Transcript AITA Forklift Safety Week 2012 Presentations
Mr. Steve Stewart
Training
• Licence is not necessarily evidence of competence.
• • WHS legislation……
Part 4.5 High risk work
• Work Health and Safety Act 2011 • Work Health and Safety Regulation 2011
• Think not about how much training will have cost you if your employee subsequently leaves…….
• Think about how much will it cost you if you do not train them - and they stay ………….
Part 3.2 General workplace management Division 1Information, training and instruction 39 Provision of information, training and instruction
(1) This clause applies for the purposes of section 19 of the Act to a person conducting a business or undertaking.
(2) instruction provided to a worker is suitable and adequate having regard to: The person must ensure that information, training and (a) the nature of the work carried out by the worker, and (b) the nature of the risks associated with the work at the time the information, training or instruction is provided, and (c) the control measures implemented.
(3) The person must ensure, so far as is reasonably practicable, that the information, training and instruction provided under this clause is provided in a way that is readily understandable by any person to whom it is provided.
•
Proper use of plant and controls
• (1) The person with management or control of plant at a workplace must take all reasonable steps to ensure that plant is used only for the purpose for which it was designed, unless the person has determined that the proposed use does not increase the risk to health or safety.
• Maximum penalty: in the case of a body corporate
• 215.
• The person must ensure that the plant does not collide with pedestrians or other powered mobile plant.
• Maximum penalty: (a) in the case of an individual or (b) in the case of a body corporate
203 Management of risks to health and safety
•A person with management or control of plant at a workplace must manage risks to health and safety associated with plant, in accordance with Part 3.1.
Note.
WHS Act —section 21 (see clause 9).
Types of training
1. Required licences (HRW etc) 2. Qualifications (Nationally Recognised Training).
3. General training in specific competences.
Types of training
1. Required licences (HRW etc) 2. Qualifications (Nationally Recognised Training).
3. General training in specific competences.
WHS Act Def:
•
plant
includes: – (a) any machinery, equipment, appliance, container, implement and tool, and – (b) any component of any of those things, and – (c) anything fitted or connected to any of those things.
Definition
• •
High Risk Work Licence - LF
forklift truck, in Schedules 3 and 4, means a powered industrial truck equipped with lifting media made up of a mast and an elevating load carriage to which is attached a pair of fork arms or other arms that can be raised 900mm or more above the ground, but does not include a pedestrian-operated truck or a pallet truck.
Definition
• •
High Risk Work Licence - LO
order-picking forklift truck, in Schedules 3 and 4, means a forklift truck where the operator's controls are incorporated with the lifting media and elevate with the lifting media.
Current Licence System
• No ‘Log Book’ system.
• Must be conducted by an RTO.
• Formal training to the approved course (UoC) is required.
– TLILIC2001A - Licence to operate a forklift – TLILIC2002A – Licence to operate an order picking forklift
• Does that cover every forklift type then?
Variables
• Type • Brand • Specifications • Mast height • Capacity • Load handling attachments • Safety features • Control types
• And then there is the peripheral skills and knowledge required!
• Most of these will fall into the ITEM 3 General training in specific competences
Peripherals
• Operator elevated equipment.
– Emergency lowering options – Fall Arrest Equipment – Emergency Descent – Rescue procedure
Peripherals
• Forklift Re-fueling safety.
– LPG cylinder change – LPG cylinder refill – Fuel storage safety
Peripherals
• Battery electric forklift.
– Battery charging safety – Battery changing safety
Non – licence equipment
• Pallet jacks • Pallet movers • Walkie Stackers • Tow motors • Low level order pickers • Anything under the plant def!
Hierarchy of controls
Eliminate Substitute Engineering Administration Personal protective equipment
Hierachy of Controls
• Remember that training is considered an administrative control.
• Should include assessment.
• Must be used in conjunction with a suite of higher level controls.
Contextualised delivery
• An RTO can encompass required site specific skills in training programmes.
• Benefit of having training conducted on-site.
Transport and Logistics
• Most Units of Competence are contained in TLI10 Training package.
• Qualification Level: Certificate • • TLIPC110 Certificate I in Transport and Logistics (Pathways) TLI10410c - Certificate I in Transport and Logistics (Rail Operations) • • TLI11310 - Certificate I in Logistics TLI11210 - Certificate I in Warehousing Operations
Thank you
Traffic Management Planning
Traffic Management Plans
Traffic Management Plans
Do we need a Traffic Management Plan?
According to WorkSafe Victoria, Forklifts cause more workplace deaths and injuries than any other piece of equipment. More than half the people killed in forklift related incidents in the last 10 years have been pedestrians.
Even when forklifts are travelling at low speeds they can crush pedestrians causing serious injury.
Where to Start?
There are numerous publications in each State and Territory designed to help businesses develop and implement effective Traffic Management Plans.
NSW Forklift Safety – Reducing the Risks Guide - Traffic Management & Forklift Safety QLD Forklift Safety – Reducing the Risk COP – Traffic Management Construction 2008 Forklift safety case study: Making traffic management systems work.
Where to Start?
There are numerous publications in each State and Territory designed to help businesses develop and implement effective Traffic Management Plans.
VIC Forklift Safety – Reducing the Risks Forklifts - Developing a traffic management plan Guide - Traffic Management & Forklift Safety ACT, SA, NT, TAS, WA, Comcare Forklift Safety – Reducing the risks AS2359.2 (Draft) Operation Appendix A – Traffic Management Plans
Where to Start?
‘ Forklift Safety – Reducing the Risks ’ Has broken down the process of developing a Traffic Management Plan into 4 simple steps.
S
POT THE HAZARD
A
SSESS THE RISK
F
IX THE PROBLEM
E
VALUATE RESULTS
Where to Start?
Legal Considerations
Before you commence your Traffic Management Plans you MUST consider the following when developing your plans.
In each State and Territory employers are responsible for providing:
• a safe work environment • safe systems of work • safe and well-maintained machinery • proper information, training and supervision.
Warehouse Design and Layout
Principles of good design are most economically applied at the start of a project and are more costly to introduce retrospectively.
There are four primary functions that your warehouse layout must accommodate: 1.
Product storage 2.
3.
4.
Inbound operations (including receiving and returns) Outbound operations (including picking and staging) Value-added processes
BARRICADES/BARRIERS/ BOLLARDS
Barriers/Barricades or bollards are designed to protect pedestrians, but also act to enforce the walkway – ie keep mobile equipment off and pedestrians within. Barriers should be provided along as much of a dedicated walkway as possible .
BARRICADES/BARRIERS/ BOLLARDS
LAYOUT/LINE MARKING
Clearly line mark pedestrian walkways, roadways and operating areas based on speed limits, stopping distances and efficient workflow.
Minimise the cross flow of traffic, intersections and blind spots Clearly define areas where powered loadshifting equipment is used as ‘ pedestrian exclusion zones ’ and clearly exclude powered loadshifting equipment from pedestrian walkways/work areas Provide line marking for: - traffic flow markings - Loadshifting equipment parking - Driver designated safe areas - Car parking - Keep clear zones - Speed humps
SIGNAGE/ WARNING DEVICES
SIGNAGE/ WARNING DEVICES
Signage Prominently display clear warning signs in relevant, well lit areas to remind persons of the traffic management hazards and requirements.
Signage examples: • Speed Limit • Give Way • Warning Forklifts in Operation Warning Devices Proximity sensing systems in their simplest form can be used to warn of mobile equipment as it approaches set locations ie doorways, blind spots and intersections.
TRAINING, SYSTEMS, POLICIES, PROCEDURES
Policies and safe work procedures ensure everyone who works within a workplace where Mobile Equipment (forklifts) operate understands how to manoeuvre safely and correctly throughout the facility without causing harm to themselves or others.
As with your traffic management plan, everyone in your workplace, including contractors and visitors, must know your policies and safe work procedures. Again, you could use induction and training sessions, and post information at workplace entrances and notice boards.
You should also review these regularly to ensure they remain appropriate. You should also ensure people are complying with them.
PERSONAL PROTECTIVE EQUIPMENT
• Ensure that High Visibility Clothing is worn by all people on site within traffic areas.
• Set policies as to appropriate footwear within the workplace eg closed-in and/or safety footwear
Mobile Equipment (Forklifts)
Safety Features: Ratchet style locking park brake lever which cannot be “ accidentally ” disengaged.
•Low cowl height for better operator vision.
•Wide foot steps and grab bar for easy access and egress.
•On trucks fitted with Oil Cooled Disc Brakes (OCDB) the improved boosted master cylinder requires less pedal effort, reducing operator fatigue.
•Reverse alarm.
•Speed limiters.
Mobile Equipment (Forklifts)
Safety Features: •Operator Sensing System (OSS) which includes: – Parking alarm – alarm warning when operator leaves seat without applying the park brake.
– Seat belt indicator – warning light illuminates for 10 secs to remind operator to fasten seat belt.
– Hydraulic function lockout – all hydraulic functions are locked out when operator has vacated the seat.
CONCLUSION
The development of traffic management plans require consultation from employees/key stakeholders.
The process is never simple, in fact it is quite complex requiring an in depth understanding of your business and its needs both now and in the future.
Thank you
Thank you
Standards
• A number of ISO standards published over the past 5 years.
• These include standards for stability, safety and brakes.
• Australian Standards will be in the main replaced by ISO standards.
• AS2359-1:1995 Powered industrial trucks – General requirements.
• AS2359-2:1985 SAA Industrial truck code Part 2 Operation.
• AS2359-6:1995 Powered industrial trucks – Safety code.
• Design requirements for industrial trucks for Australia • A number of requirements have been moved to AS2359-6 or other ISO standards i.e. stability, brakes and electrical.
• This standard is being updated with the latest version of ISO3691-1:2011 Industrial trucks — Safety requirements and verification — Part 1: Self propelled industrial trucks, other than driverless trucks, variable –reach trucks and burden – carrier trucks.
• This standard is design standard that • Europe and Japan will adopt.
• This standard is special design requirements for Australia, Japan and USA.
• Will require that interlocked seatbelts be fitted to counterbalance forklifts with logic.
• Travelling with elevated mast on battery electric forklifts.
• A number of changes have been included in the update since it was last updated in 1985.
• All users of forklifts should have a copy of this standard.
• Operators must be trained on the forklift they are operating.
• Records of training shall be maintained.
• This should include induction/familiarisation training for new models.
• Only persons who are qualified and are trained shall be authorised to use a forklift.
• A record of authorised operators shall be kept and a system implemented to limit forklift usage to authorised operators.
• Systems now include swipe cards, pin codes etc.
• Operators shall be provided with a record of authorisation.
• Users of forklifts shall have a safe system of work in place.
• Use correct forklift the task.
• Daily pre-operator checks.
• Ensure forklift and any attachments that are on the forklift that it is rated appropriately.
• Forklifts are isolated when operator leaves forklift. • Unattended forklift defined as operator more than 8m away from forklift
• Operator restraints (seatbelts) shall be used when operating counterbalance forklifts.
• Note if a seatbelt is fitted to other forklifts such as a reach truck they shall be used.
• Mobile phones shall not be used while the forklift is in motion.
• Operating procedures should be developed for devices such as scanners, touch screens, terminals etc.
• Internal combustion engine forklifts shall not be allowed to idle unnecessarily in enclosed or semi enclosed areas as it may result in an accumulation of fumes.
• If internal combustion engine trucks are used in poorly ventilated areas then it is essential that emissions are monitored.
• In such situations battery electric forklifts are the preferred option.
• A traffic management plan which includes forklift operation shall be in place for the site.
• Pedestrian paths shall be separated from forklift path by physical barriers where possible.
• Truck loading and unloading areas to be pedestrian free, this includes truck drivers.
• Speed limits.
• The objective of a TMP is to achieve as far as practicable, complete physical separation of mobile plant and people within the work area.
• Due to building codes there are requirements for drainage. As part of a “safe operating system” consideration needs to be given with operating forklifts on these inclines when loading or unloading trucks and the impact on stability.
• Turns with the forks elevated should never occur as a tip over is a possibility.
• Fork tynes shall support 75% of the load .
• A load backrest extension shall be used when handling loads which are high or segmented.
• Where a segmented load is to be carried, two thirds of the load or top tier of the load should be supported.
• Recommended that loads should be shrink wrapped.
• Work platforms are not to be used for orderpicking or for production or stores types of activity such as stocktaking.
• Should only be used for special tasks of a short duration.
• Must wear a harness and lanyard.
• A risk assessment shall be carried out before using a work platform.
• Bulker bag handling attachments considered to be a jib due to bag being able to swing freely.
• Section now included on container handling.
• When using high level orderpickers now able to use pedestrian detection systems.
• Loading docks.
• A system shall be in place to ensure no movement of the truck or trailer when loading or unloading.