DAY 1 – SAFETY FUNDAMENTALS, HAZARD IDENTIFICATION & CRITICAL SAFETY CONTROLS

Module 1 – Fundamentals of Industrial Safety

• Importance of Industrial Safety in Manufacturing
• Accident, Incident, Near Miss and Unsafe Act/Condition
• Causes of Accidents – Immediate, Basic and Root Causes
• Safety Responsibilities of Management, Supervisors and Employees
• Safety Culture and Employee Participation

Module 2 – Hazard Identification, HIRA & Risk Assessment

• Understanding Hazards and Risks
• Types of Workplace Hazards
• Hazard Identification Techniques
• HIRA / JSA Methodology
• Risk Assessment – Likelihood, Severity and Risk Ranking
• Identification of Existing and Additional Controls
• Practical HIRA Exercise

Module 3 – Hierarchy of Controls & Machine Safety

• Hierarchy of Controls – Elimination to PPE
• Selection of Effective Risk Controls
• Common Mechanical and Machinery Hazards
• Machine Guarding and Safety Devices
• Emergency Stops, Interlocks and Sensors
• Safe Operating and Maintenance Practices
• Machine Safety Case Study

Module 4 – Electrical Safety & LOTO

• Common Electrical Hazards
• Electrical Shock and Fire Prevention
• Electrical Panels, Earthing and Protection
• Lockout/Tagout (LOTO)
• Energy Isolation and Verification
• Arc Flash Awareness
• Electrical Safety Inspection – Do's and Don'ts
• LOTO Case Study

Module 5 – Fire Safety & Emergency Preparedness

• Fundamentals of Fire and Fire Classification
• Fire Prevention and Fire Extinguishers
• Emergency Exits and Evacuation
• Emergency Response Planning
• Roles and Responsibilities During Emergencies
• Mock Drills and Emergency Preparedness
• Fire Emergency Scenario

DAY 2 – OCCUPATIONAL SAFETY, HIGH-RISK ACTIVITIES & SAFETY IMPROVEMENT

Module 6 – Chemical, Material Handling & Occupational Health

• Chemical Hazards, Labelling and SDS
• Safe Chemical Storage and Handling
• Chemical Spill Prevention and Response
• Hazardous Waste Safety
• Manual Material Handling and Ergonomics
• Forklift, Crane and Lifting Safety
• Occupational Health Hazards and Workplace Hygiene
• Chemical / Ergonomic Case Study

Module 7 – High-Risk Activities & Contractor Safety

• Permit-to-Work System
• Work at Height
• Confined Space Entry
• Hot Work and Electrical Work
• Gas Testing and Atmospheric Monitoring
• Contractor Safety Management
• PPE, Competency and Supervision
• High-Risk Activity Case Study

Module 8 – Incident Investigation, Safety Audit & Safety Culture

• Incident and Near-Miss Investigation
• Evidence Collection and Root Cause Analysis
• 5 Why & Fishbone Analysis
• Corrective and Preventive Actions
• Workplace Safety Inspection
• Safety Audit vs. Safety Inspection
• Safety Observations and Reporting
• Toolbox Talks and Safety Communication
• Building a Proactive Safety Culture
• Incident Investigation & Workplace Inspection Exercise

Practical Case Studies & Group Exercises

Throughout the two days, participants will work on practical situations such as:

• HIRA/JSA preparation
• Unsafe Act vs. Unsafe Condition identification
• Hierarchy of Controls exercise
• Machine guarding case study
• Electrical safety & LOTO scenario
• Fire emergency scenario
• Chemical spill response
• Incident investigation and Root Cause Analysis
• Workplace safety inspection
• Corrective action development