Activity 002: Hazard Assessment and Safety Improvement Plan¶

Activity ID: U3M4-ACT-002 Duration: 40 minutes Objective: Students will conduct a comprehensive hazard assessment of the laser lab environment and develop a safety improvement plan based on their findings. Group Size: 2-3 students per team Materials Cost: ~$0 (assessment documentation only)

Overview¶

Students act as safety inspectors, systematically evaluating the laser lab for hazards, compliance gaps, and improvement opportunities. They document findings, assess risk levels, and propose actionable improvements. This activity develops the safety awareness mindset that distinguishes a certified operator from a casual user.

Materials & Equipment Needed¶

Hazard assessment worksheet (printed, comprehensive checklist)
Camera/phone for documenting findings
Measuring tape (for distance verification)
Clipboard and pen
Lab safety standard reference card (key OSHA/ANSI requirements)
Scoring rubric for hazard risk assessment

Instructions & Procedure¶

Phase 1: Machine Zone Assessment (10 min) 1. Inspect the laser cutter station and its immediate surroundings:

Machine Condition: - Is the machine exterior clean and undamaged? [ ] - Are all safety labels present and legible? [ ] - Is the lid interlock mechanism intact (no tape, magnets, or modifications)? [ ] - Is the E-stop button visible, accessible, and functional? [ ] - Are the exhaust connections secure and sealed? [ ] - Is the honeycomb bed clean (no excessive debris)? [ ] - Are the optics (lens, mirrors) clean enough for safe operation? [ ]

Immediate Surroundings: - Is the area around the laser clear of flammable materials? [ ] - Is there adequate workspace for material handling? [ ] - Is the floor clear of trip hazards (cables, material scraps)? [ ] - Are electrical cords in good condition (no fraying, no overloading)? [ ]

Document any deficiencies with photos and notes

Phase 2: Safety Equipment Assessment (10 min) 3. Evaluate emergency equipment:

Fire Safety: - Spray bottle: present [ ], full [ ], within reach [ ] - Fire extinguisher: present [ ], correct type [ ], gauge green [ ], accessible [ ], inspected (date check) [ ] - Distance from machine to extinguisher: ___ meters (should be <5m)

Ventilation: - Exhaust system: present [ ], running [ ], airflow adequate [ ] - If filtered: filter status indicators readable [ ], replacement date logged [ ] - Room ventilation: windows operable [ ], mechanical ventilation [ ]

Emergency Preparedness: - Emergency exit: identified [ ], unobstructed [ ], within 15m [ ] - Emergency contact numbers posted [ ] - First aid kit: present [ ], stocked [ ], accessible [ ] - Laser safety program documentation available [ ]

Material Management: - Approved materials stored and labeled [ ] - Banned materials list posted at the machine [ ] - Unknown/quarantine materials separated from approved stock [ ] - Material settings database available at the machine [ ]

Phase 3: Risk Assessment Matrix (10 min) 4. For each deficiency found, assess the risk using this matrix:

Likelihood	Severity: LOW (minor inconvenience)	Severity: MEDIUM (injury/damage)	Severity: HIGH (serious injury/death)
UNLIKELY	Risk: LOW	Risk: LOW	Risk: MEDIUM
POSSIBLE	Risk: LOW	Risk: MEDIUM	Risk: HIGH
LIKELY	Risk: MEDIUM	Risk: HIGH	Risk: CRITICAL

Classify each finding as:
CRITICAL: Must be addressed BEFORE the machine can be used (e.g., broken interlock, missing extinguisher)
HIGH: Must be addressed within 24 hours (e.g., saturated filter, poor airflow)
MEDIUM: Should be addressed within 1 week (e.g., missing labels, disorganized materials)
LOW: Should be addressed at next scheduled maintenance (e.g., minor cosmetic issues)

Phase 4: Safety Improvement Plan (10 min) 6. For each HIGH and CRITICAL finding, write an improvement action: - Finding: Describe the specific deficiency - Risk Level: Critical / High / Medium / Low - Proposed Fix: Specific, actionable step to resolve the issue - Responsible Person: Who should implement the fix? - Timeline: When should it be completed? - Verification: How will you confirm the fix was effective?

Compile your findings into a one-page Safety Assessment Report:
Summary: X findings (Y critical, Z high, etc.)
Top 3 priorities requiring immediate attention
Overall lab safety rating: Excellent / Good / Needs Improvement / Unsafe
Present your top findings and recommendations to the class (2 minutes per group)

Discussion Points¶

Were there any findings that surprised you? Things you walked past every day without noticing?
Which finding has the highest risk of causing actual harm if not addressed?
How often should this type of assessment be performed?
How does a formal hazard assessment differ from an informal "everything looks fine" check?

Expected Outcomes¶

Each group should identify at least 3-5 findings (even well-maintained labs have improvement opportunities)
Critical findings (if any) should be reported to the instructor immediately — not just documented
Students should demonstrate understanding of risk assessment (likelihood × severity)
Safety improvement plans should contain specific, actionable, measurable steps

Assessment Rubric¶

Criterion	Excellent (5)	Proficient (3)	Needs Improvement (1)
Assessment Thoroughness	All checklist areas covered, 5+ findings documented with photos	Most areas covered, 3-4 findings	Incomplete coverage, fewer than 3 findings
Risk Classification	All findings correctly classified using the risk matrix	Most findings correctly classified	Risk classifications incorrect or missing
Improvement Plan	Specific, actionable fixes with responsible person, timeline, and verification	Fixes identified but lacking specificity	Vague or missing improvement actions
Report Quality	Clear, organized 1-page report with prioritized findings	Report present but disorganized	Report incomplete or missing

Safety Considerations¶

This is an inspection activity — do NOT test safety systems that could create hazards (e.g., do not fire the laser to test interlocks during this activity; that was done in Activity 001)
If a CRITICAL safety deficiency is found (broken interlock, missing extinguisher), report to the instructor IMMEDIATELY — do not wait until the presentation phase
Take care when inspecting electrical connections — do not touch wiring or modify any component
Work in teams — one person inspects while the other documents

Last Updated: 2026-03-19