Lesson 1Mechanical hazards: rotating equipment, conveyors, forklifts, pallet storageThis part talks about mechanical dangers from spinning machines, conveyor belts, forklifts, and stacked pallets. Learners will find spots where pinching, crushing, or hitting can happen, and look at ways to guard them, control movement, and check regularly to avoid bad injuries.
Rotating equipment pinch and entanglement pointsConveyor nip points, guards, and emergency stopsForklift traffic patterns and pedestrian separationPallet stacking, racking stability, and collapse risksPre-use inspections and reporting mechanical defectsLesson 2Environmental and exposure limits: TLVs, PELs, short-term exposureThis part introduces safe limits for things like welding smoke, cleaning liquids, and dust, using TLVs and PELs. Learners will compare how long exposure lasts, learn about quick and maximum limits, and connect checking data to better air flow, protective gear, and safe work habits.
Difference between TLVs, PELs, and company limitsShort-term exposure limits and ceiling valuesReading air monitoring and sampling resultsLinking exposure data to ventilation controlsAdjusting tasks and PPE to stay below limitsLesson 3Recognizing early indicators: near-misses, symptoms of exposure, unsafe actsThis part helps spot early signs of dangers, like close calls, small hurts, signs of breathing bad air, and risky actions. Learners will learn to report them, check patterns, and fix problems before big accidents happen in the workshop.
Identifying and documenting near-miss eventsEarly symptoms of chemical or fume exposureObserving unsafe acts and at-risk shortcutsUsing checklists and simple observation toursTurning early indicators into corrective actionsLesson 4Chemical hazards: welding fumes, solvent paints, isocyanates, dustThis part looks at chemical dangers from welding smoke, paints with solvents, isocyanates, and harmful dust. Learners will use safety sheets to understand how they enter the body, what symptoms they cause, and controls like better air, gear, and safer replacements.
Key hazards in welding fumes and metal oxidesSolvent paint vapors and overexposure symptomsIsocyanate sensitization and asthma concernsDust from grinding, blasting, and surface prepUsing SDSs to identify controls and PPE needsLesson 5Fire and explosion risks: flammable liquids, combustible dust, hot workThis part checks fire and blast risks from easy-to-burn liquids, burnable dust, and hot jobs like welding. Learners will find what starts fires, follow storage and air rules, and use permits, cleaning, and grounding to stay safe.
Flammable liquid storage, transfer, and labelingCombustible metal and paint dust accumulationHot work permits for welding and cutting tasksIgnition sources from tools, sparks, and smokingVentilation and housekeeping to reduce fuel loadLesson 6Understanding the facility layout: production, paint booth, warehouseThis part shows how to read the site plan to find dangers in making areas, paint rooms, and storage places. Learners will map work paths, vehicle routes, and escape ways to spot crowds, hidden spots, and bad mixes of jobs or materials.
Reading plant floor plans and process flow mapsHazards in cutting, forming, and welding zonesPaint booth airflow, mixing rooms, and exitsWarehouse racking, aisles, and staging areasTraffic routes for forklifts, carts, and pedestriansLesson 7Ergonomic hazards: manual material handling, repetitive tasks, awkward posturesThis part deals with body strain dangers from lifting metal, moving parts, and repeating paint or grind jobs. Learners will spot bad positions, hard pushes, and repeats, and learn redesign, tools, and job swaps to cut down on body hurts.
Manual lifting of plate, bar, and finished partsRepetitive grinding, sanding, and tool vibrationAwkward postures at benches, racks, and boothsUse of carts, hoists, and lift tables as aidsJob rotation and microbreaks to reduce fatigueLesson 8Common physical hazards: cuts, slips, falls, struck-by, caught-betweenThis part covers usual body dangers like sharp cuts, slips, trips, falls, hits, and getting caught. Learners will check cleaning, guards, signs, and safe walking to lower daily hurt risks in the work area.
Sharp edges, burrs, and handling sheet metalFloor conditions, spills, and trip obstaclesWorking at heights, ladders, and platformsStruck-by hazards from moving loads and toolsCaught-between risks at presses and pinch pointsLesson 9Electrical hazards: portable tools, damaged cords, lockout/tagout basicsThis part explains electric dangers from hand tools, bad wires, and boards in metal and paint work. Learners will know shock, spark, and fire risks, and basic lock steps, checks, and safe use of long wires and safety plugs.
Recognizing damaged cords, plugs, and insulationSafe use of portable tools in metal shopsGrounding, GFCIs, and wet location precautionsOverloaded circuits, adapters, and power stripsBasic lockout/tagout steps for maintenance tasks
