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T-1060 Safe Forklift Operation

T-1060 Safe Forklift Operation

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T-1060 Safe Forklift Operation

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  1. T-1060 Safe Forklift Operation This work has been produced by DGL (Aust) Pty Ltd This Learner’s Tool is about the skills and knowledge required for Segregating Chemicals DGL (Aust) facilities. 12/07/2006 Rev B

  2. Before you get started • It is important that you complete all sections in this learning tool as it has been designed so that • You can abide by the procedures of our organization. • You can apply what you have learnt in this package in your day to day activities • This Learning Tool is designed to be relevant only to DGL (Aust) Pty Ltd employees and only applied whilst employed with DGL (Aust) Pty Ltd • You may have already acquired knowledge in the area identified in this package as you may have completed some specialized training. Or you may have been working within the industry for some time. Should you identify any improvement opportunities in the information contained in this package or have difficulties completing the package please contact National Training and Compliance Manager DGL (Aust) Pty Ltd PO BOX 1594 EAGLE FARM QLD 4009 Ph 07 3868 1001 Fax 07 3868 1055 12/07/2006 Rev B

  3. The Facts The forklift can be one of the most dangerous pieces of equipment in the workplace. From January 1985 to January 2005 , forklifts were associated with 54 reported fatalities in Victorian workplaces. All these fatalities were preventable. • 29 of these involved pedestrians, 15 hit by loads and 14 struck by a FLT. • 9 of the other deaths were FLT Operators who either jumped or fell from a FLT in a tip over and were then crushed by the FLT 12/07/2006 Rev B

  4. Program Aims • To raise awareness around the hazards associated with the use of Forklift Trucks in the workplace. • To help prevent Forklift related incidents in the workplace so as to: - protect the health & safety of all persons - prevent damage to property and the environment. 12/07/2006 Rev B

  5. Program Content • Training & Licencing • Speed & Braking Distance • Forklift Stability • Slips, Trips, Falls, Sprains & Strains • Load & Load Handling • Daily Forklift Check • Traffic Management & Pedestrians • Vital Safety Requirements 12/07/2006 Rev B

  6. Training & Licencing • Certificate of Competency is mandatory. • Workcover regulate and issue certificates in Victoria, NSW, WA whilst in QLD and SA this is regulated by other government agencies. 12/07/2006 Rev B

  7. Speed & Braking Distance • The speed that a Forklift can stop is determined by travel speed, weight of its load and the road surface. • Emergency stopping distances of fully loaded forklifts are often significantly underestimated. A laden forklift cannot use its maximum braking as the load will slide/fall from the forks, or the forklift will tip over forwards. The table below shows the minimum braking distance for common forklifts travelling on an even surface. It also assumes the Operator is alert and not distracted by other activities. 12/07/2006 Rev B

  8. Speed & Braking Distance cont. So, what does this data mean? • It tells us that at a speed of 14km/h, a forklift will travel four meters in one second and need at least 10 metres to stop safely. And that even at 6km/h (walking pace) a forklift needs at least three metres to stop. 12/07/2006 Rev B

  9. Speed & Braking Distance cont. To manage risks associated with speed, braking and instability: • Abide by site speed limits • Construct and clearly mark pedestrian walkways, that provide traffic separation based on speed limits and stopping distances. Display signs about pedestrian walkways and forklift operating areas. 12/07/2006 Rev B

  10. Forklift Stability Overturning is the leading cause of deaths involving forklifts. Fell from forklift, fork-arms or load (8) Operator crushed by unexpected movement of forklift (7) Operator overcome by exhaust fumes (1) Pedestrian crushed by falling loads (15) Operator crushed by forklift in tip over/rollover (9) Pedestrian crushed by manoeuvring forklift (7) Pedestrian struck by traveling forklift (7) 12/07/2006 Rev B

  11. Forklift Stability cont. PUT SIMPLY, FORKLIFTS OVERTURN AS A RESULT OF: • Travelling too fast. • Turning sharply. • Travelling across an incline or uneven ground. • Travelling with a raised load. • Carrying a load forwards down a slope. • Carrying an unevenly balanced load. • Forks raised with no load. • Breaking too quickly • Towing disabled Forklifts • Striking low doors or beams • Colliding with another forklift/ vehicle 12/07/2006 Rev B

  12. Forklift Stability cont. The following controls can help mitigate the effects of instability: • Establish pedestrian exclusion zones. • Ensure seatbelts are fitted and correctly worn • Implement safe speed limit around the workplace. • Know the forklift capacities and don’t exceed these. • Use dual wheeled forklifts that provide an extra margin of safety in lateral stability when lifting loads above 4.5 metres. 12/07/2006 Rev B

  13. Forklift Stability cont. • When a forklift overturns, the safest place for the operator is in the cabin with a seatbelt on. If body restraints have been fitted they should be worn. The operator is advised to hold on, stay with the truck and lean in the opposite direction of the overturn. • Almost every time an operator jumps from their forklift while it is overturning they are killed. Seatbelts can be a life saver. 12/07/2006 Rev B

  14. Slips, Trips, Falls, Sprains & Strains ! 1/3 of forklift injuries involve, slips, trips and falls while getting on or off forklifts. When getting off always check the parking brake is set, the forks are lowered and the controls neutralised. To manage risks associated with slips, trips and falls: • Ensure forklift operating and parking areas are clear of obstructions, and that uneven surfaces are removed or minimised • Do NOT jump on/ off the forklift • Use steps and grab handles to provide points of contact (hands & feet) while mounting or dismounting the forklift, maintain 3 points of contact 12/07/2006 Rev B

  15. Load & Load Handling CHECK YOUR LOAD: • If it’s not placed correctly, reload it. • Ensure that the load is within the forklift load limit listed on the load capacity plate. • If it’s particularly long or wide, check if you need to take an alternative route. • If pallets are damaged, remove them. • Ensure pedestrians are not present during forklift operations. ‘Driving with a raised load is a dangerous practice impairing stability and easily leads to tipping, especially if driving at speed, around a corner or on uneven surface’ 12/07/2006 Rev B

  16. Daily Forklift Check Completing the safety checklist must be a daily routine! • Before starting shift all operators need to check their forklift is in safe working order, ready to be used and capable of completing the tasks required of it by using the prescribed form. • If any damage or problems with a forklift are noticed, they should immediately be reported. • Conducting regular safety checks is also part of an effective forklift maintenance regime. 12/07/2006 Rev B

  17. Traffic Management & Pedestrians Even when travelling at low speeds, forklifts present significant risk to the safety of pedestrians. Half the pedestrians killed were crushed by forklifts that were barely moving! ‘Effectively separating forklifts from pedestrians reduces the risk of forklift related injuries’ STEPS TO REDUCE RISK: • All persons including visitors, must be advised of the site’s traffic management plan, pedestrian and forklift exclusion zones. Clearly mark ‘No Go’ exclusion zones for pedestrians and forklifts • Implement and enforce right-of-way procedures, clearly indicating when pedestrians and forklifts must give way to each other (what are these at your site?) • Display clear warning and traffic management signs • Ensure pedestrians wear high visibility clothing. 12/07/2006 Rev B

  18. Traffic Management & Pedestrians Discussion • What are the risks at your site? • How can we better improve forklift and pedestrian traffic management at your site? • If pedestrians and exclusion zones these are not present at your site, is it practicable to implement? 12/07/2006 Rev B

  19. VITAL SAFETY REQUIREMENTS • Do wear seatbelts, obey speed limits and any stop signs, use extra caution and avoid turning whilst on grades, ramps and inclines • Do slow down when approaching an intersection or corner • Do drive on the left hand side of roadways, were practicable • Do ensure the parking brake is set, the forks are lowered to the ground and controls are neutralised when getting off a forklift • Do drive in reverse when travelling with a load which obscures your view. • Do instruct Transport Drivers. Drivers are under the direct supervision of Forklift Operators whilst on site. 12/07/2006 Rev B

  20. VITAL SAFETY REQUIREMENTS cont. • Do ensure Drivers are in a safe position away from the forklift and remain in sight of the forklift Operator whilst loading/unloading. If Driver is not in sight, stop operating the forklift until he/she is. • Do isolate Forklift electricals using isolation switch immediately upon starting forklift (Class 1 Zone 2) • Do ensure persons being raised in a cage attachment wear a body harness and shock absorbing lanyard attached to the cage and cage is secured correctly to Forklift. 12/07/2006 Rev B

  21. VITAL SAFETY REQUIREMENTS cont. • Do not use a forklift if it is unsafe, defective, damaged or in an unserviceable condition • Do not start/ restart non Class 1 Zone 1 forklifts in a hazardous area • Do not use forklift where there is a risk of fire/explosion due to the presence of flammable or oxidising substances as a result of a spill or a leak (Class/ Subrisk 2.1 or 3 or 4.1 or 4.2 or 4.3 or 5.1 or 5.2) • Do Not use a removable attachment unless it is in good condition and securely attached • Do Not undertake operations if area is congested with other Forklifts and poses a risk 12/07/2006 Rev B

  22. VITAL SAFETY REQUIREMENTS cont. • Do Not raise people on forks or pallets. Forklifts are designed to lift/ move loads, not people. • Do Not scrape tynes on concrete. (this reduces the life of the tynes) 12/07/2006 Rev B

  23. NEWSSeventeen-Year-Old Laborer at Salvage Timber Operation Crushed by Forklift That Tipped Over The victim jumped from the operator’s seat. The victim’s head was caught between the overhead guard and the ground. Other workers heard screams and went to the forklift. They raised the machine and pulled the victim from under the overhead guard. Emergency personnel were notified and arrived within 15 minutes. The victim was transported to a local emergency room where he was pronounced dead. Photo 2. Overturned Forklift - Unsecured Operator's Seat Photo 1. Overturned Forklift. 12/07/2006 Rev B

  24. While every step must be taken to minimise the chance of an incident, it is important to know what to do in such a situation. If a side or forward rollover occurs, operators should not jump, instead they should stay in the cabin, hold on firmly and stay with the truck,leaning in the opposite direction of the overturn. A properly adjusted seatbelt will keep you safely in the cabin during an overturn. 12/07/2006 Rev B

  25. ???? 12/07/2006 Rev B

  26. Rules for Storage • Haztainers no more than four high in a block stack • Hazacons no more than four high in a block stack • IBC’s no more than four high in a block stack • Plastic drums no more than two high in a block stack • Steel drums no more than four high in a block stack • Bagged freight (eg 25kg) no more than three high in a block stack when the pallet exceeds 1.2 meters in height • Bulk Bags no more than three high when the pallet exceeds 1.2 meters in height • Do not place pallets into racks that exceed the safe working load of the rack • Freight unsecured in pallet racking at levels three and above must be secured 12/07/2006 Rev B

  27. Test your knowledge • Through the following slides you will be asked an number of questions to show that you have understood the content of this learning tool • Please record your answer on the training form F-260. • You will be required to submit the answers to the DGL HSEQ unit

  28. Question 1 It is OK not to do a pre-inspection check if you are in a hurry? a) True b) False 12/07/2006 Rev B

  29. Question 2 • Where do I record any fault with the Forklift? • a) No need to it will be fixed when serviced • b) If you remember at end of shift • c) On the daily Forklift inspection checklist 12/07/2006 Rev B

  30. Question 3 • A forklift travelling at 14km/hr will stop in what distance? • a) under 2 metres • b) at a minimum of 10 metres • c) at 8 metres • d) Forklift does not travel that fast 12/07/2006 Rev B

  31. Question 4 • What are some of the causes for Forklift to become unstable? • a) Uneven load, Turning slowly, Breaking too quickly • b) Uneven surfaces, Forks in lowered position, Even load • c) Towing disabled Forklifts, Avoiding low doors or beams • d) Colliding with another forklift/ vehicle, Travelling too fast, • Travelling with a raised load 12/07/2006 Rev B

  32. Question 5 1/3 of forklift injuries involve which of the following? a) Not wearing a seatbelt, speeding, even ground b) Slips, trips and falls while getting on or off forklifts c) Traveling on uneven ground d) Using steps and grab handles, having 3 points of contact 12/07/2006 Rev B

  33. Question 6 When Carrying a load what do you look out for? a) Ensure that the load is within the forklift load limit listed on the load capacity plate, if pallets are damaged remove them b) Birds feeding out of rubbish bin c) Supervisor is not watching you work 12/07/2006 Rev B

  34. Question 7 • When Pedestrians are near what should you do? • a) Speed up so as to avoid them • b) Ignore them • c)Drive slowly, sound warning device to warn them • d) Tell them to get out of the way 12/07/2006 Rev B

  35. Question 8 • Which is a safety requirement when operating a forklift? • a) Use a forklift even is unsafe • b) Do not isolate Forklift electricals using isolation switch immediately upon starting forklift (Class 1 Zone 2) • c) Do slow down when approaching an intersection or corner • d) Use a removable attachment when needed 12/07/2006 Rev B

  36. Additional information 12/07/2006 Rev B