Question 1: Describe three common hazards that might occur during the manufacturing of a plastic product and suggest safety precautions to prevent them.

Answer: Potential hazards include: 1) Burns from hot plastic or equipment; precautions include wearing heat-resistant gloves and using protective barriers. 2) Cuts from sharp tools or edges; precautions include using safety gloves and proper handling techniques. 3) Inhalation of fumes; precautions include working in well-ventilated areas or using fume extractors.

Question 2: Explain why it is important to wear personal protective equipment (PPE) when working on a woodworking project. List three types of PPE you should use.

Answer: Wearing PPE helps protect against injuries such as cuts, splinters, and inhalation of dust or debris. Three types of PPE include safety goggles, dust masks or respirators, and ear protection.

Question 3: Identify two safety features that should be incorporated into a newly designed electric handheld drill to make it safer for users.

Answer: Safety features could include a lock-on switch to prevent accidental activation and an automatic shut-off mechanism if the drill overheats or detects a fault.

Question 4: Sketch a simple safety guard for a circular saw. Label the key features that make it effective.

Answer: A correct sketch would show a transparent or solid guard covering the saw blade, with an opening only large enough for the blade to cut, and a mechanism to easily adjust or remove the guard. Labels should indicate 'protects user from contact,' 'adjustable,' and 'securely attached.'

Question 5: Design a plan for testing the safety of a new product intended for children, such as a toy or a household item. Include at least three testing procedures.

Answer: Testing procedures could include: 1) Mechanical safety test to check for sharp edges or small parts that could be swallowed. 2) Durability test to ensure the product withstands rough handling. 3) User safety test involving a sample of the target age group to observe potential hazards or misuse.

Question 6: Draw a cross-sectional plan of a safety lock mechanism suitable for a storage cabinet. Include labels for key components.

Answer: A correct drawing would show a latch mechanism with a key or button to lock/unlock, a strike plate, and a housing that prevents opening without the key/button. Labels should specify 'lock mechanism,' 'strike plate,' and 'housing.'

Question 7: Propose three design features that could improve the safety of a bicycle helmet.

Answer: Features could include: 1) Impact-absorbing foam liner to reduce injury. 2) Adjustable straps for a secure fit. 3) Ventilation holes to prevent overheating and increase comfort.

Question 8: Explain the importance of testing a prototype for safety before mass production. What risks does this help to prevent?

Answer: Testing ensures that the product is free from design flaws that could cause injury or harm to users. It helps prevent risks such as choking hazards, electrical faults, sharp edges, or structural failures which could lead to accidents or injuries.

Question 9: Sketch an ergonomic handle designed to reduce strain during prolonged use. Include annotations explaining your choices.

Answer: A correct sketch would show a contoured handle that fits comfortably in the hand, with textured grip areas. Annotations should mention 'contoured shape for comfort,' 'non-slip material,' and 'appropriate size for hand grip.'