How to teach newcomers about the dangers of 'the complacency of tool exchange' that can lead to accidents?
[Safety Education Video] How to Communicate to Prevent Accidents Due to Insufficient Confirmation After Changing Blades?
"I properly replaced it." Newcomers who say this may actually be setting up with insufficient torque or overlooking wear limits. Are you experiencing such "close calls" or "vague feelings" on the NC lathe shop floor? ● Continuing work without confirming the wear condition of the cutting tool, leading to ambiguous judgments ● Risks of accidents where the cutting tool loosens or flies off due to insufficient tightening of screws during processing ● "Knowing the replacement procedure = being able to do it" is not necessarily true All of these situations indicate that workers are entering the field with "shallow education on tool replacement." Replacing tools on an NC lathe involves significant safety and quality risks within the process. That’s why it’s essential to convey not just the ability to "replace," but the capability to "judge when to replace" and to provide "clear procedures for replacement." LinkStudio produces numerous educational videos that showcase the "judgment + procedures" in machining environments. If you are a team leader or educator who wants to solidify techniques that cannot be conveyed through words into video, please feel free to consult with us. *For more details, please do not hesitate to contact us.*
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Proposal for Solutions | Education to Confirm "Not just 'exchanged,' but 'properly exchanged'" Tool replacement in NC lathes is not merely a task of "just replacing." It is a process that requires the "ability to assess the condition and make judgments" and "the execution of reliable operational procedures." To achieve this, an educational design that demonstrates and teaches both judgment and action is necessary. ● Clearly show the progression of wear and its impact on machining through video. ● Visualize the correct installation, tightening, and verification actions with close-up shots and subtitles. ● Use reenactment videos of "cases where mistakes occur" to clarify "why it is necessary to do it correctly." Through this education, we can raise awareness that "replacement work = an important task that involves judgment."
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Introduction Steps | Procedures for Systematizing Tool Change Education for NC Lathes STEP 1 | Identify Common Tool Change Mistakes on the Shop Floor Gather specific examples such as overlooking wear, forgetting to tighten, and mistakes in order. STEP 2 | Create a Video that Clearly Shows "Judgment and Procedures" Use live action, subtitles, and narration to create a teaching material that allows for "learning by seeing." STEP 3 | Regularly Have Employees Watch the Video as a Pre-Check Before OJT and Work Incorporate it as a rule to establish the "correct change procedure" as a habit.
Price range
P3
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OTHER
Model number/Brand name
Custom-made training video
Applications/Examples of results
Introduction of Success Cases | Continuing Zero Accidents with "Exchange = Observe and Judge" Video Education At a precision parts manufacturer, there were frequent processing defects and machine troubles due to incorrect tool exchanges. Although the conventional manual included "exchange procedures," the "criteria for judgment" and "confirmation methods after exchange" were vague. Therefore, based on past near-miss incidents that occurred on-site, a video training material specifically focused on tool exchange was introduced. By incorporating examples of mistakes based on wear conditions and reproducing loosening incidents, the results were: ● Zero machine stoppages due to exchange errors ● Improved quality of "post-exchange checks" by newcomers, leading to a significant reduction in veteran feedback ● Change in perception of newcomers who thought, "I just need to replace the tool" The establishment of the awareness of "exchange = judgment + procedure" contributed to maintaining both safety and quality.
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| Model number | overview |
|---|---|
| Video Design 1️⃣ to Strengthen Tool Change Education | Show "Judgment of Wear Limits" through photos and videos to concretize the sense |
| Video Design 2️⃣ to Strengthen Tool Change Education | Reproduce the procedure from the operator's perspective with a camera, clearly indicating the order and points |
| Video Design 3️⃣ to Strengthen Tool Change Education | Visualize "NG Cases" to help understand the risks of mistakes in a "experiential way" |
| Video Design 4️⃣ to Strengthen Tool Change Education | Consistently repeat the "Confirmation Items" after the change is completed within the video |
