TraineeHandbook

Compiled by: Industrial Centre, The Hong Kong Polytechnic University

Pictures extracted from: The British Safety CouncilThe Labour Department of Hong Kong

Last updated: August 2008

Guidance for Trainees

TABLE OF CONTENTSPage

Section A General1. Introduction

A-1

2. Our Vision & Mission A-3

3. Our Performance Pledge A-4

4. Professional Training Requirements A-5

5. General Information and Regulations A-65.1 Enquiries

A-6

5.2 Training Programmes A-6

5.3 Groupings A-6

5.4 IC Training Timetables A-7

5.5 Exemption from IC Training A-8

5.6 IC Tutorials and Trainee Feedback A-8

5.7 Attendance and Timekeeping A-8

5.8 Leave or Absence A-9

5.9 Arrangements During Bad Weather A-10

5.10 Safety Gear A-10

5.11 Name Tags and Badges A-11

5.12 Changing Rooms & Lockers

A-11

5.13 Tools and Materials A-11

5.14 Booking of IC Facilities A-12

5.15 Cleanliness A-12

5.16 Mobile Telephones and Pagers A-12

5.17 Training Certificate/Testimonial A-12

5.18 Mandatory Basic Safety Training (MBST) Course A-13

5.19 Insurance A-13

Appendix IApplication Forms

A-14

Section B Assessment Scheme1. Introduction

B-1

2. IC Assessment B-12.1 What is Assessed?

B-1

2.2 Assessment Results B-4

2.3 Failure a) Incomplete Training B-5

b) Training Information accessible on IC Web Site B-5

2.4 Trainee Feedback Questionnaire B-6

Appendix IReport Writing: Introduction, Workshop Reports and Training Log Book B-7

PageSection C Computer Training

1. Introduction C-1

2. Modules C-1

3. Who Should Attend C-1

4. Training Pattern C-2

5. Schedule and Offering Time C-2

6. Credit C-2

7. Competency Test C-2

8. Class Enrollment C-3

9. Assessment C-4

10. Workshop Report C-4

11. Co-curricular Achievement Transcript (CAT) C-4

Section D Safety1. Introduction

D-1

2. General Safety Rules D-2

3. Personal Safety D-4

4. Safety in Bench Work D-5

5. Safety in Using Basic Machine Tools and Attachments D-9

6. Safety in Operating Grinding Machines D-13

7. Safety in Foundry D-15

8. Safety in Electroplating D-16

9. Safety in Operating Plastics Moulding Machines D-17

10. Safety in Welding D-18

11. Electrical Safety D-21

12. Safety in Building Construction Work D-23

13. Safety in Power Press Operation

D-24

14. Safety in PCM Workshop D-25

15. Safety in Operating Rapid Prototyping Systems D-26

16. Procedures to be taken in Case of Fire D-27

17. In Case of Emergency D-28

Section A: General

1. Introduction

The IC Experience - Training for Life!

Welcome to the Industrial Centre or, as it is more commonly known, the IC.

As a future IC trainee, you are about to embark on an educational adventure quite unlike anything you have ever experienced before. If you approach it in the right spirit, your IC training programme will provide you with a number of exciting opportunities - opportunities which, within the sphere of tertiary education, hardly exist elsewhere.

The IC's mission is to provide you with practical training - training which is integrated with and complementary to your academic studies. Training activities are supported by three training divisions, each of which specializes in a particular area of engineering endeavour:-

* Product Design, Prototyping, Toolmaking, Machining, Materials & Process Technologies

* CAM, Electronics, Computer Services, Automation, Informatics, Industrial Engineering

* Building & Construction, Building Services, Electrical, Maintenance, Environment & Occupational Safety and Health

During your IC training you will be exposed to a variety of practical techniques and technologies, both traditional and modern. In each workshop, after some basic instruction, you will require to immerse yourself in the practical sessions in "hands on" fashion. If you have not previously taken part in this kind of activity you will probably derive a lot of enjoyment and satisfaction out of using your hands in a productive and creative way. Learning by doing is, however, only part of the IC experience.

You will be working and studying in a simulated industrial (Model Factory) environment - quite different from the academic environment you are familiar with - in which you will require to adhere to industrial dress codes and disciplines. You will be given challenging practical exercises which we hope will stimulate your curiosity and motivate you to learn more about the principles underlying the practice. You will become involved in "real" work projects for real clients, with real quality requirements and real delivery deadlines. Depending on your academic programme, your training schedule may also require your participation in a full-scale Team Project (Manufacturing Project/Construction/Integrated Project). You will learn about computer applications in modern engineering design and manufacture. A number of other advanced manufacturing technologies may also feature in your programme. You will learn about production planning, plant maintenance, and engineering systems. You will also be given opportunities for self-learning (sometimes with the

A-1

aid of the computer). You will be shown the importance of occupational health and safety; and much, much more.

As well as providing you with a unique learning environment your IC training is also intended as a character-building experience. Like a real factory, the IC is potentially a hazardous place; it is imperative that you stay alert at all times and have proper regard for your own safety and for the safety of others around you. All safety precautions specified by the IC must be strictly observed. Throughout your training you will be expected to conduct yourself in a disciplined, diligent and responsible manner. The extent of your self-discipline will be monitored, as will your attitude towards your work assignments.

To help you develop self-sufficiency, you will sometimes be asked to work independently. At other times, to tax your inter-personal skills and leadership qualities, you will require to work as part of a team. Your IC programme is also likely to be physically demanding, particularly if and when your schedule requires you to work on site, or in non-air-conditioned workshops during the hot, humid summer months. Please accept this not as an imposition but as a test of your personal fortitude and in preparation for the conditions you may later encounter in real industrial and professional life.

The IC was established back in 1976. Thousands of students have already partaken of the IC experience and found it to be of tremendous benefit to them in their careers. Many of these former IC trainees are now captains of industry - company directors, senior executives and key decision makers. You will be following in their illustrious footsteps.

IC training is training for the future. We hope that you will find your time in the IC to be informative, challenging and envigorating, and we are confident that you will later look back on your IC experience as one of the most enjoyable and productive periods of your life.

A-2

2. Our Vision

… is to become the acknowledged global leader in the practical training of potential engineers and technologists.

Our Mission

… is to establish benchmark standards of excellence in industrial training for quality of service at a competitive cost level.

through

Absolute dedication to understanding and fulfilling our clients’ needs with appropriate services, products and price levels for each,

Steady growth and proliferation of industrial partnership programmes,

State-of-the-art technology attuned to the needs of Hong Kong industry,

A keen focus on creativity and innovation in product and process design,

An environment that recognizes and rewards achievement, enthusiasm and team spirit, and which offers each individual within the Centre excellent opportunities for personal development and growth,

Allocation of resources consistent with the workload, needs and aspirations of each operational division,

The creation of a learning organization capable of maintaining local initiative and local decision-making while working within a centrally-managed institutional framework, and

Evolution of activities and creation of new services, markets and products by single-minded commitment to continuous improvement and to anticipating and meeting the changing needs of our clients.

A-3

3. Our Performance Pledge

As a trainee we want your IC experience to be stimulating, memorable, purposeful and safe and we will do everything we can to make sure that you get the best out of the time you spend here. If you are an industrial partner or client we believe that you are entitled to expect an efficient, high added-value service at reasonable cost. In either case, all we ask is that if you’re not happy about something, please let us know immediately.

Expectations We will do our utmost to meet your expectations. If we don’t please tell us NOW.

Trained Staff Our staff are all fully trained professionals with the authority and responsibility to help you acquire the best from your IC experience or service. If you are dissatisfied about something please tell us NOW.

Accessibility Apart from some Sundays and Public Holidays the IC is open all year round and also has its own Web Page at http://www.ic.polyu.edu.hk. If you need us please contact us NOW.

Information and Advice

We are here to provide all the information and advice you require. If we can be of assistance please ask us NOW.

Prompt Service Should you have a problem, we aim to solve it today. To do this we must know about your problem NOW.

Safety and Reassurance

Your safety is our topmost priority. If you have any concerns please tell us NOW.

It’s Your IC! We will do everything we can, whenever and however we can, to make your IC experience or service the very best it can be – NOW!

A-4

4. Professional Training Requirements

The IC training programmes have been developed based partly on the perceived training needs of local industrial undertakings and partly to satisfy institutional requirements for the training of professional engineers and technologists.

Both the Commonwealth Engineering Conference and the Conference of Engineering Societies of Western Europe and the United States have defined the characteristics of the work and capabilities of the professional engineer as follows:-

* "A professional engineer is competent, by virtue of fundamental education and training, to apply the scientific method and outlook to the analysis of engineering problems.

* A professional engineer is able to assume personal responsibility for the development and application of engineering science and knowledge, notably in research, designing, construction, manufacturing, superintending, managing and in the education of the engineer.

* The work of the professional engineer is predominantly intellectual and varied and not of a routine mental or physical nature.

* It requires the exercise of original thought and judgement and the ability to supervise the technical and administrative work of others.

* The professional engineer will have been educated to be capable of closely and continuously following progress in a branch of engineering science by consulting newly published work on a world-wide basis, assimilating such information and applying it independently. The professional engineer is thus placed in a position to make contributions to the development of engineering science or its applications."

The IC training programmes, which are designed to enable you to gain a sound but broad understanding of workshop processes and industrial procedures, strongly reflect the above ideals. During your IC training you will come to understand and appreciate a variety of craft skills. In structure, style and substance, however, your IC training will be totally different from craft training and is not intended to make a craftsman of you. Repetitive exercises are normally avoided, except when a solid appreciation of a specific skill of hand is deemed to be particularly desirable.

The overwhelming majority of IC training tasks are pitched at an intellectual level appropriate to the budding young engineering undergraduate and are designed to stretch your ingenuity and imagination. Whenever possible, the training tasks allocated to you will be associated with carefully chosen, original, "real" work projects.

You will be encouraged to adopt a "deep learning" approach to your IC training and to view each task as a challenge. Personal involvement, concentration on the purpose and significance of the work rather than its literal aspects, and the integration of a sequence of tasks to produce a meaningful outcome are the objectives. You are expected to obtain the required experience by producing tangible, practical results.

A-5

5. General Information and Regulations

5.1 Enquiries

The IC Trainee Enquiry Counter is located on the 3/F of the IC Building at Room W309 (Tel: 2766 7585, e-mail: ic@polyu.edu.hk) and is open during the following hours:-

Monday - Friday 10:00 - 12:3014:30 - 17:00

Saturday, Sunday & Public Holidays Closed

If you need urgent help from the Counter other than the abovementioned hours, you may approach the IC General Office which is also located at Room W309.

5.2 Training Programmes

For every academic programme there is a specific, pre-approved programme of practical training. The training requirement for each academic programme is different. You may refer to the definitive programme document of your academic programme or IC Web Site at http://www.ic.polyu.edu.hk/student_net/train_prog.htm for details of your particular IC training programme.

Practical training in the IC is usually conducted on a modular basis. The duration of each module is normally one week.

5.3 Groupings

Most IC workshops are only able to accommodate a modest number of trainees at any one time. Before your training commences your class will therefore normally be split into several small groups, each of eight to twelve persons. Separate training timetables will be drawn up for each group. The grouping list is adhered to the training schedule in IC Web Site at http://www.ic.polyu.edu.hk/student_net/train_sched.htm.

To enhance communications within the IC, each student group will be invited to elect a group representative. Such representatives are expected to serve as focal communication points and assist the IC management/administration by disseminating information to group members when required. Periodically, group representatives may also be asked to attend meetings with the IC senior management, in which students' comments and feedback on IC training will be solicited.

A-6

5.4 IC Training Timetables

Depending on your academic programme, your pattern of attendance in IC training may be either:-

(a) block release, or (b) non-block release.

Because it is obviously the more industry-like, block release training is favoured by industrialists and by professional bodies - in particular, the Hong Kong Institution of Engineers. It is likely that your training programme will be in block release mode. If so, you will be released from the teaching activities of your academic department for continuous, extended periods, usually for several weeks at a time. On the other hand, if your academic programme requires you to attend IC training in non-block mode you will only be released by your academic department for limited periods, say for half-a-day or one day each week, over an extended time span.

The timetabling of training, both block and non-block, in the IC is an extremely complex affair - particularly so during the busy summer months. If you should require guidance on reading and understanding the timetable of IC training, please approach the IC Trainee Enquiry Counter.

Training Days

Unless otherwise specified, training will be delivered on weekday (Monday to Friday) throughout the academic year (i.e. Sem 1, Winter Break, Sem 2 and Summer Term). Training class will be suspended on public holidays.

Training Hours

08:30 - 12:15 ] Practical training work13:15 - 17:00 ]

Towards the end of each afternoon training session a short period will be set aside for tidying of equipment and machines, during which workshop staff will also be available for discussions.

In line with normal industrial/commercial practice, in addition to a one-hour daily lunch break from 12:15 till 13:15 your IC routine will usually also allow you two short tea breaks each day, one in the mid-morning (from 10:15 to 10:30) and one in the mid-afternoon (from 15:15 to 15:30).

These tea breaks should be regarded as a privilege which may be withdrawn if work requires, or if this concession is abused in any way.

A-7

5.5 Exemption from IC Training

If, for example, you are a mature or transfer student and consider that you have previously undergone a formal course of practical training essentially equivalent or similar to that which you are presently facing, or have already studied and passed the subjects to be taught in class by the IC staff, you may apply for exemption from each, or both. The authority to grant exemption rests with the IC. Applications must be made on the appropriate Form, IC-T15 (Practical Training Exemption), which is available from the IC Trainee Enquiry Counter. Late or retrospective applications will not normally be considered. You may approach the IC Trainee Enquiry Counter for more detailed information.

5.6 IC Tutorials and Trainee Feedback

A member of the IC staff will be appointed to act as your tutor and will occasionally meet your student group in class for discussions. Queries, complaints and suggestions may be channelled through him. Please feel free to approach your tutor at his office with any personal queries or problems you may have. Your tutor will look after your affairs while you are under training in the IC.

A meeting will be convened periodically between class/group representatives and the IC senior management. Any opinions or suggestions you might have regarding any aspect of IC training will be welcome.

5.7 Attendance and Timekeeping

Throughout your primary and secondary schooling you had to adhere to regular routines with rigid starting and finishing times. Now that you have entered tertiary education you have probably been introduced to the idea of "academic freedom" and will no doubt presently be enjoying a looser and more flexible lifestyle. You have to face the fact, however, that during your IC training you will be removed from the free and easy lifestyle and will be placed firmly back into the real world!

There are at least two very good reasons why the IC is compelled to maintain high standards of timekeeping discipline and we make no apology for that. First, the IC is a large and complex department. There can sometimes be as many as a thousand trainees under training in the IC Building at one time. The only way the training programmes can be organized and discharged effectively is if everyone pays ardent attention to their attendance and timekeeping. If the IC were to adopt a slack and undemanding regime, total chaos would probably result.

Second, and even more important, the IC strives for high standards of timekeeping discipline out of respect for you, the trainee. The IC is a professional training ground and has a duty to prepare you for your professional life ahead. One of the elementary rules of professional behaviour is that you should always be where you are required to be, and always on time. Life in the real world demands a high level of self-discipline. This is one of the things you will be taught during your time in the IC.

A-8

Actually, during your IC training you will be introduced to two different types of timekeeping discipline. One is industrial discipline; the other is professional discipline. Industrial discipline is imposed from without, whereas professional discipline stems from within and is part of the professional ethic.

Industrial discipline is the regular, factory-like routine to which you are required to conform throughout your modular training. As in the real industrial and business world, punctuality is vital and the attendance requirement is 100%. You must attend all your scheduled training sessions, and must be at your workplace, prepared to start work, on time. On arrival at the workshop, you will normally be asked to "sign in" on a timekeeping record sheet. Lame excuses for lateness - such as forgetfulness, oversleeping or traffic holdups - will not be accepted. Unauthorized absence or lateness will be penalized (usually in the form of extra training or work experience), the extent of the penalty being determined by the gravity of the case. If you wish to avoid such penalties all you have to do is maintain a good standard of self-discipline.

We ask you to accept the IC's industrial discipline for what it is - something which will help to build your character and prepare you for later working life. It may help if you think of this form of discipline as being a little bit like medicine. Even when you don't like the taste, you know it is doing you good! You therefore should not view the IC as a military-style establishment, but then you should not treat it as a holiday camp either. Remember, too, that IC training is an integral part of your academic programme. If you fail any training module due to lateness, poor attendance, or for any other reason, your academic award may be withheld.

Trainees participating in Team Projects (Manufacturing/Construction/Integrated Projects) are encouraged to exercise professional discipline. If your academic programme specifies one of these Team Projects as part of your IC training your project group members will be given certain freedoms to manage themselves like a team of professionals. Emphasis is placed on the team's commitment and capability to deliver the project on time and to the required standard. Team members may still follow the IC factory routine but, like true self-motivated professionals, may often also require to work outside that routine as and when the task demands. Project groups are therefore free within limits to choose and to agree among themselves their own attendance patterns. The only stipulation is that they must not disrupt the work of those trainees who are simultaneously undergoing modular training.

5.8 Leave or Absence

If you need to take leave from your scheduled IC training, you must seek prior approval, giving as much advance notice as possible, by completing form IC-T08 which is available from the IC Trainee Enquiry Counter. Retrospective approval of absence or lateness will usually only be granted on medical grounds, in genuine cases of illness. Such applications must be accompanied by a certificate from a registered medical practitioner and should be lodged with the IC Trainee Enquiry Counter immediately after the sick leave has been taken.

All other leave applications must be accompanied by supporting documents or explanatory letters and should be submitted to the IC Trainee Enquiry Counter in person. Applications unaccompanied by supporting documentation will not normally

A-9

be entertained. However, even if you have no such documents, you may seek the counsel of the IC staff in charge of Trainee Affairs who will advise you if you have a case worth considering. Please note that staff decisions in such matters are final.

Leave will not normally be granted to trainees who are sitting for external examinations.

Please note that absence from IC training for half-a-day or more, even with approval, must be made up. You are strongly advised to make up any such missed training before the finalization of result in that semester. Once the subject result has been finalized and released, your make up will not be counted. The IC Trainee Enquiry Counter will help you with the logistics.

If for any reason you are absent from training without approval a penalty will be imposed upon you. Ordinarily you will require to make up a period of training double that of the unauthorized leave.

Make-up Training can be arranged at the IC Trainee Enquiry Counter in person or by submitting online application form at IC Web Site at http://www.ic.polyu.edu.hk/student_net/makeupApp.htm. Online application will be confirmed by email.

5.9 Arrangement During Bad Weather

Please refer to the most update version of Student Handbook issued by The Hong Kong Polytechnic University.

5.10 Safety Gear

Trainees undertaking workshop training are required to wear the following: Safety shoes with non-slip soles and steel toe caps to reduce the risk of being hit

by falling object or contact with sharp object or exposure to chemical or sparks. Long trousers to reduce the risk of contact with sharp object or exposure to

chemical or sparks.

While our Electronics Workshop is exempted from wearing the safety shoes, robust shoes without the exposure of toes, instep and heels are required to be put on during the training in this workshop. In some IC workshops you will be issued temporarily with personal protective gear such as gloves, goggles, face visors, etc., the wearing of which will be compulsory if required by the instructors.

You should obey instructions on warning signs, notices and given by Workshop staff. You are not required to wear safety shoes or long trousers when attending lecture in Engineering Drawing, Safety and Computer Training.

Suppliers of personal protective gear can be found from the following web site: http://www.safetydirectory.hk/comp_ppe_tc.html.

A-10

5.11 Name Tags and Badges

For ease of identification, while under training in the IC you are required to wear a name tag. This will help the IC staff to assess individual trainee. Name tags may be purchased from the IC Trainee Enquiry Counter. As far as practicable, you should effect such purchases by group/class via a group/class representative.

5.12 Changing Rooms & Lockers

When attending workshop training, you must take along with you only your module reading materials and some writing materials. All other personal belongings must be stored inside the lockers in the student changing rooms.

Location of changing rooms:

Male Changing Room : W101Female Changing Room : W102

You must observe the following rules when using the lockers:-

1. Each trainee may use only one locker.2. You must provide your own padlock.3. You are cautioned against leaving your belongings in the changing room

unattended or storing valuable items in your locker. The IC will not be responsible for any loss or damage.

4. At the end of each training week you must clear your belongings and remove the padlock from your locker. Designated IC staff will break open lockers which are occupied by unauthorized users.

5.13 Tools and Materials

The regulations concerning the issue and return of tools and materials must be observed at all times.

You are not allowed to remove any tools or materials from a training area or store-room without the prior consent of the relevant IC staff member or storekeeper in charge. Any infringement of this rule will lead to disciplinary action; the action taken will obviously depend on the gravity of the case.

Loss of or damage to hand tools or machine tools must be reported immediately to the staff member in charge of the workshop. Trainees who are responsible for such loss or damage may be required to make good the loss/damage depending on the degree of negligence involved or the circumstances surrounding the mishap.

A-11

5.14 Booking of IC Facilities

Trainees are strongly encouraged to take full advantage of the IC's facilities. There is a considerable amount of high tech equipment within the IC Building, to at least part of which you will be given an introduction during your training programme. Time constraints inevitably mean, however, that you will seldom have the opportunity to explore the full potential of such equipment.

A number of short training programmes (normally of one or two days duration) which will enable you to become much more familiar with such modern equipment and technology are available to student groups on request. Such programmes are free of charge. Enquire about them with the workshop staff. The IC exists to serve you and all reasonable requests from student groups for additional training in specific high tech areas will be seriously considered.

If you are involved in a Team Project or other non-modular training activity, or if you simply wish to avail yourself of IC facilities, you may apply for the use of IC machine tools and other equipment by filling in Form IC-T01 which is available from the various workshops or the IC Trainee Enquiry Counter. Advance booking is required and it goes without saying that all safety rules must be observed.

5.15 Cleanliness

All workplaces must be kept clean and tidy. Cleanliness and tidiness can lead to improved productivity, and certainly to increased safety. You must take an interest in the cleanliness of your training area and help with cleaning down and oiling of machines. Smoking, eating and drinking are not allowed in the IC workshops, classrooms or other teaching areas.

5.16 Mobile Telephones and Pagers

Mobile phones, pagers and/or other devices that are unrelated to learning, and may produce disturbing noises, should be switched off in the IC workshops, classrooms or other teaching areas.

5.17 Training Certificate/Testimonial

Application should be made in writing, attaching a copy of either the examination result notification or transcript of studies.

A-12

5.18 Mandatory Basic Safety Training (MBST) Course

The IC is one of the course operators recognized by the Labour Department to offer Mandatory Basic Safety Training Course under the Section 6BA(4) and Section 6BA(2) of the Factories and Industrial Undertakings Ordinance, Cap 59. If you have undertaken IC Safety Training for 18 hours or above, you are entitled to apply for “Construction Industry Safety Training Certificate” and/or “Container Handling Industry Safety Training Certificate”, depending on the total number of hours of safety training you had undertaken.

Application should be made by class and application form (T-16) is available at IC Trainee Enquiry Counter.

5.19 Insurance

The Hong Kong Polytechnic University as an institution is insured against claims arising from accidents which may occur within its boundaries. Individuals as such are not insured and any person injured would have to lodge a specific claim for damages.

A-13

Appendix Ito Section A

Application Forms

The following is a list of various application forms which trainees may require. They are obtainable from the IC Trainee Enquiry Counter on a self-serviced arrangement. Some of the forms can also be downloaded at IC Web Site at http://www.ic.polyu.edu.hk/student_net/downloadform.htm.

Form No. Title of FormIC-T01 Request for IC Facilities/ServicesIC-T02 Request for R&D & Postgraduate Project SupportIC-T08 Application for Approval of LeaveIC-T15 Application for Practical Training ExemptionIC-T16 Application for “Mandatory Basic Safety Training Card” IC-T28 Training Attachment Application

A-14

Section B: Assessment Scheme

1. Introduction

The IC aims to provide you with relevant, high quality, practical training which is integrated with and complementary to your academic studies. The training programme for each course is different.

Training is conducted on a modular basis and each training module normally lasts one week. In most modules you will spend the entire week in a single IC workshop. Some modules may, however, require you to attend more than one workshop in the week.

Apart from workshop training, studies in Engineering Drawing (both manual and computer-aided), Computer Training and Industrial Safety may also form part of your IC programme.

Depending on your academic programme, you may be required to participate in a Team Project (Manufacturing/Construction/Integrated Project). This is also an essential part of your IC training. The assessment of your performance in such projects is carried out separately from that of your modular training.

IC training is an important and integral part of your study programme. You are advised to pay serious regard to your training assessment. Failure in any one of the assessed elements may result in your degree, diploma, or other academic award being withheld.

2. IC Assessment

2.1 What is Assessed?

a. Training Modules

All training modules are continuously assessed. The following elements are taken into account:-

i. Skills Acquisition (Assignment). While your IC training is not intended to make a craftsman of you, during your training you will naturally pick up various manual or task-oriented skills. You will be rated on these, and on the quantity and quality of your work output. Normally a mark out of 10 will be given.

ii. Technology Appreciation (Test). In most workshops, at or near the end of your training you will be given an Appreciation Test, usually in multiple choice format, to assess your understanding of the technical

B-1

principles underlying the training. Normally a mark out of 100 will be given.

iii. Workshop Report. On almost all IC training programmes, to your supervisors in every workshop in which you undertake training you must submit a short but thorough technical record of the work you have done. These reports are of paramount importance and will later be included in your Training Log Book. Your Workshop Reports must be compiled on the special four-side A4 sheets which can be purchased at the IC Trainee Enquiry Counter or downloaded at IC web site at http://www.ic.polyu.edu.hk/student_net/downloadform.htm. (Please see Appendix I for more details on how to prepare a Workshop Report). Normally a mark out of 10 will be given.

iv. Timekeeping. The IC operates like a Model Factory; your attendance requirement is therefore set at 100%. You must be present on every scheduled training day, and must attend each morning and afternoon session punctually. Unauthorized absence or lateness will be penalized. Your timekeeping performance will not affect your module overall assessment grade. However, if you have a poor attendance record and refuse to make up your training, you may be given a fail grade for that particular module.

v. Work Attitude. You are expected to take a serious and responsible attitude toward your training assignments. Only pass or fail grade will be given in this element and it will not affect your overall module assessment grade. However, if you failed in this element, you will be given a fail grade for that particular module.

You will be assessed on each of the above elements by the engineering and/or technical staff of the workshop in which the training module is conducted. In a minority of training modules one or more of the elements may be omitted from the assessment. For example, the Appreciation Test and/or Workshop Report may be waived in the case of demonstration/familiarization sessions of short duration. The workshop staff will advise you if this is the case.

b. Training Log Book

On completion of your IC training programme submission of a Training Log Book is usually mandatory. However, there is a small number of short IC training programmes for which the compilation of a Training Log Book is not required. You should check with your appointed IC tutor if you suspect that your training programme might be one of these.

Your Training Log Book should be a complete record of your training in the IC, and might be of considerable value to you in your future career, especially should you wish to enter one or more of the many Hong Kong or international professional technical/managerial Societies or Associations.

In particular, you will probably wish to note that many of the IC training programmes are officially recognized and approved by the Hong Kong

B-2

Institution of Engineers and, as such, your participation in same may exempt you from part of the professional training scheme requirements of that Institution.

Your Training Log Book will be assessed by the professional engineering staff of the IC who will take into account your report writing capability, your powers of observation, and your ability to comment and criticize in a constructive and professional manner. (Please see Appendix I for more details on how to compile your Training Log Book).

Normally a mark out of 10 will be given.

c. Engineering Drawing

The subject of Engineering Drawing is continuously assessed, consisting partly of assignments and partly of tests which respectively account for 70% and 30% of the final mark. However, some Engineering Drawings which only require a short duration of training may be solely assessed by assignments.

d. Computer Training

The subject of Computer Training is continuously assessed by assignment and exit test, which respectively account for 70% and 30% of the final mark. However, some Computer Training which only requires a short duration of training may be solely assessed by assignments.

e. Industrial Safety

The subject of Industrial Safety is assessed by portfolio, mini-project & presentation, as well as an end-of-session test which respectively account for 30%, 40% and 30% of the final mark.

f. Team Projects (Manufacturing/Construction/Integrative Projects)

Such projects are team activities which encompass design work, materials procurement, workflow planning, materials handling, on-site construction work or manufacture of equipment, quality control, assembly, testing, and evaluation. A group presentation is made just before the close of each project. The project assessment schemes will take into consideration of most/all the following: -

(i) The technical and leadership capabilities of the individual team members relating to various aspects of the project;

(ii) The initiative and effort of individual members, and the way they pull together as a team;

(iii) The competence with which the group presentation is planned and executed; and

(iv) The quality of the individual or team's final (written) project report; (v) The quality of the team’s final project/product.

Your project supervisor/tutor/mentor will give you an assessment scheme at the beginning of the project.

B-3

2.2 Assessment Results

Due to the diverse nature of the elements employed in the assessment of IC modular training the use of a grade-point system is preferred for the evaluation of trainee effort and attainment. Students may obtain either a mark out of 100 or 10, depending on which assessed element. The marks will be simplified to a ten-point system for ease of calculation. In the assessment of your IC training the following equivalence table will be used:-

Mark/Point Interpretation

10 – 9 Excellent

8 – 7 Good

6 – 5 Satisfactory

4 Marginal (Pass)

3 – 0 Failure

The result of a training module will be the average point of all of the assessed elements. If a training module is conducted in more than one workshop the assessments from the separate workshops shall be used to derive an overall average for the module.

Your attention is drawn to the fact that you will not be allowed to graduate from your academic programme if you failed your IC training.

* Please note, too, that if you submit your training assignments late or if they should require reassessment (for example, if for any reason you have to resubmit a Workshop Report or retake an Appreciation Test) you will, even if your late submission or resubmission is of fine quality, only be awarded this, the lowest pass grade. It is therefore in your best interest, and in the interest of IC discipline, that you discharge all your assignments to the best of your ability and submit them on time.

B-4

2.3 Failure

a. Incomplete Training

If you conduct yourself in a diligent and disciplined manner there is no reason why you should fail any element of your IC training. You are, however, hereby reminded that you must complete and pass all the assessed elements of all your training modules and ancillary IC studies. If you should fail in one or more element you will be required to make up the incomplete training and/or to resubmit the failed exercise or assignment. You may also incur a penalty as described in the following list:-

Failed Element Action required

i) Authorized absence - Make up the period of absence

ii) Unauthorized absence - Make up the period of absence with a penalty of additional work equivalent to the period of absence (i.e. your make-up period will be doubled)

iii) Skills Acquisition failure - Repeat the training moduleMaximum grade D

iv) Appreciation Test omitted - Take and pass the test

v) Appreciation Test failure - Retake and pass the testMaximum grade D

vi) Workshop Report overdue - Submit the ReportMaximum grade D

vii) Workshop Report failure - Resubmit the Report Maximum grade D

viii) Training Log Book overdue - Submit the Log BookMaximum grade D

ix) Training Log Book failure - Resubmit the Log BookMaximum grade D

b. Training Information accessible on IC Web Site

On the IC Web site at http://www.ic.polyu.edu.hk/sfb/makeup/makeup_ask.asp, you can check details of your incomplete training, if any, by clicking “Make-up Enquiry”. You can also submit your make-up application via the facility “Make-up Application”. You will be required to propose two time periods and a reply will be sent to you within 3 working days via e-mail. Make-up application is normally accepted at most three weeks in advance and arrangement must be made at least three working days before the scheduled training. Re-schedule/Cancellation of make-up session is normally not allowed after confirmation has been issued.

B-5

2.4 Trainee Feedback Questionnaire

In the IC we believe that assessment ought to be a two-way process. As well as having your efforts assessed by the staff of the IC, you will have the opportunity to make your own assessment, to comment on the usefulness of the various training modules which you undertake and about the manner in which the training is conducted.

Please understand that this is done out of respect for you, the trainee. It goes without saying that the staff of the IC deserve your respect and - make no mistake about it - will command your respect. At the same time, provided your behaviour is disciplined and decent, you are entitled to expect their respect in return.

At or near the end of every training module you will be asked to complete a questionnaire. Please regard this as a serious task - take your time and try to answer all the questions as honestly as possible. Feel free to offer your constructive suggestions for improvement. Your opinions and comments will be treated in strictest confidence.

Let us work together to make the IC a better place for staff and trainees alike.

B-6

Appendix Ito Section B

Report Writing

1 Introduction

Professional engineers and technologists must have the ability to prepare accurate and concise technical reports. During your IC training you will be encouraged to exercise your ingenuity and intelligence, to make observations, to ask questions, and to make value judgements on what you have done and seen. After each specific round of workshop training you will normally be asked to record your observations on a Workshop Report sheet. Later, on completion of your full IC training programme, you will require to compile these Workshop Reports into a Training Log Book.

It is vital that you take these report writing and log book compilation tasks seriously because it is on the quality of your observations and presentation therein that the major part of your IC training assessment will usually depend.

For each training module that you attend, informative and instructional reading materials will be issued to you. Even so, supplementary note taking is essential. Do bring with you some writing materials for note-taking throughout your IC training. These may then be referred to afterwards, when you are writing up your Workshop Reports.

2 Workshop Reports

On almost all IC training programmes, for every workshop in which you undertake training you are required to prepare and submit a short but comprehensive technical record of the work you did and the observations you made. Your Workshop Reports must be in your own hand-writing on the special A4 paper forms which can be purchased at the IC Trainee Enquiry Counter or downloaded at http://www.ic.polyu.edu.hk/student_net/student.htm. You are expected to use only one such form per Report. The Report should be technical in nature, with, where appropriate, sketches, diagrams, or charts to aid your presentation.

The Report should be from your personal perspective as a trainee and should focus on your work assignments and your observations. If you are given a number of jobs during a particular module it may not be possible to report all of them, in which case you will require to select one or two of the more important or interesting tasks to write about. Although the Report should contain relevant technical material it should not be a regurgitation of your module reading materials!

Each Workshop Report should contain a brief introduction followed by a main section describing matters of technical importance such as workshop procedures and processes, machine tools and equipment, factors affecting the choice of processes and tools, etc., together with an outline of industrial safety and maintenance considerations. The report should end with an overall assessment/conclusion in which constructive comments on the style, type and content of training, or any other pertinent matter, may be made.

B-7

The amount of effort required in the preparation of individual Workshop Reports may vary depending on the length of time you spend under training in any given workshop. Obviously if you spend a full week in a workshop you will be expected to learn more, and will have more to report, than if you spend only a couple of days. Generally your Workshop Reports should be as detailed and comprehensive as possible, but you must exercise your judgement and common sense as to how much effort to devote to each. In any event, you are not expected to report more than will fill up the four A4 sides of the report sheet.

You are required to submit each Workshop Report within one week after completing the relevant training module. Reports should be submitted (by group) to your workshop supervisor via your group representative. Except under special arrangements, the marked workshop reports will be returned to your group representative in our Trainee Enquiry Counter.

Should you score a failure on any Workshop Report, you will require to resubmit a fresh report, and to continue so to do until you score a pass, thereby offering you an incentive to submit good quality work in the first instance. It really is in your best interest to get your Workshop Reports right first time!

As a ‘back-up’ for your submission, you may wish to make a photocopy of your workshop report before submission. It is important that all your marked Workshop Reports, including any failed ones, must be retained, as they will later form the main body of your Training Log Book.

3 Training Log Book

Your Training Log Book should be a complete record of your training in the IC, covering your full training programme, and should reflect your personal technical, practical and industrial interests. It may also serve as an indication of your potential as an engineer or technologist.

Your (first attempt and any resubmitted) Workshop Reports make up the central core of your Training Log Book, to which you should add other related information and personal comment on your IC training. Feel free to be critical and to offer constructive suggestions for improvement where you think they are necessary or would be beneficial.

If a Team Project (Manufacturing/Construction/Integrated Project) is part of your IC training programme you should also include a few pages describing the nature of the project (with illustrations, if appropriate) and your role in it.

To help you present your Training Log Book in systematic fashion, the following format is suggested:-

i) Table of Contentsii) Introductioniii) Workshop Reports (marked)iv) Project Notes (if any)v) Comments and Conclusion (not less than 500 words)

B-8

If desired, the Table of Contents and the headings of each sub-section may be printed or typewritten. Everything else should be in your own hand-writing. The Training Log Book should be compiled within special, IC-manufactured file covers which are available for a modest fee from the IC Trainee Enquiry Counter. (As far as practicable, purchase should be made by group via a group representative).

You are required to submit your Training Log Book within four weeks of completing your whole programme of IC training (including your participation, if any, in a Team Project). Log Books should be lodged by group with the IC Trainee Enquiry Counter, and after assessment may be collected (again by group) from the same counter.

You should retain your Training Log Book after it is returned to you. Professional institutions to which you might later apply for membership may wish to inspect it.

B-9

Section C: Computer Training

1. Introduction

Computer applications are common and useful aide to professional engineers and technologists nowadays. To stay abreast of the trends, you may be required to undertake all or part of the computer training during your IC training depending on your training programme. The information is stated in your training programme which can be obtained from IC Web Site at http://www.ic.polyu.edu.hk/student_net/train_prog.htm.

The training pattern and assessment of computer training differ a lot from the normal practical training and therefore you are advised to read carefully the following information.

2. Modules

Standard modules each of 30 contact hours (except those specified) are offered as follows:

Module No. Module TitleIC3001 Computer Graphics & AnimationIC3002 Web Authoring & Internet SearchIC3003 Basic Scientific ComputingIC3004 General Computer & Network SkillsIC3005 Database & SpreadsheetIC3006 Project Planning and Business DocumentationIC3009 Database & Presentation for Electronic and Information EngineeringIC3010 Basic Scientific Computing and RhinoIC3011 Basic Computer Graphics (15 contact hours)

Some modules may be offered to some departments and programmes only. Students are requested to study carefully their programme definitive documents on which modules they need to take.

3. Who Should Attend

The Computer Training will be offered to all UGC-funded students who either have to fulfill training requirements and/or wish to better equip themselves by acquiring proficiency knowledge in the area.

C-1

4. Training Pattern

You must complete the Computer Training during the first year of their study as stipulated in relevant Definitive Course Document. For other UGC-funded students who wish to attend the Computer Training as a non-credit earning supplementary study, there is no limit to the training pattern.

5. Schedule and Offering Time

Classes will be offered throughout the academic year (i.e. Sem 1, Winter Break, Sem 2 and Summer Term) open to free booking by WEB-enrollment. Unless it is specified differently in Definitive Course Document, you can choose to take the Computer Training at any time throughout the year that best suits your own timetable.

Classes will be arranged in a non-block-week pattern during semesters or a block-week pattern during semester-breaks and summer periods. The non-block-week classes will be organized normally in 3-hour sessions in the mornings, afternoons or evenings for 10 weeks to allow you to fit in your own schedule. The arrangement can be flexibly arranged when a department releases a class of students for certain periods during the semester to attend the computer training or when students can form a group of more than 12 by themselves proposing to the Industrial Centre for a specific time-slot. Competition for places in block-week classes during semester-breaks and summer periods would be keen and you are encouraged to make early reservations for non-block-week classes so as to free summer time for attachments or co-curricular activities. You should plan carefully your schedule when taking the Computer Training and avoid overloading yourselves in one semester.

6. Credit

Upon completion of the Computer Training you will obtain subject credit accordingly as stipulated in your Definitive Course Documents. No additional credit will be awarded for extra modules. However, successfully completed extra modules can be treated as co-curricular achievements (please see Item 11).

7. Competency Test

Competency Tests (pre-tests) are available to you before you choose to attend the Computer Training. If you passed the Competency Tests, you will be exempted from attending the Computer Training and earn the credit. However, you can choose to attend the training class without attempting the competency tests.

You may attempt the Competency Test only once for a particular module. If you failed the Competence Test or did not turn up at the test, you will be required to attend

C-2

the training class and accomplish all passing requirements of the module in order to meet the training requirement for graduation/progression as stipulated in your course document.

Competency Tests will be organized periodically and appropriately as required with details announced on IC Homepage at http://www.ic.polyu.edu.hk/programmes/computer.htm. You can web-enroll and view your own result of Competency Tests on the same homepage normally not later than 2 weeks after the event is taken place.

8. Class Enrollment

You can register by web-enrollment at IC Homepage. A PIN which will be delivered to your PolyU Email box authenticates you for subsequent enquiry and add/drop modules on the Web.

If you had successfully registered on a class, you will be confirmed by email. A registered class cannot be dropped after the specified cut-off date.

If a class is full, your registration will be put on a waiting list and you will be notified by return of the ranking on the waiting list. If a seat becomes available, the first student on the waiting list will be informed by e-mail and acceptance has to be made within 24 hours after being notified. If no valid acceptance is made, the offer will be made to the next student on the waiting list.

You are not allowed to book more than three classes of the same module on the waiting list. Any successful registration on a class will forbid the subsequent registration on any classes of the same module even on the waiting list. You will be prompted for having your name removed from the waiting list before a successful registration is made on a class of the same module.

Provided seats are still available, walk-in students upon accepted by the staff in-charge after checking up for openings on the registration list will enrol retrospectively on the web as directed by the staff.

Please note that you should drop out from a class if you discovered that you are not able to attend the class after successful registration and before the first session of training. You should do so by either dropping out the class on the web before the specified cut-off date or approaching the IC Trainee Enquiry Counter for class drop out after the cut-off date. If you both do not attend and drop out from a class after successful registration, your class record will be treated as 0% attendance and a fail grade will be granted to that particular class/module. You will be requested to pay a “Late Assessment Fee” of HK$245 per module before allowing to either attempting the Competency Test again or re-taking the module. (See next section on Assessment)

C-3

9. Assessment

The assessment scheme includes Continuous Assessment (70%) and Exit test (30%) for each module. You have to obtain 40% or more on the overall to get a pass. If you failed a module, you would be required to pay a “Late Assessment Fee” of $245 per module before allowing to either attempting the Competency Test again or re-taking the module. Late assessment fee will be waived for cases on grounds other than academic. For student who is permitted to take a re-assessment on academic grounds, the maximum grade that may be awarded after re-assessment is grade D. For student who is permitted to take a re-assessment on grounds other than academic, it will be regarded as a first assessment and the actual grade will be awarded.

10. Workshop Report

Although the computer training is different from the practical training, you are still expected to complete a workshop report. The workshop report is normally one of the assignments submitted during the computer training and the IC staff will inform you about that. Similar to other Workshop Reports which you have submitted for other practical training, the Workshop Report you undertake for the computer training will also form part of your Training Log Book. You should keep a copy of your submitted Workshop Report (or assignment) for inclusion in your log book to be submitted at the end of your IC training.

11. Co-curricular Achievement Transcript (CAT)

If you have successfully attended particular Computer Training Module(s) which is(are) not specified in your Programme Definitive Document as compulsory training requirement, the training can be recognized as your co-curricular achievements. These records will be periodically sent to SAO for their compilation of Co-curricular Achievement Transcript (CAT). You may approach SAO to ask for your own CAT for reference or retention.

C-4

Section D: Safety

1. Introduction

Safety is obviously important to each of us as no normal person wants to be injured, maimed, or killed. Apart from the personal factor, safety is also important economically since injured workers inevitably disrupt the production process and place an extra burden on taxpayers in terms of hospital services/treatment, which in turn can result in additional pressures on various other social services in Hong Kong.

Good safety practice is in the first instance a personal thing and it is up to each of us to develop safe work habits. Safety is strongly emphasized in the Industrial Centre in order to educate future engineers, managers, owners and supervisors and help them to implement safe practices in local industry.

Good safety practices are a matter of thinking ahead. They are humane, and undoubtedly can improve productivity and thus make good economic sense!

Remember that your safety begins with you. We in the IC will make every effort to ensure that you work in a safe environment and that you are not injured, but in the final analysis it is up to you. Please remain vigilant at all times and have proper regard for your own safety and for the safety of others around you.

D-1

2. General Safety Rules

You Should 1. always use the correct tools for the job in hand.

2. replace tools that are worn or damaged.

3. keep tools and equipment in the proper racks or on a work-bench when not in use.

4. switch off the power supply before removing machine guards for any reason.

5. keep gangways and areas around machines clear and free of obstruction.

6. clean up your machine and your work area when you have finished work.

7. obey instructions on warning signs or notices.

The safest bench is a tidy bench

D-2

You Should Not 1. operate any machine unless you are authorized to do so.

2. allow yourself to be distracted from your work when operating any machine.

3. walk away and leave your machine running.

4. play or run in a workshop.

5. remove signs posted on a machine indicating a dangerous condition, or that it is under repair, unless you have been instructed to do so by the person in charge.

It is dangerous to let your attention wander

D-3

3. Personal Safety

You Should 1. report immediately any accident to your supervisor, however insignificant it may appear to you.

2. keep your hair short or bundle long hair.

3. wear eye protector if provided.

4. wear protective clothing up if provided.

5. roll up sleeves, or button the cuffs.

6. keep your hands away from all moving work or machine parts.

7. beware of burrs and sharp edges; wear gloves if provided.

8. ensure that everything is secure before starting a machine.

9. wear protective shoes and long trousers when in the workshops.

11. wear a safety helmet and use a safety belt when working at height 2 m or above.

You Should Not 1. lean on a machine which is running because you can easily slip into the moving parts.

2. move too close to a person concentrating on a machining operation or distract him in any way as it may annoy and/or alarm him, thus resulting in an injury or a ruined workpiece.

3. use compressed air to clean swarf from a machine; such action can turn the chips into small missiles which may cause injury, even to someone who is quite a distance away.

4. use compressed air to remove dirt from your clothes as particles may unexpectedly be directed toward your eyes.

5. wear gloves when you are close to moving work or machine parts.

D-4

4. Safety in Bench Work

A. Marking-out Tools

You Should 1. sharpen such tools as scribers, dividers and screwdrivers whenever necessary.

2. carry all sharp-pointed tools with the points held downwards.

3. place all heavy objects such as angle plates, surface plates and workpieces in such a way that they cannot drop off the bench and injure your feet.

4. form a habit of handling all tools carefully.

You Should Not 1. carry sharp tools in your pocket.

2. use dull tools.

B. Vices

You Should 1. use a brush to clean metal filings from the vice or the workpiece.

2. apply force against the fixed jaw of a vice when carrying out a bending operation.

You Should Not 1. play with the handle of a bench vice.

2. use piping as a handle to tighten a vice.

3. attempt to blow metal filings from the vice or the workpiece as they may fly back into your eyes.

C. Screwdrivers

You Should 1. use only screwdrivers which fit the screw slots correctly.

2. be able to apply more pressure with a long-handled screwdriver.

You Should Not 1. hold a small workpiece in one hand whilst turning a screw in it with other hand.

D-5

D. Hacksaws

You Should 1. learn to hold the hacksaw correctly.

2. ease off the pressure when the hacksaw is nearly through the workpiece.

3. instead of following the old cut, turn the work over and saw from the opposite side when a new blade is placed in the frame.

You Should Not 1. bend or twist the blade too much.

2. attempt to use a hacksaw blade without the frame

Dangerous Chisel and Hammers

D-6

E. Chisels

You Should 1. learn how to hold and strike a chisel correctly before attempting to use one.

2. always wear safety glasses when using a chisel.

You Should Not 1. chip in such a way that the chips fly in the direction of other persons.

2. use a chisel on hardened steel.

3. use a chisel with a mushroom head.

F. Hammers

You Should 1. before using a hammer, make sure that the handle is not broken or loose.

2. keep the handle clean and free of oil or grease.

3. grasp the handle tightly.

You Should Not 1. hold the handle near the head.

2. strike sharp, hardened edges with a hard hammer.

G. Files

You Should 1. always keep the file clean.

You Should Not 1. use a file without a handle.

2. use a file as a lever.

3. use a file to strike against other metal objects.

4. let the file touch the vice jaws.

D-7

H. Spanners and Wrenches

You Should 1. always select the best type of wrench available and check its condition before use.

2. always pull on a wrench - NEVER PUSH.

3. when using a large wrench, brace yourself so that you will not lose your balance if the wrench slips or the bolt loosens suddenly.

You Should Not 1. use a wrench as a hammer.

I. Pliers

You Should 1. select the correct type and size of pliers for the job in hand.

2. keep your fingers away from the jaws when pressure is being applied.

You Should Not 1. use pliers to turn nuts or bolts.

Strained spanner caused by extended handle

D-8

5. Safety in Using Basic Machine Tools and Attachments

You Should 1. make sure that the workpiece is set up securely and tightly with workholding devices - bolts and snap clamps, C-clamps, chucks, collets or fixtures.

2. stop the machine before changing speed, making any necessary adjustment or taking any measurements required.

3. remove wrenches and all other tools from the work area after setting up the machine.

4. when using a drift to remove a tapered-shank drill, always place a piece of wood below the drill to protect the drill point; it may also help to protect your toes.

5. stop the machine immediately if you hear unusual noises coming from it.

6. support a workpiece that extends out of the chuck by more than five times its diameter with a steady-rest or tailstock.

7. always wear eye protection.

8. always stay within easy reach of the controls while a machine is running; an unexpected emergency may require quick action on your part.

9. before operating the rapid traverse control, loosen all locking devices on the machine axis to be moved.

10. after using a shaper, clean the machine for the next operator and perform the following steps in the interest of safety:

i. remove the cutting toolsii. set the tool head to the vertical position and retract the tool

slide (THIS IS VERY IMPORTANT!)iii. set the stroke length to minimumiv. check that the clutch is disengaged

11. place cutters on a wooden board in order to protect both the cutting edges of the tools and the surface of the machine table.

D-9

Clamping the Workpiece

D-10

a. Cup Type Goggles

b. Visor Type Goggles

c. Face Shield

Three types of eye protection employing polycarbonate plastic lenses 0.080 in. thick. This material has successfully withstood a cold impact test in which a projectile was moving at 500 feet per second.

D-11

You Should Not 1. operate a machine with a guard open or if a guard has been removed.

2. try to lift heavy chucks and attachments; always seek assistance or use lifting appliances.

3. leave a chuck key in the chuck at any time.

4. allow any one but yourself to operate the machine controls.

5. wear gloves, wrist watches, long sleeves or anything that might get caught in the machine.

6. stand or permit any one to stand in front or at the back of the ram of a shaping machine.

Machinery and Machine Guards are only as Safe as the Operator will Permit

D-12

6. Safety in Operating Grinding Machines

You Should 1. wear safety goggles when grinding.

2. inspect all grinding wheels for cracks or chips (by RING TEST) before mounting.

3. handle and store grinding wheels carefully.

4. adjust the work-rest properly, positioning it no more than 3.0 mm from the grinding wheel, before starting the wheel.

5. make sure that the safety guard covers at least half the grinding wheel; never start the machine until the guard is in place.

6. after the machine and the coolant pump are turned off, allow the grinding wheel to run for several minutes in order to remove excess coolant (if this is not done, the wheel may become out-of-balance).

7. dress the grinding wheel when necessary to remove loading or glazing, both of which reduce the cutting action; dressing must be done under the direction of an IC Training Officer.

8. turn the grinding wheel over by hand to check clearance before switching on.

9. ensure that the grinding wheel is clear of the workpiece and that the feed is disengaged before starting the machine.

You Should Not 1. use grinding wheels that have been dropped.

2. exceed the maximum allowable operating speed of the grinding wheel.

3. force the workpiece into the grinding wheel.

4. mount an abrasive wheel yourself, unless you have been authorized to do so.

5. leave a grinding machine unattended; switch the machine off before you go away.

6. attempt to remove the workpiece (or open the holding vice, or shut off the magnetic chuck) until the grinding wheel clears the job and has come to a complete stop.

D-13

A wheel dresser of the revolving cutter type. Lugs at the base of the dresser fit between the wheel and the work rest to provide proper support and control.

D-14

7. Safety in Foundry

You Should 1. wear a respirator when handling dry sand or fine powders and keep the moulding bed reasonably moist; wet sand is normally not dangerous, but fine, dry silica particles, binders and dressing powders can be hazardous to health.

2. keep shovels and moulding tools in their correct places to avoid accidents.

3. always preheat the metal feedstock before placing it in the melting furnace to avoid spurting of the very hot, liquid metal.

4. wear a fire-proof apron, leg protection, and heavy duty gauntlets when handling molten metal.

5. wear leather safety shoes and long trousers before stepping into the foundry area.

6. wear a face shield before approaching a crucible or melting furnace containing molten metal.

7. when pouring molten metal, always ensure that those persons who are not taking part in the operation are kept well away from where the pouring is taking place.

You Should Not 1. apply an excessive amount of water during the mouldmaking process; if water is used in repairing a mould, the mould should be skin-dried using a blow torch.

2. touch any metal objects, bricks, ladles, etc. with your bare hands unless you are absolutely certain they are cold.

D-15

8. Safety in Electroplating

You Should 1. wear an apron, rubber gloves and boots; defective, damaged or leaking protective clothing must not be worn.

2. if you come into contact with chromium chemicals in liquid or solid form, wash the affected part at once under running water.

3. if you have a cut, graze or burn, wash it thoroughly then cover it with a sterile waterproof adhesive wound dressing and a waterproof plaster.

4. wash your hands and face thoroughly after work and before eating.

5. report to a doctor immediately if there is any sign of a skin problem or if a nasal infection appears.

You Should Not 1. bring food or drink of any kind into the Materials Surface Finishing workshop.

2. work if you have an uncovered fresh wound on your finger, hand or arm.

D-16

9. Safety in Operating Plastics Moulding Machines

You Should 1. observe the rule that only one person at a time should be in charge of the operation of a moulding machine.

2. beware of the hot melt (150C-280C) when operating Injection Moulding Machine, also to check the functionality of safety gate before operation. You must make sure yourself understand the function of each selector switches.

3. wear safety glove when performing mould assembling training practice.

You Should Not 1. remove the flash from the open mould of the injection moulding machine unless the power is off; never reach over the top of the injection moulding machine, even when the safety gate is closed.

2. change moulds on an injection moulding machine without using lifting gear.

3. open the side doors when operating Vacuum Forming Machine. You should set the selector switch to “OFF” before removing the mouldings from the frame.

4. put your fingers to the heating zone of the bending machine.

5. employ compressed air gun without wearing eye protective gear.

D-17

10. Safety in Welding

You Should 1. always protect hoses from being trampled on or run over, and avoid tangles and kinks.

2. protect hoses from flying sparks, hot slag, hot objects and open flame.

3. ensure that all connections between regulators, adapters and cylinder valves are tight; escaping gas can generally be detected by the odour; leakage can be detected by applying soapy water but never by means of an open flame.

4. when welding or cutting is to cease temporarily (e.g. during lunch hour), close the cylinder valves and release all gas pressure from the regulators by opening the torch valves until flow ceases, then release the pressure adjusting screw and close the torch valves; follow the same procedure if the equipment is to be shut down overnight or a gas cylinder has to be replaced.

You Should Not 1. strike an arc on a compressed gas cylinder.

2. weld in the vicinity of inflammable or combustible materials.

3. weld in a confined space without adequate ventilation.

4. do any chipping or grinding without suitable goggles.

5. use white lead, oil, grease or other pipe fitting compounds to make joints.

6. use matches for lighting torches (hand burns may result); instead, use suitable friction lighters.

7. attempt to relight a torch that has ‘blown out’ without first closing both torch valves; relight the torch in the proper manner.

8. hang a torch by its hose on regulators or cylinder valves.

9. torch cut material in such a position that sparks, hot metal or severed sections will fall on cylinders, hose or

D-18

Safety goggles must be worn in order to provide protection

feet; always keep the flame directed away from cylinders.

D-19

A. Safety in Using Oxygen

You Should 1. always refer to oxygen by its correct name ‘OXYGEN’ and not by the word ‘air’.

2. open the oxygen cylinder valve one full turn when in use.

3. make certain that the cylinder valve is tightly closed before handling or moving the cylinder.

You Should Not 1. store oxygen and acetylene cylinders together; they should be stacked separately.

2. use oxygen near inflammable materials, particularly grease, oil or any substance likely to cause or accelerate a fire; oxygen itself is not flammable but is a vigorous supporter of combustion.

3. permit oil or other readily oxidizable substances to come into contact with oxygen cylinders, valves, regulators, hose or fittings; do not handle oxygen cylinders with oily gloves.

4. attempt to mix gases in an oxygen cylinder.

5. attempt to draw oxygen from a cylinder without a suitable regulator attached to the cylinder valve.

6. tamper with or attempt to repair oxygen cylinder valves.

D-20

B. Safety in Using Acetylene

You Should 1. call acetylene by its correct name ‘ACETYLENE’ and not by the word ‘gas’; acetylene is far different from city or furnace gas.

2. use and store acetylene cylinders in an upright position.

3. keep sparks, flames and heat away from acetylene cylinders.

4. turn the acetylene cylinder in such a way that the valve outlet points away from the oxygen cylinder.

5. to open an acetylene cylinder, turn the cylinder valve key one full turn.

6. keep the acetylene cylinder valve key on the valve stem while the cylinder is in use so that the acetylene supply may be cut off quickly in case of emergency.

7. when returning empty cylinders, tighten the cylinder valves to prevent escape of residual gas.

8. in the event that a leak is detected in an acetylene cylinder, remove the cylinder to open air, away from fires, flames or other sources of ignition and notify the supplier at once.

You Should Not 1. attempt to draw acetylene from a cylinder without reducing the pressure through a suitable regulator attached to the cylinder valve.

2. attempt to connect acetylene regulators to oxygen cylinders, or use acetylene hose or other pieces of apparatus in the oxygen supply line.

3. attempt to transfer acetylene from one cylinder to another, nor to refill an acetylene cylinder, nor to mix any other gas or gases in an acetylene cylinder.

4. use acetylene at pressures in excess of 1.0 bar.

D-21

11. Electrical Safety

You Should 1. before working on an electrical apparatus, switch off the power supply and make sure that it cannot be accidentally switched on again; disconnect the supply if possible.

2. to remove static charges, earth high voltage circuits or capacitors after they have been disconnected.

3. check wiring and components with a suitable instrument or tester before touching electrical equipment.

4. note the colour code for three-core mains cables used with portable tools and appliances.

Live WireNeutral WireEarth Wire

Brown Blue Yellow/Green

5. report all electrical defects at once

e.g. cracked or perished insulationloose pins and plugsbadly fitting plugs and socketsdamaged switch coversdetached earth wires

6. immediately cease using electrical equipment which has been discovered to be defective and disconnect the power supply until repairs have been made.

D-22

The use of potentially unsafe temporary wiring should be avoided..

You Should Not 1. take liberties with electricity.

2. interfere with levers, knobs, push buttons or switches on electrical equipment.

3. experiment without permission; first ask your Training Officer.

4. use any damaged test equipment, meters, socket outlets or other wiring accessories, portable electric hand tools, etc.; report defects immediately.

5. touch electrical equipment with wet hands in case there is a fault in the equipment.

6. use electrical equipment or tools without a proper earth connection.

7. use any tools or equipment having incorrect polarity (the power supply must be taken from Live-Neutral terminals and not Live-Earth terminals).

D-23

12. Safety in Building Construction Work

You Should 1. stack building materials properly, leaving passageways free from obstruction.

2. remove all projecting nails from timber.

3. make sure working platforms are properly fixed and secured when you are working at a height. Platform higher than 2.0 m above ground should be surrounded by a safety fence of at least 1.0 m high and provided with safety harnesses anchored to a fixed point.

4. use a proper access ladder.

5. keep a sharp lookout on building sites for any hidden traps such as openings in the floor, manholes, trenches, projecting nails, falling objects, etc.

6. wear suitable safety helmets, protective footwear and put on appropriate personal protective equipment during construction works.

7. keep your back straight and knees bent when lifting heavy objects.

8. refer to safety measures on Electrical safety given in Section 11 before working on electrical apparatus.

9. refer to safety measures on Welding safety given in Section 10 before carrying out any steelwork welding.

You Should Not 1. drop materials, equipment or tools when working at a height.

2. wear cotton gloves when using woodworking machinery.

3. use a circular saw unless under direct supervision.

4. use compressed air to remove dirt from your clothes.

5. operate any equipment and tools without permission and guidance of instructors.

D-24

13. Safety in Power Press Operation

You Should 1. make yourself thoroughly familiar with the construction and function of the mechanism of both the press and its safety devices before using them.

2. observe the rule that only one operator at a time is allowed to operate the press.

3. if anything appears to be wrong with the tools, the materials, the press or the safety devices, notify your Training Officer immediately; on no account tamper with them yourself.

4. learn to handle strip or sheet metal, blanks, etc. as carefully as possible; carelessness in handling such materials may easily result in a lacerated hand.

You Should Not 1. set the dies with the power on; always be sure that the motor is switched off.

2. run the press over unless all guards are in the safe position.

3. lean on parts of the press that are liable to move; serious injury may result.

D-25

Automatic and Trip Guards

14. Safety in PCM Workshop

You Should 1. wear protective clothing, leather gloves, goggles, safety shoes and long trousers when operating guillotine and deburring equipment.

2. wear rubber gloves, plastic apron, goggles, face shield, protective shoes and long trousers when performing operations which involve the use of alkaline or acidic materials.

3. wear protective gloves when performing brushing operations with Brushing Machine.

4. keep the workplace clean and dry.

5. when diluting or mixing chemicals and solutions: (a) Always add acid to water-------not water to acid (b) Pour chemicals slowly and avoid splashing (c) Stir at intervals during mixing, but do not make

additions while stirring.

6. avoid inhaling chemical vapour. If enough vapour is inhaled to cause discomfort, secure first aid at once.

7. keep all containers closed after using and carefully labelled.

8. keep the chemical materials away from excessive heat and open flame.

You Should Not 1. look into the primary laser beam, or directly into reflections of the beam, and never to aim the laser beam with the eye. Do not let the laser strike exposed skin surfaces

2. handle metal sheet with bare hands. Their edges are sharp as knives.

3. lift metal sheet in coil form beyond one's capacity. If in doubt, get a fellow-worker to help. It is not advisable that weights greater than 30 Kg be lifted manually by one person.

4. store a chemical in any container other than the one in which it was shipped.

D-26

15. Safety in Operating Rapid Prototyping Systems

You Should 1. put on full coverage of face shield, aprons, gloves and safety shoes when doing post processing of SLA parts.

2. avoid skin contact with SL parts, resin and TPM.

3. prevent splashing TPM/Alcohol during the cleaning processing.

4. wash hand and forearm skin thoroughly immediately following the SL part washing.

5. wear leather gloves first before putting your hand inside the FDM building chamber.

6 wear leather glove while handling the hot building platform or FDM parts.

7. wear dust-mask and eye protection gear when removing the support structure or doing polishing of FDM parts.

8 wear respirator and safety goggle when performing part removal operation of 3D printing parts.

9 prevent excessive exposure of the fine powder when performing part removal operation of 3D printing parts.

10 wear safety glove while doing infiltration process for the 3D printing green part.

You Should Not 1. use the compressed air gun to clean up your clothes even

full coverage of face shield is employed.

2. get inside the room if the SLA machine is during maintenance or SL parts repairing operation is carried out.

D-27

16. Procedures to be taken in Case of Fire

A. In Case of Fire (i.e. if you discover a fire)

1. Do not panic.

2. Sound the fire alarm by activating the break-glass alarm switch in the corridor.

3. If time permits phone the Campus Security Control Centre by dialling 2766 7666 or using emergency telephone nearby.

4. Follow the procedures under B.

B. On Hearing the Fire Alarm

All trainees must go to the fire assembly area if the alarm sounds 30 seconds or more.

1. Switch off power/fuel supply to machinery and plant if time permits.

2. Leave the building as quickly as possible by the stairs and gather at the Podium area facing the IC Building. Do not use the lifts.

3. DO NOT return for valuables or for any other reason until the area is declared safe by the attending Fire Services personnel or the PolyU Security/Fire Protection Officer.

4. After arriving at the assembly area, approach the workshop staff as soon as possible to facilitate the taking of a head count.

C. Only tackle a fire if you are absolutely certain that there is no imminent danger. Fire hose reels and/or portable fire extinguishers can be found at various locations in the workshops, corridors and lobbies.

Report to the Campus Security Control Centre via IC staff even if the fire has been extinguished.

Trainees should familiarize themselves with the locations of the break-glass alarm switches, Emergency Exits and the Assembly areas during their daily routine around the IC building.

D-28

17. In Case of Emergency

A. Introduction

In case of emergency when life and/or property on the campus are endangered, trainees are encouraged to report promptly to the 24-hour manned Campus Security Control Centre for assistance. The well-trained security team will be dispatched to the scene to render on-the-spot assistance. If the situation demands, the Campus Security Control Centre will request assistance from other departments or Government bodies such as Police, Fire Services, Ambulance etc.

B. Nature of Incident

1. Fire2. Any accident/injury3. Electric shock4. Person reported seriously sick5. Person reported shut in lift6. Leakage/spillage of chemical7. Flooding8. Any crime9. Any other incidents that life or property is endangered.

C. Campus Security Control Centre

The centre in the Technical Services team is located at P111 which is manned by security staff 24 hours a day. In case of emergency, staff members or students can report the incident to the centre either in person or by dialing

2766 7999 (emergency line) or using emergency telephone nearby

Particulars to be reported to the Campus Security Control Centre

1. Your name and department2. Your contact telephone number3. Nature of incident with brief description4. Full detail of location of incident5. Any person(s) injured in the incident.

After the incident, you should give the details to the attending security staff or the attending Fire Services / Police personnel and the IC HSE Manager / Departmental Health and Safety Officer in order to assist them for their follow-up investigation.

D-29