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Activity 002: Pre-Cut Safety Inspection & Risk Assessment

Activity ID: U5M4-ACT-002 Duration: 30 minutes Objective: Students will perform a complete pre-cut safety inspection of the plasma cutting area, identify hazards, and complete a written risk assessment for a given cutting scenario. Group Size: 2-3 students

Overview

The instructor will intentionally introduce 8-10 safety hazards into the plasma cutting area. Students must identify all hazards, assess their risk level, and prescribe corrective actions. This trains the observational skills needed for the pre-cut safety check that must be performed before every cutting session.

Materials & Equipment Needed

  • CNC plasma table area (machine powered off)
  • Intentionally placed hazards (instructor sets up before class):
  • Cardboard box within 15 feet of the table
  • Solvent can (empty, labeled) within 20 feet
  • Frayed cable on the plasma cutter (simulated with tape marking)
  • Missing shield cup from the torch
  • Water table at incorrect level (too low)
  • Work clamp disconnected and placed on the table frame (not workpiece)
  • Safety glasses left on the table bed (loose item in cutting zone)
  • Fire extinguisher moved to 30+ feet away (behind a barrier)
  • Welding screen folded/collapsed (not deployed)
  • A polyester jacket draped over a chair in the cutting area
  • Hazard identification worksheet
  • Risk assessment matrix (provided)
  • Pens/clipboards

Instructions & Procedure

Phase 1: Hazard Identification (12 minutes) 1. Each group receives a blank hazard identification worksheet 2. Groups walk through the plasma cutting area and systematically inspect: - The machine and all connections - The cutting surface and water table - The surrounding area (35-foot radius) - Emergency equipment locations and accessibility - PPE availability - Environmental conditions (ventilation, lighting) 3. Record each identified hazard with: - Location - Description - Hazard category (electrical, thermal, radiation, respiratory, mechanical) - Severity (minor, moderate, serious, critical, fatal)

Phase 2: Risk Assessment (10 minutes) Using the provided risk assessment matrix, evaluate each hazard:

Likelihood Consequence: Minor Moderate Serious Critical
Very Likely Medium High Very High Extreme
Likely Low Medium High Very High
Possible Low Medium Medium High
Unlikely Negligible Low Medium Medium

For each identified hazard: 1. Rate the likelihood (if cutting were to proceed without correction) 2. Rate the potential consequence 3. Determine the risk level from the matrix 4. Prescribe a corrective action 5. Determine if the corrective action can be taken immediately or requires external support

Phase 3: Presentation & Debrief (8 minutes) 1. Each group presents their findings (2 minutes each) 2. Instructor reveals the complete list of planted hazards 3. Groups compare — did any group catch all of them? Which were most commonly missed? 4. Discuss: Which hazard had the highest risk rating? Which could cause the most severe injury? 5. Key question: "Would you start cutting with ANY of these hazards uncorrected?" (Answer must be NO)

Discussion Points

  • Which hazard category was most commonly found? Which was easiest to miss?
  • How does the 35-foot radius requirement change your inspection scope?
  • In a real scenario, what would you do if you identified a hazard you could not correct yourself?
  • Why is a systematic inspection (start at machine, work outward) better than a random walk-around?

Expected Outcomes

  • Students identify at least 8 of 10 planted hazards
  • Students correctly categorize hazards by type and severity
  • Students understand that ALL hazards must be corrected before cutting begins
  • Students develop the habit of systematic pre-cut inspection

Assessment Rubric

Criteria Excellent (4) Proficient (3) Developing (2) Beginning (1)
Hazard Detection 9-10 hazards found 7-8 hazards found 5-6 hazards found Fewer than 5 found
Risk Assessment All ratings justified and accurate Most ratings accurate Some ratings correct Cannot apply risk matrix
Corrective Actions Specific, actionable, and prioritized Reasonable actions for most hazards Vague or incomplete actions No viable corrective actions
Systematic Approach Organized, thorough inspection pattern Good coverage with minor gaps Random, incomplete coverage No systematic approach

Safety Considerations

  • Machine must be powered off and locked out throughout the entire activity
  • The "frayed cable" hazard should be SIMULATED (marked with colored tape) — do not actually damage cables
  • The solvent can must be empty and clean — no actual flammable contents
  • Remind students this is an inspection exercise — do not handle or attempt to fix electrical hazards
  • At the end of the activity, the instructor must restore all items to their correct positions and verify the area is properly set up

Last Updated: 2026-03-19