1. Purpose

Establish safe, systematic and standardized practical training, equipment operation, maintenance, competency assessment and recordkeeping in the TVET laboratory.

2. Scope

Applies to trainees, students, trainers, technicians, coordinators, visitors and authorized personnel across workshop, sheet metal, welding, fitting, machining, electrical/electronics, metrology and digital manufacturing activities.

3. Responsibilities

Centre Head: approve resources and procedures, review safety and performance. TVET Coordinator: schedule sessions, manage resources and records. Trainer: brief, demonstrate, supervise and assess. Technician: inspect and prepare equipment, maintain tools and records. Trainee: follow instructions, use PPE and report hazards.

4. Entry and induction

Only authorized personnel may enter. Record attendance; wear suitable clothing and PPE; store bags in designated areas; secure long hair and remove loose jewelry. Complete induction and safety briefing before practical work.

5. PPE

Select PPE by documented task risk assessment. General workshop: safety shoes and appropriate workwear. Welding: suitable welding helmet, flame-resistant clothing, gloves and safety shoes. Grinding: eye/face protection and hearing protection as indicated. Sheet metal: cut-resistant gloves for handling sharp edges (not near rotating machinery). Machining: eye protection and fitted clothing; never wear gloves near rotating equipment. Electrical: task-rated insulated equipment and PPE.

6. Pre-operation checks

Trainer/technician checks housekeeping, guards, emergency stops, electrical condition, ventilation, fire equipment, tools and consumables. Trainees identify hazards, inspect assigned tools and obtain authorization before starting.

7. General equipment operation

Follow the displayed machine-specific SOP and manufacturer instructions: inspect → set up and secure workpiece → set parameters → trial run where appropriate → supervised operation → monitor abnormalities → prescribed shutdown → clean and return tools. Do not bypass guards or interlocks.

8. General machine safety

Do not use damaged tools or equipment, touch moving parts, leave machines running unattended or clean/measure while moving. Stop, isolate and report unusual vibration, noise, overheating or electrical faults. Only trained and authorized personnel may operate equipment.

9. Electrical safety

Only authorized competent personnel may make electrical connections or repairs. Verify earthing and protective devices, avoid wet-hand operation and overloaded sockets, and isolate energy before maintenance. Apply lockout/tagout where required.

10. Welding and fabrication

Inspect leads and holders; use welding screens and appropriate fume extraction; keep combustibles clear; use task-specific PPE. Handle hot metal with tools and mark hot workpieces. Follow approved hot-work and gas-cylinder procedures where applicable.

11. Sheet metal and fitting

Inspect snips, hammers, files and hacksaws. Secure workpieces, maintain safe hand position, deburr sharp edges and store sheet metal safely. Use suitable gloves for handling sheet metal but not where they could catch in rotating equipment.

12. Machine shop

Secure tools and workpieces; remove chuck keys before starting; keep guards in place; stop the machine before adjustment or measurement. Remove chips with a brush or appropriate tool, never bare hands.

13. Metrology

Select the appropriate instrument, inspect for damage and check zero before use. Handle and store instruments carefully; maintain calibration records where applicable.

14. Housekeeping and 5S

Sort unnecessary items, set tools in designated locations, clean work areas, standardize storage and labels, and sustain through periodic checks. Keep emergency exits, electrical panels and fire equipment unobstructed.

15. Emergency response

Stop the process if safe; alert the trainer; activate emergency stop as applicable; isolate energy if safe; evacuate or move away from danger; summon trained first-aid/emergency personnel. Report and document all incidents and near misses. Restart only after authorized clearance.

16. Fire and first aid

Display emergency contacts, evacuation routes and assembly point. Maintain accessible, suitable fire extinguishers and stocked first-aid supplies. Only trained personnel should attempt firefighting when safe; otherwise evacuate.

17. Waste management

Segregate metal scrap, general waste, oily waste, e-waste and chemical waste into labeled containers. Dispose of hazardous waste using approved procedures; do not discharge chemicals into drains without authorization.

18. Preventive maintenance

Daily: visual checks, cleaning and safety-device checks. Weekly: tool, mechanical and electrical condition checks by authorized staff. Monthly/periodic: scheduled servicing, calibration as required, and documented safety inspections. Follow manufacturer intervals where stricter.

19. Training workflow

Induction → safety briefing → learning objectives → demonstration → supervised practice → independent practice when authorized → assessment → feedback → housekeeping → record completion.

20. Competency assessment

Assess safety compliance, tool selection, setup, operation, dimensional accuracy, quality, troubleshooting and housekeeping against the relevant module standard. Record competent/not yet competent outcomes and corrective coaching.

21. Required records

Maintain attendance, lab usage, inventory, tool issue/return, consumables, preventive maintenance, calibration, training, competency assessment, PPE issue, incident/near-miss and housekeeping registers.

22. Breakdown control

STOP → ISOLATE → INFORM → TAG “OUT OF SERVICE” → RECORD → REPAIR → TEST → AUTHORIZE RETURN TO SERVICE. Do not use defective equipment.

23. Closing procedure

Switch off and safely isolate equipment; close gas supplies where applicable; clean benches and machines; return tools; segregate waste; verify no hot-work hazards remain; complete the closing checklist and secure the laboratory.