SAFE CHEMICALS, SAFE PROCESSES SDS/MSDS Handling • Hazard Communication • Solvent Safety • Emergency Preparedness • OCP Development

Core philosophy

“An SDS sitting in a computer is information. An SDS converted into a safe work practice is control.”

This workshop would move participants through:

Chemical → Hazard → Exposure → Risk → Control → Emergency → Standard Work → Verification

MSDS = Material Safety Data Sheet
SDS = Safety Data Sheet

What’s the difference?

MSDS	SDS
Material Safety Data Sheet	Safety Data Sheet
Older terminology	Current internationally harmonised terminology
Formats varied between suppliers/countries	Standardised 16-section format under GHS
Often used historically in industry	Preferred/current terminology

Frequently used abbreviations:

SDS (formerly MSDS) – Safety Data Sheet

“MSDS is the old name. SDS is the current standard—but the purpose remains the same: to tell us what the chemical is, what hazards it presents, how to handle and store it safely, what PPE is required, and what to do in an emergency.”

The Chemical Abstracts Service (CAS) is a division of the American Chemical Society (ACS) that provides the world's largest and most comprehensive collection of publicly disclosed chemical and scientific research data

LEV - Local Exhaust Ventilation - An LEV system is an engineering control designed to capture and remove harmful airborne contaminants (such as toxic vapors, chemical fumes, and dust) directly at or near the source before they can spread into the workplace or be inhaled by workers.

DAY 1 — SDS, CHEMICAL HAZARDS & SOLVENT SAFETY

Activity: “What chemical do you work with?”

Give every participant a card:

Name one chemical/solvent that you personally encounter at work.

Then ask:

What is it?
Why is it used?
What is its main hazard?
What PPE do you use?
What would you do if it spills?
Where is its SDS?
When was the SDS last reviewed?

Most participants will discover that they know the chemical name, but not necessarily the control requirements.

Takeaway

“If I cannot explain the chemical's hazard, exposure route and emergency action, I am not yet controlling the chemical.”

MODULE 1 — Chemical Risk in Automotive Manufacturing

Chemical journey exercise

Show the journey:

Supplier

↓

Receiving

↓

Chemical Store

↓

Internal Transport

↓

Point-of-use Storage

↓

Mixing / Dispensing

↓

Production

↓

Cleaning

↓

Waste

↓

Emergency

Participants identify where the chemical can become hazardous.

Automotive examples

Paints
Thinners
Degreasers
Adhesives
Sealants
PU chemicals
Hardeners
Catalysts
Solvents
Cleaning chemicals
Battery chemicals
Welding gases
Hydraulic oils
Coolants
Laboratory chemicals
Waste solvents
Paint sludge

Activity: “Chemical Journey Risk Map”

Each group selects one chemical and maps:

Stage	What can go wrong?	Hazard	Existing control	Missing control
Receiving	Container damaged	Exposure/spill	Inspection	?
Storage	Incompatible storage	Fire/reaction	Segregation	?
Dispensing	Splash	Dermal/eye	Gloves	?
Usage	Vapour	Inhalation/fire	LEV	?
Waste	Wrong container	Fire/environment	Waste bin	?

Key takeaway

The SDS describes the chemical. The process determines the risk.

SDS REVEAL CARD

Chemical: Automotive Paint Thinner

What participants may initially think

Before showing the SDS, ask them to complete:

Question	“What I think”
Is it hazardous?
Main hazard?
Flammable?
Can I smell it safely?
Does PPE make it safe?
Can I use it near welding?
Can I store it anywhere?
What if it spills?
What if someone inhales it?
What chemicals must not be stored with it?

https://youtu.be/HCpskgjS1Gc?si=UeknfQ0YoKTKlDGB

THE SDS SAYS…

SECTION 1 — IDENTIFICATION

Product: Paint Thinner
Product type: Solvent / thinner for paints and coatings
Form: Liquid
Use: Paint thinning / cleaning, depending on product specification

Critical lesson

“Thinner” is not sufficient chemical identification.

Participants should ask:

Which thinner? Which manufacturer? Which product code? Which SDS revision?

SECTION 2 — HAZARD IDENTIFICATION

A representative paint-thinner SDS identifies hazards including flammability, skin/eye irritation and health effects associated with vapour exposure. Some formulations may have additional chronic-health classifications depending on their ingredients.

Typical hazard themes

🔥 Flammable liquid/vapour

⚠️ Skin/eye irritation

🫁 Harmful effects from vapour exposure

🧠 Possible nervous-system effects depending on formulation/exposure

🌱 Potential environmental hazard depending on composition

Signal word

May be:

DANGER

WARNING

depending on the specific product classification.

Trainer question

Ask:

“Did anyone say that the main risk was simply ‘chemical contact’?”

Then explain:

The risk may actually be a combination of:

Vapour + ignition source + ventilation + exposure duration + quantity + handling method.

SECTION 3 — COMPOSITION

This is where the exercise becomes interesting.

A representative published paint-thinner SDS lists a mixture containing petroleum distillates/Stoddard solvent and smaller quantities of components including mixed xylenes, trimethylbenzene, nonane, ethylbenzene and naphthalene.

Example training representation

Component category	Why it matters
Petroleum distillates	Flammability / aspiration concerns
Aromatic solvents such as xylene	Vapour exposure
Ethylbenzene	Health hazard considerations
Other hydrocarbons	Fire/exposure/environmental concerns

BIG LEARNING MOMENT

Ask:

“When the container says PAINT THINNER, does that mean it is one chemical?”

Answer:

No.

It can be a mixture of several chemicals.

Therefore:

Never assume the hazard profile of one thinner applies to another thinner.

The Railway Men - Web Series on Netflix

SECTION 4 — FIRST AID

Inhalation

Move the affected person away from exposure into fresh air and seek medical attention when symptoms or significant exposure warrant it. A representative SDS advises medical consultation following significant exposure.

Skin

Remove contaminated clothing and wash/rinse the affected area thoroughly.

Eyes

Immediately flush with plenty of water and continue rinsing; remove contact lenses if easy to do so. Seek medical attention if irritation persists or as specified by the actual SDS.

Ingestion

Do NOT induce vomiting.

Seek medical attention.

This is an excellent opportunity to ask:

“What is the first thing you should NOT do after ingestion?”

SECTION 5 — FIREFIGHTING

Representative SDS information identifies suitable media such as:

Alcohol-resistant foam
CO₂
Dry chemical

and warns against inappropriate high-volume water jets for the product. (Scribd)

Important emergency hazards

Participants should identify:

🔥 Vapour can ignite.

🔥 Fire can spread rapidly.

🔥 Containers exposed to fire can become hazardous.

🔥 Firewater/runoff can create environmental contamination.

FACILITATOR QUESTION

Ask:

“If 5 litres of thinner spills, should we immediately start cleaning it?”

Correct response:

NO — first assess the situation.

First:

Isolate → eliminate ignition sources → assess exposure → use appropriate PPE → control the spill if trained and safe to do so.

SECTION 6 — ACCIDENTAL RELEASE

Representative SDS guidance includes:

Personal precautions

Keep unnecessary people away.
Increase ventilation where safe.
Eliminate ignition sources.
Use appropriate PPE.
Approach from upwind where applicable.

Environmental precautions

Prevent entry into:

Drains
Sewers
Watercourses
Basements/confined areas

Spill control

Use appropriate non-combustible absorbent such as:

Sand
Earth
Vermiculite
Diatomaceous earth

and collect contaminated material for appropriate disposal. (afdpetroleum.com)

THE TRAINER'S TRAP

Ask:

“Where should you stand while dealing with a solvent spill?”

Participants may say:

“Near the spill so I can clean it.”

Correct thinking:

Consider wind direction and vapour movement.

Don't put yourself in the vapour path.

SECTION 7 — HANDLING & STORAGE

This is one of the most important sections for your automotive audience.

Representative SDS guidance includes:

Keep away from:

🔥 Open flames

🔥 Sparks

🔥 Hot surfaces

🔥 Smoking

🔥 Other ignition sources

Control static electricity

The SDS specifically warns that static discharge can ignite organic vapours. (Scribd)

Handling

Avoid breathing vapours.
Avoid unnecessary skin/eye contact.
Provide adequate ventilation.
Keep containers closed.
Avoid aerosol generation.
Take precautions against static discharge.

Storage

Keep containers tightly closed.
Store in a cool, dry, well-ventilated location.
Keep away from ignition sources.
Keep containers upright.
Follow the product's storage compatibility requirements. (Scribd)

PARTICIPANTS TO PONDER

Question 1

“Can I keep an open thinner container beside a welding station?”

NO.

Question 2

“Can I leave the container open because I am using it continuously?”

Not simply because it is convenient. Follow the actual SDS/OCP and use an appropriate closed/controlled system.

Question 3

“Can I transfer thinner into an ordinary plastic bottle?”

Not unless the container is approved/compatible and the workplace procedure specifically permits it.

Question 4

“Can I store it wherever there is space?”

No.

Storage must consider:

Flammability + compatibility + ventilation + quantity + ignition sources + containment.

https://youtu.be/MKecWe1-cTw?si=Nr8pCT_L6vtRi4SL

SECTION 8 — EXPOSURE CONTROLS / PPE

This is where you challenge the participants' “PPE first” mindset.

Ask:

“What PPE would you select?”

Most participants will answer:

🧤 Gloves
🥽 Goggles
😷 Respirator
👕 Protective clothing

Then ask:

“Is PPE the primary control?”

No.

The SDS may tell you what PPE is appropriate, but the workplace must first consider:

Engineering controls

Local exhaust ventilation
Closed transfer
Enclosed cleaning
Vapour capture
Appropriate ventilation

Administrative controls

Safe work procedure
Restricted access
Exposure time
Training
Chemical handling authorization

PPE

Selected according to:

Chemical
Concentration
Duration
Task
Exposure route
Manufacturer compatibility information

A representative SDS calls for appropriate eye protection and impervious protective clothing and advises that glove suitability should be discussed with the glove manufacturer/supplier. (Scribd)

CRITICAL TRAINER QUESTION

Ask:

“Is an N95/dust mask the same as protection against solvent vapour?”

Answer:

No.

A particulate mask is not automatically an appropriate control for organic solvent vapours.

Respiratory protection, where required, must be selected based on the actual chemical, exposure assessment, concentration, workplace conditions and applicable respiratory-protection programme.

SECTION 9 — PHYSICAL & CHEMICAL PROPERTIES

This section is where the participants should discover why the solvent is dangerous.

A representative paint thinner SDS reports approximately:

Appearance

Liquid

Boiling range

Approximately 158–198°C

Flash point

Approximately 39–45°C

Water solubility

Negligible

Relative density

Approximately 0.775–0.784

Auto-ignition temperature

Approximately 276°C

These values are product-specific and should be replaced with the actual customer's SDS values during training. (Scribd)

NOW ASK THE PARTICIPANTS

Question 1

“If the flash point is around 40°C, what happens in a hot Indian shop floor?”

They should start thinking:

Temperature → vapour generation → ignition potential

Question 2

“Does the absence of visible smoke mean the solvent is safe?”

NO.

Vapour can be present even when there is no visible cloud.

Question 3

“Can you smell the chemical and use smell as your exposure control?”

NO.

Odour is not a reliable substitute for exposure assessment or ventilation control.

SECTION 10 — STABILITY & REACTIVITY

A representative paint-thinner SDS identifies incompatibilities such as oxidizing agents and certain strong acids/bases/halogens depending on formulation. (Scribd)

Participants should learn to look for:

Incompatible materials

Conditions to avoid

Hazardous decomposition products

Possibility of hazardous reactions

ACTIVITY: “WHERE SHOULD THIS GO?”

Give participants:

Chemical A

Paint thinner

Chemical B

Strong oxidizer

Chemical C

Strong acid

Chemical D

Water

Ask:

“Can these all be stored together?”

Participants must refer to Section 7 + Section 10, rather than guessing.

SECTION 11 — TOXICOLOGICAL INFORMATION

This section tells participants about potential health effects.

Depending on the formulation, solvent exposure may involve:

Skin irritation
Eye irritation
Respiratory irritation
Headache
Dizziness
CNS effects
Effects from repeated/prolonged exposure
Aspiration hazards for certain hydrocarbon mixtures

Some paint-thinner SDSs specifically warn about dizziness and longer-term organ effects depending on formulation. (NextSDS)

ROLE PLAY

One participant plays:

Worker

“I feel dizzy, but I can finish the job.”

Another plays:

Supervisor

What should the supervisor do?

The objective is to reinforce:

Symptoms are not a production-delay problem. They are a potential exposure warning.

SECTION 12 — ECOLOGICAL INFORMATION

Participants should consider:

Aquatic toxicity
Persistence
Bioaccumulation where applicable
Environmental release

Ask:

“Why shouldn't solvent go into the floor drain?”

Because:

Production area → Drain → Sewer/ETP/water environment

can become an uncontrolled chemical release.

SECTION 13 — DISPOSAL

Discuss:

Used solvent

Contaminated absorbent

Contaminated PPE

Empty chemical containers

Paint/solvent waste

Participants should determine:

Who collects it?

Where is it stored?

What container?

How is it labelled?

Who is authorized to dispose of it?

SECTION 14 — TRANSPORT

Ask:

“Can we simply carry a 20-L solvent container across the plant?”

Participants must consider:

Container integrity
Closure
Labelling
Approved trolley/handling method
Spill protection
Internal transport route
Ignition sources
Quantity
Emergency preparedness

SECTION 15 — REGULATORY INFORMATION

This section should be treated as supporting information, not as a substitute for the company's legal register.

Ask:

“Does the SDS alone tell us whether our process is legally compliant?”

Answer:

No.

The plant must evaluate applicable:

Indian legal requirements
State requirements
Factory requirements
Environmental requirements
Fire requirements
Company standards
Customer/OEM requirements

SECTION 16 — OTHER INFORMATION

This is where participants should look for:

SDS revision date
Previous revision
Preparation date
Abbreviations
Sources
Classification methodology
Additional information

Critical question

“What if your department has an SDS from 2018 while the supplier has issued a revised SDS?”

That becomes a:

SDS MANAGEMENT / MOC ISSUE

MOC = Management of Change

In an automobile manufacturing plant, MOC is a formal process used to evaluate and control risks before making a change that could affect safety, quality, environment, production, or compliance.

In your chemical-safety training, MOC is especially important.

A change could be:

Introducing a new chemical/solvent
Changing the chemical supplier
Changing the chemical formulation
Increasing the quantity stored
Changing the storage location
Changing the dispensing/transfer method
Replacing manual cleaning with an automated process
Changing ventilation/LEV
Introducing new equipment
Changing the process temperature/pressure
Changing an OCP or work method
Using a chemical for a new application

Example — Paint Thinner

Suppose the plant currently uses:

Thinner A

Procurement proposes:

Thinner B — cheaper and faster-drying

It should not simply be purchased and introduced.

The MOC process asks:

MOC Question	What to check
What changed?	Chemical formulation/supplier
Is the new chemical safer?	Compare SDS
What are the hazards?	Flammability, toxicity, exposure
Is the flash point different?	Compare SDS Section 9
Are incompatible materials different?	Section 10
Is existing PPE suitable?	Section 8
Is ventilation adequate?	Exposure/control assessment
Can it be stored with existing chemicals?	Sections 7 & 10
Does the emergency response change?	Sections 4–6
Does the OCP need revision?	Yes/no
Do workers need retraining?	Yes/no
Does waste handling change?	Section 13
Are legal/company requirements affected?	Compliance review
Who approves the change?	Defined MOC authority

The key principle

No significant change should be introduced until its risks have been evaluated and the necessary controls are in place.

A simple way to teach MOC

Use this formula in your training:

CHANGE → CHECK → CONTROL → COMMUNICATE → APPROVE → IMPLEMENT → VERIFY

Example:

New solvent proposed

↓

CHECK SDS

↓

COMPARE RISKS

↓

DEFINE CONTROLS

↓

UPDATE OCP

↓

TRAIN WORKERS

↓

APPROVE MOC

↓

INTRODUCE CHEMICAL

↓

VERIFY CONTROLS

A very useful activity for your 2-day programme

Give participants this scenario:

“The new solvent is 18% cheaper, cleans faster and production wants to introduce it tomorrow.”

Then give them:

Old solvent SDS
New solvent SDS
Existing OCP
PPE specification
Chemical-store layout
Emergency response card

Ask:

“Can production start using the new solvent tomorrow?”

Teams must conduct a mini-MOC and decide:

🟢 APPROVE

🟡 APPROVE WITH CONDITIONS

🔴 DO NOT APPROVE

This is an excellent way of teaching MOC because participants experience that MOC isn't paperwork—it is a decision-making barrier against introducing uncontrolled risk.

THE BIG REVEAL

Now put these two columns on the screen:

WHAT I THOUGHT

Participant assumption	Reality
“Thinner is just paint solvent.”	It can contain multiple hazardous components.
“The main hazard is skin contact.”	Fire/vapour exposure can be major hazards.
“Gloves make it safe.”	Controls must follow the hierarchy of controls.
“If I can't see vapour, there is no vapour.”	Vapour can be present without visible indication.
“Smell tells me if exposure is dangerous.”	Odour is not an exposure-control method.
“I can use it near welding if careful.”	Ignition-source control is critical.
“All thinners are the same.”	Formulations and hazards vary by product.
“The SDS is an EHS document.”	SDS information must become operational controls.
“Spill = start cleaning.”	First assess, isolate and control ignition/exposure.
“PPE is the solution.”	PPE is one part of a hierarchy of controls.

THE FINAL “ARE YOU SURE?” ROUND

Now present these 10 statements.

Participants hold up:

🟢 SAFE

🔴 STOP

🟡 VERIFY

1.“The thinner container is labelled, so we can use it.”

VERIFY

Label alone isn't enough. Check SDS, task and controls.

2.“The SDS says flammable, so keep it away from ignition sources.”

SAFE

Correct, but determine what ignition-source controls are required.

3.“Wear gloves and start cleaning.”

STOP

Assess spill, ignition, vapour, PPE and response requirements first.

4.“There is welding 8 metres away.”

STOP

Evaluate the ignition risk and hot-work controls.

5.“The worker smells solvent.”

STOP / VERIFY

Investigate ventilation/exposure rather than treating smell as a normal operating condition.

6.“The ventilation system isn't working, but the job is urgent.”

STOP

Do not allow production urgency to override critical controls.

7.“The thinner is in a drinking-water bottle because it is only temporary.”

STOP

Unacceptable chemical identification/control practice.

8. “The SDS is available in the EHS office.”

VERIFY

Critical SDS information needs to be accessible to those who need it where the work is performed, consistent with the company's system.

9.“The operator has been doing this job for five years.”

STOP

Experience does not eliminate chemical hazards.

10.“We have PPE, therefore the chemical is controlled.”

STOP

Ask:

What is the higher-level control?

THE FINAL LEARNING MOMENT

Show this equation:

SDS ≠ OCP

Instead:

SDS

↓

Understand the hazard

↓

Assess the task

↓

Identify exposure

↓

Apply hierarchy of controls

↓

Select PPE

↓

Prepare emergency response

↓

OCP

↓

Verify every day

Participant Takeaway Card

I would give each participant this small card after the activity:

BEFORE USING A CHEMICAL

1 — IDENTIFY - What exactly is it?

2 — CHECK SDS - What can it do?

3 — ASSESS - How can I be exposed?

4 — CONTROL - Can I eliminate/substitute/enclose/control it?

5 — PROTECT - What PPE is actually required?

6 — PREPARE - What if it spills, burns or exposes someone?

7 — VERIFY - Are the controls actually working?

SDS DETECTIVE CHALLENGE

Practical Activity: Read It • Understand It • Control It

Training Programme: Safe Chemical Handling, Hazard Communication & OCP Development
Industry: Automobile Manufacturing
Activity Duration: 45–60 minutes
Team Size: 4–6 participants

1. TEAM DETAILS

Particular	Details
Team Name
Chemical Assigned
Manufacturer / Supplier
SDS Revision Date
Team Members
Work Area / Process
Facilitator

Chemical Options

☐ Xylene
☐ Toluene
☐ IPA – Isopropyl Alcohol
☐ Acetone
☐ Paint Thinner
☐ PU Adhesive
☐ Brake Cleaner
☐ Degreaser
☐ Other: ______________________

2. MISSION

Your challenge:

“You have received this chemical at your automobile manufacturing facility. Before allowing a worker to use it, prove that you understand the hazards and can establish the necessary controls.”

You must use the actual SDS provided by the facilitator.

Your team must answer:

What can hurt us? → How can it happen? → How do we control it? → What do we do if something goes wrong?

3. SDS QUICK SCAN

Locate the information in the SDS.

Question	SDS Section	Your Finding
What is the exact chemical/product name?	1
Who is the manufacturer/supplier?	1
What is its intended use?	1
What are the major hazards?	2
What are the GHS pictograms?	2
What is the signal word?	2
What are the hazard statements?	2
What are the precautionary statements?	2
What are the important ingredients?	3
What first-aid measures are required?	4
What should be done after a spill?	6
How should it be handled and stored?	7
What PPE is required?	8
What exposure limits apply?	8
What are its physical properties?	9
Is it flammable?	9
What are its incompatibilities?	10
What happens during decomposition/burning?	10
What toxicological information is given?	11
What transport precautions apply?	14
What disposal considerations apply?	13

4. “RED FLAG” HUNT 🚩

Identify the five most important safety warnings in your SDS.

No.	Red Flag / Hazard	Where Found in SDS?	Why Is It Important?
1
2
3
4
5

Team Question

If a worker remembered only THREE things about this chemical, what should they remember?

5. GHS HAZARD COMMUNICATION

Identify the symbols appearing in the SDS.

Pictogram	What does it mean?	What could happen in our workplace?

Signal Word

☐ DANGER
☐ WARNING
☐ None

What does this tell the worker?

6. HAZARD → RISK → CONTROL

Imagine this chemical is being used in your automobile manufacturing plant.

Identify realistic workplace scenarios.

Activity / Situation	Hazard	Possible Consequence	Existing Control	Additional Control
Chemical receiving
Chemical storage
Pouring / transfer
Mixing / dilution
Application / cleaning
Waste disposal
Spill / leakage

7. HIERARCHY OF CONTROLS CHALLENGE

Select one significant hazard from your chemical.

Hazard selected:

Now propose controls at each level.

Hierarchy	Your Proposed Control
1. Elimination
2. Substitution
3. Engineering Control
4. Administrative Control
5. PPE

Discussion Question

Are we relying too heavily on PPE?

☐ Yes
☐ No
☐ Partially

Why?

8. SOLVENT SAFETY CHECK

Complete this section if your chemical is a solvent or contains significant solvent content.

A. Ignition Sources

Identify possible ignition sources in the work area.

☐ Electrical equipment
☐ Welding / cutting
☐ Hot surfaces
☐ Static electricity
☐ Sparks
☐ Open flame
☐ Smoking
☐ Vehicles / forklifts
☐ Other: ______________________

B. Vapour Risk

What could cause vapour accumulation?

☐ Poor ventilation
☐ Open containers
☐ Leakage
☐ Large-volume transfer
☐ Spill
☐ High temperature
☐ Incorrect storage
☐ Other: ______________________

C. Controls

What controls would you recommend?

9. PPE DECISION

Do not simply copy the PPE recommendation from the SDS.

Discuss the actual workplace task.

PPE	Required?	Why?	Limitations
Safety goggles	☐ Yes ☐ No
Face shield	☐ Yes ☐ No
Chemical-resistant gloves	☐ Yes ☐ No
Safety shoes	☐ Yes ☐ No
Respiratory protection	☐ Yes ☐ No
Protective clothing	☐ Yes ☐ No
Other

Critical Question

What could happen if the worker selects the wrong glove material?

10. EMERGENCY RESPONSE

Imagine that 5 litres of the chemical are accidentally spilled near the production line.

What should happen FIRST?

What should NOT happen?

Emergency Response Matrix

Situation	Immediate Action	Person / Team to Notify	Required PPE / Equipment
Small spill
Large spill
Skin exposure
Eye exposure
Inhalation
Fire

11. “CAN WE START THE JOB?” DECISION

Your team has to decide whether the chemical can be released for use.

Check each condition.

Verification Point	Yes	No	Action Required
Current SDS available	☐	☐
Chemical correctly labelled	☐	☐
Container in good condition	☐	☐
Correct storage location available	☐	☐
Required PPE available	☐	☐
Ventilation adequate	☐	☐
Spill kit available	☐	☐
Emergency equipment available	☐	☐
Workers trained	☐	☐
Incompatible chemicals controlled	☐	☐
Ignition sources controlled	☐	☐
Waste disposal method defined	☐	☐

Final Decision

☐ RELEASE FOR USE

☐ RELEASE WITH ADDITIONAL CONTROLS

☐ DO NOT RELEASE

Why?

12. CONVERT SDS INTO A SHOP-FLOOR INSTRUCTION

The SDS contains technical information.

Your job is to convert it into something a production operator can understand and act upon.

Complete the following:

BEFORE USE

DURING USE

AFTER USE

IF SOMETHING GOES WRONG

STOP → __________________________________ → __________________________________

13. OCP MINI-DRAFT

Now convert your SDS findings into a basic Operational Control Procedure (OCP).

OCP Title

Safe Handling and Use of: ___________________________

Purpose

Scope

Main Hazards

Required Controls

PPE

Safe Handling Requirements

Storage Requirements

Spill Response

Fire / Emergency Response

Waste Disposal

Training Required

Inspection / Monitoring

Records to Maintain

14. THE “ONE-MINUTE WORKER TEST”

Imagine you have only 60 seconds to brief a new operator.

Complete this statement:

“Before you use ____________________, remember these five things…”

1. WATCH OUT FOR:

2. NEVER:

3. ALWAYS:

4. IF THERE IS A SPILL:

5. IF YOU ARE UNSURE:

15. TEAM PRESENTATION

Your team has 5 minutes to present.

Your presentation MUST include:

☐ Chemical and application

☐ Top 3 hazards

☐ GHS pictograms

☐ Most critical SDS information

☐ One high-risk workplace scenario

☐ Three important controls

☐ PPE requirements

☐ Emergency response

☐ One proposed OCP improvement

☐ One message for the operator

16. FACILITATOR CHALLENGE QUESTIONS

The facilitator may ask:

Question 1

Where in the SDS did you find this information?