Lesson 1Mechanical hazards: rotating equipment, conveyors, forklifts, pallet storageThis section covers mechanical hazards from rotating equipment, conveyors, forklifts, and pallet storage. Learners will identify pinch, crush, and struck-by points, and review guarding, traffic control, and inspection practices to prevent serious injuries in local shops.
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 section introduces exposure limits such as TLVs and PELs for welding fumes, solvents, and dusts. Learners will compare exposure durations, understand short-term and ceiling limits, and relate monitoring data to ventilation, PPE, and work practice controls relevant to Zambia.
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 3Recognising early indicators: near-misses, symptoms of exposure, unsafe actsThis section focuses on recognising early indicators of hazards, including near-misses, minor injuries, exposure symptoms, and unsafe acts. Learners will practice reporting, trend review, and using findings to correct conditions before serious incidents occur in manufacturing settings.
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 section reviews chemical hazards from welding fumes, solvent-based paints, isocyanates, and nuisance or toxic dusts. Learners will connect SDS data to routes of exposure, symptoms, and controls such as ventilation, PPE, and substitution in Zambian facilities.
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 section examines fire and explosion risks from flammable liquids, combustible dust, and hot work. Learners will identify ignition sources, review storage and ventilation rules, and apply hot work permits, housekeeping, and bonding and grounding practices.
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 section teaches how to read the facility layout to spot hazards in production, paint booths, and warehouses. Learners will map workflows, traffic routes, and emergency paths to identify congestion, blind spots, and incompatible activities or materials in local sites.
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 section addresses ergonomic hazards from lifting steel, handling parts, and repetitive painting or grinding. Learners will identify awkward postures, forceful exertions, and repetition, and explore redesign, mechanical aids, and job rotation to reduce strain injuries.
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 section covers common physical hazards such as sharp edges, slips, trips, falls, struck-by, and caught-between events. Learners will examine housekeeping, guarding, signage, and safe movement practices to reduce routine injury risks in the shop floor.
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 section explains electrical hazards from portable tools, cords, and panels in fabrication and painting. Learners will recognise shock, arc, and fire risks, and review basic lockout/tagout steps, inspection routines, and safe use of extension cords and GFCIs.
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
