wheels

Abrasive grinding and buffing wheels create special safety problems because they may throw off flying fragments. Abrasive wheel tools must be equipped with guards that:

Cover the spindle end, nut, and flange projections
Maintain proper alignment with the wheel
Do not exceed the strength of the fastenings

Before an abrasive wheel is mounted, it must be inspected for damage and tested periodically for cracks or defects.

To test, wheels should be tapped gently with a light, non-metallic instrument. If the wheels sound cracked or dead, they must not be used because they could fly apart in operation. A stable and undamaged wheel, when tapped, will give a clear metallic tone or “ring.”

Damaged abrasive wheels have been known to disintegrate or explode during start-up; therefore the wheel should be visually inspected before use, especially after frequent use or after sitting idle for long periods.

Allow the tool to come up to operating speed prior to grinding or cutting. The worker should never stand in the plane of rotation of the wheel as it accelerates to full operating speed. The following are safety reminders when using a powered grinder.

Always use eye or face protection
Turn off the power when not in use
Ensure guards are in place before using

Pneumatic Tools

Pneumatic tools are operated from compressed air that is fed into the tool through a hose and have three main parts; the hose where the tool is attached, the vane motor that generates the machine, and the air compressor.

Air hose connections must be checked each time a tool is used to make sure they are in good operating condition.
Compressed air must never be used to blow dirt, chips, or dust from clothing while being worn.
All pneumatic impact tools have safety clips or retainers so dies and tools won’t be accidentally expelled from the barrel.
Hoses over ½" inside diameter have regulators at the supply source, or branch lines to reduce pressure in case of hose failure.
Pneumatic tools must not be hoisted or lowered by their hoses.

On portable compressors:

Wheels are fixed, locked, or blocked to prevent rolling.
Fans are guarded with a shroud or side screens.
Air tanks are drained of liquid according to the manufacturer’s specifications.

Egonomics

Ergonomics

Ergonomic injuries are commonly associated with the use of power tools and in some cases, machines, such as lathes, drill presses, and band saws. Exposures to vibrations and the mechanics of holding and handling some tools can cause neuromuscular injuries. Colleagues are instructed to inform their supervisor immediately if an injury or symptoms of discomfort are suspected from working with tools, and a formal evaluation will be conducted.

References / Resources

REFERENCES/RESOURCES

VIDEOS

DOCUMENTS/LINKS

Glossary

GLOSSARY

Affected Employee

Tools, Electrical

An employee whose job requires them to operate or use a machine or equipment on which cleaning, repairing, servicing, setting-up or adjusting operations are being performed under lockout or tagout, or whose job requires the employee to work in an area in which such activities are being performed under lockout or tagout An affected employee does not perform servicing or maintenance on machines or equipment (this is conducted by an "authorized employee".

Authorized Employee

Tools, Electrical

A qualified person who locks out or tags out specific machines or equipment in order to perform cleaning, repairing, servicing, setting-up, and adjusting operations on that machine or equipment. Lockout or tagout is used by these employees for their self-protection. An "affected" employee becomes an "authorized" employee whenever he/she performs servicing or maintenance functions on machines or equipment that must be locked or tagged.