Lesson 1Ergonomic, organisational, and PPE measures for assembly/packaging: manual handling aids, workstation layout, job rotation, lift training, anti-fatigue mats, safe use of pallet jacksThis section addresses ergonomic, organisational, and PPE measures for assembly and packaging, including manual handling aids, workstation layout, job rotation, lift training, anti-fatigue mats, and safe use of pallet jacks to reduce strain and impact injuries.
Assessing manual handling and lifting tasksUse of hoists, conveyors, and lift tablesWorkstation layout and reach zone designJob rotation and micro-break planningSafe use of pallet jacks and trolleysLesson 2Engineering and technical controls for CNC areas: guards, interlocks, chip guards, splash containment, local exhaust ventilation, noise controlThis section explains engineering and technical controls for CNC areas, including fixed and interlocked guards, chip guards, splash containment, local exhaust ventilation, and noise control measures that reduce exposure to mechanical and physical hazards.
Fixed and interlocked guard design basicsChip guards and swarf containment methodsSplash shields and coolant containmentLocal exhaust ventilation near CNC enclosuresNoise measurement and enclosure controlsLesson 3Engineering controls for welding areas: fume extraction, welding curtains, fire-resistant screens, gas cylinder storage and restraintsThis section covers engineering controls that reduce welding hazards, including local fume extraction, welding curtains and fire-resistant screens, and safe storage and restraint of gas cylinders to prevent exposure, fires, and explosion risks in welding areas.
Design and placement of fume extraction hoodsInspection and positioning of welding curtainsUse of fire-resistant screens near combustiblesGas cylinder storage, segregation, and signageCylinder restraints, caps, and leak checksLesson 4Organisational and procedural controls for CNC areas: safe work procedures, maintenance schedules, coolant management, tool-change protocolsThis section describes organisational and procedural controls for CNC areas, including safe work procedures, planned maintenance schedules, coolant management, and tool-change protocols that reduce entanglement, splash, and unexpected startup risks.
Developing CNC safe work instructionsLockout and verification before interventionsPlanned maintenance and defect reportingCoolant selection, storage, and disposal rulesSafe tool-change steps and handover checksLesson 5PPE and training for welding staff: respirators, welding helmets, gloves, flame-resistant clothing, respiratory fit-testing and welding technique trainingThis section details PPE and training for welding staff, including respirators, welding helmets, gloves, flame-resistant clothing, and fit-testing, as well as technique training that reduces fume, burn, and eye injury risks during welding tasks.
Selecting welding helmets and filter lensesGlove and clothing protection for heat and sparksRespirator selection and fit-testing processCare, storage, and replacement of welding PPEWelding technique training and skill checksLesson 6How each measure maps to typical legal and internal safety requirements: duty of care, hierarchy of controls, training and maintenance obligationsThis section links each prevention measure to legal and internal requirements, explaining duty of care, the hierarchy of controls, and obligations for training, inspection, and maintenance, including documentation and audit expectations for safety representatives.
Duty of care and employer legal obligationsApplying the hierarchy of controls in practiceTraining, supervision, and competence recordsInspection, testing, and maintenance dutiesInternal standards, audits, and nonconformitiesLesson 7Warehouse controls: racking inspection, ladder safety policies, pedestrian/vehicle segregation, forklift safety systems, floor maintenance and spill controlThis section explains warehouse risk controls, including safe racking inspection, ladder policies, pedestrian and vehicle segregation, forklift safety systems, and floor maintenance and spill control to prevent falls, impacts, and structural failures.
Racking inspection routines and defect criteriaLadder selection, tagging, and safe use rulesPedestrian walkways and vehicle exclusion zonesForklift warning devices and safety interlocksFloor cleaning, damage repair, and spill kitsLesson 8Organisational controls for welding: hot work permits, gas cylinder handling procedures, maintenance of ventilation, welding-specific permits and fire watchesThis section focuses on organisational controls for welding, such as hot work permits, gas cylinder handling procedures, maintenance of ventilation systems, welding-specific permits, and fire watch arrangements before, during, and after hot work.
Hot work permit scope, roles, and approvalsGas cylinder handling and transport proceduresVentilation inspection and maintenance recordsWelding-specific permits in production areasFire watch duties and post-work monitoringLesson 9PPE and training for CNC staff: eye/face protection, cut-resistant gloves, hearing protection, machine-specific trainingThis section details required PPE and training for CNC staff, focusing on eye and face protection, cut-resistant gloves, hearing protection, and machine-specific instruction that supports safe setup, operation, cleaning, and troubleshooting of CNC equipment.
Selecting eye and face protection for CNC tasksCut-resistant glove types and correct usage limitsHearing protection selection and fit checksMachine-specific CNC safety training contentRefresher training and competency verification
