Lesson 1Common process hazards: cutting, welding, grinding, painting, assembly - where dem occur an exposed groupsLinks common metalworkin processes to typical hazards an exposed groups. Examines cutting, welding, grinding, painting, an assembly, highlightin task-based risk assessment an layered controls across di process flow.
Cutting operations and associated hazardsWelding fire, fume, and electrical risksGrinding sparks, noise, and wheel integrityPainting overspray, VOCs, and ignition sourcesAssembly line pinch points and tool hazardsLesson 2Manual handlin an ergonomic hazards: repetitive tasks, heavy liftin, awkward postures inna assembly an maintenanceAddresses manual handlin an ergonomic risks inna liftin, assembly, an maintenance. Covers task analysis, load design, mechanical aids, job rotation, an workstation setup fi prevent musculoskeletal disorders an fatigue.
Task and load assessment for manual handlingUse of hoists, conveyors, and lift assistsWorkstation height and reach optimizationRepetitive task redesign and job rotationErgonomic training and early symptom reportingLesson 3Electrical hazards: fixed plant, portable tools, lockout-tagout requirementsCovers electrical risks from fixed plant an portable tools inna metal facilities. Addresses inspection, maintenance, lockout-tagout, arc flash, an safe use a extension cords, panels, an temporary power durin maintenance or projects.
Fixed plant electrical risk identificationPortable tools, cords, and inspection regimesLockout‑tagout steps and documentationArc flash awareness and boundary settingTemporary power and panel access controlsLesson 4Slip, trip, an fall hazards: floor contamination, stairs, elevated platforms, storage practicesIdentifies slip, trip, an fall hazards from floor contamination, stairs, platforms, an storage. Explains inspection routines, housekeeping, drainage, edge protection, an safe access design fi production an warehouse areas.
Floor condition, drainage, and contaminationHousekeeping standards and spill responseStair design, handrails, and step visibilityGuardrails and access on elevated platformsStorage layout, stacking, and access aislesLesson 5Mechanical hazards: movin parts, machine guardin, nip points, rotatin equipmentDetails mechanical hazards from movin parts, nip points, an rotatin equipment. Explains risk assessment, machine guardin types, interlocks, emergency stops, an safe access fi cleanin, clearin jams, an maintenance.
Identification of in‑running and nip pointsFixed, interlocked, and adjustable guardsEmergency stops and isolation pointsSafe clearing of jams and blockagesMaintenance access and verification of zero energyLesson 6Physical hazards: noise, vibration, heat, cold, lightin an ergonomic risk factorsExamines physical hazards such as noise, vibration, heat, cold, an lightin inna metal plants. Describes exposure assessment, health effects, engineerin controls, PPE, an ergonomic layout fi reduce strain an fatigue inna work areas.
Noise mapping, exposure limits, and controlsHand‑arm vibration sources and mitigationHeat stress, cold stress, and work‑rest cyclesLighting levels, glare, and visual fatigueLayout design to reduce physical strainLesson 7Fire an explosion hazards: flammable liquids, paint booths, combustible dust, hot workExplores fire an explosion risks from flammable liquids, paint booths, combustible dust, an hot work. Covers ignition sources, hazardous area zonin, ventilation, housekeeping, an safe systems a work fi routine an non-routine tasks.
Flammable liquid storage and transfer controlsPaint booth design, ventilation, and ignition controlCombustible dust recognition and housekeepingHot work permitting and fire watch dutiesExplosion protection, zoning, and equipment selectionLesson 8Transport an traffic hazards: forklifts, pedestrian routes, loadin docks, rackin collapseAnalyzes transport an traffic hazards from forklifts, trucks, an pedestrians. Discusses route design, speed control, loadin docks, rackin stability, an segregation measures fi prevent collisions an structural failures.
Traffic flow mapping and route segregationForklift selection, inspection, and limitsPedestrian walkways, crossings, and signageLoading dock edge, trailer, and fall risksRacking design, loading, and impact protectionLesson 9Chemical an airborne hazards: paints, solvents, weldin fumes, metal dust - sources an exposure pathwaysReviews chemical an airborne hazards from paints, solvents, weldin fumes, an metal dust. Covers safety data sheets, exposure pathways, ventilation, respiratory protection, an monitorin strategies inna metal operations.
Inventory, labeling, and SDS interpretationWelding fumes and local exhaust ventilationSolvent vapors and confined space concernsMetal dust capture, filtration, and disposalAir monitoring and respiratory PPE selectionLesson 10Contractor an visitor-specific hazards: unfamiliarity, control a work, permit-to-work, induction an supervisionFocuses pon hazards affectin contractors an visitors unfamiliar wid di site. Explains induction, supervision, permit-to-work, interface wid production, an how fi control simultaneous operations an non-routine high-risk tasks.
Prequalification and contractor risk profilingSite induction and communication of rulesPermit‑to‑work for high‑risk activitiesSupervision, monitoring, and stop‑work authorityManaging simultaneous operations and interfaces
