Mazak Mill: Safety for the Mill 260

This class discusses common safety issues concerning the Mazak mill, as well as OSHA and ANSI requirements for Mazak mill operators.

Class Details

Class Name:
Mazak Mill: Safety for the Mill 260
Description:
This class discusses common safety issues concerning the Mazak mill, as well as OSHA and ANSI requirements for Mazak mill operators.
Version:
1.0
Difficulty:
Intermediate
Number of Lessons:
17
Additional Language:
Spanish

Class Outline

  • Objectives
  • Safety for the Mazak Mill
  • Safety Precautions
  • Key Mazak Mill Safety Tips
  • Mazak Alarm Features
  • Coolant System Maintenance
  • Chip Conveyor Maintenance
  • What Is Lockout/Tagout?
  • OSHA Requirements for Lockout/Tagout Devices
  • Lockout Devices for the Mill
  • Tagout Devices for the Mill
  • Blockout Devices and Residual Energy
  • Workplace Hazards and PPE
  • OSHA PPE Requirements
  • Eye Protection for the Mill
  • Protective Clothing for the Mill
  • Summary

Objectives

  • Describe the importance of safety for the Mazak mill.
  • Describe the three safety precaution categories used on the Mazak mill.
  • Identify key safety tips for the mill.
  • Describe Mazak alarm features.
  • Describe coolant system maintenance.
  • Describe chip conveyor maintenance.
  • Describe lockout/tagout.
  • Identify OSHA requirements for lockout/tagout devices.
  • Describe the purpose of a lockout device.
  • Describe the purpose of a tagout device.
  • Identify examples of blockout.
  • Describe the purpose of PPE.
  • Identify OSHA PPE requirements for employers and employees.
  • Identify Mazak eye protection requirements.
  • Identify Mazak PPE clothing requirements.

Certifications

Glossary

Vocabulary Term Definition
alarm An automatic warning from the control when a program or mechanical component is not functioning correctly. The alarm warning light comes on, and all alarms are displayed in the DIAGNOSIS menu.
ALARM LIST The record of an alarm code that has occurred on the Mazak mill to alert the operator of a machine error. The list includes the alarm number, message, cause, type of error, machine status when the alarm occurred, how to eliminate the alarm cause, and whether the alarm color is red or blue.
ANSI The American National Standards Institute. ANSI is a private, non-profit organization that administers and coordinates voluntary standards and systems.
ANSI B11.19 The American National Standards Institute (ANSI) standard that sets guidelines for the design, production, and use of machine tool safeguarding devices and methods. Mazak PPE requirements for machine tool safeguarding methods follow guidelines provided in the ANSI B11.19 standard.
ANSI Z87.1 The American National Standards Institute (ANSI) standard that sets guidelines for the design, production, and use of protective eyewear. OSHA requirements for eye protection follow guidelines provided in the ANSI Z87.1 standard.
ASTM The American Society of Testing and Materials. ASTM writes and updates specifications for a broad range of materials, including PPE standards for shoes and eyewear.
bleeding The process of safely removing liquid or gas from a closed system. Bleeding is a blockout method.
blockout A type of energy-isolation mechanism that physically prevents the flow or movement of energy. Blockout helps to drain systems of residual energy.
cable tie A long, thin plastic or nylon fastening device that locks when the point on one end is threaded through the loop on the other.
caution A safety precaution indicating that failure to follow specific safety instructions may result in minor bodily injuries or serious machine damage.
chapter left Also called the display select key, the key on the lower left of the Matrix display that can be used to return to the main menu.
chip conveyor A moveable belt that helps to remove chips from the interior of the machine. On a Mazak mill, the chip conveyor is placed inside the coolant tank.
Control of Hazardous Energy OSHA's proper title for the lockout/tagout safety standard. The standard protects employees by requiring practices and procedures that prevent accidental machine startup for machines that are undergoing maintenance.
coolant A cutting fluid used to decrease the temperature of the tool and workpiece to prolong tool life. Operators of the Mazak mill must wear protective gloves when handling coolant.
coolant filter A device within the coolant system that helps to clean the coolant of contaminants.
coolant pump A component of the coolant system that is used to remove coolant from the tank during servicing of the coolant system.
coolant tank A container that holds the coolant or cutting fluid used to decrease the temperature of the tool and workpiece. On a Mazak mill, the chip conveyor is placed inside the coolant tank.
danger A safety precaution indicating that failure to follow specific safety instructions may result in operator death, shop personnel death, or both.
display select key Also called chapter left, the key on the lower left of the Matrix display that can be used to return to the main menu.
downtime Unproductive blocks of time during which machine operations cease, often due to mechanical problems. Adhering to safety procedures in the workplace helps to reduce downtime.
EMERGENCY STOP Used for emergencies only, the control button that automatically shuts down all machine functions. On a Mazak mill, an emergency stop button is typically located both at the control and on the outside of the machine.
energy-isolating mechanism A mechanical device that physically prevents the transmission or release of energy, such as a circuit breaker or valve.
grounding A means of providing a safe path for electricity should it stray from its intended path. Grounding is a blockout method.
hazard A source of danger or possible injury. Hazards can be physical hazards like falling objects or health hazards like chemical exposures.
hydraulic system A power transmission system that uses the force of flowing liquids to transmit power. Blockout helps to drain residual energy from a hydraulic system.
lockout device A device that uses positive means such as a lock and key or combination lock to hold an energy-isolating mechanism in a safe position and prevent equipment or machinery from being energized.
lockout/tagout The OSHA standard which contains requirements to protect workers who are servicing machinery. Once a machine is under lockout/tagout, it is rendered inoperable to ensure that the machine is not accidentally powered on.
maintenance The necessary and basic support and repair of machines. Proper maintenance helps reduce downtime and ensure worker safety.
Occupational Safety and Health Administration OSHA. A government agency under the U.S. Dept. of Labor that helps employers reduce injuries, illnesses, and deaths in the workplace.
oil level gauge A device on the Mazak mill that measures the amount of coolant in the coolant tank. Coolant should be filled to the upper limit level of the oil level gauge, but if coolant exceeds that level, coolant will overflow the tank.
OSHA The Occupational Safety and Health Administration. A government agency under the U.S. Dept. of Labor that helps employers reduce injuries, illnesses, and deaths in the workplace.
personal protection equipment PPE. Any of the various articles of clothing or safeguarding devices that assemblers or operators are required to wear to ensure their safety. Mazak PPE requirements follow ASTM and ANSI guidelines.
pneumatic system A power transmission system that uses the force of flowing gases to transmit power. Blockout helps to drain residual energy from a pneumatic system.
PPE Personal protection equipment. Any of the various articles of clothing or safeguarding devices that assemblers or operators are required to wear to ensure their safety. Mazak PPE requirements follow ASTM and ANSI guidelines.
print format The appearance of letters on the tag or device, including style, color, and size. OSHA requires that lockout/tagout devices have a standard print format.
reset key The key on the Mazak mill used to eliminate alarm codes on the Mazak mill, once the cause of the alarm has been indentified and the error has been corrected.
tag attachment Devices such as cable ties that connect tags to energy isolation mechanisms or locks. OSHA requires that tag attachments be a one-piece, self-locking device.
tagout device A prominent warning device, such as a tag, that can be securely attached to a machine or power source to alert employees that equipment is not to be operated until the tag is removed.
warning A safety precaution indicating that failure to follow specific safety instructions may result in serious bodily harm.
zero-point energy The lowest possible energy state that a system can possess. Blockout helps to establish zero-point energy.