Lesson 1Common Process Hazards: Cutting, Welding, Grinding, Painting, Assembly - Where They Occur and Exposed GroupsConnects common metalworking processes to typical hazards and affected groups. Reviews cutting, welding, grinding, painting, and assembly, stressing task-based risk evaluation and multi-layer controls throughout the process in local plants.
Cutting operations and associated hazardsWelding fire, fume, and electrical risksGrinding sparks, noise, and wheel integrityPainting overspray, VOCs, and ignition sourcesAssembly line pinch points and tool hazardsLesson 2Manual Handling and Ergonomic Hazards: Repetitive Tasks, Heavy Lifting, Awkward Postures in Assembly and MaintenanceDeals with manual handling and ergonomic risks in lifting, assembly, and maintenance. Includes task analysis, load planning, mechanical aids, job rotation, and workstation design to avoid musculoskeletal issues and tiredness in Zimbabwean factories.
Task and load assessment for manual handlingUse of hoists, conveyors, and lift assistsWorkstation height and reach optimizationRepetitive task redesign and job rotationErgonomic training and early symptom reportingLesson 3Electrical Hazards: Fixed Plant, Portable Tools, Lockout-Tagout RequirementsAddresses electrical dangers from fixed equipment and portable tools in metal facilities. Covers inspections, upkeep, lockout-tagout, arc flash, and safe use of extension cords, panels, and temporary power during maintenance in local sites.
Fixed plant electrical risk identificationPortable tools, cords, and inspection regimesLockout-tagout steps and documentationArc flash awareness and boundary settingTemporary power and panel access controlsLesson 4Slip, Trip, and Fall Hazards: Floor Contamination, Stairs, Elevated Platforms, Storage PracticesIdentifies slip, trip, and fall risks from floor contamination, stairs, platforms, and storage. Explains inspection routines, cleaning standards, drainage, edge guards, and safe access planning for production and warehouse areas in Zimbabwe.
Floor condition, drainage, and contaminationHousekeeping standards and spill responseStair design, handrails, and step visibilityGuardrails and access on elevated platformsStorage layout, stacking, and access aislesLesson 5Mechanical Hazards: Moving Parts, Machine Guarding, Nip Points, Rotating EquipmentOutlines mechanical hazards from moving parts, nip points, and rotating equipment. Covers risk evaluation, guarding types, interlocks, emergency stops, and safe access for cleaning, jam clearance, and maintenance in manufacturing plants.
Identification of in-running and nip pointsFixed, interlocked, and adjustable guardsEmergency stops and isolation pointsSafe clearing of jams and blockagesMaintenance access and verification of zero energyLesson 6Physical Hazards: Noise, Vibration, Heat, Cold, Lighting and Ergonomic Risk FactorsReviews physical hazards like noise, vibration, heat, cold, and lighting in metal plants. Describes exposure checks, health impacts, engineering solutions, PPE, and ergonomic designs to lessen strain and fatigue in work zones.
Noise mapping, exposure limits, and controlsHand-arm vibration sources and mitigationHeat stress, cold stress, and work-rest cyclesLighting levels, glare, and visual fatigueLayout design to reduce physical strainLesson 7Fire and Explosion Hazards: Flammable Liquids, Paint Booths, Combustible Dust, Hot WorkExamines fire and explosion risks from flammable liquids, paint booths, combustible dust, and hot work. Includes ignition sources, hazardous zoning, ventilation, cleaning, and safe work systems for routine and non-routine tasks in facilities.
Flammable liquid storage and transfer controlsPaint booth design, ventilation, and ignition controlCombustible dust recognition and housekeepingHot work permitting and fire watch dutiesExplosion protection, zoning, and equipment selectionLesson 8Transport and Traffic Hazards: Forklifts, Pedestrian Routes, Loading Docks, Racking CollapseAnalyses transport and traffic risks from forklifts, trucks, and pedestrians. Discusses route planning, speed limits, loading docks, racking stability, and separation measures to avoid collisions and structural issues in warehouses.
Traffic flow mapping and route segregationForklift selection, inspection, and limitsPedestrian walkways, crossings, and signageLoading dock edge, trailer, and fall risksRacking design, loading, and impact protectionLesson 9Chemical and Airborne Hazards: Paints, Solvents, Welding Fumes, Metal Dust - Sources and Exposure PathwaysExamines chemical and airborne hazards from paints, solvents, welding fumes, and metal dust. Covers safety data sheets, exposure routes, ventilation, respiratory protection, and monitoring in metal operations across Zimbabwe.
Inventory, labeling, and SDS interpretationWelding fumes and local exhaust ventilationSolvent vapors and confined space concernsMetal dust capture, filtration, and disposalAir monitoring and respiratory PPE selectionLesson 10Contractor and Visitor-Specific Hazards: Unfamiliarity, Control of Work, Permit-to-Work, Induction and SupervisionHighlights hazards for contractors and visitors unfamiliar with the site. Explains induction, oversight, permit-to-work, production interfaces, and managing simultaneous operations and high-risk non-routine tasks in local plants.
Prequalification and contractor risk profilingSite induction and communication of rulesPermit-to-work for high-risk activitiesSupervision, monitoring, and stop-work authorityManaging simultaneous operations and interfaces
