JZGMSAT_utilization of School Facilities

8/4/2019 JZGMSAT_utilization of School Facilities

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JZGMSATUTILIZATION OFTOOLS/INSTRUMENTSANDEQUIPMENT

Technical Education and Skills Development AuthorityRegion IV-A

JACOBO Z. GONZALES MEMORIAL SCHOOL OF ARTS AND TRADESSan Antonio, Bian City


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TABLE OF CONTENTS

CHAPTER I. PROPER USE OF TOOLS AND EQUIPMENTA. Introduction..................................................................................................................3B. Objectives....................................................................................................................3

C. Definition of Terms.......................................................................................................3D. Duties and Responsibilities.........................................................................................4E. Policies on the Use of Tools/Equipment......................................................................4F. Policies on the Use of Computers and Their Peripherals............................................5

CHAPTER II. JZGMSAT QUALITY POLICY AND PROCEDUREA. Use of Training Equipment and Procedure

1.0 Purposes, Scope and Terminology......................................................................61.1 Purpose1.2 Scope1.3 Terminology

2.0 Responsibilities....................................................................................................62.1 Responsibility for the Authority and Maintenance of the Procedure2.2 Responsibility for the Implementation of the Procedure3.0 Procedure............................................................................................................73.1 Flowchart3.2 Documentation4.0Forms.....................................................................................................................95.0Related information ...............................................................................................9

CHAPTER III. MAINTENANCE OF TOOLS AND EQUIPMENTA. General Objectives....................................................................................................10B. Definition of Terms.....................................................................................................10C. Maintaining Tools and Equipment ............................................................................10

Tools and Equipment Maintenance Program

Equipment Inspection ChecklistD. Requirements for Cleaning and maintenance of Tools ............................................12

Hand Tools

Electrical Power ToolsE. Tag-out Bill.................................................................................................................13

Purpose of Tag-out Bill

Equipment Tag-out Procedure

Tag-out DocumentsF. Inventory of Tools and Equipment ............................................................................15

Purpose of Tools and Equipment Inventory

ProcedureG. 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 themaintenance. The proper use of tools and equipment is a very important task of the worker in anytrade. They must be able to use them in accordance to the manufacturers manuals as this wouldevidently extend the life of the equipment and tools.

When using equipment and simple tools, it is best to read the manufacturers and/or usersmanuals. This would indicate the part of the equipment, the functions of each part and the way tomaintain it. We must always refer to it for reference. The users manuals must be kept handy andwithin 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 hasto be provided to the faculty and students. To maintain the conditions of the workshop tools andequipment, policies and guidelines have been set.

The Jacobo Z. Gonzales Memorial School of Arts and Trades facility policies and guidelinesaim 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 goodcondition and working order.

Preventive Maintenance - Maintenance performed to PREVENT or FIND failures BEFOREthey develop into a breakdown.

Predictive Maintenance Maintenance performed at a predetermined periods when themaintenance 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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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 orequipment 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 whosename 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 clusterhead/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 immediatereplacement should be arranged.

9. All trainees are required to finish first the unit of competencies in Occupational Health andsafety/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 tothe individual concerned. However, if the items were borrowed by a group, damages areequally distributed among the group members . As much as possible, replacement ofdamaged 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 properauthorization from the supply officer. If the items are to be used outside the campus, apermit 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 thatpurpose. The trainer will not be held liable for the loss or damage of any property of anyuser 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 beimmediately reported to the trainer on duty.

2.1 Equipment and cables are to be moved by authorized personnel only. Lab users maynot attach personal hardware or software to the computer without permission from the ITtrainer.

3. Users must stay at the terminals assigned to him/ her by the trainer. Swapping of tagnumbers 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 asingle terminal .

4. A qualified user is required to log in and log out for control and monitoring purposes. Alogbook 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. Thetime 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 oneday before the intended use. It must be reflected on the logbook in consultation with theinstructor to avoid time schedule conflict.

7. Computer games are absolutely not allowed. Any user caught playing computer games willbe 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 avirus. 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 thepresence of virus.

10. No work files or documents should be stored in the hard disk. Files stored in the hard diskare to be erased.

11. Any student found violating any of the above policies will be banned from using saidequipment.

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 accessingPORNOGRAPHIC sites are strictly prohibited.

14. Persistent violators of the policies shall be sent to the Discipline Office for disciplinaryaction. A minor or major offense shall be sanctioned or penalized depending on the gravityof 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 testinstrument and its maintenance with safety precautions in order to achieve fast andeffective delivery of instruction.

1.2 Scope

The procedure covers the standard operation set by the instructor-in-charge based on theshop/classroom policies on borrowing, utilizing and returning of training tools, equipmentand 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 Responsibility

2.1 Responsibility for the Authority and Maintenance of the Procedure

The Vocational School Administrator II is responsible to ensure that this procedure ismaintained 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 SupplyOfficer 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 designatedworkstation. He/she oversees operation, maintenance, and repair of equipment. He/she isresponsible, 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

STAGE 2:Performs the actual use of Equipment


INSTRUCTOR TRAINEE/STUDENT TOOL KEEPER

Borrows tools/equipment/test

instrumentRefer 3.2.2

Issuestools/equipment/test instrument

Refer 3.2.3

Utilizes thetools/equipment/test instrument

Refer 3.2.4

Supervises/Monitors

Returns thetools/equipment/test instrument

used

Checks/receivesthe

tools/equipment/test instrument

Refer 3.2.5

Designates toolkeeper for the day

Refer to 3.2.1

Rechecksthe condition

Refer 3.2.6


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3.2 DocumentationSTAGE 1: Borrowing oftools/equipment/test instrument

FormsTimeFrame

Inputs toProcedure

3.2.1 Designates tool keeper for the day

A student who is responsible andknowledgeable about the

specification of a particulartool/equipment

3.2.2 Borrows tools/equipment/testinstrument

Fills-up on borrowing form thename/s of borrower/s, date anddescription of tools/equipment to beborrowed.

3.2.3 Issues tools/equipment/testinstrument

Checks the quantity of tools asindicated in the AcknowledgementReceipt of Equipment and thecondition of tools and equipment inthe shop.

Refers to the borrowing form thetools/equipment to be issued

UTE 01/1202

UTE 01/1202

15 min.before

laboratorytime

4 min

2-10 min AcknowledgementReceipt of

Equipment

STAGE 2: Performs the actual use ofEquipment

3.2.4 Utilizes the

tools/equipment/testinstrument

Refers to operational manual, ifavailable

Applies safety precautions in the useof tools and equipment

Uses the right tool for the job

Cleans tools and equipment. Ifpossible lubricate necessary parts foranti-corrosions/rusts

Returns the tools/equipment/ test

instrument used

3.2.5 Checks/receives thetool/equipment/test instrument

Receives and rechecks tool andequipment's condition.

Double-checks the tools andequipment borrowed.

Checks if tools/equipment/testinstrument are properly cleaned

Replaces the tools and equipment to

its proper places

UTE 01/1202

1-4 hrs

1-5 min

Equipment/testinstrumentoperationalmanual

Equipmentoperationalmanual



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Reports to instructor the condition ofreturned tools and equipment

3.2.6 Rechecks the conditiona) Visually inspects the condition of

tools and equipment.b) Reports to the Cluster head/supply

officer any damaged or losttools/equipment/test instrument.

1-5 min

4.0 Forms

UTE 01/1202 Tools/Equipment Borrowing Form

5.0 Related Information

Acknowledgement Receipt of EquipmentOperational Manual of Equipment

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 costto 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 possiblereturn 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 wouldinclude all maintenance activities to be undertaken , manpower needed, maintenancemethods to be used, all the materials and supplies needed for the maintenance andcost involved in the maintenance.

Maintenance Schedule- Is a list allocating specific maintenance of an area. Equipment andtools to a specific period. The maintenance schedule is just a part of the maintenanceprogram.

C. MAINTAINING TOOLS AND EQUIPMENT

Tools/instruments and equipment are essential parts of any trade. To be proficient, onemust be able to use and maintain a large variety of field and shop tools effectively. The main thingis that its important to keep the tools sharp and in good shape. It is important to realize the value ofproper 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 extendproductivity. We must always be aware that maintenance tasks themselves are potentiallyhazardous 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 ensuringthat blades/bits are replaced when needed and that guards or other safety devices are operableand 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. licensedmechanic).

Retaining records of maintenance/service conducted.

Specifying who is responsible for overseeing equipment maintenance and where therecords 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 asafety program. In addition to ensuring that workers use the tools and equipment properly, it is vitalthat tools and equipment be properly inspected, maintained, and kept in good repair. Themaintenance program will reduce the risk of injury, damage and lost production. Ensure that alltools and equipment are well maintained in order to reduce the risk of accidents or injuries.

1. Only properly trained workers are to use tools and equipment2. Inspect all tools and equipment before using.3. If applicable, maintenance schedules for all tools and equipment are to be respected.4. 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 themaintenance activities of an equipment is its manufacturers manual, In the absence of it, the plancan be derived from the known maintenance methods of the equipment. Below is the sampleEquipment Maintenance Schedule For Desktop Computer in the Practical Work area/ ComputerLaboratory of a Training Center for Computer Hardware Servicing. You may see that that thismaintenance schedule is for a specific equipment only, denoted by unique property code.

EQUIPMENT MAINTENANCE SCHEDULE

EQUIPMENT TYPE Desktop ComputerEQUIPMENT CODE/ NO. Computer 1 / 1001ALOCATION Practical Work Area / Computer Laboratory

ACTIVITIES MANPOWER

Schedule for the Month of_____________Daily Every

Other DayWeekly Every 15th

DayMonthly Remarks

1. Clean computers andprinters

ITPersonnel X

2.Check computer for viruses ITPersonnel X

3. Clean computer peripherals ITPersonnel X

4. Check electric andcomputer connections

ITPersonnel X

5.Turn off unit when not inuse or at the end of the day.

ITPersonnel X



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Equipment Inspection Checklist

To determine if the maintenance program is implemented according to what is planned, anassessment must be done. The result of the assessment will then be recorded and reported to theproper 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 checklistpertains to the same equipment with the Maintenance Schedule. This checklist will confirm if themaintenance 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 ofmaintenance.

MAINTENANCE INSPECTION CHECKLISTEquipment TypeProperty Code

NumberLocation

DesktopComputer

Computer 1 / 1001APractical Work Area / Computer LaboratoryYES NO 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 agood way of finishing off the cleaning process. Cleaning may involve removing the materials youhave been working with and using.

Finishing off with a spray of WD40 or wiping tools with an oily rag (if made of steel) is anexcellent way to prevent rust from damaging tools.

Maintenance of tools can be carried out as they put back into storage so that they are ingood 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 toolsshould 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 theplumb 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 ofdust 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 yourworkplace 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 anabnormal condition.

2. To provide a procedure in operating an instrument that is unreliable or not innormal operation condition.

3. To provide separate procedures when accomplishing certain plannedmaintenance system.

Equipment Tag-out Procedures

1. Post Danger Tags, Caution Tags and instrument Out-of Commission Tags/out-of Calibrationlabels following authorized procedures.



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2. Do not remove or break posted safety tags without proper authorization. Tag-out activityshould be supported by properly accomplished document.

Tag-out Documents

CAUTION TAGS (YELLOW) - precautionary measure to provide temporary specialinstruction 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 orisolated from the system

TAG OUT LOGS - used to control the entire tag-out procedure; a record of authorization ofeach 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 ofstrengthening controls and safeguarding tools and equipment most vulnerable to theft and loss byidentifying inventory units, assigning responsibility for and frequency of verification anddocumenting 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 andequipment, measuring and testing equipment, compressors, electric and electronic tools andequipment.

Procedure

1. Personnel whose position requires tool and equipment assignment will complete a "Tooland Equipment Inventory Form" for these assigned tools and equipment. The inventory listwill identify all assigned storage area related tools and equipment for which the individual isresponsible.

2. Assign the responsibility for review and approval of completed inventory lists or changes toinventory items or quantities for all employees assigned tools and equipment.

3. All personnel assigned or utilizing tools and equipment will be responsible for assuring theirsafe and proper use and will closely monitor their own assigned tools and equipment on anon-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 forreplacement.

5. The trainer/staff conduct a full physical inventory regularly. A full inventory requires that alltools and equipment be counted and verified and inventory forms completed and submittedfor 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 thathave sharp edges such as chisels and saws will blunt if stored for transport with other tools. Toavoid 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 aboard 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 andmissing tools to be easily identified. When tools are replaced, if the replacement tools has adifferent shape to the original tool, the new shape can be painted on to the board.

Storing and Protecting Tools

1. Use plastic cutlery trays to store small tools and drill bits, fasteners

2. Use lidded buckets to storage of extension cords, wire, rope

3. Use recycled jars for keeping fasteners separate from tools (see through plastic is the bestas these are unbreakable and easy to identify contents)

4. Use holes in handles of tools to hang these (e.g. from shadow board)

5. Use a bull dog clip or similar to clip instructions and maintenance directions for tools onsame hook or peg as the tools

6. Lay a strip of felt on the bottom of the tool boxes as extra protection for tools

7. Empty out tool boxes periodically and get rid of dust and dirt that accumulates there (wipeover with an oily cloth or spray with WD40 while emptying)

8. Apply sump oil (from garage or workshops) to your tool box to absorb moisture and preventrust

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-ManilaLaboratory Procedures, Policies and GuidelinesSY 2004-2005

University Research Coordination OfficeDe La Salle University-ManilaAugust 2004

http://www.tpub.com/content/advancement/14325/css/14325_560.htm

COMPETENCY BASED LEARNING MATERIALTrainers Methodology IMaintain Training FacilitiesTechnical Education & Skills Development AuthorityNATIONAL TVET TRAINERS ACADEMY

Marikina City

JZGMSAT Quality Manual2004
