Lesson 1Mechanical hazards: rotating equipment, conveyors, forklifts, pallet storageThis part covers mechanical dangers from spinning machines, conveyor belts, forklifts, and pallet stacking. Learners will identify pinch points, crush risks, and struck-by dangers, and check guarding, traffic rules, and inspection methods to avoid serious harm in local shops.
Rotating equipment pinch and entanglement pointsConveyor nip points, guards, and emergency stopsForklift traffic patterns and pedestrian separationPallet stacking, racking stability, and collapse risksPre-use inspections and reporting mechanical defectsLesson 2Environmental and exposure limits: TLVs, PELs, short-term exposureThis part introduces exposure limits like TLVs and PELs for welding smoke, solvents, and dust. Learners will compare how long exposures last, grasp short-term and ceiling limits, and connect monitoring info to ventilation, PPE, and work habits for safer Ghanaian factories.
Difference between TLVs, PELs, and company limitsShort-term exposure limits and ceiling valuesReading air monitoring and sampling resultsLinking exposure data to ventilation controlsAdjusting tasks and PPE to stay below limitsLesson 3Recognizing early indicators: near-misses, symptoms of exposure, unsafe actsThis part focuses on spotting early hazard signs, including close calls, small injuries, exposure symptoms, and unsafe behaviours. Learners will practise reporting, reviewing patterns, and fixing issues before big accidents happen in everyday work.
Identifying and documenting near-miss eventsEarly symptoms of chemical or fume exposureObserving unsafe acts and at-risk shortcutsUsing checklists and simple observation toursTurning early indicators into corrective actionsLesson 4Chemical hazards: welding fumes, solvent paints, isocyanates, dustThis part reviews chemical dangers from welding fumes, solvent paints, isocyanates, and harmful dusts. Learners will link SDS info to exposure paths, symptoms, and controls like ventilation, PPE, and replacing substances for better safety.
Key hazards in welding fumes and metal oxidesSolvent paint vapors and overexposure symptomsIsocyanate sensitization and asthma concernsDust from grinding, blasting, and surface prepUsing SDSs to identify controls and PPE needsLesson 5Fire and explosion risks: flammable liquids, combustible dust, hot workThis part looks at fire and blast risks from flammable liquids, combustible dust, and hot jobs. Learners will spot ignition sources, check storage and ventilation rules, and use hot work permits, cleaning, and earthing practices to prevent fires.
Flammable liquid storage, transfer, and labelingCombustible metal and paint dust accumulationHot work permits for welding and cutting tasksIgnition sources from tools, sparks, and smokingVentilation and housekeeping to reduce fuel loadLesson 6Understanding the facility layout: production, paint booth, warehouseThis part teaches reading the factory layout to find hazards in production areas, paint booths, and stores. Learners will map work flows, traffic paths, and escape routes to spot crowding, blind spots, and mismatched activities or materials.
Reading plant floor plans and process flow mapsHazards in cutting, forming, and welding zonesPaint booth airflow, mixing rooms, and exitsWarehouse racking, aisles, and staging areasTraffic routes for forklifts, carts, and pedestriansLesson 7Ergonomic hazards: manual material handling, repetitive tasks, awkward posturesThis part tackles ergonomic dangers from lifting metal, handling parts, and repeated painting or grinding. Learners will identify awkward positions, heavy efforts, and repetition, and look at redesigns, tools, and job shifts to cut strain injuries.
Manual lifting of plate, bar, and finished partsRepetitive grinding, sanding, and tool vibrationAwkward postures at benches, racks, and boothsUse of carts, hoists, and lift tables as aidsJob rotation and microbreaks to reduce fatigueLesson 8Common physical hazards: cuts, slips, falls, struck-by, caught-betweenThis part covers everyday physical dangers like sharp edges, slips, trips, falls, struck-by, and caught-in events. Learners will review cleaning, guarding, signs, and safe movement to lower routine injury risks in the workshop.
Sharp edges, burrs, and handling sheet metalFloor conditions, spills, and trip obstaclesWorking at heights, ladders, and platformsStruck-by hazards from moving loads and toolsCaught-between risks at presses and pinch pointsLesson 9Electrical hazards: portable tools, damaged cords, lockout/tagout basicsThis part explains electrical dangers from hand tools, faulty wires, and panels in fabrication and painting. Learners will recognise shock, arc, and fire risks, and go over basic lockout/tagout steps, checks, and safe use of extensions and GFCIs.
Recognizing damaged cords, plugs, and insulationSafe use of portable tools in metal shopsGrounding, GFCIs, and wet location precautionsOverloaded circuits, adapters, and power stripsBasic lockout/tagout steps for maintenance tasks
