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Metal Fabrication Handbook

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					Metal Fabrication
                     Table of Contents

Introduction………………………………………………………………………………………………………………….2

Statement of Safety…………………………………………………………………………………………………..3

Metal Fabrication Discipline Contract…………………………………………………………………….4

General Lab Expectations………………………………..…………………………………………………………5

Metal Fabrication Procedures…………………………………………………………………………………..6

Grading Policy………..…………………………………………………………………………………………………7-8

What Employers Want…………………………………………………………………………………………..…..9

Student Evaluation ………………………………………………………………………………………………10-11

Class Requirements…………………………………………………………………………………………………….12

Lab Requirements……………………………………………………………………………………………………….12

Description of Job Stations…………………………………………………………………………………….13

Clean-up Procedures…………………………………………………………………………………………………..14

Pages that Require Signatures…………………………………………………………………….………..4,5
Metal Fabrication


                                 Introduction

        Welcome to the Metal Fabrication program at the Coshocton County Career
Center. My name is Mr. Baughman and I am exited that you have chosen the Metal
Fabrication Program. This program is the entrance porthole to your future. By selecting
this program, you will have the opportunity to hone your skills in many fields of
employment such as aluminum welding, steel welding, pipe welding, Burning Machine
operation and so much more. With the knowledge that you will procure the next two
years will open many doors for you in the future.

         As part of your training this upcoming school year, you will be working with
Oxyfuel Cutting, Stick and Mig processes, and the safety that goes along with these
activities. In your senior year, you will focus on honing the skills you have learned this
year as well as adding the Tig process to the activities that you have mastered. These
training activities will be applied to the two-year certificate of completion also known as
a Career Passport.

        In the Welding lab you will prefect your hands on skills. All of the topics that we
cover in the related classroom will be practiced in the lab. This also includes safety.
While we are in the lab, teamwork will also be incorporated into the lab activities that
will be helpful for you to become a professional welder in the today’s mounting
economy.

        I am looking forward to getting to know you better. As we progress through the
year please do not hesitate to ask me questions on the direction that we are headed. As
your welding instructor please do not hesitate to contact me anytime during the school
day.

Sincerely,



Instructor: Mr. Baughman
Metal Fabrication


                           Statement of Safety

       Safety is a very important part of the school day both of the staff, students and
   visitors of the school district. It is our goal to provide a safe and positive learning
   environment for everyone.

       Safety by definition means: the condition of being safe; freedom from danger,
   risk, or injury. I as an instructor promise to maintain a safe lab and classroom setting
   at all times. Should the need for my attention be brought about to an area or piece of
   equipment do not hesitate to call me over and bring the problem to my attention. We
   will correct the situation immediately.



      I know this seems like a lot to take in but with your help we will have a fun,
   educational and safe year.




   Sincerely,




Instructor: Mr. Baughman
Metal Fabrication

                      Metal Fabrication Discipline Contract

             I, ___________________________ promise to abide by all
      expectations.
                                       Expectations

      1. I Will Be Prepared: When I come to class I will come with my notebook,
         paper, pencil and any other materials that may be needed. I understand that I
         will not be permitted to go to my locker.
      2. I Will Be on Time: I will be in my seat and working on the seat work
         assignment when the bell rings.
      3. I Will Be Attentive: I understand that I need to give Mr. Baughman my full
         attention and Mr. Baughman will give me his full attention. This means that I
         need to stay awake, paying attention not using any electronic device and on
         task during the instruction time.
      4. I Will Be Kind to Others: I need to treat others as I would like to be treated.
         This means other students, instructors, administrators, possible employers and
         other people that come into the classroom/shop area. I understand that this
         means no inappropriate language and behaviors.
      5. I Will Be On Task: I will do what I am supposed to do when I am asked to
         do it. I will follow the directions that are given to me. I will work until the end
         of the class time when the instructor will dismiss me.
      6. I Will Be Safe: I will exercise safe practices in the classroom and in the
         laboratory. I understand that this means no horseplay, fighting, throwing items
         across the class or lab and any other behavior that could result in injury.




             I understand that if I don’t follow the general expectations set forth I
      will have to handle the consequences.


      Student’s Signature: _________________________________ Date: _________


      Parent’s Signature: __________________________________ Date: _________
Metal Fabrication
                    General Lab Expectations

             I, ___________________________ promise to abide by all
      lab expectations.

1. Be changed and ready to work in the lab 10 minutes after the period
starts.

2. All students must have safety glasses, work shoes, clean work clothes,
   tools and welding hood to be permitted to work. SAFETY GLASSES
   MUST BE WORN AT ALL TIMES!


3. Students are to be in their assigned areas at all times.


4. No horseplay, throwing things or other dangerous acts in the lab.


5. Students must display good work habits.


6. THE INSTRUCTOR’S OFFICE IS OFF LIMITS UNLESS THE INSTRUCTOR
   HAS AUTHORIZED ACSESS.



             I understand that if I don’t follow the lab expectations set forth I will
      have to handle the consequences.


      Student’s Signature: _________________________________ Date: _________


      Parent’s Signature: __________________________________ Date: _________
Metal Fabrication


                       Classroom Procedures
   1. Attendance: The attendance will be taken promptly at the beginning of each class
       period while the students are doing there seat work assignment. If there are any
       absences they will be reported on Progress Book.
   2. Tardiness: If a student comes to class late they will be asked to present a pass or
       excuse. If they are coming from another teacher with no pass the teacher will be
       consulted. The tardiness will be documented.
   3. Handing in Assignments: When a student hands any assignment in they need to
       have their name, date and the name of the assignment in the upper right-hand
       corner of the paper.
   4. Entry Procedure: When the students enter the classroom, they need to sit down
       and begin working on any posted assignment.
   5. When Assignments are Finished: When students have completed assignments,
       tests and other things, they can work on assignments from other classes, read
       magazines or read ahead in the textbook. Students must still remain quiet until
       everyone has completed the assignment.
   6. Make Up Work: Should a student miss school for some reason, they will need to
       make up any missed assignments. See the instructor for additional instructions.
   7. Money Collection: If you need to pay school fees, pay your fees to the Clerk
       located in the Superintendents Office Complex.
   8. Leaving the Class: Should a student need to leave the class for any reason they
       will need to have a pass stating where they are going and when they need to arrive
       at the appointment.
   9. Handing Papers In or Out: When turning assignments, put the proper headings
       on the papers and place them in the “In” box. Papers will be passed out when they
       have been graded.
   10. No Paper or Pencil: If a student comes to class without paper and pencil, they
       may purchase a pencil for $0.25 or offer “collateral” that will be returned and get
       paper from the recycle bin or friend.
   11. Seating Arrangements: For the first week or two of school students will be in
       assigned seats that are in alphabetical order. After that time the seat assignments
       may be changed as necessary.
   12. Questions: If you have a question in class, feel free to ask it when there is an
       opening in the lecture. Don’t interrupt the instructor or other students when they
       are talking however.
   13. Textbooks: We have a classroom set of textbooks. You will not be able to take
       the textbooks home because of this. Should you need the info in the book the
       instructor will copy the section that you need.
Metal Fabrication


             Metal Fabrication Grading Policy
       It is important that every student and parent understand the philosophy upon
which the grading system is based, the fundamental aspects of the system and the
procedures by which the system becomes operative. It is my responsibility to assist
students and their parents to understand the purpose and the operation of the grading
system.
       Grades are never to be considered the goals of learning; they are merely the
symbols which give evidence of the extent of learning. Teaching, testing practices, study
and learning activities are all directed towards the growth and development of the student
and not toward the acquisition and distribution of grades. Grades are not a consequence
of learning and not the purpose for learning.
       Here in the Metal Fabrication department we are about fair and consistent
grading. You will earn your grades by earning points on the assignments that you are
given. In the Metal Fabrication department we do not give out grades.
       Your grades will be promptly entered in to the grade book when assignments are
turned in. Once the grades have been entered into the grade book using our grade book
software called Progress Book, they will be available for you and your parents to view
online using your username and password. The grading scale in the Metal Fabrication
department will follow the Coshocton County Career Centers grading policy. The grade
breakdown is available for viewing in your student handbook and day planner.


Grades in Metal Fabrication:
       In Metal Fabrication, you’ll be graded on the following items:
           1. You will be graded each week based upon the checklist on pages 10-11.
               You will have the opportunity to earn 100 points a week.
Metal Fabrication

           2. At the end of every nine weeks your notebook will be graded and you can
               earn a maximum of 100 points.
           3. You will be required to take safety tests on all lab equipment; they must be
               passed with 100% accuracy before you’ll be allowed to work in the lab.
               The total number of points for these tests will be listed on the top of each
               test.
           4. Tests and quizzes will be given throughout the nine weeks as deemed
               necessary by instructor. Again the total point value will be listed on the
               top of the test or quiz.
           5. Any other homework, worksheets and projects that will be graded
               accordingly and all point totals will be listed on the assignment.
How can I figure my grade if I don’t have the internet?
        You can figure out your grade by adding up the total number of points that you
have earned and dividing them by the total number of possible points. This will give you
the percentage. The letter grade can then be found by looking in your student handbook
and finding the range in which your percentage fits.
What if I have a question about a grade?
        If you have a question about any grade, please feel free to contact me and we will
set up an appointment to discuss the grade.


What is the bottom line when it comes to grades?
        The bottom line when it comes to grades is: We do not give out grades, you earn
them.




   IF YOU DIDN’T GET THE GRADE YOU WANTED IT’S HIGHLY POSSIBLE I
                         DIDN’T GET THE WORK I WANTED!
Metal Fabrication

     EMPLOYERS WANT WORKERS WHO:

1. read, write and communicate effectively,

2. have effective math skills,

3. have effective computer skills,

4. are good team members,

5. are respectful to fellow workers,

6. have good customer relations skills,

7. have a strong work ethic,

8. believe in the dignity of work,

9. recognize that work is the primary source for earning a living,

10. are committed employees,

11. are self-motivated lifelong learners,

12. have effective analytical problem solving skills,

13. follow instructions,

14. understand and apply technology,

15. are punctual and dependable,

16. are honest and trustworthy,

17. are adaptable and flexible,

18. have a good attitude,

19. have good work habits,

20. have demonstrated the capacity for work.

Jim Hoerner(1997). Virginia Tech, Blacksburg, VA 24061-0302
 Metal Fabrication

                    Metal Fabrication
               EVALUATION FOR STUDENT
                      (Worth 100 total points weekly)
Student's Name________________________________ Date of Report _________

Contractor Name _______________________________ Total Pts. For Week _____

Fill in the Boxes that Best Describe this Student. FILL In the Box Completely.
(20 Pts. Max.) ____ INITIATIVE & USE of WORK TIME

   o   Room for Improvement
   o   Average
   o   Helps Keep Job Moving
   o   Frequently Loafs
   o   Always Stays busy

(20 Pts. Max.) ____ ATTITUDE. APPEARANCE & HYGIENE

   o   Resentful – Uncooperative
   o   Acceptable
   o   Cooperative - Helpful and Alert
   o   Poor - Needs Attention
   o   Always Neat and Presentable

(25 Pts. Max.) ____ ATTENDANCE

   o   Frequently Late        FILL IN
   o   Seldom Late          ONLY 1 FROM
   o   Never Late            THIS LIST

   o   Frequently Off Work   FILL IN
   o   Seldom Off Work     ONLY 1 FROM
   o   Never Off Work       THIS LIST

(5 Pts. Max.) ____ ATTIRE

   o   Wears Proper Work Clothes
   o   Does NOT Dress for the Job

(5 Pts. Max.) ____ MECHANICAL APTITUDE

   o   Very Little
   o   Average
   o   Very High
   o   Extremely High

(5 Pts. Max.) ____ TOOLS

   o   Has Proper. Well-Maintained Tools
   o   Lacks Proper Tools
(5 Pts. Max.) ____ RESPONSIBILITY

   o   Unconcerned – Lackadaisical
   o   Acceptable
   o   Very Dependable

(5 Pts. Max.) ____ ACCURACY

   o   Makes Many Careless Errors
   o   Average
   o   Does It Right

(5 Pts. Max.) ____ COMMUNICATION SKILLS
     (Understanding Verbal Instructions)

   o   Does NOT Easily Understand
   o   Average
   o   Almost Always Understands

(5 Pts. Max.) ____ SAFETY RULES

   o   Disregards Rules
   o   Average
   o   Very Safety Conscious

Comments:
Mon. __________________________________________________________________

Tues. __________________________________________________________________

Wed. __________________________________________________________________

Thurs. _________________________________________________________________

Fri. ___________________________________________________________________



                               Supervisor’s Signature_____________________________
Metal Fabrication

                                   MATERIAL LIST

         You will need the following items to be successful in the Metal Fabrication
program. You may purchase these items from wherever you choose, listed below are
some local vendors that the tools may be purchased from. You will need all of the
equipment within the first days of school. NO tennis shoes will be permitted in the lab
area. You will need the change of clothes and shoes listed below. A lab locker as well as
a hall locker will be provided to you for storage of your materials. It is encouraged that
you buy good quality tools, as they are a necessity for success in the Metal Fabrication
program. You may also use tools from around the house if you already have them.

LAB ITEMS:
   1. 1- Flip Front Hood or Auto Darkening Hood
   2. 1- Burning Shield
   3. 1- Chipping Hammer
   4. 1- Wire Brush
   5. 1- Pair Welper Pliers
   6. 1- 25’ Tape Measure
   7. 2- Pair Gloves
   8. 1- Tip Cleaner
   9. 1- Spark Lighter
   10. 1- Ball Peen Hammer
   11. 1- Pair Vise Grips
   12. 1- 12” Crescent Wrench
   13. 1- Toolbox (To keep tools in. Needs to be lockable.)
   14. 2- Pairs of Safety Glasses
   15. 1- Flame Retardant Jacket
   16. 1- Lock with Spare Key
   17. 2- Pairs of Black or Blue Dickies type work pants
   18. 2- Black or Blue Dickies type work shirts (Button Up Type)
   19. 1- Pair High Top Leather Work Boots
These items can be purchased from:
   1. Tractor Supply Company                740.345.8185
   2. Wince Welding                         740.623.8423
   3. Columbus Glove and Safety             1.800.821.4274
   4. Valley National Gas                   330.

RELATED ITEMS:
  1. 1~ 3” Binder
  2. Notebook Paper
  3. Pencils
  4. Pens
  5. Calculator (Optional~ A TI-30X IIS will be sufficient.)
Metal Fabrication


                   Description of Job Stations

Specific Job Personnel: Each week we will have specific people assigned to the
following jobs. These people will have specific duties that will last for a period of one
week.


Shop/Safety Foreman: The foreman has the most important job of all tasks. The
foreman assigns the others specific jobs and keeps track of all progress in the clean-up
process. He/She will report any problems and questions to the instructor. They will also
help the instructor as needed during the class session. As the Shop Foreman, you must
also complete all items listed on the safety checklist.
        The foreman will also take an inventory of all tools that are going out and when
they come back in, maintain tools and report any tools that are damaged or unsafe to the
instructor.




Specific Clean-up Items: Specific clean-up details for cleaning machines or areas can be
found on the back of the clean-up lottery cards.
Metal Fabrication
       Metal Fabrication Clean-up Procedures
Philosophy: Remember it is better to do a little clean-up everyday, rather
than to spend a whole day cleaning up.

Expectations:

   1. Clean-up will begin 15 minutes before class period is over.

   2. Everyone is expected to participate.

   3. You are expected to complete each job assignment that you are given.

   4. Your job assignment will last for one week.

Clean-up Rules:

   1. Put away your own materials that you have been using to the appropriate area.
   2. Put away your own tools.
   3. After you have completed your assigned task, check with the foreman to see if
       anything else needs done.
   4. No one changes clothes until all clean up is complete.
   5. Classroom needs to be clean and orderly. Your notebook needs to be put on the
       shelf so it does not come up missing.
   6. After clean-up is complete and you have changed have a seat in the classroom
       until you are dismissed.
   7. The instructor will dismiss you at the appropriate time.

                        Clean-up Lottery Procedures
   1. Shop Foreman is in charge of assigning clean-up jobs at the beginning of the
       week. Those students who have specific jobs are not included in the lottery.
   2. If you get a certain job two weeks in a row inform the foreman and he/she will
       give you a different task.
   3. Make sure that you complete your assigned task.
Remember that everyone will help with the clean-up of the shop and classroom.

				
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