MANU 1202 / MME 1203

WORKSHOP TECHNOLOGY

INTRODUCTION
Section

CONTENT
Introductory

remarks

Taaruf
Requirements
9 Attire
9 Rules

& regulation
Relevance
Safety
Closing remarks
Assignment # 1
Q & A

Introductory Remarks
Foundation

course extremely crucial for:

Exposure to general workshop practices
Boosting self-confidence
Need serious attention
Learning opportunity not to be wasted
Not to be taken lightly people fail in this
subject!!!!
Theory classes, practical classes, workpieces, reports & final test required

The Opening Chapter

In the Name of Allah, Most Gracious, Most
Merciful

Praise be to Allah, The Cherisher and Sustainer

of the Worlds
Most Gracious, Most Merciful
Master of the Day of Judgment
Thee do we worship, and Thine aid we seek.
Show us the straight way
The way of those on whom Thou hast bestowed
Thy Grace, Those whose (portion) is not wrath,
and who go not astray.
Surah Al-Faatihah (1:1~7)

TAARUF (1)
Lecturers
Technicians - Workshop Tour
Demonstrators - during practical
sessions

TAARUF (2)
Workshop Coordination
Sen. Technical Assistant ~ Bro. Mohd Faisal
Mohd. Room
Technicians

Bro. Mohd Faisal Mohd. Room - Measurement

Bro. Ramle Ariffin Milling (Sen. Tech.)
Bro. Eddy Norhadi - Benchwork
Bro. Adanan Mat Arshat Welding / Sheet Metal
Bro. Mohd. Shukor Mohd Noh Turning
Bro. Mohd. Nazrani Mokhtar Pattern
Shop/Heat Treatment
Bro. Nazrani and Bro. Eddy Casting
Bro. Azhar Mohd. Nor Storekeeper

REQUIREMENTS

Attire

Green workshop jacket RM50.00 from

Kulliyyah Office Student Affairs (OSCENT)
Proper shoes ~ no sandal
No entry shall be given to those without
proper attires

Rules & regulations

General safety practices

Instructions given by Workshop Staff,
lecturers, assistant lecturers
Safety signs
Note: Be humble for the sake of knowledge

RELEVANCE
Exposure

to general workshop

practices

For own use

For demonstrators ~ RM 5/hr
For final year project
For research (RAs) ~ RM500/mth

Actual

working life

Maintenance & assembly, simple

machining, purchasing activities
Sampling of products to check on your
operator..
Designing new products.

COURSE OUTLINE (1)

Course Code: MANU 1202 / MME1203
Course Title: Workshop Technology
Credit Hour: 2 credits
Contact Hour: 4 ( 1 hour theory & 3 hours practical)

Course Synopsis
Engineering workshop practices, industrial safety,
health and environment issues, measurement and
measuring tools, introduction to theory and practices of
manual and NC machining processes: turning, milling,
drilling, grinding, introduction to theory and practices of
fabrication processes: bench working, woodworking,
molding and casting, welding, metal forming, heattreatment.

COURSE OUTLINE (2)

Lecture Schedule
Week
Topic
1
Introduction & Safety
2
Hazard
3
Measurements
4
Bench work
5
Wood working
6
Foundry processes
7
Welding (arc and gas) processes
8
Metal Forming
9
Heat treatment
10 Turning process
11 Milling process
12 Introduction to NC technology
13 CNC turning, and CNC milling
14 Projects and reports submission
15 Final Test

Reference

COURSE OUTLINE (5)

Assessment
1. Projects (work specimens)
2. Reports & assignments
3. Quizzes
3. End of semester test

- 40% [ 7 work-pieces ]
- 15% [individual]
- 15%
- 30% [written test]

References
1. Workshop Manual see Bro. Faisal
2. Khurmi, R. S. and Gupta, J. K. (2008). Workshop Technology
(Manufacturing Processes), S. Chand & Co.
3. Goetsch, D. (2006). Occupational Safety & Health in the Age of High
Technology: For Technologists, Engineers, & Managers, 6th. Edition,
Prentice Hall

OVERVIEW (1)

OVERVIEW (2)

OVERVIEW (3)

Parallax error

OPERATIONAL ISSUES (1)

Submission

of reports

Reports must be submitted one week after

the associated practical session(s)
completed.
Submission is only to Assisting Lecturers &
please ensure lecturers sign on receipt
Write your name & matriculation number on
every page of your report.
Staple your reports properly.
Two reports deemed copied from each other
shall receive ZERO marks.
Marks shall be deducted for late
submission

OPERATIONAL ISSUES (2)

Working

after office hours

Students are advised to plan their time
properly to avoid the need to work after
working hours.
Plan your time & work properly to avoid
rush jobs - safety
In the event that you require to do so,
permission must be obtained using the
official form:
Signature of the accompanying
technician(s)
Signature of Workshop Coordinator

OPERATIONAL ISSUES (3)

Working

after office hours

Minimum number of students working at
any time in one particular area two (2)
Maximum working time is 10:00 pm (in a
big group)

Class rules and regulations:

Be on time for your class maximum tolerable
lateness is 10 minutes for good and valid
excuses
Never sign in for your colleagues for whatever
reason this is classified as cheating both you
and your colleague will be punished
Switch off your mobile phone while you are in
the class
Use proper attire as suggested by the IIUM.
Refrain from talking and/or discussing things
with your colleagues while I am lecturing
Always use pen to write your assignments, quiz,
projects and exams

No Smoking
No Food
Bring your own
Candy & Drink

in this learning class

SAFETY

CONTENT
Relevance
Definition
Dos & Donts
Illustrations
Operational Issues
Q & A

RELEVANCE (1)
Address

two of the most

prominent safety issues
Developing a good
safety attitude in you
Providing introductory
safety training the
importance of safety
in the Kulliyyah

RELEVANCE (2)
LAWS OF MALAYSIA - Act 514
OCCUPATIONAL SAFETY AND HEALTH ACT
1994
An Act to make further provisions for securing the
safety, health and welfare of persons at work, for
protecting others against risks to safety or health in
connection with the activities of persons at work, to
establish the National Council for Occupational Safety
and Health and for matters connected therewith.

DEFINITION
Human/machine/workplace

interaction
Maximizes quality and efficiency of work
Maximizes human values such as safety,
satisfaction, comfort, learning
These two normally conflict the need
for juggling skill
Safety - judgment of the acceptability of
danger (hazard & risk) where
Hazard injury producer
Risk probability that an injury will occur
85 % of accidents caused by human:
training is extremely important to
recognize hazard & to work safely

DOS & DONTS (1)

Occupational Safety & Health Act 1994

Control of Industrial Major Accident
Hazards Regulations 1995
Control of occupational hazards
1. Elimination
2. Substitution
3. Isolation
4. Engineering controls
5. Personal protective equipment (PPE)

DOS & DONTS (2)

Dos

and Donts to prevent accidents

Wear proper attire i.e., workshop
jacket & proper shoes. Loose clothing,
finger rings and other accessories are
some possible sources of accident.
Footwear must be worn all the time to
prevent injury molten aluminum, hot
metal chips, slip
Be attentive while you are in the
workshop. Never put your hands in
your trousers lest you may be caught
in the state of non-readiness

DOS & DONTS (3)

Dos and Donts to prevent accidents

Do not run in the workshop. Be calm but
serious.
Pay attention to details. Always think before
you carry out any step.
Do not start any machine before obtaining
instructions from your instructor.
Make sure you understand your machine &
the procedures before you start working.
Check your vicinity. Ensure the floor is
clean & clear from oils, obstructions and
debris.

DOS & DONTS (4)

Dos and Donts to prevent accidents

Locate the Emergency button or foot pedal.

In the event of any accident, switch off the
machine using the Emergency button.
Never let anyone handle the starting switch
for you.
Ensure work-pieces are properly clamped or
secured to the machine. Remove any loose
parts such as chuck key, vice handle, etc.
flying chuck key (faint) & flying work-piece
Always wear goggles where fine chips are
produced bloated eye.

DOS & DONTS (5)

Dos and Donts to prevent accidents

Use machine guards all the time.
When you are operating any machine, stand
at a proper distance.
Do not use hand(s) or finger(s) to stop
moving or rotating machines or parts of
machines legs between rollers
Do not set the tools when the machine is
running. You may break the tool and worse
still, you may injure yourself.
Never handle machines or work-pieces
during running. Stop the machine first

DOS & DONTS (6)

Dos and Donts to prevent accidents

Do not distract a person while he or she is
operating a machine. Wait till he or she
completes the operation & stop the machine
before doing so Do not be playful NO
PRACTICAL JOKES
Do not use hands to clear metal chips 600
~ 700OC (chip-tool interface)
Do not take measurement while machine or
work-piece is moving
Do not blow chips, dust from vices, etc. lest
they may get into your eyes.

DOS & DONTS (7)

Dos and Donts to prevent accidents

When facing with problems or uncertainty,
stop the machine & get clarification and
help.
Stop any machine before leaving it. Never
leave any machine running unattended.
Beware of high temperatures associated
with metal chips, welding, heat treatment &
casting activities
Beware of high voltages. Ensure all
machines are properly earthed. Do not
interfere with electrical equipment or
connections.

DOS & DONTS (8)

Dos and Donts to prevent accidents

Protect your eyes from bright lights & ears from
loud sounds
Plan your time properly. Working under
unnecessary pressure may lead to accidents
Grinding tools must be set up by experienced
personnel. Grinding tools rotate at great
circumferential speed
Damaged grinding tools & wheels must not be used
Do not run any machining exceeding the maximum
allowable speeds
Beware of sharp or ragged edges

DOS & DONTS (9)

Dos and Donts to prevent accidents
Report any injury, cut or scratch, no matter
how trivial it may be to your instructor
Clean the tools, cutters, machines &
surrounding area from debris, metal chips,
oils, grease & coolants whenever necessary
and after completing your work
Clean working + good order = safety
Return all tools to store or original cabinet
Never handle heavy objects unaided.
The above list is not exhaustive. Good
understanding, calmness and common sense
prevail.

ILLUSTRATIONS (1)

ILLUSTRATIONS (2)

MATERIAL SAFETY DATA SHEET

1. What is the material, and what are its hazards?
2. What should I do if a problem occurs?
3. What precautions should I take when working
with this material?
4. Is there anything else I should know about this
substance?

ILLUSTRATIONS (3)
ELECTRICAL SAFETY

Slips, trips, and falls

account for more
workplace injuries
annually than any other
accident category. Many
of these injuries can be
disabling, or even fatal.

ILLUSTRATIONS (4)
Danger of working with
machinery
Minimizing risks by proper
installation and use of safety
guards and devices.
The risk of accidents from
powered machinery is so great
OSHA estimates that lack of
machine guarding is the
second most frequent safety
violation in industry today.

ILLUSTRATIONS (5)
Physiology of the body
Parts of the body most
effected
Eye strain
Preventative measures
Industrial Ergonomics

Correct use of office

equipment
Exercises and stress release

ILLUSTRATIONS (6)
Back Safety

Material
Handling

ILLUSTRATIONS (7)
Prevent workplace accidents by paying attention to safety
housekeeping considerations.
Good safety housekeeping can significantly reduce accidents and
injuries in any type of work environment.
By developing good safety habits / by being aware of their work
environment and any hazards associated with it, employees can help
to create a much safer workplace.
Safety awareness
Handling rubbish and excess materials
Keeping aisles and stairways clean
Using ropes and electric cords
Dealing with hazardous chemicals
Tool maintenance
Proper tool storage

ILLUSTRATIONS (8)
Authorization for welding operations
Sparking and fire risk
Guards and protective barriers
Hazardous fumes and ventilation
Proper welding safety procedures
The use of respirators
Eye protection (welding helmets, filters, glasses and goggles)
Other PPE
Inspecting welding equipment

ILLUSTRATIONS (9)
Hearing Safety

Many eye problems caused by not

paying attention to the work or by not
wearing the appropriate protective
equipment.
Reminds employees that eye injuries
can easily happen to them
Our eyes are really very fragile, and
statistics show that eye injuries occur
frequently in the workplace.

Eye Safety

Selecting and using appropriate

personal protective equipment
Short and long-term effects of eye
injuries

ILLUSTRATIONS (10)
Matching the tool to the job
Importance of state of mind
Good safety practices
Personal protective equipment
Most common cause of workplace
Tool care and maintenance injuries today is due to employees not
using personal protective equipment
(PPE) as they work.
How to properly use PPE
Matching equipment to the hazard
The limitations of various PPE
The proper use of PPE

ILLUSTRATIONS (11)

ILLUSTRATIONS (12)
Compressed gas is used for many things refrigeration, welding, heating, and a
number of other functions.
Compressed gas can be dangerous, and
employees who work with them need to
know how to handle them properly.
Associated hazards
Moving and transporting cylinders safely
Positioning cylinders properly
Proper hook-up procedures
Safe storage practices
Storage incompatibilities

ILLUSTRATIONS (13)
Workplace fires cause hundreds of millions of
dollars in damage and result in numerous
employee injuries, many of which are fatal.
Work practices can contribute to the risk of fire.
Common causes of workplace fires
Importance of good housekeeping
Other fire prevention measures
Various types of fire extinguishers
Using fire extinguishers
Evacuation and other employee responsibilities
First aid

ILLUSTRATIONS (14)
Over 90% of crane-related accidents are caused by human
error, and that they are the key to preventing these incidents.
Crane-related accidents can often be deadly, due to the
cumbersome and heavy loads that are lifted.
A small miscalculation, or a brief moment of inattention, and
tragedy could strike.
Physical and mental preparation
Equipment inspection
Hazard assessment
Overhead cranes
General and operational safety devices
Crane operations
Hand signals

ILLUSTRATIONS (15)
Sources of air contamination
Adhesives, solvents and vehicle
exhaust
A building's occupants affect
indoor air quality
Smoking and second-hand smoke
The use of humidifiers and
dehumidifiers
INDOOR AIR QUALITY

Heating and air-conditioning

systems

ILLUSTRATIONS (16)
Knowing basic first aid can often limit the severity of any type
of injury, or even prevent a death.
Not a day goes by without some type of injury occurring. It can
be as serious as a chemical burn, or as minor as a small cut.
Any injury can be painful and affect an employee's work
performance, as well as their life off the job.
Cuts and bleeding
Muscle pulls and sprains
Burns
Broken bones
Shock
Artificial respiration and CPR

ILLUSTRATIONS (17)

ILLUSTRATIONS (18)
Full cooperation with any inquiry.
Focus to determine the cause of an accident
Goal to prevent similar accidents from happening
Root-cause analysis
Importance of investigative interviews
Reporting near misses
Warning signs in accident prevention

ILLUSTRATIONS (19)

ILLUSTRATIONS (20)
How small changes in lifestyles can produce big benefits.
Good wellness and fitness can significantly help to improve
safety records.
Accidents and injuries occur less frequently with those
who are healthier and in better shape.
The importance of attitude
Blood pressure and other stress related conditions
Nutrition and weight control
Drug and alcohol use
Exercise
Smoking

ILLUSTRATIONS (21)

OPERATIONAL ISSUES (1)

Working

after office hours

Plan your time properly to avoid the
need to work after working hours.
Plan your time & work properly to avoid
rush jobs - safety
In the event that you require to do so,
permission must be obtained using the
official form:
Signature of the accompanying
technician(s)
Signature of Workshop Coordinator

OPERATIONAL ISSUES (2)

Working

after office hours

Minimum number of students working
at any time in one particular area two
(2)
Maximum working time is 10:00 pm (in
a big group)

CLOSING REMARKS
Lack

of efforts: lectures not

attended, assignments not properly
done, textbook not referred,
Time management
English language
Communication
Taiwan Chemicals (international
investment magazines) - Malays &
Muslims not performing well
State of the Muslim ummah

ASSIGNMENT NO. 1
To prepare a report containing the
following points:
1. Engineering Workshop ground floor layout
2. Workshop Organizational chart
3. Machine functions
4. Observations on housekeeping, safety, signs,
SOPs, layout with comments on possible
improvements.
5. Conclusions from Introductory session & Workshop
Tour

THE END
IQ + EQ + SQ = TQ