Forklift Operator Safety

Transcription

1 Title: Forklift Safety Effective Date: 4/1/2014 Control Number: THG_0021 Revision Number: 1 Date: 10/13/2015 Annual Review Completed: 5/13/2015 CONTENTS Forklift Operator Safety I. OBJECTIVE II. ASSIGNMENT OF RESPONSIBILITY III. FORKLIFT INVENTORY IV. DESIGNATED AREAS V. FORKLIFT CAPACITY AND ATTACHMENT LABELING VI. FORKLIFT INSPECTIONS AND MAINTENANCE VII. FORKLIFT BATTERIES VIII. OPERATOR SAFETY TRAINING APPENDICES A. Forklift Inventory Form B. Designated Facility Operating Areas C. Attachment Inventory Form D. Inspection Checklist for Electric Forklifts E. Inspection Checklist for Gas or LPG Forklifts F. Forklift Maintenance Log G. Training Attendance Log Page 1 of 12

2 I. OBJECTIVE A. The major goal of The Hillis Group, LLC in creating a Forklift Compliance Program is to minimize the number of accidents and injuries due to incidents involving forklifts which are operated by our employees. B. Because we recognize a number of employees are affected by our use of forklifts, we have committed ourselves to doing as much as is practically possible to protect them from incidents involving this equipment. II. III. IV. ASSIGNMENT OF RESPONSIBILITY A. Plan Administrator 1. The Safety Manager shall manage and update the Forklift Operator Safety Plan for The Hillis Group, LLC, and maintain all records pertaining to the plan. B. Management 1. The Hillis Group, LLC will implement this plan and provide safe equipment that, when used properly, will minimize or eliminate risk of occupational injuries and deaths. 2. The Hillis Group, LLC management will ensure proper adherence to this plan through periodic audits. C. Supervisors 1. Supervisors shall themselves follow and ensure their employees are trained in and follow proper forklift safety procedures as outlined in this plan. D. Employees 1. Employees are responsible for adhering to proper forklift safety procedures as described in this plan. 2. Employees are also responsible for reporting all accidents or near misses to the Safety Department within 24 hours. E. Contractors 1. Contract employees shall be responsible for complying with this plan, and may be provided the training described herein by the Safety Manager. FORKLIFT INVENTORY A. In order for our employees to know exactly what forklifts are available for their use, and which areas of our operation each truck can safely operate in, we periodically conduct an "Inventory" of our forklifts. (See Appendix A) The Shop Manager is responsible for seeing these inventories are completed. The inventory form allows us to record the following information about our forklifts: 1. Manufacturer 2. Model 3. Serial number 4. Capacity 5. Attachments that may be used with the forklift DESIGNATED AREAS A. To make it as easy as possible for our employees to know which of our forklifts may be used safely in the various work areas they operate, we have created a list of "Designated Facility Operating Areas" to be used as a quick reference for this information (See Appendix B). It allows us to record the following information: 1. The name of the work area 2. The location of the work area within our facility 3. Class of location per 29 CFR Table N Group of location per 29 CFR Table N-1 Page 2 of 12

3 5. Division of location per 29 CFR Table N-1 V. FORKLIFT CAPACITY AND ATTACHMENT LABELING A. We periodically inspect our forklifts to make sure they are properly labeled and/or tagged. The Shop Manager is responsible for this activity. B. To facilitate these inspections, the completed Forklift Inventory Form (Appendix A) may be used. C. The following information should appear on the label or name plate of the forklift: 1. The weight of the forklift 2. The forklift's capacity 3. The forklift's usage designation D. The Attachment Inventory Form (Appendix C) should be completed and should contain the following information from the attachment label: 1. Manufacturer 2. Model / Type 3. Serial number 4. Weight of the attachment 5. Capacity of the attachment VI. VII. FORKLIFT INSPECTIONS AND MAINTENANCE A. In order to make sure our powered industrial trucks are maintained appropriately and are functioning correctly, they are inspected daily (or in the case of trucks that are used around-theclock, after each shift). B. The Shop Manager is responsible for making sure that these inspections are carried out appropriately. To facilitate this process, and make sure the trucks are thoroughly inspected, we use the "Forklift Inspection Checklist" (see Appendices D and E). These forms list items/areas which are to be inspected to assure the forklift is in proper operating condition. C. If the inspection of one of our forklifts indicates it is in need of maintenance, or if a forklift is damaged during operation, we immediately remove the forklift from active duty. D. To make sure we have a comprehensive record of the maintenance performed on each of our forklifts, we use the Forklift Maintenance Log (Appendix F). This log allows us to record the following information: 1. Truck serial number. 2. The date maintenance was performed on the truck. 3. The type of work that was performed. 4. The employee that performed the work FORKLIFT BATTERIES A. We recognize maintaining and installing the batteries in our forklifts is one of the most dangerous maintenance activities our employees engage in. B. The Shop Manager is responsible for making sure the following are in each of our battery service areas: 1. A charged ABC fire extinguisher. 2. Protective guards around the charging apparatus. 3. Appropriate battery handling equipment. 4. Personal protective equipment. 5. A functioning eyewash station. Page 3 of 12

4 VIII. OPERATOR SAFETY TRAINING A. We understand a large percentage of accidents involving forklifts are due to operator error. In order to make sure our employees are appropriately trained before operating their forklifts, they are given both classroom and hands-on instruction in the following areas: 1. The contents of the OSHA Standard 29 CFR Types & characteristics of forklifts 3. Pre-operational inspections 4. Basic driving, stability and load handling 5. Fuels & batteries 6. Attachments B. We also provide our truck operators with retraining under the following circumstances: 1. If they have been involved in an accident or near-miss incident. 2. If they have been observed operating their truck in an unsafe manner. 3. If they have been assigned to drive a different type of truck than they have been trained on. 4. At least every 3 years. C. The Safety Manager is responsible for overseeing these training activities. 1. The Safety Manager will also make sure new employees in our facilities have had the appropriate training before they are allowed to operate forklifts, and each forklift operator undergoes a performance evaluation at least once every three years. 2. In order to make sure employees are receiving the training they need, as well as to document this training, we use the Employee Training Log (Appendix G). Page 4 of 12

5 APPENDIX A Enter Date: Forklift Inventory Form # Manufacturer Model Serial # Capacity Use Designation Attachments Page 5 of 12

6 APPENDIX B Enter Date: Designated Facility Operating Areas This table should be completed by using 29 CFR Table N-1 as a reference. Name of Area Location Description Class Group Division Page 6 of 12

7 APPENDIX C Enter Date: Attachment Inventory Form # Manufacturer Model / Type Serial # Weight Capacity Page 7 of 12

8 APPENDIX D Operator s Daily Checklist: Electric Forklift Check each item before the shift begins. Put a check in the box if the item is OK. Explain any unchecked items at the bottom and report them to a supervisor. Do not use an unsafe forklift. Your safety is at risk! Forklift Serial Number: Hour Meter Reading: Operator: Date: Visual Check Tires are inflated and free of excessive wear or damage. Nuts are tight. Forks and mast are not bent, worm or cracked. Load back rest extension is in one place and not bent, cracked or loose. Overhead guard is in place and not bent, cracked or loose. Attachments (if equipped) operate OK and are not damaged. Forklift body is free of excessive lint, grease or oil. Hydraulic system is full and free of leaks. Battery connections are tight. Covers over battery and other hazardous parts are in place and secure. Load rating plate is present and readable. Warning decals and operator s manual are present and readable. Seat belt or other restraint is accessible and not damaged, oily or dirty. Motor runs smooth without sudden acceleration. Horn works. Turn signals (if equipped) operates correctly. Lights (head, tail and warning) work and are aimed correctly. Gauges and instruments are working. Lift and lower operates smoothly without excess drift. Tilt operates smoothly without excessive drift or chatter. Control levers are labeled, not loose or binding and freely return to normal. Battery charge level is OK while holding full forward tilt. Steering is smooth and responsive, free of excessive play. Brakes work and function smoothly without grabbing. No fluid leaks. Parking brake will hold forklift on an incline. Backup alarm works. APPENDIX E Page 8 of 12

9 Operator s Daily Checklist: Gas or LPG Forklift Check each item before the shift begins. Put a check in the box if the item is OK. Explain any unchecked items at the bottom and report them to a supervisor. Do not use an unsafe forklift. Your safety is at risk! Forklift Serial Number: Operator: Hour Meter Reading: Date: Visual Check Tires are inflated and free of excessive wear or damage. Nuts are tight. Forks and mast are not bent, worm or cracked. Load back rest extension is in one place and not bent, cracked or loose. Overhead guard is in place and not bent, cracked or loose. Attachments (if equipped) operate OK and are not damaged. Forklift body is free of excessive lint, grease or oil. Engine oil is full and free of leaks. Hydraulic oil is full and free of leaks. Radiator is full and free of leaks. Fuel level is OK and free of leaks. Battery connections are tight. Covers over battery and other hazardous parts are in place and secure. Load rating plate is present and readable. Warning decals and operator s manual are present and readable. Seat belt or other restraint is accessible and not damaged, oily or dirty. Motor runs smooth without sudden acceleration. Horn works. Turn signals (if equipped) operates correctly. Lights (head, tail and warning) work and are aimed correctly. Gauges and instruments are working. Lift and lower operates smoothly without excess drift. Tilt operates smoothly without excessive drift or chatter. Control levers are labeled, not loose or binding and freely return to normal. Battery charge level is OK while holding full forward tilt. Steering is smooth and responsive, free of excessive play. Brakes work and function smoothly without grabbing. No fluid leaks. Parking brake will hold forklift on an incline. Backup alarm works. APPENDIX F Page 9 of 12

10 Forklift Maintenance Log # Serial # Date Work Completed Completed By APPENDIX G Training Attendance Log Page 10 of 12

11 Forklift Operator Safety Training Date: Time: Location: Name of Training Instructor: Printed Name Employee ID Number Signature Training materials for this session were provided by National Safety Compliance. (Signature of Instructor) Controlled Document Review and Approval Page 11 of 12

12 Procedure Number THG_0021 Revision 1 Effective Date: 4/1/2014 Originator: S.C. Brockman Signature Date Safety Committee Review Date: Chairman: History Revision Number Effective Date Pages Revised Reason for Revision 1 10/13/15 All Revised Procedure Format Page 12 of 12