Lesson 1Noise, vibration, and ergonomic hazards for operators and finishersCovers noise, vibration, and ergonomic hazards impacting operators and finishers, including exposure mapping, tool selection, workstation layout, and spotting early signs of hearing and musculoskeletal strain in daily work.
Noise source identification and mappingHand-arm and whole-body vibration risksPosture, reach, and force task analysisTool selection, grips, and anti-vibration aidsEarly symptom reporting and trend trackingLesson 2Electrical hazards: high-voltage CNC, robot drives, weld transformers, and arc flashCovers electrical hazards from high-voltage CNC systems, robot drives, weld transformers, and arc flash, emphasising boundary identification, labelling, fault scenarios, and coordination with qualified electricians for risk evaluation.
Equipment voltage classes and shock boundariesArc flash incident energy and labelingEnclosure integrity and interlock verificationGrounding, bonding, and return path hazardsCoordination with qualified electrical workersLesson 3Suspended loads and dropped-object hazards from overhead crane operationsAnalyses suspended load and dropped-object hazards from overhead crane operations, including rigging selection, travel paths, exclusion zones, and methods to identify failure points and human factors increasing risk in the yard.
Load path mapping and exclusion zonesRigging hardware selection and inspectionHook, latch, and sling attachment hazardsOperator visibility and communication limitsPre-use crane and hoist condition checksLesson 4Slip, trip, and fall hazards from workspace layout, parts, and cablingAddresses slip, trip, and fall hazards from workspace layout, parts staging, and cabling, focusing on traffic flow, housekeeping, floor conditions, and ways to identify, record, and prioritise layout-related risk fixes.
Walkway and aisle obstruction surveysFloor surface condition and drainage checksCable routing, guarding, and hose managementWork-in-process and parts staging practicesInspection checklists and near-miss reportsLesson 5Human-machine interface hazards: control confusion, teach pendant misuse, and inadequate signageFocuses on human-machine interface hazards like control confusion, teach pendant misuse, and poor signage, emphasising task analysis, labelling, and observing operator interactions with automation systems in the workshop.
Control layout, labeling, and color codingMode selection, interlocks, and overridesTeach pendant use and misuse scenariosSignage, indicators, and alarm effectivenessUser feedback and behavioral observationsLesson 6Exposure hazards to cleaning chemicals and confined-space or lockout situations during maintenanceExamines exposure hazards from cleaning chemicals and maintenance tasks in confined spaces or lockout, focusing on chemical identification, entry conditions, isolation points, and verifying energy control effectiveness.
Chemical inventory and SDS hazard reviewVapor, mist, and skin contact evaluationsConfined-space entry condition assessmentEnergy isolation point identificationVerification of lockout and zero energyLesson 7Thermal, radiant, and fire hazards from CNC plasma cutting and hot workExplores thermal, radiant, and fire hazards from CNC plasma cutting and hot work, covering ignition sources, heat-affected zones, combustible loading, and methods to assess exposure, segregate areas, and document controls.
Heat and radiant energy exposure assessmentCombustible materials and fire load mappingHot work permits and area isolationTorch, nozzle, and consumable failure modesFire watch duties and post-work monitoringLesson 8Fume and gas hazards from welding processes and ventilation considerationsDetails fume and gas hazards from welding processes, thermal cutting, and poor ventilation, addressing fume generation rates, gas accumulation, airflow patterns, and documenting exposure hotspots and control needs.
Process-specific fume generation profilesShielding gases and asphyxiation risksLocal exhaust and hood capture checksGeneral ventilation and airflow mappingAir monitoring and exposure documentationLesson 9Projectile and splash hazards from grinding, cutting slag, and plasma slag ejectionReviews projectile and splash hazards from grinding, cutting slag, and plasma slag ejection, focusing on wheel failure, workpiece projection, and identifying impact zones needing guarding or procedural controls.
Grinding wheel selection and defect checksWorkpiece clamping and restraint hazardsSpark, slag, and debris trajectory mappingGuarding, screens, and barrier placementFace, eye, and body protection needsLesson 10Mechanical hazards from moving robot arms, rotating positioners, and pinch pointsExplores mechanical hazards from moving robot arms, rotating positioners, and pinch points, emphasising reach studies, safeguarding verification, and identifying tasks placing workers in hazardous motion zones.
Reach envelopes and motion range studiesPinch, shear, and crush point surveysGuarding, fencing, and light curtain checksSafe speed, hold-to-run, and jog controlsMaintenance and teaching task exposures
