AURASA002 - Follow Safe Working Practices in An Automotive Workplace

Follow safe working
practices in an
automotive workplace
AURASA002
Follow safe working practices in an automotive workplace
Application
This unit describes the performance outcomes required to identify and follow safety
and emergency procedures in an automotive workplace. It involves those safety
procedures to be followed when using workplace hand tools and hand-held
power tools, fixed equipment, and chemicals, and when running vehicles and
machinery. It includes the individual’s responsibility for safety and emergency
response in the event of an accident or incident.
It applies to those working on agricultural machinery, heavy commercial vehicles,

light vehicles, marine vessels, motorcycles, mobile plant machinery or outdoor
power equipment in the automotive service and repair industry.
No licensing, legislative, regulatory or certification requirements apply to this unit at

the time of publication.
Pre-requisite Unit
NIL
Competency Field
Common
Unit Sector
Health and Safety
ii
Elements and Performance Criteria

ELEMENTS PERFORMANCE CRITERIA MAPPING
INFORMATION
(Describe the (Performance criteria describe the
essential performance needed to demonstrate
outcomes) achievement of the element)
1.1. Workplace procedures relating to Page 3

personal safety are identified and
followed
1.2. Unsafe situations and hazards are Page 6

identified and reported according to
workplace procedures.
1.3. Machinery and equipment breakdowns Page 39

are identified and reported according
, to workplace procedures
1. Identify and 1.4. Fire hazards are identified and reported, Page 6, 27
follow and precautions taken according to
workplace workplace procedures
safety
procedures 1.5. Workplace procedures and safety Page 53
requirements for handling and storing
dangerous goods and hazardous
substances are identified and followed
1.6. Workplace manual handling procedures Page 21 - 23

are identified and followed
1.7. Participation in any WHS consultative Page 32 - 34

arrangements established by workplace
is undertaken
2.1. Workplace emergency procedures Page 64 - 70

regarding illness and accidents are
identified and followed
2. Identify and
follow 2.2. Safety warning alarms and workplace Page 67 - 69
workplace evacuation procedures are identified
emergency and followed
procedures
2.3. Firefighting appliances and equipment Page 29 - 32
are located and identified for
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emergency use and application
2.4. Qualified persons are identified for Page 66, 67

contacting in the event of an incident,
accident or sickness of self, co-workers,
staff, customers and others
2.5. Accident and incident documentation Page 69, 70

requirements are followed according to
workplace procedures
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Knowledge Evidence
MAPPING
KNOWLEDGE OUTCOMES
INFORMATION
• Basic aspects of relevant state or territory WHS or OHS

legislation, including:
o employer responsibilities for workplace practices Page 4, 5
o employee responsibilities to participate in WHS practices Page 5
o employee responsibility to ensure own work practices Page 5

protect the safety of self, other workers and other
people in the workplace
• Purpose and structure of WHS or OHS workplace Page 3 - 5

committees, including roles of workplace personnel
• Personal safety in an automotive workplace, including:
o hearing protection Page 16, 17
o skin protection Page 17, 18
o protective clothing Page 18
o protective footwear Page 18, 19
o eye protection Page 15
• Manual handling, including:
o storing items Page 56 - 62
o planning the lift Page 21 - 23
o using correct lifting techniques and equipment Page 22, 23
• Workplace practices, including:
o housekeeping Page 25, 26
o observing personal hygiene Page 26, 27
o identifying slip hazards and trip hazards Page 24, 25
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• Meaning of WHS or OHS symbols and signs Page 35 - 37
• Machine and equipment safety, including:
o using compressed air Page 38, 39
o using machine guards Page 39, 40
o electrical tools, including:
✓ checking before use Page 40
✓ faulty equipment tagging and isolation procedures Page 40
✓ dangers of using electrical tools around water Page 40
o vehicle lifting equipment, including:
✓ using jacks and stands Page 42 - 44
✓ using hoists Page 41, 42
✓ safe working load (SWL) of jacks and hoists Page 44
• Vehicle safety, including:
o engine moving parts Page 45, 46
o engine and exhaust hot components Page 46, 47
o electrical hazards associated with:
✓ high voltage ignition systems Page 47, 48
✓ wearing jewellery while working around high current Page 48, 49

wiring systems
o batteries Page 49, 50
o fuel, including petrol, diesel and natural and petroleum Page 50, 51
gas
o high voltage in battery electrical and hybrid vehicles Page 51, 52
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• Hazardous materials, including handling and storing:
o oils Page 56
o brake fluid Page 60
o brake dust Page 61
o chemicals Page 56, 57
o cleaning products Page 59, 60
o safety data sheets (SDS) Page 53 - 55
• Emergency procedures, including:
o personnel responsibilities Page 68
o evacuation procedures and assembly points. Page 64 - 70
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Table of Contents
1 Introduction................................................................................................. 1
2 Work health and safety ............................................................................. 3
2.1 Duty of care requirements ................................................................................... 4
2.2 Employer Work Health and Safety Responsibilities ............................................ 4
2.3 Employee Work Health and Safety Responsibilities ........................................... 5
3 Workplace hazards .................................................................................... 6

3.1 Fire hazard............................................................................................................. 6
3.2 Explosions .............................................................................................................. 8
3.3 Asphyxiation.......................................................................................................... 8
3.4 Electric shock ........................................................................................................ 9
3.5 Physical injury ...................................................................................................... 10
3.6 Burns .................................................................................................................... 11
3.7 Hazardous chemicals ......................................................................................... 12
4 Personal protective equipment .............................................................. 14

4.1 PPE ....................................................................................................................... 14
4.2 Maintenance of PPE........................................................................................... 19
4.3 Sharing PPE.......................................................................................................... 20
5 Manual handling ...................................................................................... 21

6 Workplace practices................................................................................ 24
6.1 Slips, trips and falls .............................................................................................. 24
6.2 Good housekeeping .......................................................................................... 25
6.3 Foot wear ............................................................................................................ 26
6.4 Personal hygiene ................................................................................................ 26
6.5 Fire Safety ............................................................................................................ 27
6.5.1 Fire evacuation plan .................................................................................................. 28
6.5.2 Firefighting equipment .............................................................................................. 29
6.5.3 Fire Hoses ..................................................................................................................... 31
6.5.4 Fire hydrant system ..................................................................................................... 31
6.5.5 Fire blankets ................................................................................................................ 32
6.5.6 Other equipment ....................................................................................................... 32
6.6 WHS consultation ................................................................................................ 32
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7 Safety signage .......................................................................................... 35

8 Workshop equipment safety ................................................................... 38
8.1 Compressed air tools.......................................................................................... 38
8.2 Machine guards ................................................................................................. 39
8.3 Electrical tools ..................................................................................................... 40
8.4 Vehicle lifting equipment safety ....................................................................... 41
8.4.1 Vehicle hoists .............................................................................................................. 41
8.4.2 Vehicle jacks ............................................................................................................... 42
8.4.3 Vehicle stands/Jack stands ...................................................................................... 43
9 Vehicle safety ........................................................................................... 45

9.1 Engine moving parts .......................................................................................... 45
9.2 Electrical system (high current wiring system) .................................................. 46
9.3 Engine cooling system and exhaust system components .............................. 46
9.4 High voltage ignition system .............................................................................. 47
9.5 Batteries ............................................................................................................... 49
9.6 Vehicle fuel ......................................................................................................... 50
9.7 Hybrid Vehicle safety ......................................................................................... 51
10 Handling and storage .............................................................................. 53

10.1 Safety data sheet (SDS) ..................................................................................... 53
10.2 Storage of goods or material ............................................................................ 55
10.3 Handling and storing the flammable substances ............................................ 56
10.4 Handling and storing hazardous chemicals..................................................... 56
10.5 Handling and storing oil ..................................................................................... 57
10.6 Handling and storing chemical spills ................................................................ 57
10.7 Handling and storing hazardous gases ............................................................ 58
10.8 Handling and storing cylinder ........................................................................... 59
10.9 Handling and storing cleaning products .......................................................... 59
10.10 Handling and storing of brake fluid ........................................................... 60
10.11 Handling and storage of brake dust.......................................................... 61
10.12 Handling and storing hand tools ................................................................ 61
10.13 Disposal of workshop waste ....................................................................... 62
11 Emergency evacuation procedure ....................................................... 64
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11.1 Designated personnel to report in emergencies ............................................. 66

11.2 Evacuation procedures ..................................................................................... 67
11.3 Accident and incident documentation........................................................... 69
12 References ................................................................................................ 71
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1 Introduction
The automotive industry consists of a range of companies and organizations which
are involved in design, development, manufacturing, and marketing and selling of
motor vehicles. Automotive industry is considered to be one of the largest economic
sectors in terms of revenue.
In Australia, motor industry was developed in 20th century by international

manufacturers. The first major car manufacturer in Australia was Ford Australia and
the first Australian designed mass production car was manufactured by Holden in
1948.
Figure 1: Australian car manufacturing factory
Some of the famous Australian car manufacturing companies are – Mercedes-Benz,

Mitsubishi motors, Ford Australia, Nissan Australia, Renault Australia etc. As of now,
large scale manufacturers are – Bustech, Denning manufacturing, Iveco and Paccar
Inc.
Nationally recognised training for automotive is delivered under AUR automotive

industry retail, service and repair training package and AUM automotive
manufacturing training package. In Australia, there are many industry committees
that cover the automotive industry. They are –
a) Automotive light vehicle
b) Automotive heavy vehicle
c) Automotive vehicle body repair
d) Automotive allied industry
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e) Automotive strategic industry
Safety plays an important role when working in the workshop. There are many types
of hazards that occur in workshop for which the workers should have appropriate
training. This unit provides information about the hazards and safe work practices at
a workplace.
2
2 Work health and safety

Work health and safety (WHS) govern the safety, health and well-being of people
involved in work or employment. Irrespective of the nature of their work, employees
must be able to carry out their responsibilities in a safe and secure working
environment which is free from hazards.
Figure 2: Work health and safety
The objectives of WHS are to:
• ensure the health, safety and welfare of employees and other people at work;
• protect the public from the health and safety risks of business activities;
• eliminate workplace risks at the source; and
• involve employers, employees and the organisations that represent them in the
formulation and implementation of health, safety and welfare standards.
WHS play an important role in providing a safe workplace for both employers and
employees.
• Work health and safety act 2004 seek to improve the health, safety and welfare
of employees in automotive industry.
• WHS Regulations 2017 involves the safe operation of major hazard facilities,
training for high risk work, managing and removing asbestos and licenses for
specific activities
For further information on WHS regulations, visit

www.worksafe.vic.gov.au/automotive
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2.1 Duty of care requirements
Duty of care refers to the responsibility of a person or an organization to take all

measures necessary to prevent activities that may cause harm to other individuals. It
means taking care of yourself and others when they are relying on you. Regardless
of role, everyone has a duty of care towards every other person in their environment
and to themselves.
Figure 3: Duty of care
Everyone working on the site including employees, employers, supervisors,

managers, contractors, designers, manufacturers, visitors and others who come to
the workplace are responsible to ensure safety.
All the members must have a proper knowledge of workplace methods for
controlling risks and hazards. The methods must fulfil Work Health and Safety
requirements. The required information can be obtained from the supervisor or
safety officer.
An overview of employer and employee responsibilities under the Work Health and
Safety Act 2004 are –
2.2 Employer Work Health and Safety Responsibilities
• Managing hazardous substances in workshop floor.
• Testing and tagging of electrical power leads, electrical power sources and
electrical equipment.
• Workplace management such as ventilation (Exhaust fume extraction), first aid kit,
fire and emergency exit procedures.
• Ensure safety and handling of heavier equipment (Transmissions stand, engine

crane, etc.)
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• Periodically calibrate electronic and electrical equipment (Ex. Tyre changers,

wheel balancer, fuel gauges, pressure gauges etc.)
• Provision of PPE to the workers
• Place castors on heavy toolboxes.
2.3 Employee Work Health and Safety Responsibilities
• Employees must take responsibility for their own health and safety, this includes:
• Following instructions regarding hazards.
• Usage of relevant PPE based on the nature of the work
• Cleaning the slippery area around the workplace in regular intervals
• Avoid awkward posture during work
• Deflating the tyres to minimise explosion (to avoid casualties in the surroundings)
• Usage of chocks or wheel pegs to avoid vehicle rolling
• Immediately notify the workshop supervisor of any faulty or broken equipment
• Usage of recommended special tools while working on specific systems
• Report accident promptly.
• Recognise the dangers present and follow the safety guidelines set out.
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3 Workplace hazards
A hazard is any object, situation that has the potential to cause injury to people or
damage to equipment or the environment.
The types of hazards in the automotive industry are –
• Temperature – extreme temperature can cause tiredness or a reduced ability to

work
• Ergonomic – discomfort experienced when doing a task like incorrect manual

handling
• Noise – power tools, grinder
• Electrical – exposed electrical wiring
• Chemical – oils or paint
• Physical – trip over, fall into, walk into and slip on
If the hazard is significant, then it must be –
a) Eliminated
b) Isolated
c) Minimized
3.1 Fire hazard
Fire is the most common hazard that creates huge destruction in the workplace. It
results in serious injuries and is dangerous to human life.
Figure 4: Fire hazard at automotive workplace
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There are four types of fire that may occur in a workshop.
• Class A fire – These are caused by ordinary combustibles such as wood, cloth,
paper, plastic, rubber and cardboard.
• Class B fire – These occur because of flammable liquids such as petrol, oil, paint,
kerosene, lacquers, thinners and solvents.
• Class C fire – These are flammable gases such as oxy-acetylene, CNG and LPG.
• Class E fire – These are electrical fires arising from motors, generators, light fittings,
switches, switch boards and cables.
Preventive measures
➢ All workers in an automotive workshop must have responsibilities to ensure that –
o All flammable rubbish is appropriately disposed
o All flammable liquids are sealed and stored
o Fire hazards are reported to the designated personnel
o Damaged electrical equipment is never used.
➢ Set off the fire alarm so that everybody is made aware of the danger, and make
sure to call 000 for the police and fire service. Provide your name, the company
name, the address, on site location of the fire and the extent of the fire.
➢ Stay low if the workshop is filled with smoke.
➢ Use the fire extinguisher to fight the fire if possible.
➢ If the fire is beyond control, evacuate the workplace immediately.
➢ Do not re-enter until the all clear is given.
➢ Ensure that a safe escape route is always maintained in the workshop.
Figure 5: Different types of fire extinguishers
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3.2 Explosions
Explosions are normally induced when a naked flame or spark is introduced to a

chemical. Explosions result in two major hazards i.e., fire and airborne debris. These
can cause extensive physical injuries. Automotive workers must always be aware of
potential explosive hazards, particularly when working with –
a) Batteries
b) Fuel systems
c) Grinding machines
d) Welding equipment
e) Electrical equipment
Preventive measures
➢ Follow the fire evacuation procedure in case of explosion.
➢ A safety escape route must be maintained in the workshop. This will ensure that in
the event of an emergency workshop staff can leave the workshop safely and
emergency staff can gain access.
➢ Always wear appropriate personal protective equipment PPE such as face mask
to avoid inhalation of smoke.
3.3 Asphyxiation
Asphyxiation is a state of suffocation brought on by a lack of oxygen. It is generally

caused by a combination of toxic fumes and poor ventilation. The symptoms of
asphyxiation include dizziness, headache, feeling sick and loss of consciousness.
Preventive measures
➢ Work should always be carried out in well-ventilated areas.
➢ In the absence of proper ventilation, appropriate breathing equipment must be

worn like respiratory masks.
➢ Always keep the windows and doors of the workshop open for good ventilation.
➢ Use exhaust fans and minimise the running of engines.
➢ Care should be taken when exposed to carbon monoxide, isocyanates, battery

and fuel fumes.
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➢ In case of emergency, bring the employee to the fresh air and assess their
condition. Treat as necessary and send for medical help.
3.4 Electric shock
Electric shock occurs when the worker comes in direct contact with the electrical
energy source and when an electrical current pass through the body. This can result
in burns, falls and other severe injuries. In an automotive workshop an electrical
shock can be caused by –
a) Faulty electrical cable wires
b) Cables touching water
c) Vehicle ignition systems
d) Cutting through electrical cables
e) Wearing jewellery while working around high electric current systems
Figure 6: Electric current passage from cables
Preventive measures
➢ Before using electrical equipment, the following checks should be done –
o Examine the condition of the electrical tool.
o Inspect electrical cables and plugs for chafing and exposed wires.
o Ensure that a residual current device (RCD) is used when appropriate
o Remove all possible fire hazards.
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➢ Attempt to shut down the electrical circuit immediately in case of emergency.
➢ Direct skin contact with the patient should be avoided and never pull or drag wet
clothing.
Figure 7: Use wood stick to remove electric shock source
➢ Use only non-conductive materials such as wood, plastic, rubber or dry clothing.
➢ Assess condition, treat as necessary and send for medical help.
➢ Make sure all the jewellery like rings, chains, watches should be removed when
handling the electric systems. Jewellery or any accessories leads to short circuit
which could result in dangerous injuries. They can also get caught up in rotating
components as well.
3.5 Physical injury
Physical injury refers to any damage to the body. The injuries include cuts, bruises
and broken bones. Physical injuries can be caused by –
a) Slipping on a wet floor
b) Hit by falling objects
c) Tripping over objects
d) Being struck by moving objects
e) Trapping fingers in components
Preventive measures
➢ The risk of slipping on the uneven surfaces can be reduced by providing walkways
and by placing the sign boards appropriately.
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Figure 8: Slippery floor warning sign
➢ Work and storage areas must be kept tidy and keep the waste material
separately.
➢ Cordless tools must be used and make sure the cables are securely run at high
levels.
➢ Any areas that are slippery should be signposted, and footwear with a good grip
should be worn.
➢ Always wear appropriate personal protective equipment (PPE) like safety glasses,
high visibility jackets such that the moving objects are seen.
➢ Never work close to the moving object.
➢ Always be attentive of the surroundings in case there are no lights or beepers on

the objects.
3.6 Burns
There are two types of burns that workers in an automotive workshop may be
exposed to – hot burns and cold burns.
Hot burns – The burns may occur when working with hot vehicle parts and liquids
such as –
a) The exhaust system
b) Brakes and clutch parts
c) The engine
d) Engine oil or coolant or batteries
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Cold burns – These burns occur when working with compressed gases such as –
a) Liquid petroleum gas (LPG)
b) Compressed natural gas (CNG)
c) Air conditioning refrigerant
Preventive measures
➢ Appropriate PPE like hand gloves must be worn to protect from burns.
➢ Avoid getting into contact with hot touching parts.
➢ Keep the sparks and any open flames away from the combustible and
flammable material like LPG and CNG.
➢ Place warning signs near hot equipment or surfaces.
➢ Ensure that the fire extinguishers are accessible to the workers and also ensure
that all workers are trained in using them.
Figure 9: First aid kit for burns
➢ Ensure that first-aid kits are easily accessible and get trained in first-aid.
➢ Always cover the hair and wear fitted clothing.
3.7 Hazardous chemicals
Dangerous chemicals like acids, solvents, caustic soda, and ammonia are used in
motor industry.
a) Acid is used for removing rust, cleaning metals and in batteries
b) Solvents are used for thinning paints and adhesives
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c) Caustic soda and ammonia are present in cleaning solutions.
All these chemicals can cause damage to health and environment. The information
regarding the chemicals is available from manufacturer’s safety data sheets (SDS),
product labels, packaging and codes of practice that deal with the handling of
chemicals.
Preventive measures
➢ Ensuring correct labelling of containers and pipework, using warning placards

and displaying safety signs.
Figure 10: Containers displaying hazard warning signs
➢ Workshop staff must be aware of the hazards associated with each particular
chemical and the correct procedure to follow when handling them.
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4 Personal protective equipment

Personal protective equipment (PPE) is designed to protect from specific hazards
and hazardous materials. It is considered to be the final protection system to be
used and it does not reduce or eliminate the hazard but only protects the person
wearing it.
When working with the engine system, brake or clutch system appropriate PPE must
be worn all the time to prevent from any harmful injuries. Toxic gases released
causes respiratory problems and headaches. Selecting the appropriate PPE is more
important.
Figure 11: Personal protective equipment
4.1 PPE
Personal Protective Equipment are safety gears to avoid health & safety risks in the
workplace.
• Safety shoes – To protect from electric shocks, slipping, falling of heavy tools &
equipment.
• Hand gloves – To protect from chemicals, cuts and extreme temperatures.
• Safety Goggles – To protect from chemicals, dust, vapours and gases, Radiation.
• Ear muffs/plugs – To avoid very heavy noise from machinery.
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• Helmets/Head gear – To protect from falling objects and risk of bumping head.
• Welding sleeves – To avoid sparks splashing in welding process
• Vest – To avoid heat, spray from pressure leaks and chemical.
a) Eye protection and face protection – The equipment must fit properly and be
comfortable to wear. It should provide unrestricted vision and movement. It
should also be cleaned easily. The risk of eye damage might increase when
working with –
A drill press A lathe
A bench grinder Welding equipment
Compressed air hand tools Batteries
Chemicals Lubricating equipment
Air conditioning equipment Electrical hand tools
Under body vehicle components Chisels, punches, drifts
Welding equipment Cleaning solvents
Examples – Safety glasses, face shields, chemical splash goggles, tinted welding
goggles, tinted full face welding mask
Figure 12: Face shield and chemical splash goggles
b) Respiratory protective equipment – It prevents from inhaling hazardous

chemicals, asbestos, fumes, dusts etc. This equipment is worn to avoid harmful
substances damaging the lungs. Exhaust fumes from spark ignition engine
consists of carbon monoxide which causes dizziness and death upon inhalation.
Examples - Air purifying respirators, supplied air respirators
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Figure 13: Air purifying respirators
c) Hearing protective devices – These devices help in noise reduction and also
provide comfort while working. When exposed to prolonged high decibel noise,
there is a risk of industrial deafness. Industrial deafness is hearing loss that occurs
over a period of time and is painless but is permanent. These protective devices
should be worn when working with –
Grinding equipment
Hammers
Stationary engines
Air powered tools
Electric tools
Examples – Ear muffs, hearing bands, ear plugs.
Figure 14: Hearing protective devices
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Ear muffs are available in various grades. It is important to choose the appropriate
graded ear muffs as per the exposure level of noise.
d) Head protection - Head protection equipment prevents any impacts and

penetration of hazards. It protects from electrical shocks and burn hazards when
working underneath the car and working with moving automotive parts or
revolving machinery.
It may also be necessary to wear protective headwear to avoid the head injury
and the risk of having hair getting caught in rotating parts.
Figure 15: Hard hats
Examples – Safety helmet, hard hats, hair net.
e) Skin protection – Hazards like absorption of harmful substances, chemical or

thermal burns, electrical dangers, bruises, cuts and fractures can be prevented
by wearing skin protection PPE. This equipment should be worn when working
with –
Sharp objects
Welding equipment
Chemicals such as petrol, diesel, solvents and oil
Hot objects
Cooling systems
Examples – Safety gloves, finger guards, arm coverings, metal or leather mesh
gloves, sunscreen, and gauntlets.
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Figure 16: Safety leather gloves
f) Protective clothing – Various protective clothing is available to avoid hazards.

These give protections against heat, sun, cold. Overalls are designed to be fire
resistant and to protect the body from oil, grease and other solvents. It is also
important to select appropriate size overalls.
Figure 17: Protective overalls
Examples - Uniforms, caps, high visibility vests, life jackets, coveralls
g) Foot protection – When working in a workshop, it is necessary to wear proper

footwear. The footwear must –
• Support the foot and ankle joint
• Protect the foot and toes from falling objects
• Provide maximum grip
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Figure 18: Safety boots
Examples – Safety boots, rubber boots
Safety boots are manufactured as per Australian standard wherein the upper part is
made of leather, sole must be chemical resistant with hardened steel toe caps and
heel protector.
4.2 Maintenance of PPE
Proper care and maintenance is essential to ensure that PPE provides the necessary
level of protection.
Figure 19: Cleaning of PPE after usage
➢ Look for broken or damaged components before using PPE and repair or replace
it as needed.
➢ Replace PPE that has expired or reached its usable lifespan.
➢ Clean reusable PPE after use and store in a clean area such as a cupboard,
drawer or resealable container.
➢ Report broken, damaged or contaminated PPE.
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4.3 Sharing PPE
Most PPE is provided for personal use of a workers. However, PPE may be shared in
some circumstances, for example where PPE is only required for limited periods.
Shared PPE must be properly cleaned and disinfected before it is used again to
ensure there are no health risks to the next person. Refer to the manufacturer’s
instructions for appropriate methods.
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5 Manual handling
Manual handling is an activity that requires lifting, pulling, pushing or carrying heavier
equipment.
Manual handling in the automotive industry includes –
a) Lifting and moving equipment
b) Bending, kneeling or twisting while fitting heavy parts
c) Working in awkward positions such as removing or replacing engine parts under

car bonnets.
d) Working in cramped positions
e) Using excessive force with hand tools
At times, the work tasks may involve bending and stretching as well as twisting
sideways, or working with materials and equipment above shoulder height. All of
these increase the risk of manual handling injury.
Figure 20: Working under vehicle
Carrying out work at the limit of reach or in awkward postures away from the body’s
centre of gravity requires muscles to work harder. When these postures are held for
too long, muscular or spinal injuries can occur.
It is the employer's responsibility to assess and control manual handling tasks that
may present risk, and to provide instruction, training and supervision for manual
handling activities.
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Lifting equipment will be necessary for many of the tasks in an automotive workshop.
Many engine parts are too heavy to lift safely and also storage of these items such
as vehicle tyres on rack is also difficult. Rolling these items on the floor is easy but
may cause risk if attempted to lift them.
Manual lifting techniques or Back protection safety:
➢ Use of lifting equipment for heavy loads.
➢ Heavier objects can be carried with the help of others.
➢ Lift and carry heavy loads correctly by keeping the load close to the body and
lifting with the thigh muscles.
➢ Never attempt to lift or carry loads if you think they are too heavy.
➢ Use leg muscles to lift heavy loads rather than using back muscles.
➢ Heavier objects should always be stored at waist height.
Safety measures
➢ Carry out workplace inspections and observe manual tasks, check injury/hazard
reports, and identify any relevant contributing factors i.e. slippery floors.
➢ Modify workplace layout and equipment where possible - automate the manual
tasks, replace hand tools with power tools.
➢ Use lifting aids e.g. jigs, slings, dollies that are adaptable to the size/shape of
handled items like engines, transmissions.
➢ Deliver goods or equipment directly to the point of use to eliminate multiple

handling.
➢ Modify working loads - redistribute the weight, or replace heavy items with lighter,
smaller, more easily handled items.
➢ Redesign work patterns - change the frequency and type of tasks done by
workers, rotate workers between tasks).
➢ Ensure everyone has both general and specific hazardous manual task training,
especially young and new workers.
➢ Consult with workers before purchasing any new equipment and tools. Ensure
they are designed for safe use and are a best match to both the worker and task
needs.
➢ Provide personal protective equipment (PPE) that is:
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a. Suitable for the nature of the work and the hazard like workers who need to
carry out tasks in extreme heat or cold, wind or rain
b. Comfortable to wear, and of a suitable size and feet
c. Maintained, repaired or replaced when required
d. Used or worn by workers who have been trained in its use and care.
e. Examples – Protective overalls, safety gloves
Figure 21: Equipment to lift heavy objects
Equipment and device that can used to reduce manual handling are –
➢ Vacuum lifters for windscreen insertion
➢ Hoists when during vehicle servicing
➢ Engine cranes during lifting engines.
➢ Transmission Jacks during removing and installing the transmissions.
➢ Hip-height roller conveyors and ramps to load or move tyres
➢ Order picking ladders with load tables for stock access
➢ Pads and body tables for comfortable work in foot wells and under dashes
➢ Castors on heavy toolboxes.
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6 Workplace practices
There are many hazards present in an automotive workplace and it is important to
be safe to prevent injuries or serious damages. A safe workplace will help the
business by –
a) Enhancing the productivity and efficiency of workers
b) Decreasing insurance costs
c) Reducing the costs associated with replacing injured or sick employee
d) Improve the service efficiency to the clients.
Both the employee and employer are responsible for maintaining a safe hazard free
workshop. Good housekeeping will help to achieve this by creating a positive
impression for customer. The main purpose of housekeeping is to control or eliminate
workplace hazards.
Many slips and trips at the workplace are the results of poor housekeeping.
Workplace practices that are to be followed in the workshop:
• Cleaning of workshop bay to avoid slippery surface
• Obey all workshop safety and warning signs
• To avoid tripping down, cover the electrical cords running across the aisles
• Washing of hands after using chemicals, solvents, grease or petroleum by

products.
• Using masks, tissues and handkerchiefs prevents airborne contagion to other

workers.
6.1 Slips, trips and falls
Slips, trips and falls can occur in any environment. Due to the presence of uneven
surfaces and unwanted materials on site, slips, trips and falls are considered as a
common hazard. It is also a sign of lack of clear systems and responsibilities for
storage, maintenance and cleaning. These hazards cause sprains, broken bones,
back injury, burns and cuts.
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Figure 22: Slips, trips and falls
Slips
Slips occur when there is a loss of grip between the shoe and the floor. Slips occur
because of wet or oily surface, sloping surfaces, occasional spills and splashes of
liquids and loose rugs or mats.
Trips
Trips occur when a person’s foot hits a low obstacle in the person’s path, causing a
loss of balance. Often, the obstacle is not easily visible or noticed. Sometimes,
uncovered cables, wrinkled carpets and holes or cracks are also responsible for trips.
Falls
Falls may occur on surfaces that are of same level or of different heights. It can
happen at ground level where there is a risk of falling into a hole.
6.2 Good housekeeping
To achieve a tidy workplace that is free from slip, trip and fall hazards, one must
follow good housekeeping techniques. These include –
➢ Suitable storage systems – Keep the workshop equipment, vehicle parts, tools and
other items at their respective storage areas.
➢ Spill management systems – Cleaning all spills immediately like oil spills should be
soaked up with a dry absorbent and then put into a waste container.
➢ Metal shavings must be cleaned regularly.
➢ Maintenance schedules – includes day-to-day clean up and inspection to ensure

that the clean-up is complete.
➢ Repairing or replacing carpet flooring that is uneven, buckling, peeling or curled
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➢ Repairing or replacing hard surfaces that are uneven, cracked, blistered and with
height irregularities.
Figure 23: Cleaning of spills
All walkways should be kept clear and suitably illuminated, keeping all items off the
floor through storage or cable management systems. If the objects cannot be
moved, highlight them with yellow paint on edges of large equipment.
6.3 Foot wear
Foot wear plays an important role in reducing the risk of slips, trips and falls.
Footwear should be:
➢ Suitable for the type of work and work environment
➢ Comfortable with an adequate non-slip sole and appropriate tread pattern
➢ Checked regularly to ensure treads are not worn away or clogged with
contaminants.
6.4 Personal hygiene
It is a requirement for technicians to maintain high levels of personal hygiene. It refers

to the cleanliness, habits and appearance of employees at workplace. Personal
hygiene is important when meeting with customers to create a positive impression. It
also helps to prevent sickness.
Personal hygiene practices include –
a) Regular washing of face, hands and arms to remove grease and oil
b) The use of barrier cream after washing to prevent skin disease
c) Clean overalls and work boots
d) A well-groomed appearance at work
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e) Punctual to the workplace
Figure 24: Washing hands
6.5 Fire Safety
Fire is the most common hazard that creates huge destruction in the workplace. It
results in serious injuries and is dangerous to human life.
There are four Classes of fires that may occur in a workshop.
• Class A fire – These are caused by ordinary combustibles such as wood, cloth,
paper, plastic, rubber and cardboard.
• Class B fire – These occur because of flammable liquids such as petrol, oil, paint,
kerosene, lacquers, thinners and solvents.
• Class C fire – These are flammable gases such as oxy-acetylene, CNG and LPG.
• Class D fire – Burning metals, such as magnesium, sodium and lithium.
• Class E fire – These are electrical fires arising from motors, generators, light fittings,
switches, switch boards and cables.
Figure 25: Fire hazard at automotive workshop
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Preventive measures
➢ All workers in an automotive workshop must have responsibilities to ensure that –
o All flammable rubbish is appropriately disposed
o All flammable liquids are sealed and stored
o Fire hazards are reported to the designated personnel
o Damaged electrical equipment is never used.
➢ Set off the fire alarm so that everybody is made aware of the danger, and make
sure to call 000 for the police and fire service. Provide your name, the company
name, the address, on site location of the fire and the extent of the fire.
➢ Stay low if the workshop is filled with smoke.
➢ Use the fire extinguisher to fight the fire if possible.
➢ If the fire is beyond control, evacuate the workplace immediately.
➢ Do not re-enter until the all clear is given.
➢ Ensure that a safe escape route is always maintained in the workshop.
6.5.1 Fire evacuation plan
➢ Activate the fire alarm.
➢ Call 000 in case of fire emergency and provide necessary details.
➢ Assist the injured only if it is safe to do.
➢ Follow emergency exit routes to leave the area.
➢ Never use elevators to evacuate the building.
➢ Use fire extinguishers and other firefighting equipment if you are trained and if it is
safe.
➢ Stay low in the presence of smoke.
➢ Follow the instructions of emergency services personnel and chief fire wardens.
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Figure 26: Fire emergency exit signs
6.5.2 Firefighting equipment
Firefighting equipment is designed to protect the individuals by extinguishing the fire.

The equipment can be used by trained firefighters or any untrained person at the
scene of a fire.
There are several types of firefighting equipment.
Figure 27: Fire extinguishers
a) Water fire extinguishers –
• These extinguish fire by taking away the heat element from the fire triangle.
• These are used for class A fire. It should not be used for class B and C fires as it
increases the hazards.
• Never use on electrical equipment.
b) Foam fire extinguishers –
• These separate the oxygen elements from other elements.
• These are water based and also consist of a foaming agent.
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• Foaming agent has blanketing and rapid flame knock down effect. It stops the
flames and seals vapours thus preventing re-ignition.
• Suitable for class A and B fires.
c) Dry chemical powder –
• They extinguish fire by interrupting the chemical reaction of the fire triangle.
• It creates a barrier between oxygen element and fuel element on class A fires.
• It is effective on Class A, B and C fires.
d) Wet chemical –
• It extinguishes fire by removing the heat and re-ignition is prevented.
• It also creates a barrier between oxygen element and fuel element
• Never use wet chemical fire extinguisher on Class B fires.
e) Carbon dioxide –
• They remove the oxygen from the fire triangle.
• They also help in removing the heat with a very cold discharge.
• They are used on Class B and C fires. They are ideal for electrical fires also as
CO2 does not leave any harmful residue.
• They are ineffective on Class A fires.
Using a fire extinguisher:
Installation of fire extinguisher must be according to Australian standard AS2444

Portable Fire Extinguishers and Fire Blankets selection and location.
Figure 28: Operating a fire extinguisher
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➢ First, pull the pin. Hold the extinguisher with the nozzle directing away from you.
Now, release the locking mechanism.
➢ Point the extinguisher at the base of the fire.
➢ Squeeze the lever slowly and evenly.
➢ Sweep the nozzle from side to side.
Always keep your back to a clear exit so that you can escape quickly and easily in
situations where fire cannot be controlled. Also, leave the area immediately if it is
filled with smoke.
6.5.3 Fire Hoses
Fire hose is another type of firefighting equipment which carries water or other fire
retardant like foam to extinguish the fire. It is attached to a fire hydrant or a fire
engine. Fire hose reel releases a high stream of water and extinguishers large fires.
They are ideal for Class A fires.
Figure 29: Fire hose
6.5.4 Fire hydrant system
The system includes pumps, tanks, fire brigade booster etc. They are used to stop
heavy fires as they carry large amounts of water. The water is supplied with sufficient
pressure through pipes. Fire hoses are also part of fire hydrant system.
Figure 30: Fire hydrant
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6.5.5 Fire blankets
These are used in small fires that occur in the workplace vehicles. It consists of a fire-
resistant fabric which is used to reduce small fires. It can be wrapped around a
person. They are made of wool with a specially treated chemical and are flame
proof.
Figure 31: Fire blankets
6.5.6 Other equipment
➢ Sprinklers
➢ Water and sand bucket
➢ Firefighting clothing – Protective suit, Safety helmet etc.
6.6 WHS consultation
As a supervisor, the responsibility extends beyond instructing team members.

Supervisors must regularly consult the employees about safety and security related
issues. Employees must be provided with copies of establishment policies and
procedures and supervisor must ensure that they understand the information
contained within them.
Accidents generally occur in the workplace as employees do not understand the

correct work practices that need to be followed. Hence, supervisor can consult the
employees to ensure that they understand what is required by them at work place,
and are dedicated to achieve optimum health, safety and security goals set by the
organisation.
The best way to avoid WHS issues in the workplace is by communicating with the
employees as they are the ones who are directly involved in operating equipment,
utilising the work space, cleaning and interacting with customers etc.
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Consultation method must best suit the work place size and needs of the employees.
The method must provide an opportunity for the employees to contribute their views
on current and future WHS management practices.
Figure 32: WHS consultation
The regular consultative process includes:
• Consultation with all employees during the course of each day.
• A diary or whiteboard or suggestion box must be used by staff to report any issue
of concern.
• Regular staff meetings.
• Emergency staff meetings or workshops to specifically address emergency issues.
• Staff handbook which comprises WHS information.
• Checklist or questionnaire that aids in getting the employee feedback on WHS

issues.
• Fact sheets that inform employees about WHS rights and responsibilities.
• Formal meetings with agendas with action plans.
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• Staff involvement in drafting WHS policies and procedures through surveys or

questionnaires.
Visit WHS meeting template to record any formal or informal WHS meetings.
Induction training is conducted to provide awareness and knowledge about

workplace and its safety. The recommended areas of training is as under –
• Fire evacuation and emergency procedure training.
• Following hierarchy of organisation and rules, and understanding roles and

responsibilities of each individual.
• Understanding sign boards in automotive workplace.
• Cleaning and tidying of tools.
• The incident reporting process and procedures (how to call for an ambulance or
the fire service, who to report the incident to and the necessary forms to
complete).
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7 Safety signage
The importance of displaying safety signs is to warn or identify the hazards
associated with the material. Safety signs can assist in the communication of
important instructions; provide instruction for emergency situations and safety
messages.
Australian standard AS 1319:1994 outlines specific requirements for the design and
use of safety signs intended for use in the occupational environment to regulate and
control safety related behaviour, to warn of hazards and to provide emergency
information including fire protection information.
Safety signs are subdivided as follows –
• Prohibition signs - Prohibition signs indicate an action or behaviour that is not

permitted.
• Mandatory signs - Mandatory signs provide specific instructions that MUST be
carried out.
• Danger signs - Danger signs communicate a hazard, condition or situation that is

likely to be life threatening.
• Fire safety signs – Fire safety signs advise the location of fire alarms and firefighting
equipment.
• Warning signs - Warning signs warn of hazards or conditions that is not likely life
threatening. It also designates a particular area that is used to store hazardous
material.
• Emergency signs - Emergency signs indicate the location of, or directions to

emergency facilities (Exits, First Aid, and Safety Equipment etc.)
• General information signs - They communicate information of a general nature

and often refer to Housekeeping, Company Practices and Logistics.
Signs Examples
Emergency
signs
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Mandatory
Signs
Danger Signs
Fire safety signs
Warning signs
Prohibition
signs
General
information
signs
36
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8 Workshop equipment safety

There are various types of equipment that are used every day in automotive
workshops. Before attempting to use any device, it is important that you understand
the safety precautions that must be taken.
This information can be obtained from equipment manufacturer safety notices on

the equipment or packaging or from the user manual that should be obtained from
supervisor. The handling methods of some workshop equipment are -
8.1 Compressed air tools
Power tools that use compressed air are called pneumatic tools.
• Pointing compressed air towards human body will force foreign particles enter
bloodstream.
• Tools such as riveting guns should not be pointed at a person.
• Usage of goggles & face shields
• Compressed air is used to power chassis grease guns; pressurized grease can
penetrate skin.
Figure 33: Using compressed air tool
• Hold onto the air hose when uncoupling an airline so it does not fly through the
air. When possible, bleed off the air from an airline before uncoupling an air hose.
• Pneumatic tools must always be operated at the pressure recommended by the

manufacturer.
• Before using a pneumatic tool, check all the hose connections for leaks. Also,
check for airline damage.
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• When using an air nozzle, always wear safety glasses or a face shield as the dirt
particles and pieces of metal, blown by the high-pressure air can penetrate skin
or get into eyes.
• Never use compressed air to blow dirt from clothes, hair or to clean the floor or
workbench.
• Never spin bearings with compressed air. If the bearing is damaged, one of the
steel balls or rollers might fly out and cause serious injury.
8.2 Machine guards
Machine guards or safety guards are a protective cover over a moving part.
Although the safety guards/Machine guards are designed to prevent injury, you
should still wear safety glasses during machine guards equipped machines. Machine
guards are generally fitted to on Grinder, angle grinders, electric drills, wheel
balance machine.
It is a safety feature consisting of a shield or device covering the hazardous areas of

a machine to avoid contact with body parts or to control hazards like sparks coming
from the machine.
Figure 34: Machine guard fixed to the tool
• Safety guards should be fitted to all rotating parts of the objects and never to be
removed under any circumstances.
• Check for safety guards for Wheel balancing machines to avoid stones thrown at
the operator.
• Machine guards may be removed if they are designed to be removed for cutting
device changes or to make small cuts.
• Only qualified repair operators will remove all other guards.
• All irregularities in the operation of machine guards will be immediately reported

to the supervisor.
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• Check for safety guards for wheel balancing machines to avoid stones thrown at
the operator.
8.3 Electrical tools
Electrical tools are powered by electricity. Electrical equipment that is not properly
earthed or maintained can lead to electric shock, serious burns or even death.
• Always read and follow the operating procedures before using electrical
equipment.
• Keep your hands and clothing away from moving parts of electrical tools.
• Avoid contact with electrical tools using wet hands and water surroundings as it
leads to electrocution/shock.
• Do not connect multiple devices in a single outlet.
• When equipment is found to be faulty and at risk of harming other, it is important

to isolate it and attach a tag describing the fault.
• Ensure that the electrical tools are properly grounded before operating.
• Check the wiring for insulation cracks, as well as bare wires, before using it.
• Before plugging in an electric tool, make sure its switch is in the off position.
• Always turn off the tool before unplugging the tool.
• Never leave a running power tool unattended.
• When using a bench or floor grinding wheel, check the machine and the
grinding wheels for signs of damage before using them. If the wheels are
damaged, they should be replaced before using the machine.
• Although the safety guards are designed to prevent injury, one should still wear
safety glasses and/or a face shield while using the machine.
• Make sure there are no people or parts around the machine before starting it.
• Keep hands and clothing away from the moving parts.
• Maintain a balanced posture while using the machine.
Lift Safety
When working with lifts, make sure that hoist plates and adapters are positioned
properly on twin post and rail type lifts to avoid damage to the underbody of the
vehicle. Raise the lift till the supports contact the vehicle, once the lift supports are
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appropriately positioned. Inspect the support to ensure that the vehicle is in full
contact with the support. To confirm the safety of the vehicle, shake the vehicle and
then raise the vehicle to the required height.
8.4 Vehicle lifting equipment safety
8.4.1 Vehicle hoists
These portable devices are used as a lifting equipment to carry heavy loads. Failure
of these lifting equipment can cause crash injuries or fatalities. Moving vehicles on
and off hoists also presents potential hazards.
Safety measures -
• Jack must be placed securely under the vehicle and used only at correct jacking
points. Incorrect jacking point will lead to vehicle topple.
• Train the operators in safe use of hoists and ensure that they do not work under a
suspended load without checking whether the safety features are engaged and
operating correctly.
• Prominently display equipment operating and maintenance instructions as well as

safe working load.
Figure 35: Vehicle hoist
• Ensure hoists have a valid design registration number issued by a worker health
and safety regulator in Australia.
• To avoid worker entrapment, ensure that moving parts of the hoist or its load are
located at least 600mm away from other fixed structure or equipment that
moves.
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• Ensure that operator controls are undamaged, clearly marked and positioned for
effective, safe use.
• Check that the safety prop is fitted to any in-ground, hydraulic hoist.
• Conduct pre-operational inspections daily i.e., look for leaks in hydraulic and
pneumatic components.
• Inspect and maintain the hoist at least every 3 months.
• Arrange for a comprehensive annual inspection to be carried out by an

independent, qualified, competent person.
• Ensure electrical hoists and wirings are tested with reference to Australian
Standard AS/NZS 3000- Australian wiring rules.
• Record all inspections, servicing and maintenance in a log book which is

available for all users, maintenance or inspection personnel.
8.4.2 Vehicle jacks
A vehicle jack lifts up a vehicle by using the power of hydraulics and allows the
technician to change a tyre or perform repairs or maintenance. These portable
devices require experience in their placement before use to minimise risk to the
operator.
Associated risks include the sudden fall of vehicles due to overbalancing, incorrect
use of jacking points, poor maintenance or leaking hydraulic fluid, and use of jacks
on surfaces that are not level or firm.
Figure 36: Lifting equipment - Jack
Safety measures –
• Jack must be placed securely under the vehicle and used only at correct jacking
points. Incorrect jacking point will lead to vehicle topple.
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• Train the operators in the correct and safe use of the equipment ensuring that –
➢ Jacks are based on a firm, level and secure surface preferably concrete
➢ vehicle stands are used when a vehicle is raised and wheels are chocked
➢ nobody remains in a vehicle that is being jacked
➢ nobody places any portion of their body under a vehicle supported by a jack
• Prominently display equipment operating and maintenance instructions, as well

as the safe working load.
• Never use a lift or jack to move something heavier than it is designed for. Always
check the rating before using a lift or jack. If a jack is rated for 2 tons, do not
attempt to use if for a job that require a 5 ton jack. It is dangerous for you and the
vehicle.
• Conduct daily pre-operational equipment inspections.
• Inspect and maintain the jack at least every 3 months, in accordance with the
manufacturer’s instructions, to ensure it can be manoeuvred effectively.
• Record all inspections, servicing and maintenance in a log book which is

available for all users, maintenance or inspection personnel.
8.4.3 Vehicle stands/Jack stands
Vehicle stands are also a type of lifting equipment which helps to get a tyre
changed and perform any repairs. Common risks arise when stands are poorly
placed or stored and maintained.
Figure 37: Vehicle jack stands
Safety measures –
• Do not work under a vehicle that is supported only by a jack, since stands are
used to support the vehicle after it is being raised by a jack.
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• Conduct pre-operational inspections daily.
• Ensure axle stands are based on a solid (such as chassis member, frame, axle
housing), level and secure surface preferably concrete.
• Do not adjust stand heights when they are bearing weight.
• Mark ramps and stands with rated safe working load.
• Only use ramps and stands in pairs.
Safe working load (SWL)
Safe working load is the maximum force that a lifting equipment or device can
place to lift the vehicle. All lifting and supporting equipment must have the safe
working load marked on them in kilograms or tonnes. The manufacturer marks the
working load which should never exceed.
Safety - The safe working load should be correctly marked on the lifting and
supporting equipment and it is important to make sure it is not exceeded.
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9 Vehicle safety
It is important to keep the work environment safe to promote an employee to focus
on their works instead of the hazard. Safety decreases injury and also lost work hours.
Safety measures help by protecting the staff along with the customer’s vehicle which
they are repairing.
9.1 Engine moving parts
Engine moving parts include drive belts, pulleys and fans.
• Do not wear loose clothing while working on running engine parts such as belts,
pulleys & fan.
• Engine fan could start running at any time when the engine is ON, so cautious
attention is required.
• Make sure the vent system is tuned on before running the engine. If the work area
does not have an exhaust venting system, use a hose to direct the exhaust out of
the building.
• Block the wheels to prevent the vehicle from moving.
• When an engine is running, make sure that hands or clothing do not affect any
moving parts.
• A long belt is seen in many engines which are driven by a number of pulleys. Care
should be taken while working on the belt.
• Electric fans are temperature controlled, so can start at any time without warning.
• Instrument cluster must always be checked before working on the vehicle.
• In case of modern vehicles, the engine might start at any time, if the vehicle is in
the ON position. Make sure the engine is properly turned off.
• Remove tools and equipment from the engine bay before starting the engine.
• Minimize the risk of inhaling toxic fumes by ensuring adequate ventilation.
• Ensure long hair is tied back or contained in a hair net.
45
Figure 38: Vehicle engine
9.2 Electrical system (high current wiring system)
• Ensure removal of ground connections
• Avoid wearing jewelleries while working on ignition system
• Do not work on electrical system with wet hands
• Never use metal screw drivers with naked or bare wires
• Always wear appropriate personal protective equipment while performing

repairs or diagnosis.
• Always wear shock resistant safety footwear and rubber gloves while working on
the electrical systems
• Always stay cautious while working on batteries; never connect the terminals as
this may lead to explosion of the battery and cause injuries.
• Always wear chemical resistant gloves and safety glasses while working with the
battery acid, as it is hazardous and may lead to burns.
• Always use insulated tools while working on the electrical components.
9.3 Engine cooling system and exhaust system components
Hot engine and exhaust system may cause severe burns.
• Do not remove the radiator cap when the engine is hot.
• Wear proper clothing and eye protection while using coolant additives.
• Ensure that Engine ignition is off while working with cooling fan, pump or belts.
• Do not touch hot components.
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• Before working on exhaust system, the engine should be cooled down.
• Wear googles to protect from rusted metal chips.
• Always use Exhaust Extractor if engine is running.
• The exhaust manifold and other components of the system reach very high
temperatures. The parts must be allowed to cool to prevent burns.
• Wear safety hand gloves and protective overalls when handling the hot
components.
• Always wear goggles as exhaust system parts are always rusty. When turning the
rusted bolts, the hot metal chips get dislocated and may cause injury or burns
because of their sharp edges.
Figure 39: Safety goggles
9.4 High voltage ignition system
Ignition system generates a very high voltage which ignites the air-fuel mixture. Care
must be taken as these systems run on very high voltages. Contact with live parts
causes shocks, burns, fires or explosion.
• Ignition switch should be turned off while working on vehicles.
• Make sure to disconnect the battery because ignition system produces excessive
high voltage.
• Avoid wearing jewelleries while working on ignition systems.
• Avoid contact with any part of the ignition system while the engine is running.
• While working on the high voltage systems, the personnel should be qualified in
handling high voltage systems in vehicles and must follow appropriate
procedures instructed by the manufacturer.
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• One should be trained in identifying high voltage components and wiring.
• The technician should be trained in using and maintaining protective equipment

suitable for high voltage systems. They must refer to manufacturer information
while using protective equipment.
➢ Personal protective clothing: dry-electrical High Voltage safety rubber gloves,

safety goggles, electrical hazard safety shoes and acid resistant apron.
➢ High voltage rubber insulation mats
➢ High voltage insulated tools
➢ High voltage insulated stick.
• The high voltage system may remain powered up for up to 10 minutes after being
disabled. The method of disabling the high voltage system is manufacturer
specific.
• Never touch or cut or open any orange high voltage power cable or high
voltage components without wearing personal protective equipment.
• Do not cause any physical impact on the battery as the electrolyte is flammable.
The electrolyte may be flammable and/or toxic and can damage human tissue.
• Do not have any metal objects in your possession while working on the batteries.
• Components with a strong magnetic field are used in the vehicles. Operators with
a medical electric device such as pacemakers must not carry out electronic
diagnosis as strong magnetic fields can affect the function of the device.
• Never spray water or any liquids on to the electrical systems.
• Hybrid vehicles have higher voltages. Follow safety precautions and service
procedures when working with high voltage circuits for avoiding personal injury.
Safety measures while wearing jewellery and watches
Jewellery and watches are made of electricity conducting materials hence they
cause electrical shocks. The jewellery and watches are prone to heating quickly
while working on the electrical systems which leads to burning and catching up fire
for the external resources.
• To be safe, always remove watches, rings, and jewellery before starting work. Not
only is it safer to remove these items, but your valuables will not get damaged or
lost.
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• Don't wear any jewellery or other articles that could accidentally contact circuitry
and conduct current, or get caught in moving parts.
Figure 40: Jewellery and watches
9.5 Batteries
A motor vehicle battery activates the starter and ignition system. If handled wrongly,
batteries cause serious hazards such as severe skin burns. The fumes released may
cause a battery explosion.
• Disconnect the negative terminal of the battery.
• Use a battery carrier or a lift for carrying the battery.
• Disconnect the battery terminals before charging, to avoid damage of electrical

components.
• Sparks and flames should be avoided from the battery surroundings when it is in
charging mode.
• Wear Eye protection while handling batteries, to escape from the gases.
• Safety goggles must always be worn to protect the eyes from any splashes.
• Check the manufacturer’s instructions, including Safety Data Sheets, for

electrolyte spill containment, clean-up and disposal details.
• Regularly check batteries for signs of physical damage or deterioration.
• Ensure that the jumper cables are rust and corrosion free with no exposed wires.
• Keep naked flames and sparks away from the battery, as batteries contain
hydrogen gas.
• Ensure spill containment and first aid facilities are available in case of an incident.
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• Always store the battery upright.
• Avoid skin or eye contact with the battery electrolyte.
• Avoid short circuiting the terminals.
• Make sure metallic objects are not dropped on a battery as spark can ignite the
gases produced by the battery.
• Sulphuric acid stored inside the battery might spill from the vents, when it is
squeezed. A battery carrier should be used whenever available and always
handle the battery with extra care.
• Old batteries must be disposed appropriately.
Figure 41: Gloves while working on batteries
9.6 Vehicle fuel
Vehicle fuel includes petrol, diesel and other natural gases. Fuel used in motor
vehicles is flammable when mixed with air and may produce an explosive mixture.
Petrol is the most dangerous flammable fuel in an auto shop.
• Depressurize and drain the fuel lines before disconnecting them.
• Make sure to disconnect the battery because fuel system produces excessive
high voltage.
• Collect the dripping fuel in a tray.
• Fuel spill kit should be ready in case of emergency.
• Petrol and other flammables must be stored in approved, sealed containers.
• Wrap a shop rag around the fitting to keep fuel from squirting or leaking when
disconnecting a vehicle’s fuel line or hose.
• Fuel spills must be cleaned immediately.
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• Oil absorbent (oil-dry) should not be placed on petrol as the absorbent will
become highly flammable.
• Any source of heat must be kept away from fuel system parts.
• Vehicle fuels should never be used as a cleaning solvent.
• When the vehicle has LPG fitted, never work over a pit.
LPG and Natural Gas
• Since LPG is high density, it should be stored in low areas and Natural gas to be
stored in high areas.
• Ensure proper ventilation while working with them.
• Before removing any component, purge the gas from the tank.
• Gases must be cleared out before working on it.
9.7 Hybrid Vehicle safety
Hybrid vehicles run only on a combustion engine or an electric motor or a

combination of both. Hybrid vehicles use a high voltage motor generator and a
battery. Because of this high voltage range up to 650V and 60 amps instantly,
electrical energy is produced which is sufficient to cause serious injury and
electrocution.
• Five minutes of waiting period must be given while working on hybrid system
before disconnecting the high voltage cables.
• Usage of electrical insulating gloves
• Always use insulated tools.
• Use only the tools and test equipment specified by the manufacturer and follow
the test procedures defined by the equipment manufacturer.
• It is important to follow the vehicle manufacturer’s instructions and safety rules

when working on a specific model.
• Orange means high voltage. Orange-coloured high-voltage connections in a

hybrid vehicle. A trained technician needs to wear special gloves rated for 1000
volts when disconnecting these cables.
• Rubber electrician gloves should always be worn when working on a high voltage
hybrid drive system. The gloves prevent any electric shock if accidentally touched
a conductor carrying high voltage and current.
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• Near the output cables of the battery pack, most of the hybrids consist of a main
power cut-off switch or a kill switch. This switch allows the worker to electrically
disconnect the battery pack from the remaining hybrid drive system.
• The switch should be turned to the off position prior servicing a hybrid drive
system.
Figure 42: Safety equipment for handling hybrid vehicles
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10 Handling and storage

Maintenance of a hazard free workshop is the responsibility of both the employer
and employee. A well-managed workplace gains client’s trust and may lead to visit
the place again.
To minimize the risk of accidents and pollution to the environment, it is important that
safe work practices are carried out by all the members of the workplace. Safe work
practices are the instructions for the safe execution of the work.
Safe work practices outline on how to perform a job with minimum risk to people,
materials, equipment. It also makes sure that job follows risk-control, legislative and
regulatory requirements of the automotive industry.
10.1 Safety data sheet (SDS)
Figure 43: Safety data sheet
It is a sheet that contains the information for chemicals used in workshop. It consists
of the following details –
• Safe handling procedure
• Storage procedure
• Manufacturer chemical ingredients details
• Physical properties
• Precautions
• Safety handling
53
Information to include in safety data sheets
SDS must provide information on the:
➢ Hazards of the chemical and how to handle it safely, including storage and
disposal.
➢ Physical and chemical properties of the chemical, as well as potential health and
emergency response measures.
➢ Environmental effects of the chemical.
This information must be set out using the following section headings, with further
detail available in the model Code of Practice for the Preparation of Safety Data
Sheets for Hazardous Chemicals:
Section 1—Identification: product identifier and chemical identity
Section 2—Hazard(s) identification
Section 3—Composition and information on ingredients
Section 4—First aid measures
Section 5—Firefighting measures
Section 6—Accidental release measures
Section 7—Handling and storage, including how the chemical may be safely used
Section 8—Exposure controls and personal protection
Section 9—Physical and chemical properties
Section 10—Stability and reactivity
Section 11—Toxicological information
Section 12—Ecological information
Section 13—Disposal considerations
Section 14—Transport information
Section 15—Regulatory information
Section 16—Any other relevant information.
54
Chemicals that need safety data sheets
• chemicals in batteries while they are incorporated in plant
• fuel, oils or coolants in a container that is fitted to a vehicle, vessel or aircraft,

mobile plant, appliance or other device, where the fuel, oils or coolants are
intended for its operation
• fuel in the fuel container of a domestic or portable fuel burning appliance where
the quantity of fuel does not exceed 25 kg or 25 litres
• hazardous chemicals in portable fire-fighting or medical equipment for use at a

workplace.
10.2 Storage of goods or material
Proper storage of goods is important in the prevention of workplace accidents.

Never store them on stairs, platforms or floors as these areas must be kept clear at all
times, to ensure a safe passage in the event of an emergency. Storage of material
must include –
a) The storage shelving should be strong, secure and not overloaded.
b) The item should be stored upright, particularly when storing batteries.
c) Heavier items or fragile components should be stored on the bottom shelves or

steel rack.
d) Items should not protrude out from the shelves/steel rack.
e) The shelving/steel rack should be organised to allow easy access.
f) The storage instructions provided by the manufacturer should be followed.
Figure 44: Goods stored in automotive workshop
55
g) Material should be stored correctly in the place labelled as dangerous goods

area.
h) Tools and equipment should be correctly stored in the designated areas.

Damage to tools and equipment may lead to a decrease in production,
increased costs and inconvenience to the customer, and expensive cost of
repairs/replacement for the workshop.
10.3 Handling and storing the flammable substances
Flammable substances cause fire hazards and must be properly stored. Storage
procedure includes –
Figure 45: Storing flammable substances
a) Dangerous tools and equipment should be stored in an appropriate sealed and

labelled container.
b) Protective clothing must be worn when handling and storing dangerous goods.
c) A register of dangerous substances stored should be maintained.
d) The storage area must be fire proof and with proper ventilation.
e) Make sure a fire extinguisher is always present in the storage room.
10.4 Handling and storing hazardous chemicals
Isocyanates are chemicals used to make polyurethane paints, sealers, adhesives

and lacquers. Isocyanate fumes are invisible but can smell the fumes when they
reach the safe limit.
It is important that when working with paints and lacquers the correct safety
equipment is worn and that you are familiar with the emergency and first aid
procedures. The code of practice that deals with isocyanates should also be
consulted.
56
Isocyanates cause many hazards which are mentioned below along with their first
aid treatment.
a) Splashes in the eye – Leads to irritation, permanent damage of eyes. Wash eye
immediately with lot of water and continue for 15 mins. Seek medical assistance
as the chemical can cause permanent damage to the eyes.
b) Breathing the fumes – Severe irritation of the nose, throat and lungs. Can lead to
bronchitis or pneumonia. The person has to be taken outside immediately and
provide ventilation. Seek medical help.
c) Splashes on the skin - Reddening, swelling and blistering. Also lead to dermatitis.
For little splash, wash it off with soap and water and for heavy splashes, wash the
area with a hose or take a shower.
• Chemicals should always be stored in glass containers clearly labelled.
• Use appropriate gloves while handling chemicals.
• Always store chemicals close to the fire extinguishers and far from welding areas.
10.5 Handling and storing oil
• Never leave the lids open when oil is not in use.
• Different grades of oil must not be mixed.
• Oil should be clearly labelled and stored in covered areas and oil barrels must be
placed securely in bunded area.
10.6 Handling and storing chemical spills
Chemical spills are very dangerous and has to be handled carefully.
a) Use a chemical spill response kit or circle the spill area with an absorbent material.
b) Ensure that adequate ventilation is available.
c) Try to identify the material spilt. Check the container and read the advice for
dealing with a spill. Follow the instructions provided.
d) If the spill cannot be identified or is hazardous inform co-workers, supervisor and

evacuate the area. Contact the fire service and provide as much information as
possible about the material and the scale of the spill.
e) If the spill can be dealt with, cover the spill with absorbent material and when
soaked up, dispose the material in an empty container, similar to the source
57
container. Take particular care when disposing of acids. The container used must
be acid resistant.
f) Store the container safely for chemical collection.
10.7 Handling and storing hazardous gases
There are four potentially hazardous gases that workshop staff may encounter in
automotive workshops. They are –
a) Acetylene – A colourless gas that is highly flammable and is used for welding and
cutting tasks. It can be recognised by its garlic smell.
b) Carbon dioxide - A colourless and odourless gas that is used for welding and as a
fire extinguisher. Over exposure can lead to asphyxiation.
c) Liquid petroleum gas (LPG) – Also a colourless gas that is highly flammable and is
used as fuel for vehicles, for heating and for refrigeration. It is heavier than air and
can be recognised by its odour.
d) Compressed natural gas (CNG) – This is a colourless gas that is flammable and is
used as fuel for vehicles. It is lighter than air and can be recognised by its gaseous
odour.
10.7.1 Handling acetylene and carbon dioxide leak
➢ If possible, turn off the master shut off valve to close the gas flow. The shut valve is
located at the top of the cylinder.
➢ Inform co-workers, supervisor and evacuate the area.
➢ Shut down all potential ignition sources.
➢ Move the equipment and cylinder to the outer area.
➢ Pump the inert gas into the system and perform the leak test using soapy water. If
the cylinder is leaking and cannot be shut down slowly vent the cylinder, ensuring
that there are no ignition sources.
10.7.2 Handling LPG or CNG
➢ If possible, turn off the master shut off valve to close the gas flow.
➢ Inform co-workers, supervisor and evacuate the area. Shift the source outside.
➢ Shut down all potential ignition sources. If the leak is large, contact the fire service
immediately.
58
➢ Do not touch the spill as it might lead to cold burns.
➢ Ventilate the area well before re-entering the workplace.
➢ If any repairs to CNG or LPG system are required, they must be carried out by an
authorised CNG/LPG repairer.
10.8 Handling and storing cylinder
➢ Cylinder should be stored in an upright position in a well-ventilated area such as a

dangerous goods store.
➢ They should be kept away from hot surfaces or flammable materials and ignition
sources which might produce a spark.
➢ Cylinders should not be dropped or handled in such a manner that might

damage the filler.
➢ Leaking cylinders which cannot be stopped should be placed outdoors and are
repaired.
Figure 46: Cylinders at workplace
10.9 Handling and storing cleaning products
➢ Referring Safety Data Sheet (SDS) for handling of chemicals.
➢ Ensure proper storage and transportation of chemicals.
➢ Washing vehicles, degreasing motors, parts cleaning and other activities

generate waste water. This water must not be allowed to drain to stormwater
drains, street gutters or any waterway.
➢ All washing and cleaning should be carried out within a wash bay that is either
connected to the sewer under a trade waste agreement or fitted with a water
treatment and recycling system.
59
➢ Contact the local council and water authority to discuss requirements for wash
bay construction.
➢ Hand washing should be carried over a sink that is connected to the sewer
system, not under a tap where water run off to the environment.
➢ Outdoor areas that drain to the stormwater system should be hosed down as
means of cleaning.
➢ Cleaning parts using solvents such as kerosene should be carried out in a

dedicated part cleaner. It should be located within a bunded area.
➢ Minimise the use of solvents by using water-based washing or checking the

suitability of an ultrasonic cleaner.
10.10 Handling and storing of brake fluid
Brake fluid is made from polyglycol, which is water soluble, and can be considered
hazardous if it has absorbed metals from the brake system.
➢ Never leave the lids open when brake fluid is not in use.
➢ Never let the moisture enter the brake fluid.
➢ Brake fluids are to be kept away from sunlight and moisture.
➢ Brake fluids should be stored in a protected area, and in the respective labelled
containers with proper sealing.
➢ The brake fluid is collected in a clearly designated container without spilling the oil
on the floor.
➢ As the used brake fluid is hazardous, follow the safe work practices while handling
the brake fluid.
➢ Ensure that the trapped oil is stored in the labelled leak proof container
recommended by the local EPA authorities.
➢ Do not mix the brake fluid with the other oils.
➢ The filled oil containers are sent for recycling or disposal to the licenced recycler.
➢ The containers are transported to the recycler carefully.
➢ Recycle brake fluid through a registered recycler.
60
10.11 Handling and storage of brake dust
Brake dust comprises of asbestos which is harmful when it is inhaled.
➢ Before opening the braking components, spray water to avoid air borne particles.
➢ Brake dust should not be inhaled or contacted with the skin.
➢ Use the industrial vacuum cleaner to collect the brake dust.
➢ Since it contains asbestos, it must be packed and disposed at approved sites

only.
➢ Never blow the brake dust or use an air hose for cleaning.
➢ Brake dust should not be cleaned with a dry brush, wet brush, solvent spray or rag.
➢ Old brake pads and shoes must be placed in a plastic bag. The bag must be
double tied and stored in a leak-proof, air tight container.
➢ Brake linings should never be ground as it produces huge amounts of brake dust.
Instead slow lathe turning will perform the same task with less dust.
➢ All machinery must contain a HEPA equipped local exhaust dust collection system
which prevents asbestos exposure and workshop contamination.
10.12 Handling and storing hand tools
Various hand tools are used in automotive like wrenches, files, cutters, pliers, striking
tools, hammered tools, screwdrivers etc. The main function of these hand tools is to
enable safe, accurate and quick work.
Selection of appropriate tools is important for the specific task. Tools might get
damaged if an incorrect one is used. So, should use the tools only for their
appropriate purpose. All the workers must also be trained on handling the tools.
a) The tools used in an automotive workshop should be cleaned, maintained and

returned to their respected storing area after use. This will provide easy access for
everyone.
b) The tools and equipment should be kept in safe working order so that they are
readily available for use.
c) Make sure to repair the fractured tools. Replace the tools if they are beyond
repairing.
61
d) Ensure that tools are kept clean and free from grease or oil. This will prevent the
grease or oil from being transferred to the customer's vehicle and will also assist
the technician to maintain a firm grip of the tool.
10.13 Disposal of workshop waste
Workshop waste or rubbish is also considered to be a hazard and must be removed

from the work area. The waste materials in workplace includes –
➢ Scrap paper, plastic and cardboard - These are all potential fuels for fire
➢ Oil soaked rags - These are highly flammable
➢ Broken glass – These have sharp and dangerous edges
➢ Used car parts such as exhaust pipes, fuel filters, window glass, and damaged
panels – The parts can be flammable or have sharp and dangerous edges
➢ Broken tools and equipment such as hack saw blades and drill bits – These also
comprise of sharp edges
➢ Machine swarf – Can cause cuts
➢ Flammable liquids and gases
Disposal of wastes -
Waste products that are potentially flammable or that have sharp dangerous edges
must not be left in the workshop.
• Any flammable liquid or gas containers must be stored in the dangerous goods
store until they can be collected by the recycling agent.
• Used car parts should be taken to the workshop recycling bin.
• Scrap paper, plastic and cardboard materials should be placed in the workshop
rubbish bin
• Broken glass should be wrapped in paper and placed in a steel workshop rubbish
bin.
• Make sure protective clothing such as overalls; safety gloves and safety footwear
are worn when disposing the waste materials.
62
Figure 47: Personal protective equipment
63
11 Emergency evacuation procedure

An emergency is an unplanned event that has the potential to harm the life, health,
or safety of a person, or to damage the environment or public property.
There are many types of emergencies occurring at a workplace.
• Fires and explosion
• Severe weather
• Hazardous material spills
• Terrorist activity
• Electrocution
• Utility outages
• Structural damages
Australian standard AS 3745 – planning for emergencies in facilities helps in

identifying risks that initiates the preparation of emergency plan. This Standard
outline the minimum requirements for the establishment, validation and
implementation of an emergency plan for a facility to provide for the safety of
occupants of that facility and its visitors leading up to, and during an evacuation.
Every employee must assemble in the assembly point area after the emergency
alarm goes off. A key staff who has been trained to handle evacuation of
individuals, signs throughout the building leading to exit points in case of
emergencies (for example, fire) must co-ordinate the evacuation process. Everyone
must be aware of general emergency contact numbers such as fire service,
Ambulance and police.
Every workplace requires an emergency response plan. The plans will differ based
on the size and complexity of the emergency. An effective plan must consider the
below mentioned steps:
A) Assessment or hazard identification – How the hazard has happened and

consequences has to be assessed.
B) Emergency resources – Verify the resources that are available for the hazards that
are identified. Call 000 to inform about the emergency. The tripe zero (000) service
is used to contact Police, Fire or Ambulance services in life threatening or
emergency situations.
It is important to maintain on-site resources like fire extinguishers, spill contaminant

equipment and first aid kits.
64
Emergency escape procedures and route assignments, such as floor plans,

workplace maps, and safe or refuge areas;
C) Communication system - Various communication systems are present in the site to

enable emergency services and to be contacted without delay. Emergency
phone numbers along with the site address or location should be posted next to
the emergency phones. Speak clearly so that the emergency services must
understand to what you are saying.
Figure 48: Training staff on fire evacuation plan
D) Administration of the plan – Supervisor or the person in charge of the emergency

response plan should make sure that –
• There are sufficient emergency resources available
• An evacuation policy and procedure
• The roles and responsibilities are understood by everybody like who should shut
down or who should handle the fire extinguisher etc.
• On regular basis, the plan has to be monitored and reviewed. The plan must be
reviewed after emergency as well.
E) Emergency response procedures – The basic steps for emergency responses are –
• Stay calm – Make sure you remain calm as your behaviour might influence
others.
• Take command – Take charge of the situation. Call the emergency services or
ask someone to call.
• Assess the situation – Determine what has happened at the situation with
utmost caution and try to remove or control the cause of the emergency. This
will reduce any further danger to others and injured worker. Make sure to give
first aid to the injured workers.
65
• Provide protection – The area has to be secured such that any further losses
can be avoided. Help to control fire, prevent objects from falling, shut down
equipment, and divert traffic. Victims, equipment, materials, environment must
be protected from further hazards.
• Preserve the incident area – Erect appropriate barricade, ropes at the incident
area. Do not disturb the area except for saving a life or relieving human
suffering or to prevent immediate losses.
• Follow procedures – The procedures mentioned in the emergency plan must be

followed. Mange people at the area by giving them first aid or help the people
who are already providing the first aid. Workers must be sent to safe location
and dispatch personnel to guide emergency services on arrival.
11.1 Designated personnel to report in emergencies
a) Supervisors – Supervisor will plan an evacuation procedure and assign the

responsibilities to the workers. Supervisor also provides resources to ensure that the
procedures are implemented properly.
b) Safety officers – Safety officer have specific training skills which help in identifying
the source to reduce the loss. Required actions will be taken to decrease further
hazards. Safety officer will coordinate with the supervisor and help in shifting the
workers to a safe area.
Figure 49: Designated personnel to report emergencies
c) Emergency medical service personnel – They provide immediate care to the

critically ill and injured. They give CPR, control bleeding and take care of burns.
They assess the nature and extent of injury and also assess the hazardous material
to provide decontamination techniques.
d) Firefighters – Firefighters recover and manage the hazardous, toxic and

flammable materials. Carry out building inspections to prepare risk assessments
66
and pre-incident plans. They also provide basic first aid until an emergency
service provider arrives.
11.2 Evacuation procedures
Evacuation is the process of moving people from a dangerous place to a safe

place. Several kinds of emergencies will lead to an evacuation. It is important to
prepare a proper evacuation plan.
Evacuation plans benefits and organise both employer and employee actions when
needed. The plan must be clear and easy to understand and should not lead to
confusion, as it may result in injuries and damage.
The plan comprises of the evacuation procedures, the roles and responsibilities of
every individual, escape routes etc.
Fire warning alarms must be installed in all the buildings to decrease the severity of
workplace accidents. The alarms alert the people in the workplace to any fire
outbreak before it becomes life threatening. The warning alarms must provide a
sound level which is clearly heard throughout the workplace. All the workers must be
accustomed with the warning alarms.
Figure 50: Fire alarm
Providing training to the staff – Organisations should train the workers and explain the
evacuation procedure. This helps in organising and coordinating the action. Workers
are informed to follow the evacuation procedure in a step wise manner keeping in
mind that safety is always the first priority. Make sure emergency evacuation drills
are taking place regularly.
67
Figure 51: Training staff on fire hazard
Employer’s role in emergencies evacuation process:
• Ring the alarm and inform employees to evacuate the area.
• Alert the designated personnel i.e., firefighters, superior staff, emergency medical
service providers etc.
• Assist any worker in immediate danger.
Figure 52: Fire evacuation sign
Employee roles:
• Workers must identify the alarm sound or signalling method of fire evacuation.
Also, should know the location and usage of alarms.
• They should be trained in worksite emergency evacuation plan.
• Employees must know who to contact in an emergency and how to contact

them.
• Must follow the evacuation plan and should be prepared for any kind of
situations.
68
11.3 Accident and incident documentation
All the workplace accidents have to be properly documented to prevent work

related injuries and deaths. Notifying the concerned personnel will help identify the
cause of accidents and prevent similar incidents at the workplace.
A notifiable incident is –
• A death of a person
• A serious injury or illness
• A dangerous incident
Only the most serious health or safety incidents that are work-related are notifiable.
Serious illness or injuries like burns, spinal injury is notified if the person requires
immediate treatment.
Once the incident has been notified, it has to be immediately informed by the
fastest possible means – which could be by telephone or in writing i.e., an email.
The following information is usually requested for a follow-up investigation.

What happened: an • Provide an overview of what happened.
overview
• Nominate the type of notifiable incident—was it
death, serious injury or illness, or ‘dangerous
incident’ (as defined above)?
When did it happen Date and time.
Where did it happen Incident address.
Details that describe the specific location of the

notifiable incident—for example section of the
warehouse or the particular piece of equipment that
the incident involved—to assist instructions about site
disturbance.
What happened Detailed description of the notifiable incident.
Who did it happen to • Injured person’s name, date of birth, address and
contact number.
• Injured person’s occupation.
• Relationship of the injured person to the entity
69
notifying.
How and where are they • Description of serious injury or illness—i.e. nature of
being treated (if injury
applicable)
• Initial treatment of serious injury or illness.
• Where the patient has been taken for treatment.
First aid
It refers to the immediate assistance to any accident or health sickness in the

workplace. A workshop with at least one fully trained personnel is required to provide
first aid in case of an emergency.
70
12 References
http://jobsafesa.asn.au/?page_id=367
https://www.safework.sa.gov.au/sites/default/files/automotiveworkshopsafetyguide
book.pdf?v=1554168338
https://www.education.vic.gov.au/Documents/school/students/beyond/automotiv
eprint.pdf
https://www.safework.nsw.gov.au/safety-starts-here/safety-overview/emergency-
plans
https://www.safeworkaustralia.gov.au/slips-trips-falls
www.safeworkaustralia.gov.au
http://www.ohs.net.au/
https://www.safeworkaustralia.gov.au/system/files/documents/1702/how_to_manag
e_whs_risks.pdf
https://www.worksafe.vic.gov.au/hazardous-manual-handling-safety-basics
https://www.safeworkaustralia.gov.au/incident-reporting
* All images are taken from Google and clipart
71

AURASA002 - Follow Safe Working Practices in An Automotive Workplace

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AURASA002 - Follow Safe Working Practices in An Automotive Workplace

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Follow safe working

It applies to those working on agricultural machinery, heavy commercial vehicles,

No licensing, legislative, regulatory or certification requirements apply to this unit at

Elements and Performance Criteria

1.1. Workplace procedures relating to Page 3

1.2. Unsafe situations and hazards are Page 6

1.3. Machinery and equipment breakdowns Page 39

1.6. Workplace manual handling procedures Page 21 - 23

1.7. Participation in any WHS consultative Page 32 - 34

2.1. Workplace emergency procedures Page 64 - 70

emergency use and application

2.4. Qualified persons are identified for Page 66, 67

2.5. Accident and incident documentation Page 69, 70

• Basic aspects of relevant state or territory WHS or OHS

o employer responsibilities for workplace practices Page 4, 5

o employee responsibilities to participate in WHS practices Page 5

o employee responsibility to ensure own work practices Page 5

• Purpose and structure of WHS or OHS workplace Page 3 - 5

• Personal safety in an automotive workplace, including:

o hearing protection Page 16, 17

o skin protection Page 17, 18

o protective clothing Page 18

o protective footwear Page 18, 19

o eye protection Page 15

• Manual handling, including:

o storing items Page 56 - 62

o planning the lift Page 21 - 23

o using correct lifting techniques and equipment Page 22, 23

• Workplace practices, including:

o housekeeping Page 25, 26

o observing personal hygiene Page 26, 27

o identifying slip hazards and trip hazards Page 24, 25

• Meaning of WHS or OHS symbols and signs Page 35 - 37

• Machine and equipment safety, including:

o using compressed air Page 38, 39

o using machine guards Page 39, 40

o electrical tools, including:

✓ checking before use Page 40

✓ faulty equipment tagging and isolation procedures Page 40

✓ dangers of using electrical tools around water Page 40

o vehicle lifting equipment, including:

✓ using jacks and stands Page 42 - 44

✓ using hoists Page 41, 42

✓ safe working load (SWL) of jacks and hoists Page 44

• Vehicle safety, including:

o engine moving parts Page 45, 46

o engine and exhaust hot components Page 46, 47

o electrical hazards associated with:

✓ high voltage ignition systems Page 47, 48

✓ wearing jewellery while working around high current Page 48, 49

o batteries Page 49, 50

o high voltage in battery electrical and hybrid vehicles Page 51, 52

• Hazardous materials, including handling and storing:

o brake fluid Page 60

o brake dust Page 61

o chemicals Page 56, 57

o cleaning products Page 59, 60

o safety data sheets (SDS) Page 53 - 55

• Emergency procedures, including:

o personnel responsibilities Page 68

o evacuation procedures and assembly points. Page 64 - 70

3 Workplace hazards .................................................................................... 6