BTEC Level 3 National Engineering Teaching Resource · PDF fileUnit 1 Health and safety in the engineering workplace BTEC Level 3 National Engineering ... reference and combine assignment
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Unit 1 Health and safety in the engineering workplace
This unit gives learners an understanding of the key features of health and safety legislation and regulations and how these are applied in engineering to ensure safe working conditions.
The unit could form a key component in many learning programmes since the content is highly applicable to many manufacturing, engineering and industrial situations. The unit includes the roles and responsibilities of persons involved in engineering, and the association between hazards and risks within the workplace and the environment.
Delivery can be by PowerPoint presentation, whole-class teaching, group discussion and individual research.
On completion of this unit, learners will: LO1 Understand the key features of health and safety legislation and regulations LO2 Know how to identify and control hazards in the workplace LO3 Be able to carry out a risk assessment, identifying control measures LO4 Understand the methods used when reporting and recording accidents and incidents
Unit contents The scheme of work for this unit links to the following resources to help you deliver Unit 1.
All of these resources can be found on the accompanying @t Work CD-ROM, as well as an editable version of the scheme of work and answers to questions in the Student Book.
Learning outcome can be covered by assessment activity 1.2 from the Student Book, and learning outcome 4 by assessment activity 1.3.
Links to other units Unit 1 links to a number of other units, as shown below, and provides a lot of opportunities to cross-reference and combine assignment work for these units.
● Unit 12 Applications of mechanical systems in engineering
● Unit 15 Electro, pneumatic and hydraulic systems and devices
● Unit 21 Engineering secondary and finishing techniques and processes
● Unit 22 Fabrication processes and technology
Unit delivery Delivery can be achieved through front-of-class teaching and group and individual working. Use of discussion after inspection of working environments would benefit the learning experience.
It would be appropriate for the unit to be taught with some practical applications, for example the identification of the hazards and associated risks in a hands-on experience within an engineering workshop. This will have the effect of bringing the unit to life through use of the relevant tools and machinery used by practising engineers. The learner can be given support and guidance while carrying out a range of simple engineering tasks. The tasks will allow the learner to prepare the environment, prepare for the activity and complete the task within the requirements of the unit.
Use of the internet to research health and safety legislation and regulations would be highly beneficial, as well as cost saving in resources. The scheme of work indicates the various areas of teaching.
Assessment The assessment process
The unit requires the completion of some assignments; three have been included as the number suggested in the outline learning plan. All assignments are assessed internally.
The three included assignments are based on health and safety legislation, risk assessment and the reporting of accidents. Included are activity sheets to reinforce the learning and to help the learner to achieve these weekly activities. Those based on workplace environments give a real-life experience that will help when completing the assignments.
Evidence for assessment
Evidence of learners reaching the required criteria for each part of the unit content can be collected from case studies, assignments and activities. These should enable the learner to explore the application of legislation, regulations, hazards and associated risk in a typical engineering workplace. Three assignments and a number of activities are included in the unit and Teaching Resource Pack. These can also be adapted to suit the needs of a centre.
Grading
The grading criteria are shown in the unit specification under the heading Assessment and grading criteria. Careful reading of this and cross-checking with the assessment method in the Programme of suggested assignments will assist the grading of work produced by learners.
The pass grade specifies the minimum acceptable level required by learners. This minimum acceptable level should demonstrate that the learner has an understanding of health, safety and welfare issues as applied to engineering processes and companies. They need to be able to explain the key features of legislation, the roles and responsibilities of key individuals, and show an understanding of the connection between hazards, associated risks and the possibility of accidents.
Achievement of merit and distinction grades requires learners to provide answers that demonstrate additional depth and/or breadth of understanding of the topic area.
Unit 1 Health and safety in the engineering workplace
The three assignments included in the unit and the Teaching Resource Pack evidence the required levels for pass, merit or distinction, so they can be used as a model for other assignments.
Useful resources
Information on health and safety legislation can be resourced from:
● www.hse.gov.uk
● Spoodle: a specialised health and safety site
● Health and Safety at Work etc. Act 1974 (The Stationery Office) ISBN 978-0-10-543774-1
● Management of Health and Safety at Work Regulations (HSE) ISBN 978-0-7176-2488-1
● COSHH 2002 (HSE) ISBN 978-0-7176-2981-3
● PUWER 1998 (HSE) ISBN 978-0-7176-6285-2
● Personal Protective Equipment 1992 (HSE) ISBN 978-0-7176-6139-3
● Manual Handling Regulations 1992 (HSE) ISBN 978-0-7176-2823-X
● Workplace Health, Safety and Welfare Regulations 1992 (HSE) ISBN 978-0-11-886333-9
Scheme of work Unit 1 Health and safety in the engineering workplace Broad aim: To give learners the opportunity to understand the application of health and
safety in an engineering workplace.
Tutor(s):
SB = Student Book
AS = Activity Sheet
AT = Active teach
PPT = Presentation
R = Research
NS = Non-supervised individual study time
Academic year:
Number of weeks: 30
Duration of session: 2 hours
Guided learning hours: 60
Credits: 10
Week Outcome/topic Content Learner activity Resources Assessment and PLTS
Stretch and support
1 LO1 Understand the key features of health and safety legislation and regulations
Introduction to Health and Safety at Work Act 1974
Whole class teaching: introduction of unit, scheme of work, assessment methods, features of H&S legislation, internet research
PPT01 and AS1 Health and Safety at Work etc. Act 1974
Hard copies of Health and Safety at Work Act
AS1 Health and Safety at Work etc. Act 1974
Independent enquirers
English, ICT
SS1 Health and safety law
2. LO1 Introduction to Employment Act 2002, Regulatory Reform (Fire Safety) Order 2005, Employment Equality (Age) Regulations 2006
Whole class teaching: introduction to the statutory acts and regulations. Use of internet
PPT01 and AS2 Fire detection and fire precautions in work areas
Hard copies of acts and regulations
AS2 Fire detection and fire precautions in work areas
Independent enquirers, effective participators
English, ICT
SS2 Fire detection and fire precautions
3 LO1 Introduction to Management of Health and Safety at Work Regulations 1999, PUWER 1998, COSHH 2002
Whole class teaching: introduction to statutory regulations
PPT01 and AS3 Checklist for differing types of work equipment in the area
Hard copies of regulations
Internet access
AS3 Checklist for differing types of work equipment in the area
Independent enquirers, effective participators
ICT, English
SS3 Differing types of work equipment
4 LO1 Introduction to LOLER 1998, MHOR 1992 and PPE 1992
Whole class teaching: introduction to LOLER, MHOR, PPE
Internet research
AS4 Checklist for different types of PPE worn in a work area
Hard copies of regulations
AS4 Checklist for different types of PPE worn in a work area
Week Outcome/topic Content Learner activity Resources Assessment and PLTS
Stretch and support
5 LO1 Introduction to Confined Spaces Regulations, Electricity at Work Regulations, Control of Noise at Work Regulations
Whole class teaching: introduction to Confined Space, Electricity at Work, Control of Noise Regulations
Internet research
AS5 Noise and sound, confined spaces and RIDDOR
Copies of regulations
AS5 Noise and sound, confined spaces and RIDDOR
Independent enquirers, effective participators
ICT, English
SS5 Noise
6 LO1 Introduction to RIDDOR Working Time Regulations
Whole class teaching: introduction to RIDDOR
AS5 Noise and sound, confined spaces and RIDDOR
Hard copies of regulations
AS5 Noise and sound, confined spaces and RIDDOR
Independent enquirers, effective participators
ICT, English
7 LO1 Introduction to Workplace (Health, Safety and Welfare) Regulations, First Aid Regulations Supply of Machinery Regulations 2008
Whole class teaching: introduction to the Welfare, First Aid and Machinery Supply Regulations
Use of internet
AS6 First-aid boxes and first aiders in a work area
Hard copies of regulations
AS6 First-aid boxes and first aiders in a work area
Independent enquirers, effective participators
ICT, English
SS6 First-aiders in the workplace
8 LO1 Roles and responsibilities of employers and employees
Whole class teaching: explanations of roles and responsibilities of employers and employees from criminal and civil law, analysis of health and safety policy
Hard copies of HASAWA and H & S policies
Independent enquirers, effective participators
ICT, English
9 LO1 Roles and responsibilities of HSE, span of authority and right of inspection
Whole class teaching: explanation of the authority and the rights of HSE Inspectors
Hard copy of HASAWA Effective participators
ICT, English
SS7 HSE inspectors’ rights on entry
10 LO1 Roles and responsibilities of management, subcontractors, public, suppliers, customers and visitors
Whole class teaching: explanation of roles and responsibilities of management, subcontractors, public, suppliers and customers from civil and criminal perspectives
AS7 Roles and responsibilities from the Health and Safety at Work etc. Act 1974 and organisational policies
SB Assessment activity 1.1, page 17
Hard copies of HASAWA and H & S policies
AS7 Roles and responsibilities from the Health and Safety at Work etc. Act 1974 and organisational policies
30 mins Tutor gives introduction to Health and Safety at Work etc. Act 1974 by PowerPoint
Whole class teaching
Learners listening and making notes
Learners share ideas on ways to remember the Act
Learners ask questions
SB
Paper
Whiteboard/interactive whiteboard
Pen
PPT. Session 1 slides 1–13
Hard copies of Health and Safety at Work etc. Act 1974
Learners may be grouped deliberately to balance or according to stretch and support needs
Effective participators Speaking and listening: make a range of contributions to discussions and make effective presentations in a wide range of contexts
30 mins Tutor supervising internet access
Internet research of the Act
Internet access
AS1 Worksheet
Learners may be grouped deliberately to balance or according to stretch and support needs – AS1
Effective participators
Team workers
Access, search for and use ICT-based information and evaluate its fitness for purpose.
25 mins Tutor goes through the PowerPoint slides that are provided on Health and Safety at Work Act etc. 1974
Learners listening and making notes
Learners share ideas on ways to remember the Act
Learners ask questions
SB
PowerPoint supplied
Handouts
Pen
Paper
Projector/whiteboard
Learners may be grouped deliberately to balance or according to stretch and support needs
Effective participators
Team workers
Speaking and listening: make a range of contributions to discussions and make effective presentations in a wide range of contexts
10 mins
Plenary
Review the aims of the lesson with learners and go through the ‘Knowledge Check’
Learners reviewing learning points and answering ‘Knowledge Check’
SB
Unit 1 Health and safety in the engineering workplace
Act 1974 Look at each of the statements and tick in the box to show where the statement matches what you have learned about the Act. If you agree then tick the true box; if you disagree then tick the false box. If you are not sure then tick that box. Each correct ‘True’ tick is worth 4, each correct ‘False’ tick is worth 3 and ‘Not sure’ ticks are worth minus 1.
Statement True False Not sure
The Act became law on 1 October 1974.
Lord Robens chaired the committee that produced the Act.
The Act protects everybody at work.
An employee is in control of an organisation.
Employees supervise employers.
A contractor is a person with specialist skills.
Persons who comply with the law are breaking the law.
A person breaking the law could face fines and imprisonment.
Section 2 of the Act formalises the employer’s duties.
Totals
Add up your score and see how close it comes to 33, the total points available for this activity.
in work areas Investigate the work area and list types of fire precautions, fire detection and firefighting appliances or equipment. Note with a tick or cross in the last column whether the items have been maintained in any way. This could be evidenced by fingerprints on the item, or by reference to the site or facilities manager. Another example would be a date recorded on a sign on a fire extinguisher.
Fire precautions Yes Position/place Maintained
Fire doors
Emergency lighting
Safe condition signs
Instructions fire safety
Fire detection
Smoke detectors
Flame detectors
Firefighting
Extinguishers
Fire hoses
Fire blankets
Sprinkler systems
Inert gas systems
Increase your communication functional skills by drawing a floor plan of the work area showing the position of the fire precautions, fire detection and firefighting appliances or equipment.
AS2
Unit 1 Health and safety in the engineering workplace
work equipment in the area Investigate the work area for the types of work equipment listed below. Enter your findings while carrying out a visual inspection of the work equipment.
Types of work equipment
Your findings of the individual equipment and a comment on its condition
Hand tools
Machinery
Appliances
Powered tools
Assembly or components
Increase your communication functional skills by pasting photographs of the work equipment in this space.
PPE worn in a work area Investigate a work area of your choice for different types of personal protective equipment (PPE) being used; list them below. Choose four different types of PPE and describe in each case the part of the body they are protecting.
Type of PPE Part of body Protection against Cost
To increase your ICT functional skills, search the internet for manufacturers or suppliers for each of your choice of PPE. Try to determine an approximate cost for each, and enter this in the last column.
AS4
Unit 1 Health and safety in the engineering workplace
In your opinion, are there more deaths from accidents at work per year than from work-related ill health? Could you provide approximate figures for each?
work area First aid is a legal requirement in all workplaces. Could you write a definition for first aid?
How would you know who are the first-aiders in a workplace?
Investigate a typical workplace to determine the location of the first-aid boxes. Then try to find out how often they are checked for their contents. Enter your findings below.
AS6
Unit 1 Health and safety in the engineering workplace
and working at height Imagine that you are the Chief Engineer on a project to build a bridge across a 150 m wide tidal river. Discuss with your team the hazards that your employees could experience when working above the water. Select two hazards. Think about the control measures that you would need to put in place to protect your employees. Use the table below to record your discussion.
Hazards to employees from working above water Control measures to be implemented to protect the employees
1
1
2
2
Would there be different hazards and control measures for working at height?
Hazards from working at height
Control measures to be implemented
AS8
Unit 1 Health and safety in the engineering workplace
You have to give a short presentation to a group of employees on electrical hazards and chemical hazards.
List three hazards from electricity that you would include.
Hazards to employees from electricity
1
2
3
Choose two chemicals used in a workplace of your choice. List the hazards from the chemicals. Describe the control measures for each chemical including the risk and safety phrases. (Useful tip: information can be obtained from the container, or research on the internet.)
Trivial versus significant risk Look at the table below. Now complete a similar table for a task of your choice. The task must be capable of being carried out in a simple and a complex manner.
Task type Equipment used Hazards Outcomes
Simple task: Remove corroded nut
Cold chisel to split nut Hitting hand with hammer Flying steel particle into eye
Bruise on hand Loss of sight
Complex task Operating pneumatic jack hammer to split nut
Flying particle into eye Noise Vibration Compressed air Manual handling of equipment
Loss of sight Temporary loss of hearing Vibration white finger High pressure air into eye High pressure air into cut on hand – embolism – could cause death Strains/sprains or long-term muscular injuries to back
Task type Equipment used Hazards Outcomes
Simple task
Complex task
AS10
Unit 1 Health and safety in the engineering workplace
and its effects By the use of research from your course notes, books and/or the internet, describe the effects on the human body of contact with 230 V AC electricity.
Effects on the human body
Describe, in a logical sequence, what you would do if a person that you were working with suffered an electric shock, had collapsed and was still in contact with the live conductor.
Machinery hazard controls Referring back to the Student Book and your experience of carrying out an inspection of a workshop, determine which type of machine would incorporate the following types of control measures.
Control measure Machine type
Fixed guard with open mesh
Fixed guard fully enclosed
Electrically interlocked guard
Sensors – either pressure mat or light system
Push stick
You could use a digital camera to photograph each of the above to insert into this worksheet.
Use the internet for research if you cannot access the information from a workshop.
Stretch and support The following suggested activities can be used by or adapted for learners who demonstrate a need for stretch or support activities.
Health and safety law
Support
Choose one of the following tasks.
1. Locate the HSE Poster ‘Health and Safety for All’ in your centre and check your answers for AS1.
2. Look on the Spoodle website (www.spoddle.org.uk) and check your answers in the Health and Safety at Work etc. Act 1974.
3. Refer to Section 6 of the Health and Safety at Work etc. 1974 and write a short brief about who it places duties on.
Stretch
Investigate Section 7 of the Health and Safety at Work etc. 1974 (www.spoodle.org.uk will help you here).
Using the words from Section 8 of the Health and Safety at Work etc. 1974, carry out research among people you know, perhaps members of your family or friends, to find out if they have ever had to pay for personal protective equipment at work. Write a short briefing note on your research.
Fire detection and fire precautions
Support
Choose one of the following activities:
● After obtaining permission from one of your tutors, complete a plan of an engineering workshop showing the fire detectors and fire precautions. Then get together with a partner or a tutor to discuss your plan.
● Research the internet for a fire risk assessment. You will find that the local Fire and Rescue service will be listed. An example from the Essex County Fire and Rescue service can be found at www.essex-fire.gov.uk. Read through the document and write a 250-word summary of the key information presented.
Stretch
Discuss the arrangements for evacuation of your school/college in an emergency with the facilities/site manager or a senior teacher or lecturer.
Try to discover:
● whether there are any general problems in evacuating the buildings
● the time requirements to evacuate completely to the assembly points
● whether a roll call is carried out
● whether fire marshals are used to ‘sweep’ the building to ensure complete clearance.
Draw up a table of the key points that emerged from your discussions.
Unit 1 Health and safety in the engineering workplace
25
. Different types of work equipment
Support
Carry out an inspection of part of your school/college to determine whether small electrical equipment has been given a ‘portable appliance test’ (PAT). You can find this out by checking whether appliances have a green and white PAT label.
Create a table to show your findings. Your table should include the dates of the tests and should show which school/college buildings were investigated.
Discuss your findings with others in your group.
Stretch
Discuss with the technicians or tutors in the engineering workshop, or a similar area, the maintenance procedures for the machines and tools.
Write a 200-word report on your findings.
Types of PPE
Support
Choose one of the following tasks.
1 Research at least three different types of PPE. Your research should cover a range of costs, applications of the PPE and the differences between them. A report should be written covering the benefits and limitations of each PPE type. A discussion could then follow with your tutor.
2 Write a short briefing on the types of ‘fall arrestors’ that are available to steel-erecting companies. The findings of the briefing note are to be discussed with members of your group.
Stretch
Read through the following scenario.
You work for an engineering company as an assistant in the Health and Safety Department. You have been asked by your manager to prepare a short briefing for all departmental managers. The briefing is on the importance of wearing eye protection while operating machinery. It has been noted during inspections of the workplace that a number of machine operators are ignoring their ‘Safe Systems of Work’ and putting themselves at risk. The points to be covered in the briefing will be:
● different types of eye protection
● supply, storage and cleaning of eye protection
● legal requirements
● training, instruction and supervision
● lack of complaince and disciplinary action
● why operatives should protect their eyes
● types of injury.
Your manager then says that a presentation should be prepared which will cover all the points. You should put together the presentation deciding the ‘best order’ in which to cover the points listed.
Prepare the PowerPoint and some prompt cards. Try out the presentation on other members of your group and your tutor, so that feedback can be given. Feedback can be given in the form of an evaluation sheet. The table below gives an example.
Unit 1 Health and safety in the engineering workplace
27
Noise
Support
Noise is unwanted sound. So what is sound? Is there a difference between noise and sound? Discuss this in a group of four, recording the important points of the discussion, making reference to differing types of sound/noise. After about 15 minutes, be ready to report the findings in a whole-group discussion.
Stretch
You have been asked by your tutor to explain the differences between temporary and permanent threshold hearing loss. Prepare a report of approximately 250 words explaining the differences between
the two work-related hearing problems.
First-aiders in a workplace
Support
Arrange to carry out an interview with a first-aider in an area that you are familiar with. Ask the first-aider some prepared questions.
For example:
● how they were trained in first aid
● when the training took place
● whether they have received any refresher training.
Write up your notes on the interview and then discuss the results with your group, or with your tutor.
Stretch
At your appraisal meeting you ask if you can become a first-aider. Your manager replies to your request in a positive manner. You are told to find out about local courses in first aid, which will involve research into local course details from providers such as St John Ambulance.
Gather all the details you need and write a report on the courses, including the costs. Your report should include a justification of how the training would make you a good first-aider.
HSE inspectors’ rights on entry to a workplace
Support
An HSE inspector can enter a workplace at any reasonable time. Discuss with your group, or your tutor, what is meant by a reasonable time. Write a short report to a manager who is unsure of the meaning. The report should be based on your findings.
Stretch
The HSE inspector has certain powers when they enter a workplace. Choose four of these powers and write a short paragraph explaining, to someone who does not know the powers of the inspector, the reasoning behind their having these powers.
Before use, all ladders have to be inspected by a competent person. In a whole-group discussion, led by your tutor, determine what is meant by a competent person in this context. Make notes of the discussion so that you can write a brief definition for competence. Ensure that your tutor agrees with your definition.
Stretch
Using either the internet, or discussion with other competent persons, find a ‘safe system of work’ (SSoW), or a procedure for the use of ladders.
Using the research create your own SSoW for an electrician replacing electric bulbs to outside wall-mounted security lamps.
You may have to find the area where SSoWs are shown in the course book. Discuss with your tutor your completed SSoW for the activity.
DC/AC circuits
Support
You are to give a 15-minute toolbox talk (TBT) to a group of six new apprentices on the basic differences between DC and AC electrical supplies. Discuss in a group of four for about 15 minutes how this would be best carried out. Then write a list of the topics to be covered in the TBT; afterwards discuss your list of topics with your group and your tutor.
Stretch
From the support area you have previously decided to show a simple circuit diagram for DC and AC current systems as part of the TBT. Draw the two simple circuits showing the differences and all the relevant parts. Ask your tutor for conformation that your circuits are correct.
Changing a car wheel
Support
You are required to complete a safe-system-of-work observation sheet for the task of changing a punctured tyre on a car wheel. You should create a table using MS Word so that the step-by-step procedure can be shown. The best method for this support activity is to observe someone carrying out the wheel-change task. It would also be good practice if a team of four of your group observed the task so that a discussion could take place to determine the correct process. The actual wheel-changing task must be carried out by a competent person in a safe manner. Discuss this with your tutor before starting the task. Your table could look like this. [See following page.]
Unit 1 Health and safety in the engineering workplace
29
Safe System of Work – observation sheet
Activity: Changing a car wheel Prepared by: Date:
Step Part activity carried out
1 Open boot
2 Remove spare wheel
3 Remove jack and wheel nut wrench
4 Carry on until completion
5
6
Stretch
You have been requested to add two extra columns to your table showing the hazards and the trivial or significant risks. Complete the table below and discuss your findings and decisions with the whole group through a seminar session with your tutor. Your table could now look like this.
Safe System of Work – observation sheet
Activity: Changing a car wheel Prepared by: Date:
Step Part activity being carried out Hazard Trivial/significant
1 Open boot No real hazard Trivial
2 Remove spare wheel Manual handling/weight of wheel/difficult to grasp
Significant
3 Remove jack and wheel nut wrench Sharp edges/trapping of fingers Significant
1. There are health and safety issues if fluid leaks from a hydraulic cylinder when it is being tested. Describe two of them.
2. Suppose a high-pressure test went wrong and an employee was injured. Describe a typical reporting procedure which the company would follow to deal with the problem.
3. Describe how a new employee is likely to be given health and safety training before starting work with the company.
The motor industry: Jaguar Cars
1. Jaguar use robots for lifting heavy components in the assembly area. Describe the safety systems and procedures that will be in place to safeguard people who work in the vicinity of robots.
2. A small group of learners from the local college is soon to visit the assembly area. Their tutor has to risk assess the activity. Outline how they will do this.
Food manufacturing: Ginsters
1. Ginsters have set up a complex system of conveyor belts and robotic handling equipment. Suppose a conveyor needs to be serviced and this involves a technician crawling underneath it so that they can replace an electric motor. Describe the specific hazards of working with machinery that features rollers, belts and electric motors.
2. Although not mentioned in the video, Ginsters will, like any other company, have a procedure for dealing with accidents and emergences in its manufacturing area. The Health and Safety Executive (HSE) requires that all businesses have a written health and safety policy. Ask your tutor or training manager to show you an example of one. How often should it be updated?