Lesson 1Common physical hazards: unguarded blades, rotating parts, hot surfaces, sharp edgesLooks at physical dangers from unguarded blades, spinning parts, hot surfaces, and sharp edges. You'll check guarding methods, safe distances, and cleaning practices that cut down contact, catching, and burn risks at machines and work areas.
Types of machine guards and interlocksSafe distances from rotating partsManaging hot surfaces and burn risksControlling sharp edges and burrs on metalPreventing entanglement with loose clothingLesson 2Mechanical and vehicle hazards: forklift interactions, moving pallets, pinch pointsCovers common mechanical and vehicle risks in metal workshops, like forklifts, moving loads, and pinch points. Teaches safe movement, keeping people and vehicles apart, and controls to avoid crushing, hitting, and catching injuries.
Forklift routes, blind spots, and speed controlSafe pedestrian walkways and exclusion zonesSecuring and stacking pallets and heavy loadsRecognizing and guarding pinch and crush pointsSpotter roles and safe reversing proceduresLesson 3Hazard severity and likelihood: basic qualitative risk rating and prioritization methodsIntroduces simple ways to rate risks using severity and likelihood. You'll practise basic charts, ranking hazards, and prioritising so the biggest risks get controlled first with proper measures.
Defining severity and likelihood levelsUsing a simple risk matrix step by stepRanking hazards for action and resourcesReassessing risk after controls are appliedCommunicating risk ratings to the teamLesson 4Slip, trip, fall and ergonomic hazards: spills, uneven floors, poor stacking, manual handlingExamines slip, trip, fall, and body strain risks in metal workshops. Covers floor conditions, storage habits, and lifting techniques to reduce strains, twists, and falls, focusing on real Kenyan workshop setups and daily jobs.
Identifying slip and trip hotspotsHousekeeping for clear walkways and aislesSafe use of steps, ladders, and platformsManual handling and lifting best practicesAdjusting work height and reach to reduce strainLesson 5Chemical and respiratory hazards: solvents, oils, welding fumes, compressed gasesDetails chemical and breathing risks like solvents, oils, welding smoke, and gases. You'll review labels, safety sheets, ventilation, and mask use, learning to control exposure by swapping, containing, and handling safely.
Reading labels and Safety Data SheetsVentilation and local exhaust at workstationsSafe handling and storage of solvents and oilsManaging welding fumes and smoke exposureSelecting and using respirators correctlyLesson 6Recording and reporting hazards: checklists, hazard logs, and inspection templatesTeaches how to record and report hazards using checklists, logs, and forms. Stresses quick reporting, clear notes, and follow-ups so risks get tracked, prioritised, and fixed, not overlooked.
Designing simple hazard report formsUsing daily and weekly inspection checklistsMaintaining a central hazard log or registerEscalating urgent hazards for quick actionTracking corrective actions to completionLesson 7Systematic walk-through techniques for workshop stations (cutting, drilling, welding, storage, loading)Covers step-by-step walk-throughs for workshop stations. Practise using checklists, watching tasks, and asking workers about risks at cutting, drilling, welding, storage, and loading spots to get the full risk view.
Planning the walk-through route and timingUsing station-specific hazard checklistsObserving tasks, tools, and worker behaviorsDocumenting findings with notes and photosFollowing up on identified hazards and actionsLesson 8Electrical hazards: damaged cords, improper grounding, wet work areasFocuses on spotting electrical risks like faulty wires, poor earthing, and wet spots. Explains earthing, lockout, and checks, showing how to prevent shocks, burns, and fires around metal tools and portable gear.
Inspecting cords, plugs, and outletsGrounding, bonding, and GFCI protectionSafe use of extension leads and power stripsControlling moisture and wet work conditionsLockout and tagout basics for electrical workLesson 9Regulatory basics and standards relevant to workshops: PPE requirements, machine guarding, labeling, and storageIntroduces key rules and standards for Kenyan metal workshops. Explains PPE needs, machine guards, labelling, and safe storage, helping workers grasp legal duties and how following them boosts safety.
Employer and worker legal responsibilitiesCore PPE rules for eyes, hands, and hearingMachine guarding and emergency stop rulesLabeling of equipment, chemicals, and areasStorage rules for materials and cylinders
