Shop Safety Lesson Plan
CTE Automotive Technology
60–75 Minutes Introductory Module
Shop Safety Lesson Plan
OSHA General Industry Standards, PPE Compliance, Chemical HazCom, and Lift Rigging Protocols
Standards
ASE / ASE-NATEF & OSHA 1910
Personal safety gear, hazardous chemical communication, and tool staging.
Essential Question
"How do professional technicians systematically eliminate catastrophic risk in a high-pressure, fluid, and mechanical environment?"
Core Policy
100% Mastery Required
Zero-tolerance compliance before operating any powered equipment or lifts.
Performance Objectives (SWBAT)
- • Inspect, select, and don OSHA/ANSI Z87.1 certified eye protection, proper footwear, and nitrile gloves prior to crossing the shop threshold.
- • Interpret & apply Safety Data Sheets (SDS) and GHS chemical pictograms to identify flammability, toxicity, and spill containment procedures.
- • Execute a pre-operational safety audit of a two-post hydraulic lift, verifying mechanical lock engagement, arm pad placement, and vehicle center of gravity.
PPE & Staged Materials
- • ANSI Z87.1 approved safety glasses with side shields
- • Nitrile chemical gloves & oil-resistant shop footwear
- • Class A/B/C/D dry chemical fire extinguishers (inspected)
- • Standard SDS yellow master binder & eyewash station
Critical Shop Hazard Vocabulary
Lockout/Tagout: Disabling power during servicing.
Pinch Points: Machinery points where body parts can get caught.
Flash Point: Lowest temp liquid ignites vapor.
Jack Stand: Mechanical safety backup under lifted load.
Pacing Part 1: Hazard Reality & Direct Instruction 00 – 30 Min
Phase 1: Real-World "Near Miss" Case Briefing (Hook) 10 Min
Instructor Protocol: Present real-world scenario: "A tech used a hydraulic floor jack without mechanical jack stands to inspect brake pads. The hydraulic seal blew under 3,800 lbs."
Discussion & Reality Check: Contrast mechanical locks vs. hydraulic pressure. Emphasize that fluids compress and seals fail; metal locks hold lives.
Phase 2: The Safety Triangle & PPE Walkthrough (Direct Instruction) 20 Min
Demonstration Checklist: Model the 4 foundational safety stations across the shop:
1. Eyewash 15-min continuous flush; hands-free lever test.
2. Fire Protocol PASS method (Pull, Aim, Squeeze, Sweep) & Class B/C.
3. HazCom & SDS GHS pictograms, solvent storage, oil rags in red cans.
4. Lift Locks Asymmetric arms, pinch hazards, mechanical click test.
CTE Automotive Program • General Industry Module Page 1 of 2 Shop Safety & Hazard Management Protocol
Shop Safety Lesson Plan (Continued)
Practical Hazard Audit, Rigging Simulation, 100% Clearance Rubric & Adaptations
Minutes 30 to 75
Pacing Part 2: Hands-On Hazard Audit & Lift Rigging 45 Min Total
Phase 3: The "Fatal Five" Live Hazard Hunt (Guided Inquiry) 20 Min
Students work in technician pairs conducting a live audit of a staged shop bay containing 5 deliberate violations: (1) uncoiled high-pressure air line across walkway, (2) unlabeled secondary solvent bottle, (3) cracked polycarbonate face shield, (4) vehicle on floor jack without jack stands, (5) oily rags outside fireproof container.
Pair Task: Document violation, cite applicable OSHA rule, and execute the physical corrective remedy.
Phase 4: Two-Post Lift Pre-Operational Demonstration (Skill Check) 15 Min
Each pair rotates to a certified lift station: identify manufacturer pinch points, position rubber lift pads on factory pinch weld points, raise vehicle 6 inches, perform the physical "bumper shake test", and visually verify secondary mechanical safety dogs lock before proceeding.
Phase 5: Shop Clean-Down Protocol & Safety Debrief (Closure) 10 Min
Execute 5S shop discipline: sweep bay perimeter, store air hoses on reels, return all PPE to sanitation rack, and complete the Safety Commitment Ticket.
Assessment: 100% Safety Clearance Standard
Prerequisite for Shop Lab Access
Disqualified (0–89%)
Misses any critical PPE rule or misidentifies lift lock status. Retesting required before touching tools.
Provisional (90–99%)
Mastery of physical PPE but needs minor review on secondary chemical labeling or SDS lookup speed.
Cleared Technician (100%)
Flawless demonstration of PPE, lift rigging, eye-wash operation, and safety agreement sign-off.
Support & Accommodations (ELL/IEP)
- • Pictographic GHS chemical reference badge attached to lanyard.
- • Color-coded lift arm alignment guides and bilingual safety placards.
- • Pair novice technicians with senior peer mentors for bay walkthrough.
Extensions & Advanced Techs
- • Electric Vehicle (EV) high-voltage protocol (orange cables, 1000V gloves).
- • NFPA 70E arc flash boundary assessment and service disconnect isolation.
- • Designate advanced student as designated "Shop Safety Officer" for the week.
Critical Shop Safety Misconceptions (Red Flags)
Dangerous Myth 1: "Safety glasses on top of the head or around the neck are fine when I'm just watching." Correction: Pressurized fluid sprays, exploding belts, and grinding grit travel across entire bays. Glasses stay on at all times.
Dangerous Myth 2: "A hydraulic floor jack is fine to hold the car for just a 2-minute quick check." Correction: Hydraulic seals blow without warning or noise. Never place any body part under a vehicle without mechanical jack stands.
CTE Automotive Program • General Industry Module Page 2 of 2 Shop Safety & Hazard Management Protocol
