Lesson 1Common process hazards: cutting, welding, grinding, painting, assembly - where they occur and exposed groupsConnects usual metal work steps to common dangers and groups at risk. Looks at cutting, welding, grinding, painting, and putting together, pointing out job-based risk checks and layered controls through the work flow.
Cutting jobs and linked dangersWelding fire, smoke, and power risksGrinding sparks, noise, and wheel strengthPainting spray over, bad air, and fire startsPutting together line pinch spots and tool dangersLesson 2Manual handling and ergonomic hazards: repetitive tasks, heavy lifting, awkward postures in assembly and maintenanceDeals with hand lifting and body strain risks in lifting, putting together, and upkeep. Covers job checks, load plans, machine helps, job switches, and work spot setups to stop muscle pains and tiredness.
Job and load checks for hand liftingUse of lifts, movers, and help toolsWork spot height and reach best setupRepeat job redesign and worker switchesBody strain training and early sign reportsLesson 3Electrical hazards: fixed plant, portable tools, lockout-tagout requirementsCovers power risks from fixed machines and hand tools in metal spots. Deals with checks, upkeep, lock-stop tags, flash arcs, and safe use of extra cords, boards, and temp power in upkeep or projects.
Fixed machine power risk spottingHand tools, cords, and check plansLock-stop tag steps and papersFlash arc knowledge and limit settingTemp power and board entry controlsLesson 4Slip, trip, and fall hazards: floor contamination, stairs, elevated platforms, storage practicesSpots slip, trip, fall dangers from floor dirt, stairs, high platforms, and storing ways. Tells about check routines, clean habits, water drain, edge guards, and safe entry designs for making and store areas.
Floor state, drain, and dirt spotsClean rules and spill quick fixesStair setup, rail holds, and step seesGuard rails and entry on high platformsStore layout, stack ways, and path aislesLesson 5Mechanical hazards: moving parts, machine guarding, nip points, rotating equipmentTells details of machine dangers from moving parts, pinch spots, and turning gear. Explains risk checks, guard types, locks, stop buttons, and safe entry for cleaning, jam clears, and upkeep.
Spotting pull-in and pinch spotsFixed, lock, and adjust guardsStop buttons and cut-off spotsSafe jam and block clearsUpkeep entry and zero power checksLesson 6Physical hazards: noise, vibration, heat, cold, lighting and ergonomic risk factorsLooks at body dangers like noise, shakes, hot, cold, and light in metal plants. Describes exposure checks, health harms, build controls, safety gear, and body layout to cut strain and tiredness in work spots.
Noise maps, exposure limits, and controlsHand-arm shake spots and fixesHot stress, cold stress, and work-rest timesLight levels, blind spots, and eye tirednessLayout design to cut body strainLesson 7Fire and explosion hazards: flammable liquids, paint booths, combustible dust, hot workLooks into fire and blast risks from fire liquids, paint rooms, burn dust, and hot jobs. Covers fire starts, danger zone plans, air flow, clean habits, and safe work ways for regular and special tasks.
Fire liquid store and move controlsPaint room setup, air flow, and fire start controlBurn dust spot and clean habitsHot job papers and fire watch jobsBlast guard, zone plans, and gear picksLesson 8Transport and traffic hazards: forklifts, pedestrian routes, loading docks, racking collapseChecks moving and traffic dangers from forklifts, trucks, and walkers. Talks route setups, speed rules, load spots, rack steady, and split ways to stop crashes and build fails.
Traffic move maps and path splitsForklift picks, checks, and limitsWalker paths, cross spots, and sign boardsLoad spot edges, trailer, and fall risksRack setup, loads, and hit guardsLesson 9Chemical and airborne hazards: paints, solvents, welding fumes, metal dust - sources and exposure pathwaysReviews chemical and air dangers from paints, cleaners, weld smokes, and metal dust. Covers safe papers, exposure paths, air flow, breath guards, and watch plans in metal works.
Stock lists, labels, and safe paper readsWeld smokes and spot air pullCleaner airs and tight space worriesMetal dust catch, filter, and throw awayAir watch and breath gear picksLesson 10Contractor and visitor-specific hazards: unfamiliarity, control of work, permit-to-work, induction and supervisionFocuses on dangers for outside workers and guests not knowing the place. Explains welcome training, watch, work papers, links with making, and control of same-time works and special high-risk jobs.
Before pick and outside worker risk typesPlace welcome and rule talksWork papers for high-risk jobsWatch, check, and stop-work powerHandle same-time works and links
