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Activity 002: Safety Audit and Emergency Procedure Walkthrough

Activity ID: U8M4-ACT-002 Duration: 35 minutes Objective: Conduct a machine shop safety audit and demonstrate emergency response procedures for common machining incidents.

Overview

Students conduct a systematic safety audit of the machine shop, identifying hazards, verifying safety equipment, and practicing emergency procedures. This activity reinforces the safety culture mindset and ensures students know how to respond to incidents.

Materials & Equipment Needed

  • Safety audit checklist (provided)
  • Machine shop with lathe and mill
  • First aid kit
  • Eyewash station
  • Fire extinguisher
  • SDS binder
  • Emergency stop buttons on all machines
  • Safety signage
  • PPE (safety glasses, face shields, hearing protection—for demonstration)

Instructions & Procedure

Phase 1: Shop Safety Audit (15 minutes)

Working in pairs, complete the safety audit checklist by physically inspecting each item:

Machine Safety: - [ ] All emergency stop buttons functional (press and verify on each machine—instructor resets) - [ ] Guards and shields in place on all machines - [ ] Chuck keys have spring-loaded ejection (or are tethered) - [ ] No chuck keys left in chucks - [ ] Machine areas are clear of tools, stock, and debris - [ ] All machines are off and controls are in neutral

Shop Environment: - [ ] Floor clean, no oil spills or chip accumulation - [ ] Walking paths clear of obstructions - [ ] Adequate lighting at all work stations - [ ] Ventilation functioning - [ ] Noise level signage posted where required

Safety Equipment: - [ ] Eyewash station accessible and functional (test flow) - [ ] First aid kit stocked and accessible - [ ] Fire extinguisher charged and accessible (check gauge) - [ ] SDS binder available and current - [ ] Emergency exit paths clear and marked - [ ] Emergency contact numbers posted

PPE Station: - [ ] Safety glasses available in multiple sizes - [ ] Face shields available and in good condition - [ ] Hearing protection available - [ ] Barrier cream and hand cleaner available

Phase 2: Emergency Procedure Walkthrough (12 minutes)

Instructor leads a walkthrough of each emergency scenario. Students physically demonstrate the response:

  1. Eye injury from chip: Student walks to eyewash station, demonstrates proper use (hands-free activation, 15-minute flush protocol, head position).
  2. Entanglement: Student identifies emergency stop location on each machine, presses it (from multiple positions/angles), describes the DO NOT PULL rule.
  3. Fire: Student locates nearest extinguisher, describes PASS technique (Pull pin, Aim low, Squeeze handle, Sweep side to side). Do not discharge the extinguisher.
  4. Severe laceration: Student demonstrates direct pressure with clean cloth from the first aid kit, describes when to call 911.
  5. Chemical splash: Student locates SDS binder, identifies the correct SDS for cutting fluid, finds first aid information.

Phase 3: Hazard Identification Exercise (8 minutes)

The instructor has pre-staged 5-8 intentional safety violations in the shop: - Chuck key left in a lathe - Safety glasses missing from a work station - Oil spill on the floor - Tool left on the mill table near the cutter - Guard removed from a grinder - Chips accumulated on a machine surface - Loose electrical cord across a walkway - Expired fire extinguisher sign (simulated)

Students walk through the shop and identify as many violations as possible in 5 minutes. Discuss findings as a group.

Discussion Points

  • What was the most surprising hazard you found during the audit?
  • Why is the "staged violation" exercise important for building awareness?
  • How does housekeeping relate directly to safety?
  • What would you do if you saw a fellow student working unsafely?

Expected Outcomes

  • Students complete the safety audit checklist thoroughly
  • Students can locate and demonstrate use of all emergency equipment
  • Students identify the majority of staged hazards
  • Students articulate the correct response for each emergency scenario

Assessment Rubric

Criteria Excellent (4) Proficient (3) Developing (2) Beginning (1)
Audit Thoroughness All items checked and verified 1-2 items missed 3-5 items missed Superficial inspection
Emergency Response Correct procedure for all 5 scenarios 4/5 correct 3/5 correct Fewer than 3 correct
Hazard Identification Found 7-8 of staged violations Found 5-6 Found 3-4 Found fewer than 3
Safety Mindset Proactively identifies additional hazards Follows the checklist Needs prompting Disengaged from exercise

Safety Considerations

  • This activity involves activating emergency stop buttons—instructor must reset machines after each test
  • Do not discharge fire extinguishers during the exercise
  • Eyewash stations should be tested with a brief flow—do not waste water
  • All staged hazards must be corrected immediately after the exercise
  • Maintain shop safety standards throughout the activity—the audit does not exempt participants from PPE requirements

Last Updated: 2026-03-19