DON BOSCO BOYS HOME AND VOCATIONAL

TRAINING CENTER, INC

Sector: METALS AND ENGINEERING

Qualification: SHIELDED METAL ARC WELDING (SMAW NC

I)

Module Title: PRACTICE HOUSEKEEPING PROCEDURES

Name:

Signature: Cell #:

Instructor: Signature:

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 DON BOSCO BOYS HOME AND VOCATIONAL TRAINING CENTER, INC
P.D.M.S. dumangas, Iloilo, Tel. no. (033) 393-3677; Cel#: 0923-740-1911
TVET Center and Senior High School Sectors
FB Account: Don Bosco Dumangas;Email :donboscodgas@gmail.com

MODULE CONTENT
QUALIFICATION: SHIELDED METAL ARC WELDING (SMAW NC I )
MODULE TITLE: PRACTICE HOUSEKEEPING PROCEDURES
INTRODUCTION:
This unit covers the knowledge, skills and attitudes required to apply the basic
housekeeping procedures.
NOMINAL DURATION: 6 HRS
LEARNING OUTCOMES:
LO1. Sort and remove unnecessary
items LO2. Arrange items
LO3. Maintain work area, tools and equipment
LO4. Follow standardized work process and procedures
ASSESSMENT CRITERIA:
 Reusable, recyclable materials are sorted in accordance with company/office
procedures
 Unnecessary items are removed and disposed of in accordance with company
or office procedures
 Items are arranged in accordance with company/office housekeeping
procedures
 Work area is arranged according to job requirements
 Activities are prioritized based on instructions.
 Items are provided with clear and visible identification marks based on
procedure
 Safety equipment and evacuation passages are kept clear and accessible
based on instructions
 Cleanliness and orderliness of work area is maintained in accordance with
company/office procedures
 Tools and equipment are cleaned in accordance with manufacturer’s
instructions/manual
 Minor repairs are performed on tools and equipment in accordance with
manufacturer’s instruction/manual
 Defective tools and equipment are reported to immediate supervisor
 Materials for common use are maintained in designated area based on
procedures
 Work is performed according to standard work procedures
 Abnormal incidents are reported to immediate supervisor

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 Work is performed as per instruction
 Company and office decorum are followed and complied with.
 Work is performed in accordance with occupational health and safety (OHS)
requirements

INFORMATION SHEET 4.1-1

(LO1 Sort and remove unnecessary items)

Learning Objectives:
After reading this INFORMATION SHEET, you must be able to execute
correctly the procedure in sorting and remove unnecessary items, maintain
work areas, tools and equipment, follow standard work procedures and
perform work spontaneously.
Introduction:
This course is designed to enhance the knowledge, desirable attitudes and
skills to perform Shielded Metal Arc Welding work to the standard expected in
the workplace.

I. PRINCIPLE OF 5S

A. 5S is the name of a workplace organization

method that uses a list of five Japanese
words: seiri, seiton, seiso, seiketsu, and
shitsuke. Transliterated or translated into
English, they all start with the letter "S". The
list describes how to organize a work space for
efficiency and effectiveness by identifying and
storing the items used, maintaining the area and items, and sustaining the
new order. The decision-making process usually comes from a dialogue
about standardization, which builds understanding among employees of
how they should do the work.

 THE 5S ARE:
1. Seiri (Sort)
o Remove unnecessary items and dispose of them properly
o Make work easier by eliminating obstacles
o Reduce chance of being disturbed with unnecessary items
o Prevent accumulation of unnecessary items
o Evaluate necessary items with regard to cost or other factors.
o Remove all parts not in use.

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 2. Seiton(Straighten)
o Arrange all necessary items in order so they can be easily picked for use
o Prevent loss and waste of time
o Make it easy to find and pick up necessary items
o Ensure first-come-first-served basis
o Make workflow smooth and easy
o Can also be translated as "set in order" or "streamline"

3. Seiso(Shine)
o Clean your workplace completely
o Use cleaning as inspection
o Prevent machinery and equipment deterioration
o Keep workplace safe and easy to work
o Can also be translated as "sweep"

4. Seiketsu(Standardize)
o Maintain high standards of housekeeping and workplace organization
at all times
o Maintain cleanliness and orderliness
o Maintain everything in order and according to its standard.
o Everything in its right place
o Prominently display a picture or diagram showing the proper layout of
the workspace.

5. Shitsuke(Sustain)
o To keep in working order
o Also translates as "do without being told", (though this doesn't begin
with S).
o Perform regular audits

B. Additional S's Safety, Security and Satisfaction

Other phases are
sometimes included e.g.
safety, security, and
satisfaction. These
however do not form a
traditional set of
"phases" as the
additions of these extra
steps are simply to
clarify the benefits of 5S
and not a different or
more inclusive
methodology.

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C. What Are the Benefits of 5S Implementation?

1. Productivity
o Every organization desires improved productivity, as it increases overall
return on investment. The 5S implementation process frequently
provides this improvement, reports Strategos. The removal of
unnecessary items and maximization of workspace efficiency alone can
help to create improved productivity by limited the amount of time
wasted. The less time spent searching through unnecessary items or
moving through poorly organized workspace means more time spent
actually working.

2. Safety
o Improved safety represents another benefit of 5S implementation,
according to Strategos. A clean working environment, especially in
manufacturing, can significantly reduce the number of injuries sustained
by workers. Spills of chemicals or liquids that go unattended magnify the
chances of slips and falls. Methodical cleaning procedures limit the
probability of such an event. Reduction in the amount of travel through
the work environment also minimizes this risk by limiting unnecessary
exposure to hazards elsewhere in the facility. This provides an added
benefit of improving morale, as a low incidence of injury conveys a
concern on the part of the employer for worker safety.
3. Reduced Waste
o Quality Management reports that 5S implementation typically yields a
reduction in lost and damaged items. A workspace with clear
organization and labeling allows the workers to replace items in a
designated position, minimizing the number of lost tools. The appropriate
management of tools and parts also means diminished odds of a stray
tool or part damaging a product during the production process. A
secured tool cannot fall onto a half-finished product. Sustaining the
cleaning and organization practices makes this waste reduction possible
in the long term.

4. Worker Commitment
o According to EMS (Environmental Management System) Consulting
Group, achieving worker commitment to the principles of 5S is a major
goal of a 5S implementation, as they will be largely responsible for using
it on the ground. However, 5S also encourages worker participation in
the workplace design and maintenance. This involvement serves to
engage the workers in the long-term sustainability of the workplace and
can enhance their commitment to and pride in the work

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 INFORMATION SHEET 4.2-1
(LO 2 Arrange items)

Learning Objectives:
After reading this INFORMATION SHEET, you must be able to execute
correctly the procedure in Arrange items.
Introduction:
This course is designed to enhance the knowledge, desirable attitudes and
skills to perform Shielded Metal Arc Welding work to apply the basic
housekeeping procedures Workplace hazards and risks

I. Well-organized shop

A. Well-organized in the welding shop

environment is a key feature that all
shops should possess. Without an
organized shop many things we don't
want to happen could occur. Cleaning
up our shop area is just as important as
making a good weld. Someone who
takes pride in their work also takes
pride in their work environment. Many
shops have a lot of stuff stored in and
around the shop, it's been there for
years and is rarely used. Some shops have so much stuff in it you can
barely move around or find anything. Other shops or well-organized and
everything has a place and everything is in its place.

1. Benefits of well-organized shop:

 Save time
 save money
 save effort
2. Advantage of properly stored material:
 It easy and quick to locate the proper material

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  It makes it very easy for the shop project manager or plant manager to
inventory the materials and see what's present.
 Will help eliminate duplicate material orders for something we already
have in stock.

 Since safety is a key component of everything we do in the welding world,

housekeeping is just as critical to safety as wearing safety glasses, the
proper clothing, boots, face and eye protection. Having our tools, equipment,
hoses, cords, welding leads and our material well-organized in and around
where we're going to do our fabrication, eliminates many of the tripping
hazards and
Other safety issues associated with our welding shop environment. Having
an injured shop employee does not help meet deadline or get work done, it’s
only a setback to the company.

3. How to eliminates tripping hazards and other safety issues on work

shop
 Research safety vulnerabilities
 Pay extra attention to common accidents and develop strategies to
keep these setbacks from happening.
 Don’t take shortcuts
 Accidents happen when employees skip steps to complete a job
ahead of schedule. Make sure all instructions are clear and
organized to prevent undue in the workplace.
 Keep an orderly workplace
 Poor housekeeping can cause serious health and safety hazards.
The layout of the workplace should have adequate foot path
markings, be free of debris, and stations for cleaning up spills.

 Just as important as having a well-organized shop at the beginning of the

project, cleaning up our mess, returning everything to its proper location
and returning the materials to where they belong.

1. . A Tidy Workshop

 One of the most important factors to improve efficiency is to

ensure that the workplace is relatively clean and tidy. The
unnecessary jigs, fixtures, piles of scrap should be disposed of from
time to time. Removal of unwanted material in the workshop has
the effect of releasing space which can then be used to much
greater advantage.

2. . Lighting
 Adequate lighting in the workplace is essential and goes a very
long way to improving efficiency. In most workshops, natural

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 daylight is enhanced indoors by overhead lighting, usually
provided by fluorescent strip tubes. These provide a good level of
background lighting,

3. . Flooring
 Concrete is hard stuff and even harder on the legs, especially when
you’ve had to do a full eight hours in the workshop. Unfortunately,
most professional workshops are in buildings or units where the
floor is concrete which is ideal for supporting heavy machinery,
but not for the soles of your feet!

 The best way to organize our welding shop is to think about the flow of work
through it and place the materials, machines and equipment in a logical
place and manner that meets your requirements and keeps the operation
efficient. Look around your shop open up your eyes and think about what
you could do to improve your area. In all our shops we can easily find
something that we could do better and if we focus on those single items and
continue to improve bit by bit, item by item, over the long time we will see
the benefits of having a well-organized shop, improved safety and cost
savings.

II. The Right Way to Store Welding Equipment

A. You may have welding technique nailed

down to a tee, but you will come away
disappointed in the quality of your work if
you do not store your equipment properly.
Here you will find a comprehensive guide
on how to properly store your welding
equipment.

1. How to Store Welding Equipment?

Welding equipment includes the:
 welding machines
 cables
 welding handle
 gas cylinders, and other attachments.
 hoses
The proper storage of this equipment is essential to the performance of your
operation. Storage activities should include efforts to keep the equipment from

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taking on excess dirt, debris, and moisture. Engaging in proper storage
techniques will extend the lifespan of your welding equipment to a significant
degree. The time may come periodically when you need to find a place to store
your welder or welding machine itself. There is a way to properly store your
welder that will prevent it from taking on dust and debris while it sits in the
corner.
Pick out an area in the shop for the welder where it will not be disturbed or
potentially knocked over by accident. Make sure that all the dials(regulators)
are turned off or turned to zero and that cables and hoses have been
removed. Then cover the machine with a small blanket or tarp to keep dust
from accumulating in the machine while it sits.

2. How to Safely Store Gas Cylinders for Welding?

 The proper storage of gas cylinders is of absolute necessity for keeping
your workspace safe. It also ensures that your welding equipment will
continue to run smoothly. Care must be taken to make sure that
cylinders are still able to regulate pressure after being stowed away for
an extended period of time.

 In order to keep your workspace safe, take these steps:

1. Close the valve every time you are finished with your work
2. Never attempt to move the gas cylinders without first making sure
that the valves have been closed
3. Keep Oxygen cylinders and acetylene cylinders at least 20 feet apart
or separated by a firewall
4. Keep cylinders as far as practical from fire, hot slag, and flame

 All of the regulators, hoses, and other such components need to be stored in
dry, clean, and well-ventilated space when they are not in use. Excess
moisture can potentially lead to the rusting of the metal components of the
gas delivery system.

B. Where Should I Store Excess Hoses/Cable Lead?

 The welding cable is the electrical conductor
for the welder current. If stored improperly,
the cable leads for your welder will begin
malfunctioning. In the absolute worst-case
scenario, they will become a safety hazard.

 The reasoning behind the loose cooling of the

cable is to prevent it from becoming strained.
Even little nicks and rubs can become a
safety hazard, as stated by OSHA. Small sections of worn cable can also be
repaired with electrical or rubber insulation tape. Still, these types of
repairs signal that the cable is coming to the end of its lifetime, perhaps
prematurely.

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 You can keep your welding cables and hoses from fraying by wrapping them
around a hose wheel. In the alternative, you may consider wrapping the
cables carefully by hand and hanging them from a shop hook when they are
not in use.

C. Where Do I Store My Welding Helmet?

 It’s a common habit for welders to set aside their welding helmets on the top
of their workbench at the end of the day or to stow their safety glasses on
the dash of their truck between jobs. Proper welding helmet care calls for a
greater effort to store the helmets in a location where they will not
accumulate rapid wear and tear.
 A quality welding helmet can come at a high cost, be sure to store your
helmet(s) locations where the lenses will not become scuffed up. Welding
helmet bags come in a variety of types and at a diverse range of price
ranges.
 The most affordable option is drawstring pouches such as this helmet
backpack. At the other end of the spectrum are gear packs such as this
one that offer multiple separate pouches for all of your protective welding
equipment.
 Any kind of a backpack or gear pack is certainly a vast improvement over
leaving your welding helmet on a workbench or on the floor or dash of your
work truck. The gear packs are an excellent option for mobile welders who
spend most of their days traveling from site to site.
 You can also find protective cases for safety glasses, including cases with a
protective felt lining on the inside. It’s far too easy to scuff up and scratch
safety glasses. A quality protective case will extend the lifetime of your
safety glasses or goggles so that you do not find yourself continuously
replacing them with new pairs.

D. How do I store welding clothing?

 You are encouraged to designate a spot in your shop where you can store all
your protective clothing, including gloves, welding jackets, welding aprons,
and overalls. This should prevent you from losing track of protective
clothing.
 You will also probably want to avoid taking your welding gear home with
you too often as the clothing may harbor some noticeable and sometimes
unpleasant fumes. Storing all your welding clothing in a proper manner
should help prevent unnecessary wear and tear resulting from wrinkling.
Being organized will also make you look more
professional.
 Aprons, jackets, coveralls, and other articles of
clothing should be hung from hooks at the
designated location. You might consider getting
a wall-mounted coat rack for your welding shop or
mounting a horizontal pole that you can place
clothes hangers-on.

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 E. How do I store Welding Gloves?
 Welding gloves must be kept dry. Otherwise, they will lose their ability to
protect your skin from the intense heat, as well as the UV and infrared
radiation. Water transfers heat better than air, hence the reason while you
will also burn yourself if you use a damp or wet oven to pull something out
of the oven.
 You can hang gloves from a hanger, such as the clothes hanger mentioned
in the section above. Another option is to store the gloves within an airtight
container such as the Storage Container. You may also store the gloves
within a designated drawer in a toolbox.

F. How to Store Welding Electrodes?

 The Proper storage location for your welding electrodes will depend upon a
variety of factors, including the chemical composition of the electrode, the
use of the electrode, and the anticipated lifespan of the electrode.

 1. Stick Electrodes
o Stick electrodes include any electrode that is used in shielded metal arc
welding (SMAW). The fact that these electrodes are consumables may
give you the false impression that storage is not of the utmost concern.
Nothing could be further from the truth. Stick electrodes require special
care to ensure that they perform as expected.
o This is particularly the case with some of the specialty electrodes, such
as low hydrogen or cast iron electrodes, that absolutely must be kept dry
if you are expecting them to perform as expected. Not all stick electrodes
are created equally, either. Recommended storage practices differ
amongst electrodes based upon what type of coating the electrode has.

 2. Low Hydrogen Electrodes- Welding Rod Oven

o Low hydrogen electrodes include those designated as having a last digit
number of 5, 6, or 8 in the American Welding Society (AWS) classification
system. As an example, the E7015, E7016, and E7018 electrodes would
all be examples of low-hydrogen electrodes.
o These electrodes need to be stored in a location where they will be kept
dry since they are particularly vulnerable to humidity. Low hydrogen
electrodes begin to absorb moisture as soon as you open the
package containing the electrodes. Low hydrogen electrodes typically
come in either hermetically-sealed cans or vacuum-packed.
o The proper storage technique for low hydrogen electrodes involves storing
them within an oven that will be kept between 225 and 300 degrees
Fahrenheit after the sealed package has been opened, per
the instructions of many manufacturers.

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 o Mild steel electrodes such as the E6010 and E6011 can be stored at air
temperature without becoming damaged. Other electrodes, such as cast
iron electrodes, for example, do also need to be stored in an oven such as
this one.

INFORMATION SHEET 4.3-1

(L0 3 Maintain work area, tools and equipment)
Learning Objectives:
After reading this INFORMATION SHEET, you must be able to execute
correctly the procedure in Maintain work area, tools and equipment
Introduction:
This course is designed to enhance the knowledge, desirable attitudes and
skills to perform Shielded Metal Arc Welding work to apply the basic
housekeeping procedures.
I. How to Maintain work area

1. Workplace cleanliness
 Before you can improve workplace cleanliness, you must identify and
prioritize areas of concern. Conduct a full-scale facility assessment to
determine which areas of your facility are prone to spills, clutter and
other environmental ailments that affect employee health and safety.

2. Make Daily Cleanup a Routine Habit

 Require that each employee takes responsibility for their workstation
each day before leaving. If each employee does their part and develops
the habit of caring for cleaning their area.

Here are some tips:

o Post signage that reminds employees
to keep cleanliness in mind.
o
Create a checklist that applies to

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 each employee’s work area with actionable items they can scan and sign
off on before leaving each day.

o Checklist include making sure floor areas are clear of any spills, debris
or other hazards, tools and equipment are wiped down, powered off and
properly stored for the night, work surfaces are clean and organized, and
trash cans are empty.

3. Make It Easy for Employees to Be Clean

 Make it as easy as possible by strategically placing cleaning supplies in
appropriate areas around your facility.

o Stock paper towels, all-purpose cleaner and other cleaning products in

areas that routinely get messy, like the staff kitchen, restrooms or break
rooms.
o If a particular area of your factory is prone to spills, keep absorbent pads
and cleaners within reach to avoid unaccompanied hazards.

4. Make Hygiene a Priority

 To decrease the spread of germs, install hand-sanitizing stations and
encourage employees to wash their hands frequently, especially during
the cold and flu season.

5. Control Dust
 Dust accumulation can cause major issues for a facility, including poor
air quality, fire and explosion hazards, and malfunctioning equipment.
Regular surface cleaning will help reduce these risks. If your facility
produces a lot of dust, an industrial vacuum is the safest and most
effective way to manage dust removal. You also should have your air
ventilation system cleaned and checked regularly (at least annually.

II. Regular maintenance tools and equipment

A. Regular maintenance of equipment

is an important and necessary
activity. The term ‘maintenance’
covers many activities, including
inspection, testing, measurement,
replacement and adjustment, and is
carried out in all sectors and
workplaces. It has a vital role to play
in reducing the risk associated with
some workplace hazards and
providing safer and healthier working conditions. Insufficient/inadequate

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 maintenance can cause serious (and potentially deadly) accidents or health
problems.

PUWER (Provision and Use of Work Equipment Regulations 1998) states

that ‘all work equipment be maintained in an efficient state, in efficient
order and in good repair.’ Machinery that has a maintenance log needs to be
kept up to date and maintenance operations need to be carried out safely.

There are two types of maintenance

a. Routine maintenance is planned and focuses on preventing future
problems.
b. Corrective maintenance is reactive and happens when equipment
goes wrong and needs to be fixed

1. Routine maintenance-

 Are maintenance activities such as regular inspections or machine

servicing. Routine maintenance is done on a regular basis, whether that be
daily, weekly, monthly, or yearly. Routine maintenance is an important part
of keeping systems up to date and functional.

 Gives technicians an opportunity to regularly “lay their eyes on” important

components of a production line or specific system as well as a chance to
catch any other potential problems that are lurking.

Benefits of routine maintenance

 prevents larger problems from occurring.
 Taking good care of equipment, machines, and facilities.
 extends their overall life.
 keep them performing at their best.

2. Corrective maintenance
 is a maintenance task performed to identify, isolate, and rectify a fault so
that the failed equipment, machine, or system can be restored to an
operational condition within the tolerances or limits established for in-
service operations?

Benefits of doing corrective maintenance the right way

o reduced duration of both planned and unplanned downtimes.
o reduced cost of running a reactive maintenance strategy.
o reduced overall cost of your maintenance operations.
o reduce further damage to the equipment.
o Prolong the running hours of usage of the equipment.
o reduced the delaying time cause by malfunctioning of the equipment.

Maintenance and Assessment

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An assessment should be carried out before any maintenance work begins and
work should be planned. It is best practice to keep a maintenance log which is
regularly updated. Workers should be involved in the risk assessment process
as those carrying out a maintenance task are often in the best position
to identify hazards and the most efficient ways of dealing with them.

INFORMATION SHEET 4.4-1

(L0 4 Follow standardized work process and procedures)

Learning Objectives:
After reading this INFORMATION SHEET, you must be able to execute
correctly the procedure in Follow standardized work process and procedures
Introduction:
This course is designed to enhance the knowledge, desirable attitudes and
skills to perform Shielded Metal Arc Welding work to apply the basic
housekeeping procedures.
I. Standardized work process and procedures

STANDARDIZED WORK
A. Standardized work is one of the most powerful but least used lean tools. By
documenting the current
best practice,
standardized work forms
the baseline for
continuous
improvement. As the
standard is
improved, the new
standard becomes
the baseline for further
improvements,
and so on. Improving
standardized work is a
never-ending process.

 Basically,
standardized work
consists of three elements:

1. Take time, which is the rate at which products must be made in a

process to meet customer demand.
2. The precise work sequence in which an operator performs
tasks within take time.
3. The standard inventory, including units in machines, required to keep
the process operating smoothly.
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 Establishing standardized work relies on collecting and recording data on a
few forms. These forms are used by engineers and front-line supervisors to
design the process and by operators to make improvements in their own
jobs. In this workshop, you'll learn how to use these forms and why it will
be difficult to make your lean implementations "stick" without standardized
work.

 Benefits of standardized work:

 Reduces variability,

 Helps your people

 Increases safety

 Improvement continuous improvement

1. Reduces variability
 By standardizing the most efficient way to perform processes, standardized
work reduces variations in the output. Work becomes predictable: quality,
costs, required inventory, and delivery times can be anticipated.

2. Helps your people

 Shop floor operators are sometimes under the impression that their highly
variable work cannot be standardized, or that implementing standards will
make their work boring. Enforcing standardized work increases efficiency,
thus making more time for creative work.

 Standardized work also helps operators structure their work. It removes

pressure on operators by reducing the stress of performing tasks
improperly.
.
3. Increases safety
 Standardized work, by definition, establishes the safest method to go
perform tasks. When operators systematically execute tried-and-true
methods, the number of injuries decreases, and risks are averted.

4. Improves continuous improvement

 Another Lean principle, is the
concept of continuous
improvement. Standardized
work provides a basis for
Kaizen. Indeed, it is only
possible to evaluate
improvements objectively
when existing procedures are
standardized and

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 documented. As standards improve, the new standard becomes the basis for
further improvements: improving standardized work is a never-ending
process.

II. FOLLOW 6 STEPS TO APPLY FOR STANDARDIZED WORK

1. Collect data on your current operations

 The first step is to establish your work sequence and Take time. Through
the connected tools and cloud computing, modern manufacturers can
collect data automatically
 Manufacturers gain real-time visibility into their operations,
meaning they know exactly how tasks are currently executed.

2. Notice variations and issues

 Often there are several ways to perform a task, but only one of these
ways uses resources–materials, machines, and operators–in the most
efficient way possible.
 Look at the data you have collected, and notice variations. Are there
workers that perform the same tasks, but the output varies greatly? Are
some operators taking longer than Take time? Could some tasks be
combined? Where are safety or quality issues occurring?

3. Find the most efficient way to run your operations

 This is where you want to use Lean tools to optimize your work
sequence and procedures. For example, you could use value stream
mapping to identify non-value adding steps to mistake-proof your
processes. Your goal is to find methods that are practical, useful to
everyone, and free of difficulty.
4. Document everything
 There are many ways you can go about doing this. One of the simplest
ways is in digital work instructions. Media-rich and interactive, they
guide operators through processes step by step.
 Digital work instructions ensure that operators follow each and every
step properly, Therefore, as your standardized work evolves, you can
easily keep it documented and up-to-date.
5. Adapt your training programs
 It is important that employees understand the new standard procedures
and adhere to them. This might require re-training current workers.
Furthermore, you want to make sure that your new employee training
programs are based on your standardized work.

6. Continuously improve the standard

 A common mistake is to think that after establishing standardized work,
you are done.

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 Once standardized work is implemented, it becomes a lot easier to
identify abnormalities and issues. Perform root-cause analysis for every
problem that occurs, and create a new standard that solves the problem.

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