is.11016.1984

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इंटरनेट मानक

Disclosure to Promote the Right To Information


Whereas the Parliament of India has set out to provide a practical regime of right to
information for citizens to secure access to information under the control of public authorities,
in order to promote transparency and accountability in the working of every public authority,
and whereas the attached publication of the Bureau of Indian Standards is of particular interest
to the public, particularly disadvantaged communities and those engaged in the pursuit of
education and knowledge, the attached public safety standard is made available to promote the
timely dissemination of this information in an accurate manner to the public.

“जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न' 5 तरफ”


Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru
“The Right to Information, The Right to Live” “Step Out From the Old to the New”

IS 11016 (1984): General safety requirements for machine


tools and their operation [PGD 3: Machine Tools]

“!ान $ एक न' भारत का +नम-ण”


Satyanarayan Gangaram Pitroda
“Invent a New India Using Knowledge”

“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता ह”


है”

Bhartṛhari—Nītiśatakam
“Knowledge is such a treasure which cannot be stolen”
UDC 621’0 : 614’8
IS: 11016- 1984
I.
( Reaffirmed 2005 )
Indian Standard

Is1
1I GENERAL SAFETY REQUIREMENTS FOR
MACHINE TOOLS AND THE~IR OPERATION

I. Scope
1.1 Identifies the basic requirements with regard to safety provisions for machines tools and their
accessories and is applicable for new designs as well as re-designs and modifications and describes the
safety measures to be adopted (~a ) at the actual place of working; and (b) for setting, utilisation and
maintenance of machine tools and their accessories.

1.2 Provides a general guidelines for safety on machine tools and their operations.

1.3 Provides a general guideline and wherever specific limits are to be applied for values such as noise,
vibration, etc, reference shall be made to relevant standards on specific subjects.

Note l- In all such cases where it has not been possible to identify specific causes or identify specific
limiting valUeS the best possible safety practices identified to overcome such specific cases should be practclsed.

Note 2 -A number of related standards have been identified and listed and given in Appendix A. However,
wherever a doubt arises regarding the application of a particular standard, a decision regarding the applicability to
be taken keeping in mind the safety requirements to be provided.

2. Terminology
2.0 For the purpose of this standard, the following definitions shall apply.

2.1 Normal Working Area - Area occupied by the machine tool and all its accessories and that
required for operation, maintenance and material handling.

2.2 Hazardous Working Area -Area i,n which the actual machining operation is carried out. This
includes (a ) the area taken up for the movement of tools and workpieces, (b) the area required for
material handling in the proximity of both the tool and the workpiece, (c) the area required for the
movement of clamping elements, and (d) the area endangered by the flying of chips.

2.3 Hazardous Points - Freely accessible points between relatively moving parts of the machine and
between these parts and the workpieces where there is a possibility of the operator being injured either
during machining or during setting.

2.4 Cutting Fluid - Fluid, which serves to reduce -heat and friction between the tool and the
work-piece, and aids in easy removal of the chips fermed during machining.

2.5 Machine Tool --Metal cutting machine tool is a power-driven machine, generally not portable by
hand while in operation, which works metal by cutting, forming, physico-chemical processing or by a
combination of these techniques.

2.6 Standard Accessories -These are tools and aids which are necessary for proper setting,
functioning, control, service and maintenance of machine tools.

2.7 Special Accessories - These are tools and aids which increase the scope of function of machine
tools.

2.3 Machine Tool Equipment -These include standard and special accessories as per the technical
requirements, supplied in accordance with the agreement between the manufacturer and the customer.
They include the servicing and instruction manuals.

2.9 Control Elements - These are elements such as levers, hand-wheels, push buttons, etc, required
for ~controlting the various functions o-f the machine tool mechanically, electrically, hydraulically or
pneumatically.

2.10 Clamping E/em&s-These are elements such as collets, chucks, arbors, etc, required for
clamping of either tools or workpieces.

Adopted 11 August 1984 Q January 1985, ISI 6r 6


I I
INDIAN STANDARDS INSTITUTION
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110009
IS:11016-1964

3. Basic Regulations
3.1 Every manufacturer and user of machine tool shall ensure the safety and protection requirements
under the Factories Act and this standard as well as the operating, servicing and maintenance manuals
are properly complied with.

3.2 Besides other technical requirements, every machine tool shall conform to the safety requirements
specified in this standard.

4, Design Requirements

4.1 General Principles

4.1.1 Machine tools and their accesso:ies shall be so designed that they can be safely operated as per
the instructions indicated in the operating manual of the respective machine tool.

4.1.2 While designing machine tools and their accessories, the physiological and psychological factors
coupled with the safety and hygienic factors of the operator shall be considered as a composite of the
requirements.

4.1.3 Sources of danger, wherever possible, shall be eliminated completely.

4.1.4 In a situation where it is not possible to eliminate the sources of danger, care shall be taken to
incorporate safety precautions which will reduce the risk of accidents to a minimum.

4.1.4.1 Protective equipment shall be simple, reliable and convenient for use as well as inspection.

4.1.4.2 Protective equipments shall not themselves be sources of accident and shall not hinder the
setting, normal working and maintenance of the machine tool.

-4.1.4.3 Protective equipment shall be so designed that it is possible to get them mutually
interconnected with the control mechanism. This will ensure such equipment to be brought
automatically into action, once the machine tool is switched on, and does not get disconnected till the
machine tool is switched-off.

4.2 External ~Arrangement and Shape

4.2.1 As far as possible, the external surfaces shall be free from sharp edges, sharpcorners, projections
and cavities. Projections and sharp corners shall be avoided in close proximity to control elements and
in all such places where there is a risk of the operator getting injured.

4.2.2 For such of the machine tool parts which cannot be covered and which protrude into the
working region either temporarily or permanently ( for example, clamps, clamping screws, ect. ) it is
necessary to minimise the risk of an accident by:

a) preventing accessibility to such parts, by incorporating suitable protective guards, railings or


partition;

b) judiciously locating such parts and providing suitable shape;

c) providing convenient guiding system for tubes, hoses and electrical wires, so that while the
machine tool is in operation, there will be no obstruction from theme; and

d) cautioning against danger by means of warning colour markings.

4.2.3 The external shape of the machine tool and its protective equipment shall be such that the
operator is able to see the workspot without any obstruction and is able to operate without getting
unduly strained.

4.3 Painting

4.3.1 Colour schemes for machine tools shall be selected so as to provide an optically suitable and
balanced appearance of t.he machine tool without causing any strain to the operator.

4.3.2 The painted surface of the machine tool should be smooth and attractive.

4.3.3 When controls are confined to distnict regions of the machine tool, the control area should be
painted with a suitable shade which provides a convenient neutral base for coloured indication plates.

4.3.4 For rapid assessment of hazards and for identification and location of safety facilities and
equipment, suitable safety colours shall be used.

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IS : 11016 - 1984

4.4 Maintenance and Operation

4.4;1 The design of machine tool shall permit easy cleaning and safe removal of chips. All such
places which are required to be manually cleaned, shall be easily accessible.

4.4-2 Parts requiring adjustment, cleaning, direct lubrication, etc ( for example: clutches, bearing,
cams, stop drums, etc ) shall be easily accessible. Special care shall be taken while locating such parts
requrring regular setting and cleaning, to restrict any possibility of an accident while operating the
machine tool.

4.4.3 Standardized symbols shall be marked at all lubricating points according to the periodicity of
lubrication.

4.4.4 Coolant tank/filters and their distribution piping shall be so designed as to permit easy cleaning/
replacement and it shall also be possible to drain off the coolant completely.

4.4.5 Parts located below the hazardous working area shall be safely accessible for the purposes of
maintenance and repairs and suitably provided. with protective guards.

4.4.6 All control elernents shall be located at a suitable height convenient for normal operation of the
machine tool.

4.4.7 Where necessary, suitable slip proof platforms shall be provided for the operator. Where such
platforms exceed a height of 500 mm, they shall be provided with guard rails.

4.5 Transportation, Mounting and Installation

4.5.1 Design of machine tools shall enable easy assembly and dismantling for the purposes of repairs
or replacements.

4.5.2 Machine tools and their individual component parts shall be so designed as to facilitate safe
handling during transportation, assembly, maintenance or manufacture. For this purpose it is essential
to provide, wherever necessary, on individual parts and/or on sub-assembly units, suitable lugs,
eyebolts, opening for wire ropes, etc. Suitable provision for slinging of wire ropes should be provided
and such provisions should be rounded so that the slinging rope does not get damaged. While
providing these handling facilities, due regard should be given to the position of the centre of gravity
and the strength of the material.

4.5.3 The instruction manual or service manual shall clearly state the best and safe method of
slinging for the purposes of transporting and installation.

4.5.4 The base of the machine tool shall be so designed that it is possible to use levers for easy
mounting and installation.

4.5.5 To help easy and safe installation, the machine tool shall be provided with sufficient number
of lugs and holes for fixing the base, safely and rigidly on the foundation.

4.6 Design of Moving Parts

4.6.‘l All moving parts likely to cause hazards shall be provided with protective guards.

4.6.1.1 Driving and transmission mechanism -forming an integral part of the machine tool shall be
completely enclosed within the framework.

4.6.1.2 When the driving and transmission mechanism does not form an integral part, but has to
be provided within the reach of the operator, shall be positioned at a convenient height and covered
by protective guards.

4.6.2 Whenever moving parts are enclosed by hinged and locked protective covers, it shall be
ensured that it is not possible to remove them during operation.

4.6.3 The protective equipment shall be designed with due consideration to the surroundings in which
it will be installed and fabricated from non-inflammable material which cannot be easily damaged and
which is capable of getting cleaned easily.

4.6.4 In such machine tool where the weight of the moving parts is balanced by counterweights,
which shall be located inside the machine frame or suitably covered by protective guards.

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OS:11016 -1964

4.6.4.1It shall also be ensured that both the counterweights and the balanced parts do not move
unless they are operated.

4.6.4.2 There shall be easy access to the balancing equipment for inspection purposes.

4.7 Design of Braking and Loching Equipment

4.7.1 Wherever necessary the design of machine tool shall provide for a reliable and efficien1 braking
system enabling quick stopping of the movement of either the workpiece, or the tool or any other part
of machine tool.

4.7.1.1 For hydraulic or pneumatic braking system, the design shall provide for suitable
precautionary measures to bring the machine tool to a stop automatically when the fluid pressure drops
below the limiting pressure at which the braking efficiency would be affected.

4.7.2 In case the machine tool has a provision for loading and removal of heavy workpieces only in
certain positions of the work table, the design shalt provide for suitable braking device to stop the
auxiliary motions of different parts of the machine, when the work table is positioned at these points.

4.7.3 Machine tool shall be suitably designed to-prevent undesirable hazardous movements of parts
due to either a drop in the fluid pressure, a drop in the supply voltage, power failure or due to damage
of the threads of the bearing nut.

4.7.4 Suitable safety devices such as locking switches, shear pins, couplings, temperature relays,
pressure switches, etc, shall be provided to eliminate any possibility of an accident as a result of neither
overloading or damage of individual parts.

4.7.5 In atl cases where there is an independent feed drive, suitable system shall be provided to
switch-off the feed drive before switching-on the main drive. It will be ensured that the feed is
switched-off automatically if there is an interruption to the main drive.

4.6 Desfgn of l-lydraulic Equipment

4.8.1 The design of hydraulic equipment for machine tools shall be noise free and it is ensured that
the fluid is discharged only into the concerned receiver or tank.

4.8.2 For controlling the fluid pressure and level, suitable devices shall be incorporated in the design.
The design shalt also provide for overload-protective device.

4.8.3 The design shaH atso provide for suitable equipment for the release of air at ail places where
there is a possibility of forming of air cushion.

4.8.4 Suitable controls shalt be incorporated in the design for cautioning an eventual fault in any
part of the circuit such as choking of oil filter, temperature of oil in excess of normal range, etc.

4.9 Design of Clamping Equipment

4.9.1 Clamping equipment for cramping of either the workpiece or the tool shatl facilitate easy and
safe clamping and unclamping. If the unit comprises several dismantleable parts, then assembling and
d;smantling of the unit shall be as smooth as possible and shall not be a somce of injury to the
operator.

4.9.1.1 Loading and unloading positions on the machine tool shatt be so arranged that any
manipulation on the clamping unit is done at a safe distance from the dangerous parts. The design of
clamping unit shall also permit easy and safe removal of the chips.

4.9.2 Rotating clampinq units shall have a provision for locking against self-release either during
braking or during rotation-in the opposite direction.

4.921 All projecting parts of the rotating clamping unit shail be covered by protective guards.

4.9.3 In case the clamping units are designed only for a limited range and not the entire range of
speeds and feeds of the machine tool, suitable locking system shall be provided for preventing any
possible over-running of the machine toot beyond the range of the clamping unit.

4.9.4 For clamping equipmmt operated either electrically, electro-magnetically, pneumatically or


hydrualcally, suitable safety precautions shall be taken either to bring the machine to a dead stop 01:to

4
IS: 11016 - 1984

move the tool away from the workpiece, whenever there is a drop in the clamping force. This drop in
the clamping force may be either due to an interruption of the power supply or due to a drop in the
fluid pressure. A suitable warning signal should be incorporated to warn the operator of any fault or
of the eventual stopping of the machine.

4.9.5 If possible, protective equipment should also be able to prevent the starting of the machine tool
when the minimum clamping force is not attained.

4.9.6 The design should also provide for a means of preventing the workpiece from getting itself
released during machining due to accidental operation of the release button.

4.10 Designing for Protection Against Chips and Cutting Fluid

4.10.1 The design of a machine tool should ensure protection to operator from the action of chips,
cutting fluid, grinding dust, broken tool particles, etc. For this purpose the design should provide for
adjustable protective guards capable of arresting chips from flying hazardously and preventing the
splashing of cutting fluid.

4.10.1.1 These guards should not come in the way of normal manipulations required on the
workpiece or the tool. They should also not cause an obstruction to the operator in carrying out his
normal duties nor should~they obstruct the light needed at the cutting zone.

4.10.1.2 The protective equipment shall be sufficiently rigid and form an integral part of the
machine tool. The transparent part of the equipment shall be made out of abrasion resistant material
which can be easily cleaned and if damaged shall be capable of being replaced easily and safely.

4.10.2 The design should also enable easy and quick removal of chips from the hazardous working
places, by providing suitable inclination and smooth surfaces.

4.10.3 The design should also provide for suitable equipment for cleaning the cutting fluid for removal
of foreign matter.

4.11 Design of Control Equipment

4.11.1 The design and location of control panel shall ensure an accurate, easy and quick manipulation
and reading.

4.11.2 Every machine tool shall be provided with a IfMain Switch’ by -operating which the entire
machine tool gets disconnected from energy source.

4.11.3 The location of all control elements such as levers, hand wheels, switches, buttons, etc. shall
ensure:

a) easy and safe operation with least physical strain,

b) that they are within easy reach of the operators from their normal working place in all
positions of control,

c) that there is no danger to the operator from the hazardous moving parts while operating the
controls, and

d) that they do not come in the way of normal movements of the operator.

4.11.4 Different control units for various motions ~which do not simultaneously set in shall be
mutually blocked.

4.11.5 Control elements shall be so designed as to prevent their changing of positions by themselves,
and foot-operated controls shall be locked against accidental release.

4.11.6 For machine tools having more than one control station, the design should ensure that it is not
possible to simultaneously operate from different control positions by providing suitable interlocking
facility except for emergency stop push button.

4.11.7 Provision of automatic disengagement shall be made for manual control elements for
preventing any forceful operation during the cutting process.

4.11.6 The control elements shall be easily distinguishable by shape, colour or symbols or by suitable
combination of these.

5
ISrllOl(i- 1984

4.11.9For recommended practice regarding the direction of cperation of controls, IS : 2987-1983


‘Recommendations for direction of operation of controls for machine tools ( first revision )’ shall be
followed.

4.11.10 Suitable control stops shall be provided near the places of danger or at ail control points by
means of which the machine may be brought to a total stop, However, for machine tools which have
a single operating position, only one such stop will suffice.

4.11.11 Whenever indication plates are used to clearly indicate the purpose of control elements
then symbols to be used in siich indication plates shall be in accordarxe with IS : 2182-1962
‘Recommendation for symbols to be given on indication plates for machine tools’.

4.11.12 Electrical control elements intended for stopping the machine or its parts shall be in red
colour, or be indicated by red colour light signals. Similarly, control elements intended for starting
shall be in green colour, or be indicated by green-colour light indication.

4.11.13 In general, control elements for electrical equipment of tools shall be in accordance with
IS : 1356 ( Part 1 )-t972 ‘Specification for electrical equipment 01 machine tools: Part 1 Electrical
equipment of machines for general use ( second revision )‘.

4.11.14 For all machine tools, especially for automatic and programme controlled machine tools,
auxiliary manual controls enabling manual operations of tables, slides, etc, shall also be provided to
meet emergency requirements. (For example during failures of electric supply, or during accidents.)

4.11.15 For programme-controlled machines operating with a tape, it should be so controlled that the
machine comes to a-dead stop when the tape is broken or when there is an error in tape movement.
Sufficient care should also be taken while designing the control system for such machine tools to
prevent the starting of the working cycle when the tape iswrongly introduced.

4.12 Design of Electrical Equipment

4.12.1 Regarding the safety requirements of electrical equipment for machine tools, standards have
been formulated both at the International and national levels. IS : 1356 ( Part 1 )-I972 serves to the
needs of the designers as regards the safety requirements of electrical equipment for machine tools, as
applicable in India.

4.12.2 In addition, special care shall be taken regarding the tropicalization and climate proofing of
electrical equipment for machine tools.

4.13 Design of Exhaust Equipment

4.13.1 The design of exhaust equipment should take into consideration the general hygienic and
safety regulations prevailing. In addition, the following points are required to be borne in mind while
designing the exhaust equipment.

4.13.1.1 They should not obstruct the operation, impair the work and the view of the working
area.

4.13.1.2 They should be noisefree in operation and should be capable of being easily assembled
and disassembled.

4.13.1.3 The suction head of the exhaust equipment shall cover the entire area of all sources of
dust particles and shall be located in the immediate vicinity in such a way that the direction of suction
is the same as direction of flow of the dust.

4.13.1.4 If the sources of dust get shifted during machining, the suction head should also be made
to shift simultaneously to the proper suction position.

4.13.2 The exhaust equipment shall be so designed as to prevent any choking-up of the piping.

4.13.3 The exhaust pipes, dust separator and other rigid parts shall be so designed as to enable easy
dismantling and cleaning.

4.13.4 The exhaust equipment should not be a source of danger either due to excess noise or due to
excessive cooling down of the working area and the surroundings of the machine tool.

4.14 Design with Regard to Noise and Vibration


4.14.1 Design should take care of the permissible noise levels for different types of machine tools and
maintain the noise levels within these limits; if necessary, with the aid of separate noise suppressors
and vibration dampers.

6
IS: llOlQ -1984

4.14.2 Vibration and noise shall be kept to minimum by proper design of kinematic mechanism,
proper balancing, accurate manufacture of components and proper use of scund insulating materials, etc.

4.14.3 The instruction manual shall provide the correct information regarding type of foundation and
their isolation.

4.14.4 If pneumatic clamping units are used, then the design shall include suitable damping of the
air exhaust noise.

5. Additional Requirements

5.1 Instructions for Servicing of Machine Tool


5.1.1 With each new machine tool, the manufacturer ( supplier) shall provide the customer ( the
person who orders ) with at least two copes of detailed and legible descriptions of the machine tool,
its equipment and accessories, with necessary drawings and schematic diagrams of electrical
connections together with instructions for its correct and safe installation, adjustment, maintenance and
operation.

5.1.2 Similar descriptions and instructions shall also be prepared for the existing machine tools by the
users.

5.2 Training of Operators


5.2.1 Every machine tool user shall carefully consider the provision of training of operators from the
point of view of safe working as soon as they are employed. If necessary, refresher courses may also
be arranged as and when required.

5.2.2 The training course should preferably include the safe and suitable methods of machining
adopted in various machine tools, setting up of the machine tool, cutting tool, etc, proper use of
measuring instruments, and care to be~taken while using the cutting fluid, during material handling and
during machining. The operators should also be taught the principles of frrst aid, action to be taken in
case of emergency, etc. They should also be taught the proper outfit to be worn during machining.

5.3 Requirements of the Shop Floor and the Arrangement of Machine Tools

5.3.1 The ~floor area alloted to each machine tool and the operator shall be in accordance with the
valid health’ regulations. In addition to this, necessary space required for storing the auxiliary
equipments, raw materials, tools, etc, shall be provided.

5.3.2 Machine tools shall be so located that they are at a distance -of at least 600 mm from the
permanent obstructions (walls, columns, etc) and at least 100 mm in cases where the operator is
constantly stationed at one place during the operation. The dimensions shall be measured when the
moving parts of the machine are positioned at their extreme positions in that direction.

5.3.3 Parts of machine tools which exceed the average height of the surrounding machines, may be
marked in warning colours or provided with danger lights at their topmost points, if an overhead
travelling crane travels above them.

5.3.4 Machine tools shall be located in the most faverable conditions for natural light. If natural light
is inadequate, proper artificial lighting should be provided. Additionally, operating zones shall be
illuminated properly, if required.

5.3.5 Old machines equipped with belt transmission from the line shali have a free pulley and a
shifter which could be controlled from the normal place of operation of the machine. However, in
majority of the cases, it may be necessary to change~over to unit drives.

5.3.6 Additional adjustable lights on machine tools shall be provided to illuminate to the operational
zone.

5.4 Working Place

5.4.1 Working places shall be selected with due care to see that the operator is not disturbed by the
neighbouring work places and that there is no obstruction to his movement during working.

6.4.2 The working floor should be insulated against dampness and should enable easy movement of
the workers.

5.4.3 The working place shall be maintained clean and tidy, cleaning of chips shall be preferably
mechanised and done regularly.

7
BS : 11018- 1984

5.4.4 Spilling of oily substances on the floor to be cleaned and dried by saw dusts immediatety.

5.4.5 Working area shall be illuminated adequately by overhead illumination and shall conform
the requirements of IS : 6665-1972 ‘Code of practice for industrial lighting’.

5.4.6 All waste material shall be dumped in a separate portable waste bin, which ensures safety
while transporting. The load-carrying capacity of the bin shall be clearly marked on it.

5~4.7 While stacking combustible and light inflammable materials ( solvents, lubricants, etc ) at the
working place, suitable safety procedures currently in vogue may be followed.

5.4.6 Used cleaning material ( cotton waste, etc) shall be staked in separate metallic containers with
lids, and they shall be regularly emptied.

5.4.9 Tools, gauges, etc, shall not be placed on the frames, tables or beds of the machine toolsunless
separate space specially for keeping them is provided.

5.4.10 While stacking the raw material at the work place, the stack shall preferrably be not higher
than 100 mm and the width of the passage between the stacks or between the staek and the machine
be not less than 800 mm. To prevent sliding of the stack and falling of the workpieces, suitable
supports shall be provided.

5.5 Movemenf of Objects (Material Handling )

5.5.1 For clamping and removal of heavy fixture, tools and workpieces, suitable lifting equipment
shall be made available. Lifting equipment shall enable reliable gripping of the object and its
convenient and safe lifting and-location on the machine.

5.5.2 Workers engaged in lifting operations shall be suitably trained and provided with all auxiliary
equipments.

5.6 Working with Cuffing Fluid

5.6.1 Protection of the worker shall be ensured against any possible harm being caused due to the
action of the cutting fluid. Only such cutting fluids, which have been approved by the competent
authorities shall be used and all precautions taken as per regulations provided in corresponding
health code.

5.6.2 Instructions shall be given to concerned workers regarding the safe methods of preparation and
use of cutting fluids. They shall be provided with suitable protective equipments according to safety
requirements.

5.6.3 Cutting fluid shall be regularly changed as per recommendation of the supplier. During each
change, the tank and the entire system shall be washed with hot water and soda. If any disinfectant is
used for cleaning, this should be later washed off from the tank.

5.6.4 Such workers who are suffering from skin diseases or those who are liable to contact them
when they are in contact with the cutting fluid, shall not be encouraged to go near the places where
the cutting fluid is being used.

5.7 Ufilisafion of Machine Tools

5.7.1 Machine tool shall be used only for such work for which it is intended and which corresponds
to its type, size and capacity.

5.7.2 While machining special metals and alloys, due care shall be taken to meet the specific health
and safety repuirements.

6. Duties of the Operator

6.1 Duties of fhe Operator Before Starting fhe Work on the Machine Tools

6.1.1 Before starting the work, the operator shall attend to the following:

a) Examine the machine tool, check its parts, safety equipments, starting and stopping switches,
etc. Any discrepancy or damage should immediately be reported to his supervisor.

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IS : 11018 - 1984

b) Check the oil level to make sure about the correct functioning of the lubrication equipment.

c) Check the functioning of the clamping equipment.

d) Carry out proper selection of the tools and check their use.

e) Check whether the controls are in correct positions.

f) Adjust the protective guards to their active positions.

6.2 Dufies of fhe Operator While Working on fhe Machine

6.2.1 Safe and proper method of working on the machine tool shall be followed. It is necessary to
follow strictly the instructions provided in the instruction manual taking all precautions as prescribed.

6.2.2 While lubricatting or cleaning or while leaving the workspot, the machine tool shall be brought
to a total stop.

6.2.3 While changing the tools, checking the surface of the workspot, clamping and removing the
workpiece, and while measuring, the spindle of the~machine tool, shall be stopped. However, if there
is a clamping equipment of tools or workpieces designed for safe clamping during motion, and if there
is a -provision for automatic measurement, this need not be done.

6.2.4 During any interruption in thesupply of the elecIric current, the operator shall switch-off the
main switch immediately and all other control elements brought to such a position that once the supply
is restored, the machine tool does not get started automatically.

6.2.5 If rapid traverse is switched-on, the operator shall carefully observe the parts approaching the
workpiece, and switch-off the rapid traverse at a safe distance.

6.2.6 For workpieces which project beyond the~clamping surface its surface of revolution should be
checked as to whether it exceeds the maximum swing diameters and similarly for workpieces whose
width exceeds the clamping width of the table, it shall be checked as to whether there is sufficient
space for the movement of the workpiece between frames, cross-rails, etc.

6.27 The workpieces-shall be clamped by the right clamping equipment depending upon the shape
and size of the workpiece to ensure perfect clamping.

6.2.8 Workpieces having irregular shape and centre of gravity outside the axis of rotation shall be
properly balanced before machining to prevent any increase in vibration of the machine tool. ~Defective
( broken ) workpieces shall not be machined.

6.2.9 While clamping heavy objects, the object shall remain supported by the lifting equipment until
it is set and clamped. For supporting, correct and undamaged clamps and supports shall be used.

6.2.10 Bearing surfaces of clamping equipments shall be clean and undamaged. Tool shall be~safely
clamped and its overhang shall be adjusted such that during machining, unnecessary and dangerous
stresses are not set up and that chip formation is easy and uniform.

6.2.11 Only suitable and undamaged tools shall be clamped. It is not permitted to leave the
clamping key inserted in the clamping unit when it is in motion. For driving a higher force, suitable
leverage should be made use of.

6.2.12 If the machine is not equipped with protective guards against chips or the guards cannot be
used even if provided, then the operators shall use separate personal protection ( goggles, face covers,
etc),

6.213 All tools, gauges, clamping keys, etc, shall be stacked in their definite positians.

6.2.14 Manual slipping and lubrication of belts during run shall be prohibited.

6.3 Duties of the Operator After Complefing fhe Shiff

6.3.1 After completion of the work, the operator shall arrange his working place properly, remove the
chips and used cutting fluid, clean the places meant for gauges, tools, etc. All cleaning aids shall also
be suitably stacked.

6.3.2 If there are any faults or short-comings on the machine observed during the shift, the same
should be reported to the superior for repair or remedy and for proper care to be taken by the operator
working in the next shift.

9
IS : 11016- 1984

7. Outfit of the Operator

7.1 The operator should preferably wear close fitting dress without any loosely hanging part; loose
shirts should be tucked in the trousers. A close fitting apron covering up to the knees may be used.

7.2 The operator should preferably wear a suitable head cover (cap or kerchief ) to protect the hair.

7.3 The operator should preferably wear a working shoe to protect his feet. Use of open sandals
should be restricted.

7.4 Workers having bandages on their hands or on fingers shall not work on machine tools where there
is change of his hand or the fingers coming in contact with the rotating part ( drilling machine, lathe,
etc ).

7.5 Protective hand gloves should preferably be worn while handling workpieces or tools or while
clamping them in the hazardous working region. However, for normal working operations gloves need
not be worn.

7.6 Wherever needed suitable eye protection equipment such as ‘safety goggles’ should be worn for eye
protection.

8. Removal of Chips

8.1 In general, chips shall not be removed when the machine tool is running unless the operation of
the machine tool itself permits it.

8.2 F~or removing the chips when the machine tool is running, hooks, scrapers and long-handled
brushes shall be used as and when necessary. Dusters and waste may be used for cleaning only when
the machine tool has been stopped and after removing the chips by scrapers, etc.

8.3 In~general, cleaning of the machine tool by compressed air is prohibited. powever, if it is necessary
as per the technological processes to use compressed air for cleaning the workpiece, clamping fixture,
etc, then the air nozzle shall be covered and the pressure reduced to 1 atmosphere. In such cases the
operator shall wear protective facial covers.

9. Setting up and Maintenance

9.1 Setting up of the machine tool and its maintenance shall be in accordance with the instructions
given in the manual of instructions for operation and maintenance of the machine.

9.2 Before setting up the machine, it must be ensured that all safety and protective equipments are
working properly and are positioned in accordance with the instructions.

9.3 While setting, it must be ensured that the cutting speed, change of tool and the working cycle do
not cause any harm or injury to Ihe near by operators (due to dust, noise, spray of cutting fluid, etc ).
Also all valid safety instructions and standards shall be strictly followed.

9.4 Routine inspection of the-machine tools shall be carried out at regular intervals, particularly with
regard to parts which are liable to fail or break down. Any fault shall be immediately rectified. Work
shall never be carried out on defective machines.

9.5 A regular preventive maintenance schedule shall be worked out for each one of the machine
tools and this schedule shall be strictly followed.

9.6 Before repairing the machine tools, a fool-proof arrangement shall be made to ensure that it is not
started by unauthorised persons. It can be accomplished by several ways as for example, by
switching-off the electric motor and removing the pull~eey belts or by pressing the main switch to the
netural position, etc. In addition to this, a suitable placard reading MACHINE UNDER REPAIR - DO
NOT OPERATE shall be placed near the control switch. Restarting of the machine tool shall be done
only after the repair and inspection of all protective guards have been completed.

IO
IS : 11016- 1884

APPEN-DIX A
( Clause 1.2, Nofe 2 )
LIST OF RELATED INDIAN STANDARDS

IS : 818-1968 Code of practice for safety and health requirements in electric and gas welding and
cutting operations (first revision )
IS : 1179-1967 Equipment for eye and face protection during welding ( first revision )
IS : 1991-1973 Safety code for the use, care and protection of abrasive wheels (first revision)
IS : 25581971 Safety glass ( second revision )
IS : 2925-1975 Industrial safety helmets ( first revision )
IS : 3616-1982 Code of practice for fire precautions in welding and cutting operations ( first revision )

IS : 3103-1975 Code of practice for industrial ventilation ( first revision )


IS : 3483-1965 Code of practice for noise reduction in industrial buildings
IS : 4167-1980 GLossary of terms relating to air pollution ( first revision)
IS : 4501-1981 Aprons, rubberized, acid and alkali resistant ( first revision )
IS : 4770-1968 Rubber gloves for electrical purposes
IS : 5216-1969 Guide for safety procedures and practices in electrical works
IS : 5983-1980 Eye protector’s ( first revision )
IS : 6153-1971 Protective leather clothing
IS : 6229-1980 Method of measurement of real-ear protection of hearing protectors and physical
attenuation of earmuffs (first revision )
IS : 6665-1972 Code of practice ~for industrial lighting
IS : 6994 ( Part 1 )-1973 Industrial safety sloves: Part I Leather and cotton gloves
IS : 7194-1973 Assessment of noise-exposure during work for hearing conversation purposas
IS : 8235-1976 Guide for safety procedures in hand operated hand tools
IS : 8519-1977 Guide for selection of industrial safety equipment for body protection
IS : 8520-1977 Guide for selection of industrial safety equipment for eye, face and ear protection
IS : 8964 ( Parts I to XXIV ) Recommendations for safety conditions for woodworking machines
IS : 9474-1980 Principles of mechanical guarding of machinery
IS : 9637-1980 Guidelines for presentation of information in technical manuals

EXPLANATORY NOTE

This standard has been formulated to lay down the principles of providing maximum safety and
protection to the personnel operating all types of ~metal cutting machine tools and to provide general
guidelines for safety on machine tools and their operations. The specific requirements concerning any
particular kind to machine tool or accessory will be delt with separately in individual safety standards to
be prepared later.

Notwithstanding the requirements indicated ir this standard, if a particular requirement has been
covered by any other legal document such as, Factories Act, Electricity Act, etc, the conditions stipula-
ted in these legal documents should Abe satisfied completely.

This standard has been prepared mainly based upon various Indian Standards published on
safety aspects and experience gained by our industry. However, certain assistance has been derived
from JIS B 6014-1980 ‘General code for safety for machine tools’ published by the Japanese Industrial
Standards Committee.

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Printed at Arcee Cress, New Delhi, lndlo

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