Lesson 1Cutting and press operation hazards: lacerations, amputations, noise, vibrationThis section addresses hazards from cutting and press operations, including lacerations, crush injuries, amputations, noise, and vibration, and details guarding, lockout, and maintenance practices that reduce mechanical and hearing risks in local workshops.
Point-of-operation and pinch-point risksMachine guards, light curtains, and interlocksLockout/tagout during setup and jamsNoise exposure assessment and controlsHand-arm vibration and tool selectionLesson 2Risk assessment techniques: job hazard analysis (JHA), task observation, risk matrix and severity/probability scoringThis section presents practical risk assessment techniques for metal fabrication, including job hazard analysis, task observation, and risk matrices, and explains how to score severity and probability to prioritise corrective actions in South African contexts.
Breaking jobs into discrete task stepsIdentifying hazards at each task stepEstimating severity and likelihood ratingsBuilding and using a simple risk matrixPrioritising and tracking risk reductionsLesson 3Ergonomic hazards: prolonged standing, repetitive motion, manual handling and low-back strainThis section examines ergonomic hazards in metal fabrication, such as prolonged standing, repetitive tool use, awkward postures, and heavy manual handling, and shows how to assess and control low-back strain and cumulative trauma disorders in factory settings.
Identifying high-risk postures and motionsAssessing lifting tasks and load limitsWorkstation layout and tool positioningJob rotation and microbreak strategiesUse of hoists, carts, and lift tablesLesson 4Overview of metal parts factory processes and typical hazard sourcesThis section introduces common metal parts factory workflows, from raw material receipt to finished product shipping, and highlights where mechanical, chemical, ergonomic, and physical hazards typically arise along each process step in South African operations.
Material receiving and storage hazardsCutting, shearing, and punching operationsForming, bending, and press brake activitiesWelding, grinding, and finishing tasksAssembly, packaging, and shipping areasLesson 5Chemical storage hazards: solvents, oils, flammability, skin absorption, MSDS useThis section explains chemical storage and handling hazards in metal fabrication, focusing on solvents, oils, cleaners, and coatings, and shows how labelling, segregation, ventilation, and SDS use prevent fires, burns, and absorption in local facilities.
Labelling, pictograms, and hazard classesFlammable cabinet and drum storage rulesSpill control, absorbents, and drainageSkin contact, dermatitis, and barrier creamsUsing SDS to plan controls and trainingLesson 6Welding hazards: fumes, UV radiation, burns, eye injury, fire riskThis section covers welding hazards including fumes, gases, UV and IR radiation, burns, eye injuries, and fire risk, and explains how ventilation, work practices, PPE, and housekeeping prevent acute and chronic health effects in South African workshops.
Welding fume composition and health effectsLocal exhaust and general ventilation optionsUV, IR, and visible light eye protectionFire watch, sparks, and hot work permitsGloves, clothing, and skin burn preventionLesson 7Hierarchy of controls: elimination, substitution, engineering, administrative, PPEThis section details the hierarchy of controls, from elimination and substitution through engineering and administrative measures to PPE, and shows how to apply this framework to typical metal fabrication hazards and tasks in South African environments.
Eliminating unnecessary hazardous tasksSubstituting safer materials or processesEngineering controls for machines and layoutAdministrative rules, training, and signageSelecting and maintaining effective PPELesson 8Loading dock and forklift hazards: struck-by, runovers, vehicle blind spotsThis section focuses on loading dock and forklift hazards, including struck-by incidents, runovers, tip-overs, and blind-spot collisions, and explains how layout, traffic rules, and visibility controls reduce risks for operators and pedestrians in factories.
Typical loading dock traffic patternsForklift stability, speed, and braking limitsPedestrian walkways and exclusion zonesSpotters, mirrors, and visual warning aidsSafe pallet stacking and load securementLesson 9How to document findings and create a brief evidence-backed risk summary (using OSHA, NIOSH, EU-OSHA guidance)This section explains how to document hazard findings clearly and concisely, using checklists, photos, and simple summaries, and how to reference OSHA, NIOSH, and EU-OSHA guidance to support evidence-based risk decisions in South African compliance.
Standardised inspection and JHA formsUsing photos and sketches to show hazardsCiting OSHA, NIOSH, and EU-OSHA sourcesSummarising risks for managers and workersTracking actions, owners, and due dates
