Fig 16 shows a student about to use a pillar drill in a school workshop. (a) (i) State two items of personal protective equipment (PPE) the student should w...

(a)(i) Two items of PPE for using a pillar drill:

1. Safety goggles (eye protection). [1]
2. Apron or workshop coat. [1]

(Accept dust mask if drilling MDF.)

(a)(ii) Why each is necessary:

• Safety goggles protect the eyes from flying swarf, chips, or fragments that are ejected at speed during drilling. Even small metal or plastic particles can cause serious eye injury. [1]
• An apron or workshop coat protects clothing from damage and, more importantly, prevents loose clothing (ties, scarves, open jacket fronts) from being caught by the rotating chuck or drill bit, which could pull the operator into the machine. [1]

(b)(i) A risk assessment is a systematic process of identifying hazards present in a work activity [1] and evaluating the likelihood and severity of harm they could cause, in order to decide what control measures are needed to reduce the risk to an acceptable level. [1]

(b)(ii) Three hazards associated with using a pillar drill:

1. The rotating drill bit or chuck could catch loose clothing, long hair, or jewellery and cause entanglement, pulling the operator into the machine. [1]
2. Sharp swarf or hot chippings could fly off the workpiece and injure the operator's eyes or skin. [1]
3. The workpiece could spin violently if not clamped, striking the operator or flying off the table. [1]

(b)(iii) One control measure for each hazard:

1. Tie back long hair, remove jewellery, and tuck in or remove loose clothing before operating the machine. [1]
2. Wear safety goggles to protect eyes from flying swarf and debris. [1]
3. Clamp the workpiece securely in a machine vice or with a G-clamp to the drill table before starting. [1]

(c)(i) The machine guard encloses the rotating chuck and drill bit area, [1] creating a physical barrier that prevents the operator from accidentally touching the spinning components. It reduces the risk of entanglement, cuts, and contact with hot swarf. [1]

(c)(ii) A clear plastic telescopic guard that surrounds the chuck and drill bit. [1] It can be adjusted in height to accommodate different workpiece thicknesses while still providing visibility of the cutting action and a barrier between the operator and the rotating parts. [1]

(d)(i) Clamping prevents the workpiece from rotating with the drill bit. [1] If the drill bit catches in the material, the torque can spin an unclamped workpiece violently, causing it to strike the operator or fly off the table at speed, causing serious cuts or impact injuries. [1]

(d)(ii) The drill bit can catch in the material and cause the workpiece to spin suddenly and unexpectedly, which could cut, bruise, or break the student's fingers or hands. [1]

(e)(i) Use a dustpan and brush or a workshop vacuum cleaner to collect the swarf from the floor and all work surfaces. [1] Dispose of the collected swarf in the correct waste bin (not a general rubbish bin), as metal and plastic swarf may need to be separated for recycling. [1]

(e)(ii) Swarf from drilling has very sharp edges that can easily cut the skin, and freshly produced swarf (particularly from metals and plastics) may still be hot from the friction of the drilling process. [1]

(f)(i) Machining MDF produces extremely fine dust particles that are easily inhaled deep into the lungs. [1] MDF dust contains urea-formaldehyde resin (the adhesive used to bind the wood fibres), which is a known carcinogen and respiratory sensitiser. Prolonged exposure can cause chronic respiratory conditions, nasal irritation, and allergic reactions. [1]

(f)(ii) Wearing a dust mask or respirator rated for fine particulates when working with dusty materials. [1] (Also acceptable: ensuring good general ventilation in the workshop; using a local exhaust ventilation system at the machine.)