Lesson 1Noise, vibration, and ergonomic hazards for operators and finishersAddresses noise, vibration, and ergonomic hazards for operators and finishers, including exposure mapping, tool choice, workstation setup, and spotting early signs of hearing loss and muscle strain.
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 hazards from high-voltage CNC, robot drives, weld transformers, and arc flash, stressing boundary marking, labelling, fault scenarios, and working with qualified 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 operationsAnalyses suspended load and dropped-object risks from overhead cranes, including rigging choice, travel paths, exclusion zones, and spotting failure points and human factors 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 cablingTackles slip, trip, and fall hazards from workspace layout, parts staging, and cabling, focusing on traffic flow, housekeeping, floor conditions, and prioritising layout fixes.
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 interface risks like control confusion, teach pendant misuse, and poor signage, using task analysis, labelling, and watching operator interactions with automation.
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 confined spaces or lockouts, covering chemical ID, entry conditions, isolation points, and energy control checks.
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 thermal, radiant, and fire risks from CNC plasma cutting and hot work, including ignition sources, heat zones, combustible loads, and assessing exposure with area segregation.
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 generation rates, gas buildup, airflow, and documenting exposure hotspots and controls.
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 projectile and splash risks from grinding, cutting slag, and plasma slag, focusing on wheel failures, workpiece projection, and guarding impact zones.
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, rotating positioners, and pinch points, with reach studies, safeguarding checks, and identifying tasks in hazardous motion areas.
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
