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Trainee

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									Trainee
Handbook




Compiled by: Industrial Centre, The Hong Kong Polytechnic University

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



Last updated: August 2008
Guidance for Trainees
TABLE OF CONTENTS
                                                                               Page
Section A     General
  1.    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-6
        5.1     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 I
        Application Forms                                                      A-14


Section B     Assessment Scheme
  1.    Introduction                                                           B-1
  2.    IC Assessment                                                          B-1
        2.1    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 I
        Report Writing: Introduction, Workshop Reports and Training Log Book   B-7
                                                              Page
Section 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      Safety
  1.    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
     aid of the computer). You will be shown the importance of occupational health and
     safety; and much, much more.
                                           A-1
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     We are here to provide all the information and advice you require. If
 Advice              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          Your safety is our topmost priority. If you have any concerns please
 Reassurance         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 - 12:30
                                                           14:30 - 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 work
             13:15 - 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             :      W101
              Female 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 I
                                                                                to 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 Form
 IC-T01      Request for IC Facilities/Services
 IC-T02      Request for R&D & Postgraduate Project Support
 IC-T08      Application for Approval of Leave
 IC-T15      Application for Practical Training Exemption
 IC-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
                 principles underlying the training. Normally a mark out of 100 will be
                 given.
                                          B-1
     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
     Institution of Engineers and, as such, your participation in same may exempt you
     from part of the professional training scheme requirements of that Institution.


                                     B-2
     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 module
                                                     Maximum grade D

           iv)    Appreciation Test omitted     -    Take and pass the test

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

           vi)    Workshop Report overdue -          Submit the Report
                                                     Maximum grade D

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

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

           ix)    Training Log Book failure -        Resubmit the Log Book
                                                     Maximum 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 I
                                                                                     to 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 Contents
    ii)    Introduction
    iii)   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 Title
     IC3001           Computer Graphics & Animation
     IC3002           Web Authoring & Internet Search
     IC3003           Basic Scientific Computing
     IC3004           General Computer & Network Skills
     IC3005           Database & Spreadsheet
     IC3006           Project Planning and Business Documentation
     IC3009           Database & Presentation for Electronic and Information Engineering
     IC3010           Basic Scientific Computing and Rhino
     IC3011           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
     the training class and accomplish all passing requirements of the module in order to


                                           C-2
     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 tools
                        ii.  set the tool head to the vertical position and retract the tool
                             slide (THIS IS VERY IMPORTANT!)
                        iii. set the stroke length to minimum
                        iv. 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 (150C-280C) 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
                          feet; always keep the flame directed away from cylinders.




                                                    Safety goggles must be worn
                                                    in order to provide protection




                                  D-18
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-19
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-20
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 Wire                      Brown
                         Neutral Wire                   Blue
                         Earth Wire                     Yellow/Green


                  5.    report all electrical defects at once

                         e.g.    cracked or perished insulation
                                 loose pins and plugs
                                 badly fitting plugs and sockets
                                 damaged switch covers
                                 detached earth wires




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




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



                                D-21
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-22
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-23
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.




                                                            Automatic and
                                                            Trip Guards




                                  D-24
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-25
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-26
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-27
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.   Fire
    2.   Any accident/injury
    3.   Electric shock
    4.   Person reported seriously sick
    5.   Person reported shut in lift
    6.   Leakage/spillage of chemical
    7.   Flooding
    8.   Any crime
    9.   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 department
    2.   Your contact telephone number
    3.   Nature of incident with brief description
    4.   Full detail of location of incident
    5.   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-28

								
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