Lesson Plan

• Describe the purpose and five key stages of a standard risk assessment in product design.
• Evaluate hazards using the likelihood‑severity matrix and calculate risk ratings.
• Apply the hierarchy of controls to select appropriate mitigation measures.
• Produce a concise risk‑assessment record for a given manufacturing scenario.
• Review and update a risk assessment when design or process changes occur.

• Projector and screen
• Whiteboard and markers
• Printed risk‑assessment worksheet (template)
• Sample design brief – CNC milling project
• Risk matrix handout
• PPE examples (gloves, goggles, hearing protectors)
• Laptop with presentation slides

Begin with a quick brainstorm of accidents students have witnessed in the workshop to hook interest. Recall previous lessons on tool safety and ask how systematic assessment could prevent those incidents. Explain that by the end of the lesson they will be able to carry out a full risk assessment and justify control choices.

1. Do‑now (5’) – Students list hazards observed in recent practical sessions (activates prior knowledge).
2. Mini‑lecture (10’) – Present the five‑step risk‑assessment procedure and demonstrate the risk matrix.
3. Guided practice (15’) – In pairs, analyse the CNC milling example, fill out the worksheet, calculate risk ratings.
4. Group discussion (10’) – Share identified controls and map each to the hierarchy of controls.
5. Whole‑class activity (10’) – Create a flowchart of the assessment process on the board.
6. Formative check (5’) – Exit ticket: one key takeaway and one remaining question.

Recap the five steps and emphasise the importance of documentation and review. Collect exit tickets to gauge understanding and assign homework: complete a risk assessment for a personal project idea, using the provided template. Remind students that safe design starts with thorough risk analysis.