Training for machine operators Hervey Bay QLD

The advances in machinery over the last decade or so have resulted in machines that are more effective, i.e., faster setup, less waste of material and additional safety features.

With the use of both computer setup and digital readout, setup time has been reduced to a fraction of what was acceptable only a few years ago. The simplest of these readouts, the digital scale, uses a series of rotating gears inside of a housing to indicate the position of the cutting spindle. For these units to work properly, the operator must adjust the spindle movement in the same direction every time, thus eliminating any backlash in the system.

Failure to allow for the backlash can result in incorrect numbers appearing in the readout. It should be noted that woodworking machinery normally has some backlash designed into the system to allow for the dusty environment.

The other thing required for the effective use of the digital readout is an accurate method of measuring the radius or diameter of the head body. This can be achieved by a simple measuring stand (Image A) or by the use of a multidirectional stand (Image B). Both systems will produce a satisfactory result.

Some machines use a slightly more advanced digital readout system that links back to the main control panel. When the desired spindle position is entered into the panel, the readout is then set to either zero or to a desired finished dimension. These systems have worked well, but there is a potential for incorrect setting of the spindle due to incorrect information entered into the system or a failure in the connection from the panel to the readout.

The computer setting of machines has reached a level on some machines, where the operator simply, installs a cutter, programs the parameters of the tool and the desired finished dimensions. With a push of a button, the computer control can then set the remainder of the machine.

From a training perspective, each of these systems has its advantages and disadvantages. In some respects, the simpler the machine the better for many operations, especially the smaller operation where the machines are not in production on a daily basis. The simple digital readouts found on machines allow for quick and accurate setting without the risk of expensive repairs. With the increase of speed and efficiency comes the risk of increased parts failures. For example, some computer machines do not allow for manual override in the event of a computer failure.

If the computer fails, the machine can be out of service. For certain machines, the downtime can be significant. Some machine manufacturers stock a good parts inventory, while others offer no parts from stock. If the electronics fail and no parts are available, the machine is down for an undetermined length of time.

Another key factor that is more common is outdated electronics. Recently, a customer had a computer card go out on his machine. The cost to replace the card was over $6,000. The customer replaced the entire computer with an off-the-shelf low-cost system and had a local computer company come in and install a CAM (computer aided manufacturing) system. The entire install with training and software was under $2,500.

From a production perspective, there are definite advantages to having increased technology if the cost of potential repair is not a concern. For many companies, if the machine requires a $5,000 repair, they simply cannot justify the expense. For others, the cost savings over the productive time easily offsets the potential repair cost. Each company should look at its own situation prior to deciding which style of machine to purchase.

From a safety point of view, the objective is to reduce operator exposure to the cutter head and other moving parts of the machine. The older style machines, some with digital readout, offer less protection to the operator. Normally, technology advances run parallel with safety advances. Computer setting machines can greatly reduce operator risk by having the moving parts totally enclosed prior to any movement of machine parts. It should be noted that the older machines can also be improved in this area. The addition of electronic brakes, reduced depth cutting tools, electronic floor matting and electronic curtains can reduce the exposure to the operator.

Some simple things that can be done to reduce the risk:

• TRAIN THE OPERATORS USING SKILLED TECHNICIANS

  Some companies have in-house trainers that do an excellent job while others will need to use outside technicians and manuals.

• WEAR PROTECTIVE EQUIPMENT

  The use of safety glasses and hearing protection is required by OSHA, but it is not always used. Many small shops do not utilize these inexpensive safety items. The use of Kevlar gloves when handling tooling can greatly reduce the minor cuts and injuries that can cost up to a few thousand dollars.

• USE PROPER SETTING TOOLS

  One area that many companies overlook is using boxed-end wrenches to replace the open-end style. Open-end wrenches slip much more often and can result in skinned knuckles or the loss of a hand if the hand slides into a rotating cutting tool. Use the correct size tools.

• HOUSEKEEPING

  Make sure the floor is clean so that the risk of slipping is minimized.

  Handle cutting tools correctly. Many times operators will carry a sharpened cutter head through the production environment. Use carts to greatly reduce the risk of injury resulting from a mishandled head.

• USE GUARDS

  Machine guards are designed to reduce the risk of operator injury. Failure to use these guards results in a potential injury that can be devastating.

  Use interlocks. Many machines are equipped with electronic and mechanical interlocks that prevent the operator from injury during certain processes the machine goes through. An example, is an electrical hood interlock that does not allow the hood to be raised until the cutter heads are in a stopped condition.

• USE LOCKOUT/TAGOUT

  Always lock out the machine prior to cutterhead change and maintenance. There are several good manuals available that deal with this subject. Also remember, this is the law and does reduce and eliminate injuries and accidents.

Ed. note: Dr. David Rankin, known as "The Moulder Doctor"™ is president and founder of Moulder Services, Inc. in Troutman, N.C. Dr. Rankin holds his Ph.D. in safety engineering and is available for preaccident machine consultations and for post-accident investigation. Dr. Rankin has spent the last 25 years working on woodworking machinery throughout the world and holds several patents in cutting tool design and safety systems. Visit his website at www.moulderservices.com or send him an e-mail, dave@moulderservices.com.