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JZGMSAT UTILIZATION OF TOOLS/INSTRUMENTS AND EQUIPMENT

Technical Education and Skills Development Authority Region IV-A JACOBO Z. GONZALES MEMORIAL SCHOOL OF ARTS AND TRADES San Antonio, Bian City

TABLE OF CONTENTS
CHAPTER I. PROPER USE OF TOOLS AND EQUIPMENT A. Introduction..................................................................................................................3 B. Objectives....................................................................................................................3 C. Definition of Terms.......................................................................................................3 D. Duties and Responsibilities.........................................................................................4 E. Policies on the Use of Tools/Equipment......................................................................4 F. Policies on the Use of Computers and Their Peripherals............................................5 CHAPTER II. JZGMSAT QUALITY POLICY AND PROCEDURE A. Use of Training Equipment and Procedure 1.0 Purposes, Scope and Terminology......................................................................6 1.1 Purpose 1.2 Scope 1.3 Terminology 2.0 Responsibilities....................................................................................................6 2.1 Responsibility for the Authority and Maintenance of the Procedure 2.2 Responsibility for the Implementation of the Procedure 3.0 Procedure............................................................................................................7 3.1 Flowchart 3.2 Documentation 4.0 Forms.....................................................................................................................9 5.0 Related information ...............................................................................................9 CHAPTER III. MAINTENANCE OF TOOLS AND EQUIPMENT A. General Objectives....................................................................................................10 B. Definition of Terms.....................................................................................................10 C. Maintaining Tools and Equipment ............................................................................10 Tools and Equipment Maintenance Program Equipment Inspection Checklist D. Requirements for Cleaning and maintenance of Tools ............................................12 Hand Tools Electrical Power Tools E. Tag-out Bill.................................................................................................................13 Purpose of Tag-out Bill Equipment Tag-out Procedure Tag-out Documents F. Inventory of Tools and Equipment ............................................................................15 Purpose of Tools and Equipment Inventory Procedure G. Tools Safe-keeping/Storage......................................................................................16 Storing and Protecting Tools REFERENCES....................................................................................................................17

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CHAPTER I
PROPER USE OF TOOLS AND EQUIPMENT
A. INTRODUCTION
The proper use of the training tools and equipment is the first and foremost task in the maintenance. The proper use of tools and equipment is a very important task of the worker in any trade. They must be able to use them in accordance to the manufacturers manuals as this would evidently extend the life of the equipment and tools. When using equipment and simple tools, it is best to read the manufacturers and/or users manuals. This would indicate the part of the equipment, the functions of each part and the way to maintain it. We must always refer to it for reference. The users manuals must be kept handy and within the Quality Control Area where the equipment is kept for immediate reference.

B. OBJECTIVES
JZGMSAT Tools and Equipment Utilization Procedures, Policies and Guidelines Safety awareness has to be observed while in the workshop and the right information has to be provided to the faculty and students. To maintain the conditions of the workshop tools and equipment, policies and guidelines have been set. The Jacobo Z. Gonzales Memorial School of Arts and Trades facility policies and guidelines aim to: ensure the safety and health of JZGMSAT trainees, trainers/instructors and staff; promote safety awareness and encourage safe work practices in the use of school facilities; observe the proper and safe utilization of tools and equipment; extend the useful life of physical facilities identify non-functional tools and equipment by using tag-out bills; know the importance of proper maintenance as vital part of workplace safety; establish formal method of strengthening controls and safeguarding tools and equipment

C. DEFINITION OF TERMS
Maintenance - work that is done regularly to keep equipment ,building and grounds in good condition and working order. Preventive Maintenance - Maintenance performed to PREVENT or FIND failures BEFORE they develop into a breakdown. Predictive Maintenance Maintenance performed at a predetermined periods when the maintenance activity is most cost effective and before the equipment fails. Corrective Maintenance - Maintenance performed to CORRECT or REPAIR a failure. Tag-out bill - A system of documents being applied to warn or let you know whether something in your workplace should either be operated with extra care or left alone.
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JZGMSAT UTILIZATION OF TOOLS/INSTRUMENTS AND EQUIPMENT

D. DUTIES AND RESPONSIBILITIES


1. Trainer Takes direct responsibility and accountability for all equipment, instruments, parts, tools, apparatus, pieces of furniture, and fixtures found in his designated workstation Oversees operation, maintenance, and repair of equipment. Observes good housekeeping Keeps an inventory of equipment in their respective workshop Submits requisitions for materials, supplies and facilities 2. Cluster Head Keeps an inventory of equipment in their respective laboratories Oversees operation, maintenance, and repair of equipment. Coordinates and schedules the use of tools and equipment Recommends the approval of annual procurement program

E. POLICIES ON THE USE OF TOOLS AND EQUIPMENT


1. Borrowers must fill up Tools/Equipment Borrowing Form every time a particular tools or equipment will be used. 2. Any malfunctioning equipment should be immediately reported to trainer. 3. Transfer of tools and/or equipment to other borrowers is not allowed. The person whose name appears on the borrowing slip is responsible for returning all items borrowed. 4. Tools and equipment should have a maintenance record to be monitored by the cluster head/shop room trainers. 5. Trainees should not use any of tools and equipment unless approved by the shop room trainer. 6. Schedule of use of instruments/tools and equipment should be agreed upon. 7. Good housekeeping and safety precautions should be observed at all times 8. Breakages due to misuse must be reported immediately to the trainer and an immediate replacement should be arranged. 9. All trainees are required to finish first the unit of competencies in Occupational Health and safety/5S and/or use hand tools prior to their actual use of tools and equipment. 10. Unauthorized person is not allowed to modify, repair, or alter any equipment. 11. Strictly observe safety all the time. Wear appropriate personal protective equipment or PPE when using/operating tools and equipment. 12. Operating manuals for tools/instrument and equipment should be available to the borrowers (students and instructors). 13. All damages and/or losses of items like tools, instruments, and equipment are charged to the individual concerned. However, if the items were borrowed by a group, damages are equally distributed among the group members . As much as possible, replacement of damaged items is made with the same specifications and brand.

14. No items, tools, or equipment can be taken out of the school premises without the proper
authorization from the supply officer. If the items are to be used outside the campus, a permit must be secured from the Supply office with recommendations from the instructor/ cluster head.

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F. POLICIES ON THE USE OF COMPUTERS AND THEIR PERIPHERALS


1. Everyone must leave his/her personal belongings on the shelves designated for that purpose. The trainer will not be held liable for the loss or damage of any property of any user inside the laboratory. 2. No one is allowed to alter the setting configuration of any computer without proper authorization from the trainer. Any malfunction or damage in the terminals used must be immediately reported to the trainer on duty. 2.1 Equipment and cables are to be moved by authorized personnel only. Lab users may not attach personal hardware or software to the computer without permission from the IT trainer. 3. Users must stay at the terminals assigned to him/ her by the trainer. Swapping of tag numbers is not allowed. Loitering in the computer laboratory is also prohibited. 3.1 Only one student should occupy one computer terminal 3.2 In case of group work, the trainer may allow a maximum of two students to occupy a single terminal . 4. A qualified user is required to log in and log out for control and monitoring purposes. A logbook is provided for this purpose. (Qualified users include the faculty, technicians, students, as well as the staff). 5. For students, the maximum allowable time of usage is two hours per use/sitting per day. However, the user can continue if a qualified user has not reserved the next time slot. The time extension allowed may not be longer than one hour. 6. Reservation is made on a first-come, first-served basis and may be accepted at least one day before the intended use. It must be reflected on the logbook in consultation with the instructor to avoid time schedule conflict. 7. Computer games are absolutely not allowed. Any user caught playing computer games will be banned from using the computer thenceforth. 8. The user is not allowed to boot from his/her diskette so as not to infect the hard disk with a virus. The hard disk is used when booting. 9. The user can bring his/her own flash disc and to scan it before use to determine the presence of virus. 10. No work files or documents should be stored in the hard disk. Files stored in the hard disk are to be erased. 11. Any student found violating any of the above policies will be banned from using said equipment. 12. Only the registered user for a particular hour/ period is allowed to sit in front of the console/ terminal. 13. Any form of CHAT or of use of any social networks during office/class hours, and accessing PORNOGRAPHIC sites are strictly prohibited. 14. Persistent violators of the policies shall be sent to the Discipline Office for disciplinary action. A minor or major offense shall be sanctioned or penalized depending on the gravity of the offense.

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CHAPTER II

JZGMSAT QUALITY POLICY AND PROCEDURE


A. USE OF TRAINING EQUIPMENT PROCEDURE
1.0 Purpose, Scope and Terminology 1.1 Purpose This procedure aims to ensure the proper use of training tools, equipment and test instrument and its maintenance with safety precautions in order to achieve fast and effective delivery of instruction. 1.2 Scope The procedure covers the standard operation set by the instructor-in-charge based on the shop/classroom policies on borrowing, utilizing and returning of training tools, equipment and test instruments. 1.3 Terminology The definitions of terminologies used in this procedure are as follows: 1) Borrowing - the act of securing or requesting equipment/tool from the tool keeper. 2) Borrowing Slip/Form - a form indicating the name of the borrower, date borrowed and date returned and the description of the equipment/tool to be used. 3) Equipment - refers to any machine that requires manipulative skill and usually runs by a current or motor. 4) Maintenance - work that is done regularly to keep equipment ,building and grounds in good condition and working order. 5) Test Instruments - refer to the tools that are used to test an electronic component/circuit or use in troubleshooting. 6) Tool - a device that is manipulated by hand or electric power of less than Php. 10,000.00 worth. 7) Tool keeper - a selected responsible student who is in charge of distributing and collecting the equipment/tool. 2.0 2.1 Responsibility Responsibility for the Authority and Maintenance of the Procedure The Vocational School Administrator II is responsible to ensure that this procedure is maintained at the school level. 2.2 Responsibility for the Implementation of the Procedure The implementation of the procedure is the responsibility of the cluster head and the Supply Officer who keeps the records and manages all the training equipment/tools being used in the school.
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The instructor-in-charge takes direct responsibility and accountability for all equipment, instruments, parts, tools, apparatus, pieces of furniture, and fixtures found in his designated workstation. He/she oversees operation, maintenance, and repair of equipment. He/she is responsible, if in case, the tools/test instrument/equipment has been damaged or lost. 3.0 Procedure 3.1 Flowchart

STAGE 1: Borrowing of Tools, Equipment and Test Instrument

INSTRUCTOR
Designates tool keeper for the day Refer to 3.2.1

TRAINEE/STUDENT

TOOL KEEPER

Borrows tools/ equipment/test instrument Refer 3.2.2 STAGE 2: Performs the actual use of Equipment Supervises/ Monitors Utilizes the tools/equipment/ test instrument Refer 3.2.4

Issues tools/equipment/ test instrument Refer 3.2.3

Returns the tools/equipment/ test instrument used

Checks/receives the tools/equipment/ test instrument Refer 3.2.5

Rechecks the condition Refer 3.2.6

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3.2

Documentation STAGE 1: Borrowing of tools/equipment/test instrument 3.2.1 Designates tool keeper for the day A student who is responsible and knowledgeable about the specification of a particular tool/equipment Borrows tools/equipment/test instrument Fills-up on borrowing form the name/s of borrower/s, date and description of tools/equipment to be borrowed.

Forms

Time Frame 15 min. before laboratory time

Inputs to Procedure

3.2.2

UTE 01/1202

4 min

3.2.3

Issues tools/equipment/test instrument Checks the quantity of tools as indicated in the Acknowledgement Receipt of Equipment and the condition of tools and equipment in the shop. Refers to the borrowing form the tools/equipment to be issued STAGE 2: Performs the actual use of Equipment 3.2.4 3.2.5 Utilizes the tools/equipment/test instrument Refers to operational manual, if available Applies safety precautions in the use of tools and equipment Uses the right tool for the job Cleans tools and equipment. If possible lubricate necessary parts for anti-corrosions/rusts Returns the tools/equipment/ test instrument used Checks/receives the tool/equipment/test instrument Receives and rechecks tool and equipment's condition. Double-checks the tools and equipment borrowed. Checks if tools/equipment/test instrument are properly cleaned Replaces the tools and equipment to its proper places

UTE 01/1202

2-10 min

Acknowledgement Receipt of Equipment

1-4 hrs

Equipment/test instrument operational manual

UTE 01/1202

1-5 min

Equipment operational manual

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Reports to instructor the condition of returned tools and equipment 1-5 min

3.2.6 Rechecks the condition a) Visually inspects the condition of tools and equipment. b) Reports to the Cluster head/supply officer any damaged or lost tools/equipment/test instrument. 4.0 Forms UTE 01/1202 5.0 Related Information Acknowledgement Receipt of Equipment Operational Manual of Equipment Tools/Equipment Borrowing Form

UTE 01/1202

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CHAPTER III
MAINTENANCE OF TOOLS AND EQUIPMENT
A. GENERAL OBJECTIVE
To maintain the optimum condition of physical facilities at acceptable levels and minimum cost to satisfy the expected demands of TVET programs and activities. Specific Objectives: To extend the useful life of physical facilities To assure the operational readiness of installed equipment and maximum possible return on investments. To properly discard hazardous wastes To ensure the safety of personnel using the facilities, physical properties and the environment.

B. DEFINITION OF TERMS
Maintenance Program- is a comprehensive list of maintenance and its incidents. This would include all maintenance activities to be undertaken , manpower needed, maintenance methods to be used, all the materials and supplies needed for the maintenance and cost involved in the maintenance. Maintenance Schedule- Is a list allocating specific maintenance of an area. Equipment and tools to a specific period. The maintenance schedule is just a part of the maintenance program.

C. MAINTAINING TOOLS AND EQUIPMENT


Tools/instruments and equipment are essential parts of any trade. To be proficient, one must be able to use and maintain a large variety of field and shop tools effectively. The main thing is that its important to keep the tools sharp and in good shape. It is important to realize the value of proper maintenance of all your tools and equipment. Preventive maintenance is the systematic care and protection of tools, equipment, machines and vehicles in order to keep them in a safe, usable condition, limit downtime and extend productivity. We must always be aware that maintenance tasks themselves are potentially hazardous and can result in injury. The successful maintenance program is: well organized and scheduled, controls hazards, defines operational procedures, and trains key personnel. Power tools should be maintained in good working order. This may be limited to ensuring that blades/bits are replaced when needed and that guards or other safety devices are operable and any damaged electrical cords/plugs are repaired or replaced. Damaged or defective equipment/tools should be tagged and removed from service.
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General requirements for equipment maintenance include: Obtaining a copy of the maintenance schedule recommended by the manufacturer. Ensuring that maintenance is performed as required. Ensuring that the person(s) performing the maintenance are competent (e.g. licensed mechanic). Retaining records of maintenance/service conducted. Specifying who is responsible for overseeing equipment maintenance and where the records are kept. Set up a system for removal and tagging of damaged or defective tools and equipment. Tools and Equipment Maintenance Program This policy is intended to highlight the importance of proper maintenance as a vital part of a safety program. In addition to ensuring that workers use the tools and equipment properly, it is vital that tools and equipment be properly inspected, maintained, and kept in good repair. The maintenance program will reduce the risk of injury, damage and lost production. Ensure that all tools and equipment are well maintained in order to reduce the risk of accidents or injuries. 1. 2. 3. 4. Only properly trained workers are to use tools and equipment Inspect all tools and equipment before using. If applicable, maintenance schedules for all tools and equipment are to be respected. Appropriate personnel should conduct regular inspection of all tools, equipment and vehicles on the site. This inspection is recorded using an Inspection Checklist. 5. If at any time a worker judges that a tool or equipment is unsafe for use, they are to properly tag the item and inform the supervisor immediately. 6. Tools and equipment that are tagged unsafe shall be either repaired or replaced. Supervisor shall be informed. In order to perform the maintenance of specific equipment, a Maintenance Schedule is drawn to guide the personnel in the proper methods system . One best source of the list of the maintenance activities of an equipment is its manufacturers manual, In the absence of it, the plan can be derived from the known maintenance methods of the equipment. Below is the sample Equipment Maintenance Schedule For Desktop Computer in the Practical Work area/ Computer Laboratory of a Training Center for Computer Hardware Servicing. You may see that that this maintenance schedule is for a specific equipment only, denoted by unique property code.

EQUIPMENT MAINTENANCE SCHEDULE


EQUIPMENT TYPE EQUIPMENT CODE/ NO. LOCATION
ACTIVITIES MANPOWER

Desktop Computer Computer 1 / 1001A Practical Work Area / Computer Laboratory Schedule for the Month of_____________
Daily Every Other Day Weekly Every 15th Day Monthly Remarks

1. Clean computers and printers 2.Check computer for viruses 3. Clean computer peripherals 4. Check electric and computer connections 5.Turn off unit when not in use or at the end of the day.

IT Personnel IT Personnel IT Personnel IT Personnel IT Personnel

X X X X X

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Equipment Inspection Checklist To determine if the maintenance program is implemented according to what is planned, an assessment must be done. The result of the assessment will then be recorded and reported to the proper authorities for immediate action. Regular inspections are conducted to assure that the maintenance activities are done on the date and time it was planned and that the performance levels adhered to the defined standard. Below is a sample Maintenance Inspection Checklist. You may note that this checklist pertains to the same equipment with the Maintenance Schedule. This checklist will confirm if the maintenance activities have been performed in order to prolong the life of this particular equipment. The Inspection items are stated in a question form as these serve as the criteria or standards of maintenance.

MAINTENANCE INSPECTION CHECKLIST


Equipment Type Property Code Number Location YES NO Desktop Computer Computer 1 / 1001A Practical Work Area / Computer Laboratory INSPECTION ITEMS 1. Are the peripherals (keyboard, mouse, etc.) returned to their proper places? 2. Is the computer unit turned off when not in use? 3. Is the computer unit in good working condition? 4. Is the equipment arranged for the purpose of safety and ease in maintenance? 5. Is the auto- voltage regulator (AVR) and/or UPS turned off when not in use? 6. Is the computer unit free from any virus.?

D. REQUIREMENTS FOR CLEANING AND MAINTENANCE OF TOOLS


After use, tools should be cleaned off and left dry. A coating of oil or rust inhibitor is a good way of finishing off the cleaning process. Cleaning may involve removing the materials you have been working with and using. Finishing off with a spray of WD40 or wiping tools with an oily rag (if made of steel) is an excellent way to prevent rust from damaging tools. Maintenance of tools can be carried out as they put back into storage so that they are in good condition for the next user. These may involve sharpening of blades. Other checks should be made on tools such as: Is the handle or head of tool loose? Are tools out of shape (jaws of plier meet, straight edge still straight)? Are any parts missing (end section of ruler or tape)? Are wooden handles splintered or broken (hammer, chisels)? 1. HAND TOOLS a) Clean the given tools using a clean cloth. Use brush to remove dust and dirt on hard to reach areas.
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b) Remove rust, on metal parts of the tools using sand paper. Stubborn cement on tools should be removed using scraper. c) Apply a thin coat of oil on metal surfaces of hand tools to prevent it from rusting. d) After cleaning, replace the sharp edges of the tools using its cover or scabbard or wrap the plumb bob in oil-soaked paper. e) Keep the tools on its proper storage area and/or rack after cleaning. f) Segregate and label non-functional tools.

2. ELECTRICAL POWER TOOLS a) Keep all power tools, especially the housing intake and exhaust holes, clear and free of dust and dirt at all times. b) Examine power-tool cords for exposed loose wires and for damaged insulation. c) Wipe power cords frequently to prevent deterioration from oil or grease. d) Check cord plugs for loose prongs or cracked casings. e) Never hold or drag electrical tools by the cord. f) Apply a light coat of oil to the cutting surfaces of tools to prevent rusting.

g) Store power tools in their properly designated containers when not in use. h) Segregate and label non-functional equipment according to classification.

E. TAG-OUT BILL
A system of documents being applied to warn or let you know whether something in your workplace should either be operated with extra care or left alone. Purposes of Tag-Out Bill 1. To provide a procedure to prevent the improper operation of a component, piece of equipment a system, or portion of a system that is isolated or in an abnormal condition. 2. To provide a procedure in operating an instrument that is unreliable or not in normal operation condition. 3. To provide separate procedures when accomplishing certain planned maintenance system. Equipment Tag-out Procedures 1. Post Danger Tags, Caution Tags and instrument Out-of Commission Tags/out-of Calibration labels following authorized procedures.

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2. Do not remove or break posted safety tags without proper authorization. Tag-out activity should be supported by properly accomplished document. Tag-out Documents CAUTION TAGS (YELLOW) - precautionary measure to provide temporary special instruction or to show personnel that they must use extra caution in operating equipment DANGER TAGS (RED) - could cause injury or death; could cause damage to equipment OUT OF CALIBRATION LABELS (ORANGE) - identify instruments that give inaccurate measurements because they are out of calibration OUT OF COMMISSION LABELS (RED) - identify instruments that are defective or isolated from the system TAG OUT LOGS - used to control the entire tag-out procedure; a record of authorization of each effective tag-out action

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F. INVENTORY OF TOOLS AND EQUIPMENT


Purpose of Tools and Equipment Inventory The purpose of inventory of tools and equipment is to establish a formal method of strengthening controls and safeguarding tools and equipment most vulnerable to theft and loss by identifying inventory units, assigning responsibility for and frequency of verification and documenting loss. An inventory of tools and equipment will be maintained and updated on a regular basis. These inventories will include hand tools, power tools, pneumatic and hydraulic tools and equipment, measuring and testing equipment, compressors, electric and electronic tools and equipment. Procedure 1. Personnel whose position requires tool and equipment assignment will complete a "Tool and Equipment Inventory Form" for these assigned tools and equipment. The inventory list will identify all assigned storage area related tools and equipment for which the individual is responsible. 2. Assign the responsibility for review and approval of completed inventory lists or changes to inventory items or quantities for all employees assigned tools and equipment. 3. All personnel assigned or utilizing tools and equipment will be responsible for assuring their safe and proper use and will closely monitor their own assigned tools and equipment on an on-going basis, making sure all lost or stolen equipment is reported to their supervisor for replacement. 4. Submit "Tool Replacement Form" prior to requisitioning for replacement of worn, damaged, lost or stolen tools and equipment. Worn or damaged tools and equipment will be sent for replacement. 5. The trainer/staff conduct a full physical inventory regularly. A full inventory requires that all tools and equipment be counted and verified and inventory forms completed and submitted for review.

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G. TOOL SAFE-KEEPING/STORAGE
Its is important to store tools correctly to gain the maximum life out of these tools. Tools that have sharp edges such as chisels and saws will blunt if stored for transport with other tools. To avoid this, covers and protecting guards should be put around tools. Storage of tools in a workshop or storage box can make use of a shadow board. This is a board fixed to the wall with nails or other fixings to place tools on and the outline of the tool painted (often in black) onto the board. This enable tools to be easily replaced in the same place and missing tools to be easily identified. When tools are replaced, if the replacement tools has a different shape to the original tool, the new shape can be painted on to the board. Storing and Protecting Tools 1. 2. 3. 4. 5. 6. 7. 8. Use plastic cutlery trays to store small tools and drill bits, fasteners Use lidded buckets to storage of extension cords, wire, rope Use recycled jars for keeping fasteners separate from tools (see through plastic is the best as these are unbreakable and easy to identify contents) Use holes in handles of tools to hang these (e.g. from shadow board) Use a bull dog clip or similar to clip instructions and maintenance directions for tools on same hook or peg as the tools Lay a strip of felt on the bottom of the tool boxes as extra protection for tools Empty out tool boxes periodically and get rid of dust and dirt that accumulates there (wipe over with an oily cloth or spray with WD40 while emptying) Apply sump oil (from garage or workshops) to your tool box to absorb moisture and prevent rust

9. Keep a magnet in your tool box to pick up screws and nails, etc., that you drop

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REFERENCES De La Salle University-Manila Laboratory Procedures, Policies and Guidelines SY 2004-2005 University Research Coordination Office De La Salle University-Manila August 2004 http://www.tpub.com/content/advancement/14325/css/14325_560.htm COMPETENCY BASED LEARNING MATERIAL Trainers Methodology I Maintain Training Facilities Technical Education & Skills Development Authority NATIONAL TVET TRAINERS ACADEMY Marikina City JZGMSAT Quality Manual 2004

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