Safety Guidelines for Lift Trucks and Conveyors

1. Safety in the Movement of People and Materials Lift Trucks Conveyors Automated Warehouses

2. Types of Lift Truck

3. Counterbalance Lift Truck

4. Reach Truck

5. Rough-terrain Counterbalance

6. Telescopic Materials Handler

7. Side-loading Lift Truck

8. Pedestrian Controlled Lift Truck

9. Large Lift Truck

10. Lift Truck Hazards • Collision with people or vulnerable plant • Overturning • Items falling from racking or forks • Explosion from some batteries • Hot exhaust • Dangerous parts e.g. chains, drive shafts etc. • Driving off edges, into pits etc. • Placing loads onto peoples feet

11. Lift Truck Hazards • Fumes • Noise • Whole body vibration • Load slipping from forks

12. Lift Truck Control Measures

13. Driver Selection • Reliable and mature attitude • Physically & mentally fit • Intelligent • Over school leaving age • Not under influence of drink/drugs • Good vision • Good hearing

14. Driver Training • Supervisors should receive an appreciation • Competent Instructor • Records should be kept • Test at end of training • Employees should be given written authorisation at end of training • Refresher training as necessary

15. Work Area • Separate traffic routes where possible • Routes should have sufficient width and clearance for largest trucks used • Prevent pedestrians entering lift truck areas • Eliminate sharp bends or overhead obstructions wherever possible • Where hazards cannot be removed, use clearly marked barriers

16. Work Area • Signs, warning devices, mirrors etc. • Instructions to sound horns and restrict speed • Flexible doors of transparent material where lift trucks have to pass through

17. Work Area • Edges of loading bays, excavations & pits should be clearly marked

18. Work Area • Where possible, edges should be fitted with barriers

19. Work Area • Operating areas should be as free as possible of obstructions, but supports, columns, pipework, racking or other plant may need to be protected by special impact barriers

20. Work Area • Firm and level surface, ideally concrete or similar • Potholes should not be allowed to develop • Steep gradients should be avoided • Adequate lighting • Trucks should be parked in a secure area • Keys should be kept in a secure place

21. Protecting Pedestrians & Operators • Segregate pedestrians and vehicles

22. Protecting Pedestrians & Operators • Clearly mark traffic routes • Use audible and visual warning devices • High-visibility clothing may be necessary, as well as safety boots and hard hats • A Roll Over Protection Structure should be fitted where there is a risk of overturning and crushing operator

23. Protecting Pedestrians & Operators • Seat belts may be required • Falling object protection structures should be fitted where there is significant risk of falling materials • Anyone driving a lift truck on a public road should comply with road traffic legislation

24. The Lift Truck • Suitable for its intended purpose • Travel with loads in lowered position • Do not load beyond SWL (safe working load) • Dangerous parts should be guarded • Eliminate ignition sources in battery charging areas • Adequate ventilation to disperse fumes

25. Operation of Lift Trucks • Issue keys only to authorised people • Lower forks when parked • Keep to left when operating • Sound horn at danger spots • Avoid violent braking or sudden changes in direction • Never travel down slopes with load in front

26. Maintenance • Follow manufacturers recommendations • Operators should not carry out repairs • Trucks that are on loan still need to be checked and maintained

27. Operator Checks • At beginning of each shift, operator should check the following and report any defects to his supervisor: • Tyre pressure and damage; • Steering and brakes; • Fuel, water and oil levels; • Battery levels; • Masts and hydraulics; • All controls; • Horns and other warning systems; and • Lights & mirrors

28. Conveyor Belts

29. Conveyor Hazards • In-running nips • Entanglement points at rollers • Contact with moving parts • Materials falling from conveyor • Manual Handling/Ergonomics from incorrectly set speeds

30. Conveyor Controls • Guard in-running nips

31. Conveyor Controls • Emergency trip wires or stop buttons • Guard power drives and other dangerous parts • Nobody allowed to ride on conveyor • Operatives should be trained and instructed in safe use

32. Conveyor Controls

33. Automated Warehouses & Order Picking Machines (OPMs)

34. OPM Hazards • Overturning e.g. overloading, gradients • Falls of people, goods or materials • Trapping of people in mechanisms • Trapping of people against fixed structures • People struck by moving OPM • Failure of platform supporting mechanism • People stranded on platform due to power failure • Inadvertent movements e.g. misapplication of controls

35. OPM Controls • Only trained and authorised persons • Comply with SWL • Tested and examined every 6 months (LOLER) • Prevent access to dangerous parts e.g. chains, mast sections etc. • Edge protection • Suitable overhead guards

36. Automated Warehouse Hazards • Collision between AGVs and people • Trapping points between AGVs and stationary objects or fixed structures • Inadvertent movement of AGVs • Collapse of palletised loads • Collapse of AGV • Slips on oil from machines

37. Automated Warehouse Controls • Segregate AGVs from pedestrians • Trip devices on vehicle bumpers • Sensors on vehicles to slow it to a crawl • Ensure accurate positioning of AGV at transfer points • Easily accessible emergency stops • Automatic monitoring of safety system

38. Automated Warehouse Controls • Audible and visual signals • Guard dangerous moving parts • Prevent unauthorised human access • Pressure sensitive mats • Interlocked access gates • Permit systems for maintenance • Clear warning notices