Lesson 1Noise, vibration, and ergonomic hazards for operators and finishersCovers noise, vibration, and body strain hazards for operators and finishers, including mapping exposure, choosing tools, setting up workstations, and spotting early signs of hearing loss or muscle problems.
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 dangers from high-voltage CNC, robot motors, weld transformers, and arc flash, stressing boundary marking, labeling, fault cases, and working with skilled 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 operationsLooks at hanging load and falling object risks from overhead cranes, including rigging choices, travel paths, no-go zones, and ways to find weak points and human errors that raise risks.
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 cablingDeals with slip, trip, and fall risks from workspace setup, part storage, and cables, focusing on traffic flow, cleaning, floor states, and ways to spot, note, and fix layout risks first.
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 risks like control mix-ups, wrong use of teach pendants, and poor signs, stressing task checks, labeling, and watching how operators work with automated systems.
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 tight spaces or lockouts, focusing on chemical IDs, entry rules, isolation spots, and checking energy controls work well.
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 heat, light, and fire risks from CNC plasma cutting and hot jobs, covering fire starts, heat zones, burnable loads, and ways to check exposure, separate areas, and note needed 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 build-up, air flows, and ways to note exposure spots and control needs.
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 flying bits and splash risks from grinding, cutting slag, and plasma slag throws, focusing on wheel breaks, part throws, and spotting impact zones needing guards or rules.
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 robot arms moving, spinning positioners, and pinch spots, stressing reach checks, guard verifications, and spotting tasks putting workers in danger zones.
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
