Lesson 1Noise, vibration, and ergonomic hazards for operators and finishersDiscusses noise, vibration, and ergonomic hazards impacting operators and finishers, including exposure mapping, tool choices, workstation setups, and spotting early signs of hearing and muscle strain issues.
Noise source identification and mappingHand-arm and whole-body vibration risksPosture, reach, and force task analysisTool selection, grips, and anti-vibration aidsEarly symptom reporting and trend trackingLesson 2Electrical hazards: high-voltage CNC, robot drives, weld transformers, and arc flashCovers electrical hazards from high-voltage CNC systems, robot drives, weld transformers, and arc flash, stressing boundary marking, labelling, fault scenarios, and working with qualified electricians for risk checks.
Equipment voltage classes and shock boundariesArc flash incident energy and labelingEnclosure integrity and interlock verificationGrounding, bonding, and return path hazardsCoordination with qualified electrical workersLesson 3Suspended loads and dropped-object hazards from overhead crane operationsAnalyses suspended load and dropped-object risks from overhead crane work, including rigging choices, travel paths, exclusion zones, and identifying failure points and human factors that heighten dangers.
Load path mapping and exclusion zonesRigging hardware selection and inspectionHook, latch, and sling attachment hazardsOperator visibility and communication limitsPre-use crane and hoist condition checksLesson 4Slip, trip, and fall hazards from workspace layout, parts, and cablingTackles slip, trip, and fall risks from workspace layout, parts staging, and cabling, focusing on traffic flow, cleaning, floor conditions, and ways to identify, record, and prioritise layout fixes.
Walkway and aisle obstruction surveysFloor surface condition and drainage checksCable routing, guarding, and hose managementWork-in-process and parts staging practicesInspection checklists and near-miss reportsLesson 5Human-machine interface hazards: control confusion, teach pendant misuse, and inadequate signageFocuses on human-machine interface risks like control mix-ups, teach pendant misuse, and poor signage, emphasising task analysis, labelling, and observing operator interactions with automation.
Control layout, labeling, and color codingMode selection, interlocks, and overridesTeach pendant use and misuse scenariosSignage, indicators, and alarm effectivenessUser feedback and behavioral observationsLesson 6Exposure hazards to cleaning chemicals and confined-space or lockout situations during maintenanceLooks at exposure risks from cleaning chemicals and maintenance in confined spaces or lockout, focusing on chemical identification, entry conditions, isolation points, and checking energy control effectiveness.
Chemical inventory and SDS hazard reviewVapor, mist, and skin contact evaluationsConfined-space entry condition assessmentEnergy isolation point identificationVerification of lockout and zero energyLesson 7Thermal, radiant, and fire hazards from CNC plasma cutting and hot workExplores thermal, radiant, and fire risks from CNC plasma cutting and hot work, covering ignition sources, heat zones, combustible loads, and assessing exposure, separating areas, and documenting controls.
Heat and radiant energy exposure assessmentCombustible materials and fire load mappingHot work permits and area isolationTorch, nozzle, and consumable failure modesFire watch duties and post-work monitoringLesson 8Fume and gas hazards from welding processes and ventilation considerationsDetails fume and gas risks from welding, thermal cutting, and poor ventilation, addressing fume rates, gas buildup, airflow, and documenting exposure hotspots and control requirements.
Process-specific fume generation profilesShielding gases and asphyxiation risksLocal exhaust and hood capture checksGeneral ventilation and airflow mappingAir monitoring and exposure documentationLesson 9Projectile and splash hazards from grinding, cutting slag, and plasma slag ejectionReviews projectile and splash risks from grinding, cutting slag, and plasma slag ejection, focusing on wheel failures, workpiece projections, and impact zones needing guards or procedures.
Grinding wheel selection and defect checksWorkpiece clamping and restraint hazardsSpark, slag, and debris trajectory mappingGuarding, screens, and barrier placementFace, eye, and body protection needsLesson 10Mechanical hazards from moving robot arms, rotating positioners, and pinch pointsExplores mechanical risks from moving robot arms, rotating positioners, and pinch points, emphasising reach studies, safeguarding checks, and tasks placing workers in hazardous motion areas.
Reach envelopes and motion range studiesPinch, shear, and crush point surveysGuarding, fencing, and light curtain checksSafe speed, hold-to-run, and jog controlsMaintenance and teaching task exposures
