1 © 2008 all rights reserved a training for the metalworking industries safe operation of forklift
TRANSCRIPT
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A TRAINING FOR THE METALWORKING INDUSTRIES
SAFE OPERATION OF SAFE OPERATION OF FORKLIFTFORKLIFT
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Introduction
Risk management on forklift
Common forklift hazards
Route plan
Training for forklift operators
Pre-operation checks
Load assessments
Common safe practices
Forklift traffic control
Table of ContentsTable of Contents
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Forklift can be hazardous if not handled properly
Forklift accidents can cause serious injury, death,
property and product damage
This poses a serious problem
for everyone
Accidents can be prevented if risk assessment and
safe work procedures (SWP) are followed.
IntroductionIntroduction
Picture source: Picture source: http://www.thompsonandjohnson.com/images/accident1.jpg http://www.thompsonandjohnson.com/images/accident1.jpg
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Forklift Fatalities in SingaporeForklift Fatalities in Singapore
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
Total
Forklift 5 2 2 1 1 1 1 6 0 3 9 31Motor vehicles NEC
0 0 4 0 3 1 1 1 3 0 2 15
Others 1 0 0 0 0 0 1 2 1 0 4 9
Lorries 0 2 1 0 0 0 0 0 1 0 1 5
Trucks 0 0 2 0 0 0 0 1 0 0 1 4
Mechanical Conveyors 0 0 0 0 1 1 `0 0 0 2 0 `4
Source: Ministry of ManpowerSource: Ministry of Manpower
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Potential Forklift AccidentsPotential Forklift Accidents
Picture source: Picture source: http://marbella.to/humour/sep00/forklift.jpghttp://marbella.to/humour/sep00/forklift.jpg
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Potential Forklift AccidentsPotential Forklift Accidents
Picture source: http://www.facelift.co.uk/images/roguesgallery/forklift_no-Picture source: http://www.facelift.co.uk/images/roguesgallery/forklift_no-no1.jpgno1.jpg
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Forklift AccidentsForklift Accidents
Picture source: Picture source: http://siri.uvm.edu/graphics/Industrial_Operations/Forklift_accident.gifhttp://siri.uvm.edu/graphics/Industrial_Operations/Forklift_accident.gif
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Forklift AccidentsForklift Accidents
Picture source: Picture source: http://www.jicosh.gr.jp/english/cases/cases/case105.gifhttp://www.jicosh.gr.jp/english/cases/cases/case105.gif
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Forklift AccidentsForklift Accidents
Picture source: European Industrial Gases AssociationPicture source: European Industrial Gases Association
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Risk Management on Operation of ForkliftRisk Management on Operation of Forklift
Required to manage risks under WSH (risk management) regulations
Assess the risk
Take all reasonably practical steps
Eliminate any risks
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Risk Management on Operation of ForkliftRisk Management on Operation of Forklift
Step 1: Identification of hazard
Picture source: Picture source: http://www.safetyworld.com/images/101.gifhttp://www.safetyworld.com/images/101.gif
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Common Forklift HazardsCommon Forklift Hazards
Overloading
Unsafe stacking
Speeding
Raised forks
Unauthorized operation of forklift
Untrained forklift operators
Picture source: Picture source: http://www.iqsdirectory.com/info/fork-lift-trucks/images/fork2.jpghttp://www.iqsdirectory.com/info/fork-lift-trucks/images/fork2.jpg
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Common Forklift HazardsCommon Forklift Hazards
Lifting of persons on forks
Pedestrians and forklifts moving in the same place
Travelling on slope
Obstruction in the path e.g. overhead, blind corners
Poor ground conditions e.g. slippery, uneven, potholes
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Common Forklift HazardsCommon Forklift Hazards
Body/limbs caught in moving parts of the forklift
Falling loads
Poor condition tyres e.g. without thread markings
Electric Shock (Battery operated forklift)
Source: Ministry of Source: Ministry of ManpowerManpower
Picture source: http://www.cdc.gov/niosh/face/images/96nj062.jpgPicture source: http://www.cdc.gov/niosh/face/images/96nj062.jpg
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Common Forklift HazardsCommon Forklift Hazards
Picture source: http://www.safetyworld.com/images/67.gifPicture source: http://www.safetyworld.com/images/67.gif
Pedestrians and forklift moving in same place
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Common Forklift HazardsCommon Forklift Hazards
Picture source: http://www.sandhillquilting.com/images/M-16-SYS-8436-L.jpgPicture source: http://www.sandhillquilting.com/images/M-16-SYS-8436-L.jpg
Forklift traveling on slope
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Common Forklift HazardsCommon Forklift Hazards
Picture source: Picture source: http://eternitycaptured.com/blog/wp-content/uploads/2007/04/bigstockphoto_Road_Cracks_And_Potholes_http://eternitycaptured.com/blog/wp-content/uploads/2007/04/bigstockphoto_Road_Cracks_And_Potholes_606173.jpg606173.jpg
Poor ground conditions
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Common Forklift HazardsCommon Forklift Hazards
Picture source: Picture source: http://www.riverina.coop/depts/Realestate/Other/forsale_auctions/whybro/RIMG2040.JPGhttp://www.riverina.coop/depts/Realestate/Other/forsale_auctions/whybro/RIMG2040.JPG
Worn out tyres
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Common Forklift HazardsCommon Forklift Hazards
Picture source: http://www.locknpop.com/images/img_fork.gifPicture source: http://www.locknpop.com/images/img_fork.gif
Unsecured load
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Common Forklift HazardsCommon Forklift Hazards
Picture source: http://www.ubuyme.com/img_prod/679/pic1.jpgPicture source: http://www.ubuyme.com/img_prod/679/pic1.jpg
Electric shock from battery
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Common Forklift HazardsCommon Forklift Hazards
Picture source: http://www.ttt-services.co.uk/Healthandsaftey/forklift_web.jpgcPicture source: http://www.ttt-services.co.uk/Healthandsaftey/forklift_web.jpgc
Lifting Persons on Forks
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Risk Management on Operation of ForkliftRisk Management on Operation of Forklift
Step 2: Assess the risk
Dependent on severity of risk and likelihood of hazards occurring
severity X likelihood = risk level
Risk Level = Low, Moderate or High
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Risk Management on Operation of ForkliftRisk Management on Operation of Forklift
Low
Severity
Likelihood
Minor
Moderate
Major
Remote Low Medium
Occasional Low Medium High
Frequent Medium High High
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Risk Management on Operation of ForkliftRisk Management on Operation of Forklift
Step 3: Select Measures to Control and Reduce Risk
Based on hierarchy of hazards control
1st – Remove the hazard (E.g. Forklift operations route separated from workers)
2nd – Guard the remaining hazards (E.g. Erect physical protective barriers)
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Risk Management on Operation of ForkliftRisk Management on Operation of Forklift
HIERARCHY OF HAZARDS CONTROL
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11stst Remove the Hazards – Forklift Route Remove the Hazards – Forklift Route PlanningPlanning
Picture source: Picture source: http://maaw.info/images/Figure8-10.gifhttp://maaw.info/images/Figure8-10.gif
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Route PlanRoute Plan
• Efficient workplace layout/plan
• Floors and surfaces in good condition
• Fixtures which are clearly visible
• Forklift operating and pedestrian paths identified and clearly marked
• Designated maintenance, parking and battery charging areas
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Forklift Operation Separated from Worker Forklift Operation Separated from Worker AreaArea
Forklift operation area
Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc
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Allocated Goods AreaAllocated Goods Area
Goods sitting area
Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc
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Designated Battery and Parking AreaDesignated Battery and Parking Area
Forklift battery charging and parking area
Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc
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22ndnd Guard the Remaining Hazards: Protective Guard the Remaining Hazards: Protective BarriersBarriers
Brightly coloured barriers
Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc
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Risk Management on Operation of ForkliftRisk Management on Operation of Forklift
3rd – Mitigate impact of hazard (E.g. Operator to wear an seat belt)
Source: Source: Ministry of Manpower
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Risk Management on Operation of ForkliftRisk Management on Operation of Forklift
Risk assessment to be done for every forklift tasks
To identify the risk and control measures
Establish safe work procedures (SWP)
Inform staff of SWP
Staff to follow SWP
Source: Source: Ministry of Manpower
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Risk Management on Operation of ForkliftRisk Management on Operation of Forklift
Forklift Safe Work Procedures (SWP)
Forklift TrainingForklift Training
Pre-Operation CheckPre-Operation Check
Load AssessmentLoad Assessment
Common Safe PracticeCommon Safe Practice
Traffic ControlTraffic Control
Source: Source: Ministry of Manpower
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Forklift Training Forklift Training
Under Factories (Safety Training Courses) Order, all forklift operators shall undergo a Forklift Drivers’ Training Course
Conducted by a MOM Accredited Training Provider
Consists of 1-day theory course
And 4 or 2 days practical course
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Why Conduct Forklift Training Why Conduct Forklift Training
Ensure forklift drivers are competent
To train driver in basic forklift operation
To provide knowledge of safe operating practices for forklift
Picture source: http://www.crowndfw.com/training.htmlPicture source: http://www.crowndfw.com/training.html
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Why Conduct Pre-operation Why Conduct Pre-operation Checks?Checks?
Ensure efficient and safe operation of forklifts
Prevent workplace injuries
To remove inefficient forklift practices
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Under WSHAC Forklift Checklist, Pre-Under WSHAC Forklift Checklist, Pre-operation Checks Includes:operation Checks Includes:
Tyres and wheels Forks/attachments Chains, cables and hoses Safety devices (e.g. seat belts, warning devices, rear mirror and etc.) Leaks Hour meter Battery/LPG system Battery connector Guards Structural damage
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Pre-operation Checks 1Pre-operation Checks 1
Source : http://www.thefabricator.com/Images/96/forklift-truck-Source : http://www.thefabricator.com/Images/96/forklift-truck-diagram.jpgdiagram.jpg
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Pre-operation Checks 2 – Propane ForkliftPre-operation Checks 2 – Propane Forklift
Picture source: Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gifhttp://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif
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Pre-operation Checks 3 – Electric ForkliftPre-operation Checks 3 – Electric Forklift
Picture source: Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gifhttp://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif
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Pre-operation Checks 4 – Yard ForkliftPre-operation Checks 4 – Yard Forklift
Picture source: Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gifhttp://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif
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Forklift Load Assessments 1Forklift Load Assessments 1
• Forklift can only handle loads within rated capacity
• Follow forklift manufacturer’s load chart
Picture source : Picture source : http://gmesupply.com/images/product_desc_images/forklifts/load-chart.jpghttp://gmesupply.com/images/product_desc_images/forklifts/load-chart.jpg
Forklift Model
Length of fork
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Forklift Load Assessments 1Forklift Load Assessments 1
• When attachments are used, the total weight of the load and attachment must not exceed the lifting capacity
Picture source : http://www.kinggroup.com.auPicture source : http://www.kinggroup.com.au
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Forklift Load Assessments 1Forklift Load Assessments 1
• Don’t increase the capacity of the forklift using personnel as additional counterweights
Picture source : http://www.staugustinelighthouse.com/blog/forklift.jpgPicture source : http://www.staugustinelighthouse.com/blog/forklift.jpg
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Forklift Load Assessments 2Forklift Load Assessments 2
• Only handle stable or safely arranged loads
• Care to be taken when handling extra long or high load
• When loads can’t be centered, the forklift should be operated with caution
Source: CP 101: 2004 Code of practice for safe use of powered counterbalanced forkliftsSource: CP 101: 2004 Code of practice for safe use of powered counterbalanced forkliftsPicture source: http://www.baileypottery.comPicture source: http://www.baileypottery.com
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Load Assessments – Weighing the LoadLoad Assessments – Weighing the Load
Picture source: http://www.weighing-systems.com/TechnologyCentre/forkliftweigh.htmlPicture source: http://www.weighing-systems.com/TechnologyCentre/forkliftweigh.html
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Load Assessments – Weight at Centre of Load Assessments – Weight at Centre of GravityGravity
Picture source: Picture source: http://www.morsemfgco.com/images/forklift_sm.gif
Forklift
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Load Assessments – Weight at Centre of Load Assessments – Weight at Centre of GravityGravity
Picture source: Picture source: http://www.rentrain.com/resources/fork_21.gif
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Load Assessments – Weight at Centre of Load Assessments – Weight at Centre of GravityGravity
Picture source: http://www.ccohs.ca/images/J05-2.gifPicture source: http://www.ccohs.ca/images/J05-2.gif
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Load Assessments – CharacteristicsLoad Assessments – Characteristics
Picture source: Picture source: http://www.thetoyspace.com/images/planforklift.gif
Unstable load
Picture source: Picture source: http://user1292213.sites.myregisteredsite.com/sitebuildercontent/sitebuilderpictures/forklift.gifhttp://user1292213.sites.myregisteredsite.com/sitebuildercontent/sitebuilderpictures/forklift.gif
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Load Assessments – ShapeLoad Assessments – Shape
Picture source: http://www.nepowder.com/images/FORKLIFT%20II.JPGPicture source: http://www.nepowder.com/images/FORKLIFT%20II.JPG
Odd shape load may hit pedestrians causing injuries
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Load Assessments – ShapeLoad Assessments – Shape
Picture source: Picture source: http://www.fremantleports.com.au/About/PhotoGallery/North_Quay_forklift_operations_at_night_rdax_77http://www.fremantleports.com.au/About/PhotoGallery/North_Quay_forklift_operations_at_night_rdax_772x526.jpg2x526.jpg
View blocked, the forklift may hit another container or somebody
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Common Safe PracticesCommon Safe Practices
Don’t drive a forklift unless you are trained and authorized
Use seatbelts
Wearing seatbelts
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Common Safe PracticesCommon Safe Practices
Report to your supervisor on any forklift damage or problems
Don’t use a forklift to lift worker
Use caution on slopes or ramps
Picture source: http://www.liftomatic.comPicture source: http://www.liftomatic.com
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Common Safe PracticesCommon Safe Practices
While on slopes, tilt the load back and raise it above road surface
Don’t raise or lower the forks while the forklift is moving
Don’t handle loads that are above the weight capacity of the forklift
Follow the speed limit
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Common Safe PracticesCommon Safe Practices
Slow down and sound the horn at crossings and locationswhere view is blocked
Focus on the travelling path and keep a clear view of it
When leaving a forklift, pull the parking brake, lower the forks and neutralize the controls
Picture source: Picture source: http://www2.worksafebc.com/i/posters/2003/ha0313_forklift.htm
Hand brake not engaged
Source: Source: NIOSH Publication No. 2001-109
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Common Safe PracticesCommon Safe Practices
Attend briefing on forklift operations
Follow traffic management
Carry out daily forklift pre-operation checks using checklist
Ensure that the forklifts are well maintained
Use rear view mirrors while reversing
Give way to pedestrians
Park forklift at approved locations.
Picture source: Picture source: http://www.safety-mirrors.co.uk/cabfront.jpg
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Common Safe PracticesCommon Safe Practices
Source: Source: Ministry of Manpower
Operate forklifts with forks at low position at all times
Don’t drive and raise load at the same time
Don’t make sudden sharp turns
Don’t brake suddenly when the forklift is
loaded
Watch out for overhead structures (e.g. pipes & beams)
Travel in reverse when front view is blocked
Picture source: Picture source: http://www.iqsdirectory.com/info/fork-lift-trucks/images/fork1.jpg
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Traffic ControlsTraffic Controls
• Follow the forklift route plan and pedestrian path
• Obey the speed limits, pedestrian crossings and one way signs etc.
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Traffic ControlsTraffic Controls
• Follow site rules and inform all staff and visitors
• Operate forklift only in clearly marked areas
• Lookout for people opening doors
• Check back when reversing
• Give way to pedestrians
Picture source: http://www.derrycity.gov.uk/Site_Images/forklift.jpgPicture source: http://www.derrycity.gov.uk/Site_Images/forklift.jpg
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Traffic ControlsTraffic Controls
• Wear high visibility clothing
• Be cautious on road slopes
• Park on flat surfaces
• Avoid driving over objects on the road surface
• When making turns, reduce speed to safe level
Picture source: http://www.thompsonandjohnson.com/newsletter/images/tip70509.jpgPicture source: http://www.thompsonandjohnson.com/newsletter/images/tip70509.jpg
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Summary of Key PointsSummary of Key Points
Training for forklift operators
Pre-operation checks
Load assessments
Route plan
Common forklift hazards
Forklift common safe practices
Forklift traffic control
Risk management on operation of forklift
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All accidents are All accidents are preventablepreventable
Be proactive: it is up to Be proactive: it is up to US to prevent itUS to prevent it
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Thank YouThank You
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1. WSHAC Occupational Safety & Health Technical Advisory – Safe Operation of Forklift Truck
2. WSHAC Forklift Safety Checklist3. CP: 101: 2004 Code of Practice for Safe Use of Powered
Counterbalanced Forklifts4. MOM Case Studies on Forklift Accidents5. NIOSH Publication No. 2001-109 NIOSH Alert: Preventing
Injuries and Deaths of Workers Who Operate or Work Near Forklifts
6. Chisholm Institute (Warehouse Task – Drive a forklift) (http://olvc.chisholm.vic.edu.au/warehouse/D10/Virtualwarehouse/D10Tasks/D10tasks.htm)
References:References:
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Appendix 1Appendix 1
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Appendix 1Appendix 1
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Appendix 1Appendix 1
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Appendix 2Appendix 2
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AppendixAppendix