WORKSHOP PROCESSES Module 1

DEFINATIONS OF TERMS

A WORKSHOP: Is a designed place where maintenance, or service or repair or

assembling work of motor vehicles or other equipments are carried
out.

SAFETY: Is the freedom from danger – awareness of risks of injury, death or

damages at place of work.

DANGER: Is or means chances of suffering liability to suffer injuries or loss of life.

ACCIDENT: Is an unplanned occurrence that could be caused by one’s carelessness

or negligence which might cause injury or loss of life or equipment.

HAZARD: A potential of a substance, activity or process to cause harm.

RISK: Is the likely hood of a substance, activity or process to cause harm.

DANGEROUS OCCURANCE: It is any incident that could have resulted in an accident

“Near miss”.

WELFARE: The provision of facilities at workplace to maintain the health and well-
being of an individual at the work place.

OSHA: This represents Occupational Safety and Health Administration

APPLYING ELEMENTS OF 5S

Introduction

The 5S method is a workplace organization system originating from Japan.

It focuses on improving efficiency, safety, and quality by organizing the workplace.
In an automotive workshop, applying 5S ensures tools, equipment, and work areas are
orderly, clean, safe, and efficient.

1. Sort (Seiri) – Remove what is not needed

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  Definition: Separating necessary items from unnecessary items and removing
the latter from the workplace.
 Purpose:
o Prevents clutter.
o Frees up space for essential tools and parts.
o Reduces the risk of accidents and mistakes.
 How to Apply in a Workshop:
o Inspect all tools, equipment, and materials.
o Remove broken or unused tools, scrap parts, and outdated materials.
o Keep only tools and equipment relevant to the current job.
 Example: Removing rusty spanners, empty oil containers, or old tyres from the
work bay.

2. Set in Order (Seiton) – Arrange tools and materials for easy use

 Definition: Organizing necessary items so they are easy to find, use, and return.
 Purpose:
o Saves time when looking for tools.
o Prevents workplace confusion.
o Improves workflow.
 How to Apply in a Workshop:
o Assign a specific storage place for each tool.
o Use tool boards with outlines for each item.
o Label shelves, drawers, and storage bins.
o Arrange frequently used tools closer to the work area.
 Example: Having sockets and spanners organized in labelled drawers in size
order.

3. Shine (Seiso) – Clean the workplace and equipment

 Definition: Keeping the workplace clean and well-maintained.

 Purpose:

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 o Improves safety and prevents hazards.
o Extends the life of tools and machinery.
o Creates a professional image for customers.
 How to Apply in a Workshop:
o Clean workbenches, floors, and tool surfaces daily.
o Remove oil spills immediately.
o Inspect equipment for leaks, wear, or damage while cleaning.
 Example: Wiping grease off wrenches after use and mopping up oil spills near a
lift.

4. Standardize (Seiketsu) – Create consistent procedures for organization and

cleaning

 Definition: Establishing rules and schedules to maintain the first three S’s.
 Purpose:
o Ensures a consistent level of cleanliness and order.
o Makes it easy for everyone to follow the same system.
 How to Apply in a Workshop:
o Create a cleaning and inspection checklist.
o Develop color-coded storage systems.
o Assign specific responsibilities for tool storage and cleaning.
 Example: A daily ―end of shift‖ routine where mechanics return tools to their
assigned places and clean their work bays.

5. Sustain (Shitsuke) – Maintain and improve the system over time

 Definition: Making 5S a regular habit and part of the workshop culture.

 Purpose:
o Prevents the workshop from falling back into disorganization.
o Encourages continuous improvement.
 How to Apply in a Workshop:
o Train all staff on 5S principles.

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 o Conduct regular audits to ensure compliance.
o Reward teams for maintaining 5S standards.
 Example: Monthly 5S inspections with recognition for the cleanest and most
organized work bay.

Benefits of Applying 5S in an Automotive Workshop

 Increased productivity.
 Improved safety.
 Better quality of work.
 Professional appearance for customers.
 Reduced tool and equipment loss.

CARRYING OUT HOUSEKEEPING DUTIES IN AN AUTOMOTIVE WORKSHOP

DEFINITION OF HOUSEKEEPING

 Housekeeping in an automotive workshop refers to the systematic cleaning,

arranging, and maintaining of the work environment to ensure safety,
efficiency, and professionalism.
 It includes keeping the workplace clean, orderly, and free from hazards so that
work can be done effectively.
 Purpose:
o Improve safety by reducing accident risks.
o Increase efficiency by making tools and parts easier to locate.
o Maintain a professional image for customers.
o Protect tools, equipment, and components from damage.

PRECAUTIONS FOR BETTER HOUSEKEEPING

The following precautions must be observed;

1. Always walk – never run.

2. Never throw rubbish on the floor.

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 3. Keep gangways and work areas free of metal bars, components etc.
4. Keep to gangways when moving about – never take short cuts.
5. If oil, water or grease is spilled, wipe it up immediately.
6. Wear safety shoes – shoes are available with anti-slip soles and with metal
toe-caps to protect the feet from falling objects.
7. Never use unstable piles of boxes, inadequate scaffolding, or unsecured
ladders for working at heights.
8. Always check ladders for damage before use.
9. Always position ladders on a firm base at the correct angle-the height of the
top support should be about four times the distance out at the base.
10. Ensure the ladders are long enough.

PERFORMING HOUSEKEEPING

a) Cleanliness

 Meaning: Keeping the workshop floor, benches, tools, and machinery clean.
 Importance:
o Prevents slips, trips, and falls.
o Reduces risk of fire from oil or fuel spills.
o Improves the working life of tools and machines.
 Examples of Application:
o Sweeping floors at regular intervals.
o Wiping down workbenches after each job.
o Removing grease, oil spills, and dirt immediately.
o Cleaning tools before storage.

b) Orderly Arrangement of Tools and Components

 Meaning: Storing tools and components in their proper places so they are easy
to locate and return.

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  Importance:
o Saves time searching for equipment.
o Reduces tool loss or misplacement.
o Prevents damage to delicate parts.
 Examples of Application:
o Using labelled tool boards and drawers.
o Arranging tools by type and size.
o Keeping spare parts in designated bins or shelves.
o Storing hazardous materials in marked safety cabinets.

c) Clearing Work Area of Obstacles

 Meaning: Removing unnecessary items, debris, and obstructions from the

workshop floor and workstations.
 Importance:
o Prevents accidents such as tripping or bumping into sharp objects.
o Improves workflow by ensuring free movement.
o Complies with workplace safety regulations.
 Examples of Application:
o Moving unused equipment away from walkways.
o Disposing of scrap parts, packaging, and waste promptly.
o Keeping emergency exits and fire extinguishers accessible.
o Ensuring vehicle lifts and bays are free from clutter.

BENEFITS OF GOOD HOUSEKEEPING IN A WORKSHOP

 Safer work environment.

 Increased productivity and efficiency.
 Reduced risk of equipment damage.
 Enhanced customer trust and satisfaction.
 Compliance with health and safety standards.

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ORGANISING PHYSICAL WORKSPACE FOR FUNCTIONALITY AND
PRODUCTIVITY

Introduction

A well-organized automotive workshop is safe, comfortable, and efficient.

Proper workspace organization reduces accidents, improves workflow, and ensures
high-quality work output.
Key factors include ventilation, temperature, room dimensions and space, lighting,
and proximity of tools and equipment.

1. VENTILATION

 Definition: The movement of fresh air into and out of the workshop.
 Importance:
o Removes fumes from exhaust gases, paints, solvents, and chemicals.
o Reduces risk of respiratory illness.
o Prevents overheating of equipment and workspace.
 Methods:
o Installing extraction fans or fume extractors near exhaust testing areas.
o Keeping windows and vents open when possible.
o Using portable ventilators in enclosed areas.
 Example: A spray painting booth fitted with a filtered exhaust system.

2. TEMPERATURE

 Definition: The level of heat or cold in the workshop environment.

 Importance:
o Comfortable temperature improves worker focus and efficiency.
o Prevents overheating of sensitive components and machinery.
o Avoids discomfort that could lead to safety mistakes.
 Control Methods:
o Installing fans, air conditioners, or heaters.

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 o Using heat-resistant roofing or insulation to reduce excessive heat.
o Scheduling heavy or hot jobs during cooler parts of the day.
 Example: Keeping indoor workshops between 18°C and 24°C for optimal
comfort.

3. ROOM DIMENSION AND SPACE

 Definition: The size and layout of the workshop area.

 Importance:
o Adequate space prevents accidents from crowding and clutter.
o Allows smooth movement of vehicles, tools, and personnel.
o Accommodates specialized equipment (vehicle lifts, alignment machines).
 Recommendations:
o Allocate enough space per vehicle bay for doors to open freely.
o Keep clear pathways for moving heavy tools and vehicles.
o Separate storage areas from repair bays.
 Example: Designing a service bay with at least 3–4 meters clearance around
the vehicle.

4. LIGHTING

 Definition: The amount and quality of light in the workshop.

 Importance:
o Improves accuracy when working on fine details.
o Prevents mistakes caused by poor visibility.
o Reduces eye strain and fatigue.
 Lighting Tips:
o Use bright, shadow-free overhead lighting.
o Supplement with portable work lamps for detailed tasks.
o Prefer LED lights for energy efficiency and brightness.
 Example: Overhead LED lights combined with magnetic LED work lights for
under-the-hood repairs.

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5. PROXIMITY OF TOOLS AND EQUIPMENT

 Definition: The arrangement of tools and machinery close to the point of use.
 Importance:
o Saves time spent walking to retrieve tools.
o Reduces unnecessary movement, increasing productivity.
o Improves workflow efficiency.
 Methods:
o Store frequently used tools near each work bay.
o Use mobile tool trolleys for flexibility.
o Arrange heavy equipment (e.g., tyre changers, compressors) near related
work areas.
 Example: Keeping a hydraulic jack, wheel balancer, and tyre changer together in
the tyre service section.

BENEFITS OF AN ORGANIZED WORKSHOP

 Increased productivity.
 Reduced accidents and injuries.
 Improved work quality.
 Better worker morale and comfort.
 Professional image to customers.

IDENTIFYING HEALTH AND SAFETY HAZARDS

DEFINING HAZARDS

 Hazard: Any source of potential damage, harm, or adverse effect to people,

property, or the environment.
 In an automotive workshop, hazards can cause:
o Injuries (cuts, burns, fractures)
o Illness (from dust, fumes, chemicals)
o Equipment damage

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  Hazards are generally classified into:
o Health hazards – affect physical or mental health over time.
o Safety hazards – cause immediate physical injury or accidents.

HEALTH HAZARDS

These are hazards that can negatively affect a worker’s health, usually over prolonged
exposure.

a) Dust

 Comes from grinding, sanding, brake lining wear, and painting.

 Can cause:
o Respiratory problems (asthma, bronchitis)
o Eye irritation
 Control measures:
o Use dust masks/respirators
o Wet methods for dust suppression
o Proper ventilation

b) Radiation

 Sources: welding arcs (UV and IR radiation), bright lights, and certain testing
equipment.
 Can cause:
o Eye damage (―arc eye‖)
o Skin burns
 Control measures:
o Welding helmets with correct filter shade
o Protective clothing and screens

c) Fluids

 Includes fuel, lubricating oil, brake fluid, coolant, battery acid.

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  Hazards:
o Skin irritation and dermatitis
o Poisoning if swallowed or inhaled
o Corrosion and burns from acids
 Control measures:
o Wear gloves and protective clothing
o Proper storage and labeling of fluids
o Use spill kits for cleanup

d) Noise

 Sources: pneumatic tools, hammering, engine running, grinding.

 Hazards:
o Hearing loss (gradual or sudden)
o Fatigue and stress
 Control measures:
o Ear defenders or ear plugs
o Maintain equipment to reduce noise
o Limit time in noisy areas

e) Temperature

 High temperatures from engines, exhaust systems, welding.

 Low temperatures in some refrigerated environments or winter work.
 Hazards:
o Burns or heat stress
o Hypothermia in cold conditions
 Control measures:
o Heat-resistant gloves
o Allow cooling time before handling hot components
o Proper workshop heating/cooling

SAFETY HAZARDS

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These hazards can cause accidents or injuries immediately if not controlled.

a) Falling Objects

 Sources: tools on high shelves, unsecured vehicle parts, overhead work.

 Hazards:
o Head injuries, bruises, fractures
 Control measures:
o Store items securely
o Wear hard hats in risk areas
o Use tool lanyards when working at height

b) Rolling Objects

 Sources: moving vehicles, rolling wheels, loose parts on sloped floors.

 Hazards:
o Crushed feet or legs
 Control measures:
o Wheel chocks
o Flat, level work surfaces
o Keep pathways clear

c) Electricity

 Sources: power tools, battery systems, wiring, test equipment.

 Hazards:
o Electric shock or electrocution
o Burns from short circuits
 Control measures:
o Proper insulation and grounding
o Do not work on live circuits unless necessary
o Use insulated tools

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d) Rotating Components

 Sources: fans, belts, pulleys, grinding wheels, drills.

 Hazards:
o Entanglement (clothing, hair, jewelry)
o Cuts, amputations
 Control measures:
o Keep guards in place
o Avoid loose clothing
o Tie back long hair

e) Heavy Equipment

 Sources: vehicle lifts, jacks, hoists, engines being removed.

 Hazards:
o Crushing injuries
o Equipment tipping over
 Control measures:
o Use equipment rated for the load
o Follow safe lifting procedures
o Regular inspection and maintenance

KEY POINTS FOR SAFE PRACTICE

 Always perform a risk assessment before starting work.

 Use Personal Protective Equipment (PPE) relevant to the task.
 Maintain good housekeeping — clean, organized workspaces reduce accidents.
 Follow manufacturer’s instructions for tools and machinery.

IDENTIFYING HAZARDOUS WORKPLACE MATERIALS

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Hazardous workplace materials are substances that can harm people, property, or the
environment.
They may be solid, liquid, or gaseous, and can cause:

 Health problems (poisoning, burns, respiratory illness)

 Environmental pollution
 Fire or explosion hazards

1. SOLID HAZARDOUS MATERIALS

a) Cyanide

 Source: Used in some metal cleaning, electroplating, and coating processes.

 Hazards:
o Highly toxic — can cause death if inhaled, swallowed, or absorbed
through skin.
o Interferes with body’s ability to use oxygen.
 Control measures:
o Only trained personnel should handle it.
o Wear gloves, masks, and protective clothing.
o Store in secure, clearly labelled containers.

b) Solid Workshop Waste

 Source: Scrap metal, worn brake linings, grinding dust, packaging.

 Hazards:
o Cuts, punctures, trip hazards.
o May contain toxic substances (asbestos, lead dust).
 Control measures:
o Dispose of waste promptly in designated bins.
o Wear gloves when handling waste.
o Follow environmental disposal regulations.

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c) Used Filters

 Source: Oil filters, fuel filters, air filters.

 Hazards:
o Contain residual oil, fuel, or dust.
o Can cause skin irritation or environmental contamination.
 Control measures:
o Drain fluids before disposal.
o Store in sealed containers for recycling or safe disposal.
o Avoid direct skin contact.

d) Used Batteries

 Source: Vehicle lead-acid or lithium-ion batteries.

 Hazards:
o Contain corrosive acid and toxic lead or lithium compounds.
o Risk of explosion if short-circuited.
 Control measures:
o Store upright in acid-resistant trays.
o Avoid sparks and open flames nearby.
o Send to certified recycling facilities.

2. LIQUID HAZARDOUS MATERIALS

a) Oils

 Source: Engine oil, transmission fluid, hydraulic oil.

 Hazards:
o Skin irritation, dermatitis.
o Fire risk if spilled near ignition sources.
o Environmental pollution if spilled.
 Control measures:
o Store in sealed, labelled containers.

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 o Use drip trays and absorbent material for spills.
o Wear gloves during handling.

b) Fuels

 Source: Petrol, diesel, LPG.

 Hazards:
o Highly flammable — explosion risk.
o Toxic fumes.
 Control measures:
o Store in approved safety containers.
o Keep away from sparks, flames, and heat.
o Ensure good ventilation when refuelling.

c) Coolant

 Source: Radiator antifreeze (ethylene glycol or propylene glycol).

 Hazards:
o Poisonous if ingested.
o Can cause skin and eye irritation.
 Control measures:
o Avoid ingestion and skin contact.
o Store securely and clearly labelled.
o Clean spills immediately.

d) Acids

 Source: Battery acid (sulphuric acid), cleaning agents.

 Hazards:
o Corrosive — causes burns to skin and eyes.
o Damages clothing and equipment.
 Control measures:
o Wear acid-resistant gloves and goggles.

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 o Neutralise spills with baking soda or lime.
o Store in acid-resistant containers.

3. GASEOUS HAZARDOUS MATERIALS

a) Carbon Monoxide (CO)

 Source: Incomplete combustion in petrol and diesel engines.

 Hazards:
o Odourless, colourless gas — deadly in high concentrations.
o Causes headaches, dizziness, unconsciousness, death.
 Control measures:
o Ensure good ventilation when running engines.
o Use exhaust extraction systems.
o Avoid idling engines in enclosed spaces.

b) Nitrous Fumes (NOx)

 Source: Vehicle exhaust gases, welding fumes.

 Hazards:
o Irritate lungs, eyes, and throat.
o Can contribute to long-term respiratory disease.
 Control measures:
o Use fume extraction systems.
o Wear respirators when necessary.
o Maintain engines for cleaner combustion.

c) Sulphurous Fumes (SO₂)

 Source: Burning sulphur-containing fuels, some chemical cleaning agents.

 Hazards:
o Causes respiratory irritation and coughing.
o Contributes to acid rain.

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  Control measures:
o Avoid prolonged exposure.
o Use proper ventilation.
o Store chemicals securely and handle with PPE.

KEY SAFETY PRACTICES FOR HAZARDOUS MATERIALS

 Always label containers clearly with hazard warnings.

 Store materials according to safety data sheets (SDS).
 Use correct Personal Protective Equipment (PPE) for each hazard.
 Dispose of hazardous waste according to environmental laws.
 Keep spill kits and fire extinguishers nearby.

USING CORRECT PERSONAL PROTECTIVE EQUIPMENT (PPE)

1. INTRODUCTION TO PPE

 Definition: Personal Protective Equipment (PPE) refers to specialized clothing or

equipment worn by workers to protect themselves from hazards in the workplace.
 Purpose:
o Minimize exposure to hazards that can cause injuries or illnesses.
o Provide a barrier between the worker and the hazard.
 Importance in Automotive Workshops:
o Workshops involve mechanical, chemical, thermal, and electrical hazards.
o Proper PPE prevents accidents and long-term health problems.

2. TYPES OF PPE IN THE AUTOMOTIVE WORKSHOP

A. Head Protection

 Equipment:
o Hard Hat:
 Protects against falling objects, head bumps, and electrical
hazards.

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  Used when working under raised vehicles or in construction areas
within the workshop.

B. Eye Protection

 Equipment:
o Safety Goggles:
 Protect eyes from dust, flying particles, and splashes.
o Welding Shield:
 Protects face and eyes from intense light, sparks, and heat during
welding.
o Cutting Goggles:
 Protect eyes from sparks and hot metal fragments when using
cutting tools.
o Welding Goggles:
 Specifically for gas welding and brazing; filters harmful radiation.

C. Ear Protection

 Equipment:
o Ear Plugs:
 Small devices inserted into the ear canal to reduce noise levels.
o Ear Muffs:
 Cover the entire ear to protect from high noise levels from grinders,
compressors, and pneumatic tools.

D. Body Protection

 Equipment:
o Overalls / Work Suit:
 Protect skin and clothing from dirt, oil, and minor abrasions.
o Safety Belt & Safety Harness:

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  Used when working at heights or on elevated platforms to prevent
falls.
o Apron:
 Protects against heat, sparks, and chemical splashes during
welding or chemical handling.

E. Respiratory Protection

 Equipment:
o Dust Mask:
 Filters dust particles during sanding, grinding, or cleaning.
o Rescue Pack:
 Emergency breathing equipment used in confined spaces or rescue
situations.
o Gas Mask:
 Filters harmful gases and vapors, used when working with strong
chemicals or in poorly ventilated areas.

F. Foot Protection

 Equipment:
o Safety Boots:
 Steel-toe protection against heavy falling objects.
o Safety Shoes:
 Similar to safety boots but lighter; used for less heavy-duty work.
o Gum Boots:
 Waterproof protection for wet or chemical spill areas.

G. Hand Protection

 Equipment:
o Leather Gloves:

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  Protect hands from cuts, burns, and abrasions when handling
rough or hot objects.
o PVC Gloves:
 Protect hands from chemicals, oils, and solvents.

3. CORRECT USE OF PPE

 Always inspect PPE before use (check for cracks, tears, or wear).
 Wear the correct PPE for the specific task.
 Ensure proper fit and adjustment for comfort and safety.
 Keep PPE clean and store it properly after use.
 Replace damaged or worn-out PPE immediately.

4. Summary

PPE is essential in automotive workshops to:

 Prevent injuries.
 Protect against long-term health risks.
 Comply with safety regulations.

IDENTIFYING WORKSHOP LAYOUT

1. INTRODUCTION

 Definition: Workshop layout refers to the planned arrangement of work areas,

equipment, pathways, and safety facilities in the workshop.
 Importance of a Good Layout:
o Improves workflow and productivity.
o Reduces risk of accidents.
o Ensures quick access to tools, machinery, and emergency equipment.
o Complies with safety regulations.

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2. KEY FEATURES OF A WORKSHOP LAYOUT

A. Work Areas

 Description:
o Designated zones where specific tasks are carried out, such as engine
repair, welding, painting, and assembly.
 Purpose:
o Organize tools and equipment for efficiency.
o Reduce movement of parts and workers.
o Minimize interference between tasks.

B. Walkways

 Description:
o Clearly marked paths for movement of workers within the workshop.
 Purpose:
o Prevent accidents by separating pedestrian traffic from moving vehicles or
machinery.
o Allow safe and quick evacuation during emergencies.
 Features:
o Painted lines or floor markings.
o Non-slip surfaces.

C. Emergency Exit and Assembly Point

 Emergency Exit:
o Clearly marked doors for quick escape during fire or other emergencies.
o Should be unobstructed at all times.
 Assembly Point:
o Safe location outside the workshop where workers gather after
evacuation.
o Used for headcount and ensuring everyone is safe.

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D. Fire-Fighting Equipment Location

 Types of Equipment:
o Fire extinguishers (different types for electrical, flammable liquids, and
solid fires).
o Fire hose reels.
o Sand buckets.
 Placement:
o Easily visible and accessible.
o Positioned near high-risk areas (e.g., welding bay, fuel storage).

E. Location of First Aid Box / Eye Wash Station

 First Aid Box:

o Stocked with bandages, antiseptics, gloves, and basic medical supplies.
o Positioned in an easily accessible, clearly marked area.
 Eye Wash Station:
o Used for rinsing eyes in case of chemical splashes or dust entry.
o Located near chemical storage and work areas with high dust or splash
hazards.

F. Location of Service Pit / Hoist

 Service Pit:
o A below-ground workspace for accessing the underside of vehicles.
o Should have protective barriers when not in use.
 Vehicle Hoist (Lift):
o Used for raising vehicles for inspection and repair.
o Positioned in areas with adequate ceiling height and floor strength.

G. Location of Flammable and Hazardous Substances

 Examples: Petrol, diesel, solvents, paint thinners, and lubricants.

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  Storage Requirements:
o Stored in flameproof cabinets or designated rooms.
o Away from heat sources, welding areas, or open flames.
o Clearly labeled containers.

H. Location of Battery Charging Bay

 Description:
o A separate, well-ventilated area for charging vehicle batteries.
 Safety Considerations:
o Isolated from open flames and sparks due to hydrogen gas emission
during charging.
o Equipped with spill kits and acid-neutralizing agents.

3. Summary

A well-planned workshop layout improves safety, productivity, and organization by

ensuring:

 Clear division of work areas.

 Safe pedestrian movement.
 Quick access to safety equipment.
 Proper storage of hazardous substances.
 Designated emergency exits and assembly points.

APPLYING ISOLATION AND TAG OUT PROCEDURE (LOCKOUT/TAGOUT)

1. INTRODUCTION

 Definition of Isolation and Tagging Out:

o Isolation: The process of physically disconnecting and securing energy
sources so machinery or equipment cannot be started accidentally.
o Tagging Out: Attaching a warning tag to isolated equipment indicating it
must not be operated until the tag is removed by the authorized person.

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  Purpose:
o Prevent accidental startup or release of energy during maintenance or
repair.
o Protect workers from injury and prevent equipment damage.

2. IDENTIFYING ISOLATION POINTS

 Isolation Points: Locations where energy can be disconnected or shut off from
equipment.
o Examples:
 Electrical disconnect switches.
 Main power switches.
 Fuel supply valves.
 Hydraulic shut-off valves.
 Pneumatic air supply valves.
 Battery terminals.

3. Placing Notice – “Work in Progress”

 Before starting work:

o Place a visible “Work in Progress” sign.
o Inform all workers in the area.
o Attach the notice at the main control or entry point.

4. Isolating and Testing

 Steps:
1. Shut down the equipment using normal stopping procedures.
2. Disconnect the energy source at the isolation point.
3. Test controls to ensure the equipment does not start.
4. Verify zero energy by using appropriate testing tools (e.g., voltage tester).

5. Locking and Getting the Key

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  Place a lock on the isolation device to prevent it from being turned on.
 The key should be kept by the person performing the work.
 Only the authorized worker should remove the lock after completion.

6. Identifying Hazardous Energy Sources

 Mechanical: Moving parts, belts, gears.

 Electrical: Stored electrical energy in circuits or batteries.
 Gravitational: Elevated parts or suspended loads.
 Thermal: Hot surfaces, steam, heated fluids.
 Hydraulic: Pressurized oil in hoses and cylinders.
 Pneumatic: Compressed air systems.
 Chemical: Hazardous fluids or gases under pressure.
 Master Switch: Main on/off switch for equipment.
 Ignition Switch: Key-operated switch in vehicles.
 Control Levers: Operational controls that may start movement.

7. Identifying Hazards

 Sharp Objects: Blades, cutting tools.

 Rotating Devices: Shafts, fans, drills.
 High Pressure: Hydraulic or pneumatic lines.
 Electrical Shocks: Live wires, faulty insulation.
 Suspended Objects: Loads lifted by cranes or hoists.

8. Demonstrating Correct Lock Out and Tagging Procedures

Steps:

1. Park the machine on level ground.

2. Chock wheels to prevent rolling.
3. Secure steering frame (if applicable).

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 4. Isolate source of power (switch off engine, disconnect battery, or shut down
electricity).
5. Lower/support all implements to the ground or secure them with supports.
6. Apply park brake.
7. Put a tag and a lock on the isolation point.
8. Keep the key with the person doing the maintenance.
9. After work, remove the lock and tag only when it is safe to restart.

APPLYING SAFETY, HEALTH AND ENVIRONMENTAL REGULATIONS

THE HEALTH AND SAFETY AT WORK ACT

PURPOSE

1. To safeguard the health, safety and welfare of the persons at work.

2. To protect the general public from risks to health and safety caused by the
activities of persons at work.
3. To control the keeping and use of explosives or highly flammable or otherwise
dangerous substances, and, generally prevent the unlawful acquisition,
possession, and use of such substances.
4. To control the emission into the atmosphere of harmful or offensive substances
from premises.

DUTIES OF EMPLOYERS

The employer should provide:

1. Healthy and safe plant and systems maintained in good order.

2. Healthy and safety facilities for handling, storage and transport of articles and
substances.
3. Healthy and safety information, instruction, training and supervision.
4. A healthy and safe place of work maintained in good order, with a safe means of
getting to and from it.

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 5. A healthy and safe working environment with adequate facilities and
arrangements for welfare.
DUTIES OF EMPLOYEES

It shall be the duty of every employee while at work:

1. To take reasonable care of the health and safety of himself or herself, other
workers, and the general public.
2. To observe the provisions of the ACT wherever applicable to him/her or matters
under his/her control.
3. To co-operate with his employer in complying with the Act.
4. No person shall intentionally or recklessly interfere with or misuse anything
provided in the interests of health, safety or welfare to meet the legal
requirements of the act.
5. To read the warning labels on materials.
6. Follow the instructions and warnings very carefully.
7. To use common sense when working with hazardous materials.
8. To take time to learn how to use protective materials.

1. IMPORTANCE OF SAFETY

 Safety protects workers from injuries and accidents.

 Ensures a healthy working environment.
 Prevents damage to equipment and property.
 Complies with legal regulations and workplace standards.
 Improves productivity by reducing downtime from accidents.

2. IDENTIFYING WORKSHOP HAZARDS

 Mechanical Hazards:
o Lifting appliances (cranes, hoists) that may fail.
o Running machines with moving parts (belts, gears) causing entanglement
or crushing.

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  Noise:
o High noise levels from machinery causing hearing loss.
 Chemical Hazards:
o Exposure to toxic substances such as solvents, paints, and fuels.
 Toxic Substances:
o Harmful fumes or liquids that can cause poisoning or respiratory problems.
 Electrical Hazards:
o Risk of shocks or fires from faulty wiring or equipment.
 Fire Hazards:
o Flammable liquids and sparks leading to fire outbreaks.
 Oil Spillage:
o Causes slips and falls; environmental contamination.
 Pressurized Systems:
o Hydraulic or pneumatic lines that may burst causing injury.
 Improper Ventilation:
o Leads to accumulation of harmful fumes and poor air quality.
 Poor Lighting:
o Increases risk of accidents due to poor visibility.

3. PERSONAL PROTECTIVE EQUIPMENT (PPE) – TYPES AND USES

 Head Protection: Hard hats.

 Eye Protection: Safety goggles, welding shields.
 Ear Protection: Ear plugs, ear muffs.
 Body Protection: Overalls, aprons, safety harness.
 Respiratory Protection: Dust masks, gas masks.
 Foot Protection: Safety boots/shoes, gumboots.
 Hand Protection: Leather gloves, PVC gloves.

4. PROPER DISPOSAL OF ENVIRONMENTALLY HAZARDOUS MATERIALS

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  Dispose of oils, solvents, batteries, and chemicals according to environmental
regulations.
 Use designated containers and waste disposal sites.
 Avoid dumping hazardous waste into drains or open areas.
 Promote recycling and safe handling to protect environment.

INDUSTRIAL DERMATITIS

Dermatitis – Is The Reaction Of The Skin To Substances Used In The Industry.

- Can Take Many Different Forms, But Usually Starts With Redness And Irritation.
- Is Not Contagious, But Any Part Of The Body Which Comes In Contact With The
Substance May Be Affected.
Causes of Dermatitis

The Main Substances Which Cause Industrial Dermatitis Are:

a) Mineral Oil Used As A Cutting Fluid In Many Applications.

b) Chemicals Such As Chromic Acid (Used In Chromium Plating) And Synthetic
Resins.
c) Solvents Such As Paraffin, Trichloroethylene, And Turpentine – These
Dissolve The Natural Grease From The Skin And Allow Entry Of The Irritant.

Precautions To Be Taken

a) The Use Of Mechanical Aids Such As Tongs, Scrapers And Splash Guards
Should Be Encouraged.
b) Wearing Protective Clothing, This Should Be Regularly Cleaned And Kept
Apart From Other Clothing.
c) Using Washing Facilities With Hot Water And Clean Towels.
d) Using The Appropriate Barrier Creams.
e) Having First-Aid Treatment For Every Injury, However Trivial.

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APPLYING FIRST AID

1. Defining First Aid

 Immediate care given to an injured or ill person before professional medical help
arrives.

2. Importance of First Aid

 Saves lives by providing quick intervention.

 Prevents injuries from worsening.
 Reduces pain and promotes recovery.
 Provides reassurance and comfort to the injured.

3. First Aid Box and Its Contents

 Bandages, gauze, adhesive tape.

 Antiseptic solutions and creams.
 Scissors and tweezers.
 Gloves (disposable).
 Eye wash solution.
 Pain relief tablets.
 CPR mask or shield.

4. Identifying Different Types of Accidents

 Cuts and wounds.

 Burns and scalds.
 Fractures and broken bones.
 Electric shocks.
 Falls and blunt injuries.
 Chemical exposures.

5. Making Judgements to the Type of Accident

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  Assess the injury type, severity, and required treatment.
 Identify if the injury requires emergency services.
 Decide on the immediate first aid needed.

6. Defining Shock

 A life-threatening condition where the body’s organs do not get enough blood
flow.
 Caused by severe injury, bleeding, burns, or allergic reactions.

7. Identifying Signs of Shock

 Pale, cold, clammy skin.

 Rapid, weak pulse.
 Shallow breathing.
 Dizziness or fainting.
 Weakness or confusion.

8. Applying Shock Treatment

 Lay the person down on their back.

 Elevate the legs slightly (unless injury prevents it).
 Keep the person warm and comfortable.
 Do not give food or drink.
 Call for medical help immediately.

9. Applying Methods of Resuscitation

 Mouth to Mouth Method:

o Tilt victim’s head back, pinch nose, seal your mouth over theirs, and
breathe in and out.
 Mouth to Nose Method:
o Use if mouth is injured or cannot be opened; cover nose instead and blow
air into lungs.

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10. Handling Personal Injuries

 Brain Injury:
o Keep victim still and calm; avoid moving the head.
o Call emergency services immediately.
 Broken/Fractured Bones:
o Immobilize the injured part with a splint.
o Avoid moving the injured limb unnecessarily.
 Burn/Fire Injuries:
o Cool the burn with running water (not ice).
o Cover with clean cloth and seek medical help.
 Electrocution:
o Do not touch victim if still in contact with electricity.
o Turn off power source first.
o Call for medical help immediately.
 Spinal Cord/Back Injury:
o Do not move the victim unless absolutely necessary.
o Support the head and neck.
o Call emergency services.

Summary

 Safety, health, and environmental regulations protect workers and the

environment.
 PPE is essential for personal safety.
 Proper disposal of hazardous waste is critical to prevent pollution.
 First Aid is vital for managing injuries and saving lives in the workshop.

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