Lesson 1Vehicle and mobile plant hazards: forklifts and overhead cranesDis section analyse hazards from forklifts, overhead cranes, an oda mobile plant, focusin on traffic management, operator competence, signalin, load security, an shared-space rules fi prevent collisions, crush injuries, an dropped loads.
Traffic flow planning and exclusion zonesForklift stability, loads, and blind spotsOverhead crane pre-use checks and slingingPedestrian routes, crossings, and spottersParking, battery charging, and refueling areasLesson 2Chemical hazards: solvents, paint fumes, welding gases, metal dustDis section explain chemical hazards from solvents, paints, weldin fumes, an metal dust, focusin on exposure routes, health effects, monitorin, an layered controls like substitution, ventilation, safe storage, an proper PPE selection an use.
Solvent and paint components and exposure routesHealth effects of welding fumes and shielding gasesMetal dust generation, inhalation, and ingestion risksEngineering controls and local exhaust ventilationSafe storage, labeling, and PPE for chemicalsLesson 3Noise and vibration sources and effects in workshopsDis section discuss noise an vibration sources in workshops, dem health effects, exposure assessment, an control strategies, includin engineerin solutions, maintenance, administrative limits, an correct selection an use a hearin protection devices.
Main workshop noise and vibration sourcesHearing loss, fatigue, and other health impactsNoise surveys, dosimetry, and exposure limitsEngineering and administrative noise controlsHearing protection selection, fit, and careLesson 4Ergonomic hazards and manual handling during assembly and material storageDis section examine ergonomic an manual handlin risks durin assembly an material storage, includin liftin, pushin, awkward postures, an repetitive tasks, an present methods fi redesign, mechanical aids, an trainin fi prevent musculoskeletal injuries.
Task analysis for lifting and carrying activitiesUse of hoists, jacks, and mechanical handling aidsLayout design to reduce bending and reachingSafe storage heights and rack organizationTraining on body mechanics and team liftingLesson 5Electrical hazards: fixed machines, portable tools, temporary wiringDis section cover electrical hazards from fixed machines, portable tools, an temporary wirin, emphasizin shock, arc, an fire risks, lockout procedures, inspection routines, groundin, an coordination wid qualified electricians fi installation an repairs.
Electrical shock, arc flash, and burn mechanismsInspection of cords, plugs, and portable toolsLockout tagout for maintenance and cleaningSafe use of temporary power and extension leadsGrounding, bonding, and residual current devicesLesson 6Thermal and fire hazards: hot work, sparks, flammable liquids and vaporsDis section address thermal an fire hazards from hot work, sparks, an flammable liquids or vapors, detailin ignition sources, fuel controls, hot work permits, fire watch duties, housekeeping, an emergency response plannin fi workshop operations.
Ignition sources in cutting, welding, and grindingControl of flammable liquids, gases, and vaporsHot work permits and pre-job area checksFire watch roles, equipment, and responseHousekeeping and segregation to limit fire spreadLesson 7Common physical hazards: sharp edges, moving parts, pinch points, falling objectsDis section review common physical hazards like sharp edges, movin parts, pinch points, an fallin objects, explainin typical incident scenarios an practical controls includin guardin, barriers, signin, an safe handlin an stackin a materials.
Sharp edges, burrs, and sheet metal handlingMachine guarding and access to moving partsPinch points in presses, rollers, and clampsControls for falling objects and dropped toolsSignage, barriers, and safe walkwaysLesson 8Workforce factors: shift work, mixed experience levels, contractors and temporary staffDis section explore how workforce composition an organization influence risk, coverin shift work fatigue, differin experience levels, language barriers, an integratin contractors an temporary staff into site rules, supervision, an safety culture.
Shift patterns, fatigue, and error likelihoodManaging mixed skill and experience levelsOnboarding and supervision of contractorsTemporary staff induction and task assignmentCommunication, language, and safety cultureLesson 9Overview of metal fabrication processes: cutting, grinding, welding, painting, assemblyDis section outline main metal fabrication processes an dem risk profiles, showin how cuttin, grindin, weldin, paintin, an assembly steps interact, where hazards arise, an how plannin, layout, an standardized procedures reduce incidents an rework.
Typical workflow from raw stock to finished productCutting and grinding methods and related hazardsWelding and thermal cutting process risk overviewPainting, coating, and curing process safetySafe assembly, fit-up, and in-process inspections
