Lesson 1Noise, vibration, and ergonomic hazards for operators and finishersThis covers loud noise, shaking, and body strain dangers for machine runners and finishers, including mapping exposure, picking tools, work spot setup, and spotting early signs of ear and body hurt.
Finding noise sources and mappingHand-arm and full body shake risksBody position, reach, and force checksTool picking, holds, and anti-shake helpsEarly signs report and trend watchLesson 2Electrical hazards: high-voltage CNC, robot drives, weld transformers, and arc flashThis covers electric dangers from high power CNC, robot motors, weld power boxes, and flash bursts, stressing area marking, labels, fault cases, and working with skilled electric people for risk checks.
Machine power levels and shock areasFlash burst energy and labelsBox strength and lock checksGrounding, joining, and return path dangersWorking with skilled electric workersLesson 3Suspended loads and dropped-object hazards from overhead crane operationsThis looks at hanging load and falling item dangers from big crane work, including tie picking, move paths, no-go zones, and ways to find fail points and people factors that raise risk.
Load path mapping and no-go zonesTie tools picking and checksHook, catch, and sling attach dangersRunner sight and talk limitsBefore use crane and lift checksLesson 4Slip, trip, and fall hazards from workspace layout, parts, and cablingThis deals with slip, trip, and fall dangers from work area setup, part placing, and wires, focusing on people flow, cleaning, floor state, and ways to spot, note, and fix layout risks first.
Path and walkway block checksFloor state and water flow checksWire paths, guards, and hose keepingWork in progress and part place waysCheck lists and close miss reportsLesson 5Human-machine interface hazards: control confusion, teach pendant misuse, and inadequate signageThis focuses on people-machine link dangers like control mix-up, wrong use of teach tools, and poor signs, stressing task checks, labels, and watching how runners work with auto systems.
Control setup, labels, and color marksMode pick, locks, and over ridesTeach tool use and wrong use casesSigns, shows, and alarm workUser feedback and behavior watchLesson 6Exposure hazards to cleaning chemicals and confined-space or lockout situations during maintenanceThis looks at exposure dangers from cleaning chemicals and fix tasks in tight spaces or locked out, focusing on chemical marking, enter conditions, cut off points, and checking energy control works.
Chemical list and danger sheet reviewVapor, mist, and skin touch checksTight space enter state checkEnergy cut off point markingCheck of lock out and no energyLesson 7Thermal, radiant, and fire hazards from CNC plasma cutting and hot workThis explores heat, light ray, and fire dangers from CNC plasma cutting and hot jobs, covering start sources, heat hit zones, burnable loads, and ways to check exposure, keep areas apart, and note needed controls.
Heat and ray energy exposure checkBurnable materials and fire load mappingHot work permits and area cut offTorch, tip, and supply fail waysFire watch jobs and after work watchLesson 8Fume and gas hazards from welding processes and ventilation considerationsThis details smoke and gas dangers from welding steps, heat cutting, and poor air flow, dealing with smoke make rates, gas build up, air move patterns, and ways to note exposure hot spots and control needs.
Step specific smoke make profilesShield gases and no air risksLocal pull out and hood catch checksGeneral air flow and mappingAir check and exposure notingLesson 9Projectile and splash hazards from grinding, cutting slag, and plasma slag ejectionThis reviews flying bits and splash dangers from grinding, cut waste, and plasma waste throw, focusing on wheel fail, work piece throw, and finding hit zones that need guards or step controls.
Grinding wheel pick and fault checksWork piece hold and stop dangersSpark, waste, and bits path mappingGuarding, screens, and block placeFace, eye, and body safe needsLesson 10Mechanical hazards from moving robot arms, rotating positioners, and pinch pointsThis explores machine dangers from moving robot arms, turning holders, and squeeze points, stressing reach studies, guard checks, and finding tasks that put workers in danger move zones.
Reach areas and move range studiesSqueeze, cut, and crush point checksGuarding, fence, and light barrier checksSafe speed, hold to run, and slow controlsFix and teach task exposures
