Question 1: Identify three common hazards that could occur during the manufacturing process of a metal product and explain how to prevent each one.

Answer: Hazards include: 1) Sharp metal edges that could cut workers; prevent by filing edges or using protective gloves. 2) Hot metal surfaces that could cause burns; prevent with proper PPE and cooling times. 3) Heavy lifting causing injury; prevent by using lifting equipment or team lifting.

Question 2: Describe the safety features that should be incorporated into a power drill to protect the user during operation.

Answer: Features include: a safety clutch to prevent sudden torque, an emergency stop button, a guard around the drill bit, and a trigger lock to prevent accidental activation.

Question 3: Design Brief: You are creating a small storage box for tools. List three safety considerations you must address in your design to ensure user safety during use.

Answer: Considerations include: 1) Rounded edges to prevent cuts; 2) Secure locking mechanism to prevent accidental opening; 3) Non-slip base to prevent slipping during use.

Question 4: Sketch a simple ergonomic handle for a hand tool that minimizes the risk of strain or injury. Label key features that improve safety and comfort.

Answer: A correct sketch would show a handle with a comfortable grip, possibly with textured surface for slip resistance, and an appropriate angle to reduce wrist strain. Labels should include 'non-slip grip', 'ergonomic shape', and 'appropriate size'.

Question 5: Explain why it is important to conduct a risk assessment before starting the manufacturing of a plastic product. What are the key points to consider?

Answer: Risk assessment helps identify potential hazards to prevent accidents. Key points include materials used, machine safety, ventilation for fumes, protective equipment required, and emergency procedures.

Question 6: Identify and describe two safety regulations or standards relevant to the use of electrical tools in a workshop setting.

Answer: Examples include: 1) The use of Residual Current Devices (RCDs) to prevent electric shock; 2) Compliance with the Electrical Safety Standards (e.g., BS 7671) for proper wiring and insulation.

Question 7: Design Brief: You are developing a new children's toy that includes moving parts. Outline the safety features you will incorporate to protect children from injury.

Answer: Features include: smooth edges and rounded corners, no small parts that pose choking hazards, enclosed moving parts to prevent pinching, and non-toxic, durable materials.

Question 8: Describe the purpose of personal protective equipment (PPE) in the manufacturing process and give three examples relevant to metalworking.

Answer: PPE protects workers from injuries and hazards. Examples include: safety goggles to protect eyes from sparks and debris, gloves to prevent cuts and burns, and ear defenders to protect against noise.

Question 9: Sketch a safety sign that could be used in a workshop to warn of a hot surface. Label the symbols and instructions included.

Answer: A correct sketch would show a triangular warning sign with a symbol of a hand near a hot surface, and labels indicating 'Hot Surface' and 'Caution'.

Question 10: Explain the importance of proper waste disposal and cleanliness in a workshop environment for safety reasons.

Answer: Proper disposal prevents accidents caused by slips, trips, and falls. Cleanliness reduces fire hazards and ensures safe operation of tools and machinery.