LICENCE TO OPERATE AN ORDER PICKER

Transcription

1 Module 1 and 2 ONE DAY Order Picker Course (Learner Pack 1) Content: 1. Plan Work (OHS / Legislation) 2. Check and Operate 3. Order Picking 4. Shutdown 5. Calculations TLILIC2002A Powerpoint Presentation LICENCE TO OPERATE AN ORDER PICKER

2 So where do we start? Welcome to Staltari OHS Training & Assessment In the following order now check-off all Learner Packs required for learning: 1. Learner Pack 1 = Singular guide covering both Modules 1 and 2 (reflecting classroom.ppt presentation. 2. Learner Pack 2 = Student Activity Book for your sample answers The following documents will be discussed during actual enrolment therefore there is nothing for you to study regarding these at this point: a) Work Health & Safety Common Terms & Definitions (communications) b) Safe Work Method Statement (Policy & Procedure) c) Risk Analysis Matrix (Relative to final Safe Work Method Statement) d) SWMS / JSA e) Hazard Report Form, comprising six (6) sections NOTE Only in-experienced candidates are to be issued with a (3 day) HRWL log book which must be signed off by the senior area workplace supervisor. The HRWL Log Book is a separate work tool and is not included in any Learner pack. 2

3 Must Read Once you have checked the required documents are all present find a quiet place conducive to learning (a cold beer is optional but don t go overboard). The idea of attending a 1 day order picker course is to demonstrate over an eight hour period your ability to have learned prior to the set course date and continue learning once attended, so we may assess you both theoretically and practically against the full Unit of Competence TLILIC2002A. This is the most important area of your learning as a successful result leads to the issuing of a Statement of Attainment. Without proven competence in this area of Order Picker operations, you will not be permitted to proceed to the WorkSafe Assessment. 3

4 Learning Rationale The reason you were permitted to enrol in a 1 day course is you were either an: in-experienced operator who has now completed the 3 day High Risk Work log book (supplied with this Learner Pack) or an experienced operator who was not required to complete the log book. Whichever of these above categories you fall into during your enrolment, all HRWL candidates must complete Modules 1 and 2, aligned against the latest Work Place Health and Safety laws as part of the National Harmonisation Agenda across Australia. In effect since 1 April The only other pathway to achieve the required Statement of Attainment is via an RPL. Our professionally tailored program is designed to be easier and more effective to complete when compared to a Recognition of Prior Learning process for your SOA. The problem with completing an RPL for your SOA is of all the experienced operators we have, history shows they lack the current required knowledge, regarding the new OHS requirements now covered by Module 1 and 2. 4

5 Let s Get Started with your Learning You are completing Module 1 and 2 as a practice run only for the actual assessment for your Statement of Attainment during enrolment. Therefore, we are now going to look at the following slides/pages in order to understand how forklifts and the related legislation were designed to work hand in hand. Once you have read and understood the entire Module 1 and 2 Learner Pack 1, have a go at completing the questions in your Learner Pack 2. This will ensure the basis of your learning via practice. In class we will revise and double check your answers with your trainer prior to further revision in preparation for your closed book [formal] written assessment for your SOA. NOTE: All Learner Pack 2 s are to be handed in to your trainer prior to this assessment. In the spirit of valid responses, no notes allowed during actual assessment. All correct information you are required to learn will be highlighted in colour blue in Learner Pack 1. Remember, read and learn, then practice your written answers in Learner Pack 2 and remember to bring to your 1 day course in order to maintain your enrolment conditions. 5

6 1. Plan Work (OHS/Legislation) Remember, you need to read and understand the relevant section you are studying and look for the blue answer/s that will form part of your practice assessment at home. TIP: Anything written in green is used to help clarify information. 6

7 OHS/WHS Requirements Occupational Health & Safety/Work Health & Safety (OHS/WHS) is defined as laws and guidelines to help keep your workplace safe. These can be broken down into four main types: Acts Regulations Codes of Practice Australian Standards Laws to protect the health, safety and welfare of people at work. Gives more details or information on particular parts of the Act. Are practical instructions on how to meet the terms of the Law. Give you the minimum levels of performance or quality for a hazard, work process or product. Remember answers are always highlighted in blue. 7

8 What is Duty of Care? All personnel/workers have a legal responsibility under duty of care to do everything reasonably practicable to protect others from harm by complying with safe work practices, including activities that require licences, tickets or certificates of competency or any other relevant state and territory OHS/WHS requirements. 8

9 What are Safe Work Practices? Safe work practices are methods that must be implemented to make sure a job is carried out as safely as possible. Safe work practices include: Day-to-day observation of OHS/WHS policies and procedures. Emergency procedures. Risk assessment. Use of basic fire-fighting equipment. 9

10 What is a SWMS? A Safe Work Method Statement (SWMS) details how specific hazards and risks, related to the task being completed, will be managed and is developed by the employer/pcbu for their employees/workers. SWMS fulfill a number of objectives: They outline a safe method of work for a specific job. They provide an induction document that workers must read and understand before starting the job. They assist in meeting legal responsibilities for the risk management process, hazard identification, risk assessment and risk control. They assist in effectively coordinating the work, the materials required, the time required and the people involved to achieve a safe and efficient outcome. They are a quality assurance tool. 10

11 The 3 Stages of Risk Management Risk management is made up of the following stages: Identification, Assessment, Treatment Consultation and communicating with others, as well as monitoring and review, should be planned for and carried out at every stage of the risk management process. 11

12 Consultation & Communication Why is it so important to coordinate with others during the risk management process? To Identifying risks and hazards and coming up with ways of controlling them includes talking to the people with knowledge of the situation, or who are directly affected by any action you may take. Controlling a hazard can be a team effort and it s important that everybody knows what they need to do and how/if they need to change their work process to suit. 12

13 Hazard Identification What is a Hazard? A RISK is the chance of a hazard hurting you or somebody else or causing some damage. A HAZARD is the thing or situation that causes injury, harm or damage. If you can remove or at least control a HAZARD you can reduce the RISK involved. 13

14 Risk / Hazard Identification #1 Look for one hazard on each of the following slides Common workplace hazards include: Ground conditions: Condition of pavement. Underground services. Non-weight bearing surfaces. Wet or slippery surfaces. Variable operating surfaces/routes e.g. slopes, ramps or other imperfections. Overhead hazards: Electric/Power lines. Overhead service lines. Bridges. 14

15 Risk / Hazard Identification #2 Look for one hazard on each of the following slides Poor lighting. Surrounding structures: Buildings. Obstructions. Traffic: Pedestrians. Vehicles. Other plant. 15

16 Risk / Hazard Identification #3 Look for a final hazard on this slide Weather: Wind. Lightning. Rain. Forklift instability: Overloading. Poor load placement. Irregular loads. Other hazards: Dangerous materials. Falling from the order picker platform. 16

17 Consider Hazard / Risk Control Strategy Options The following is provided as an explanation only of the hierarchy of hazard controls. 1. Elimination 2. Substitution Completely remove the hazard. This is the best kind of hazard control. Swap a dangerous work method or situation for one that is less dangerous. 3. Isolation Isolate or restrict access to the hazard. 4. Engineering Controls Use equipment to lower the risk level. 5. Administrative Controls Site rules and policies attempt to control a hazard. 6. Personal Protective Equipment The least effective control. Use PPE while you carry out your work. This should be selected at the planning stage of your work, and checked before starting the job. 17

18 Consider Hazard / Risk Control Strategy Options The Hierarchy of Hazard Control is the name given to a range of control methods used to eliminate or control hazards and risks in the workplace. The Hierarchy has 6 levels: YIP: Remember, use an acronym to easily recall the answer: ESIE-AP Pronounced easy-ap 18

19 Safety Equipment for Order Picker It is important to use appropriate safety equipment when working at height. All safety equipment should be selected at the planning stage. Safety equipment includes: PPE per site. Safety harness. Energy absorber. Lanyard. Tip: only 3 answers required. 19

20 Choosing the right Order Picker Select the right Order Picker for the job is important. Before starting the job you will need to think about: The ground conditions. How much room you have to work in. The height of loads that need to be accessed. The type of load and tasks to be performed. Tip: only 3 answers required. These factors will influence your choice of order picking forklift truck. 20

21 3 Things That Cause Instability If the CG moves forward of the drive axle, the truck tends to tip forward (longitudinal). If the CG moves outside of the stability triangle, the truck tends to turn on its side (lateral). The centre of gravity, and therefore the stability, of the loaded truck is affected by a number of factors including size, weight, shape, and position of the load. Also, the height to which the load is elevated, tyre pressure, and the dynamic forces created when the truck is moving. 21

22 Check The Path of Movement? Before you get started it s a good idea to check the path that you re intending to take to make sure that you identify all hazards in the path of movement and implemented effective control measures. Check that the order picker will fit and that there are no obstacles in the way. Also check for any other equipment or people working in the area. ng 22

23 3 Types of Daily Instructions As an order picker driver you need to be able to communicate with those around you while you work, and you need to be able to understand the instructions to use the forklift safely. These can include: Manufacturer s guidelines (instructions, specifications, checklists). Industry operating procedures. Workplace procedures (work instructions, operating procedures, checklists). 23

24 3 Daily Communication Methods FORKLIFT ACCESS Workplace communications may take the form of: Verbal and non-verbal language. Written instructions. Signage. Hand signals. Listening. Questioning to confirm understanding, and appropriate worksite protocol. 24

25 2. Check and Operate Remember, you need to read and understand the relevant section you are studying and look for the blue answer/s that will form part of your practice assessment at home. TIP: Anything written in green is used to help clarify information. 25

26 3 Examples of Visual Checks Before you do anything, walk around the order picker and check to see if there is any visible damage. Make sure that you check: The condition of the forks. The condition of the platform. Under the order picker for oil leaks. The condition of the mast and of the hydraulic rams and hoses. For visual evidence of structural weaknesses (including paint separation or stressed welds). 26

27 Following Basic Procedures Check that the order picker has the appropriate signage and labels. This includes the data plate. Make sure you can read it clearly and that it is firmly attached to the forklift. DO NOT USE AN ORDER PICKER WITHOUT A DATA/LOAD PLATE! If the order picker does not have a data/load plate, or you cannot read it, you must Remove Key, Tag, Report. 27

28 Daily Fluid Checks Check the following fluid levels (as appropriate to the order picker you are operating: Hydraulic oil. Engine oil. Transmission oil. Brake fluid. Cooling water. Battery electrolyte level in each cell. TIP: 3 answers required only 28

29 Checking for information If you are unsure of the order picker controls and or unable to locate controls, refer to the operator s manual. 29

30 Examples of Safety Devices #1 Choose only two from the following slides Check that the forklift has the appropriate safety devices fitted. These can include: Lights: Flashing amber light. Head lights. Brake lights. Reverse lights. 30

31 Examples of Safety Devices #2 Choose only two from the following slides Guards: Overhead guard (including attachment/anchor point for harness). Safety gates and interlocks. Seat belt (where fitted). 31

32 Examples of Safety Devices #3 Choose only two from this last safety slide Devices: Emergency descend device (hydraulic release). Dead man switch. Pallet clamp/pallet locking device. 32

33 Adding Attachments Make sure any attachments (including the forks) are securely fixed. Check that modifications are approved and that attachments are fitted to the manufacturer's specifications (e.g. as per order picker or attachment data plate). Question: Should you ever use an order picker that has been modified beyond the manufacturer's recommendations?. Hint: The answer is a simple NO. 33

34 Checking the Log Book What is checked for in the order picker Log Book and why? Any previous faults with the order picker to make sure these faults have been fixed before use. 34

35 Abnormal Noise Upon Start Up Once you have visually checked the order picker, start it as per the manufacturer s guidelines. Listen for any abnormal noises during start-up as these may indicate a fault. 35

36 OPERATIONAL CHECKS All order picker movements and control functions are smooth and comply with operating requirements (e.g. dead man control). Steering, transmission and brake functions comply with operating requirements. CHECK ALL Items on Checklist and MOVEMENTS AND FUNCTIONS TO THEIR FULL EXTENT! 36

37 Report Faults If you find anything wrong with the order picker during your checks you must: 1. Immediately stop the order picker and remove the keys. 2. Tag the order picker as out of service to stop anybody using it. 3. Record the problem in the logbook or on the inspection checklist. Give as much detail as possible. 4. Report the fault to your supervisor or other authorised person. 5. Do not operate the order picker until repairs are carried out. 37

38 Safety When Operating You must be located within the control platform at all times while operating the order picker. The handrail (is one item) on the platform (if fitted) must be close at all times while the order picker is moving. Make sure you are secured to a harness/ lanyard (is a second item) and anchor point before stepping out onto the load platform. 38

39 Apply Hazard Control Measures #1 TIP: Use the next two slides to choose 3 answers total Control measures could include: Disconnecting power when working near electric/power lines or overhead services. Putting safety tags on electrical switches/isolators to stop somebody from turning the power back on while you are working on or near electric/power lines. Insulating electric/power lines. 39

40 Apply Hazard Control Measures #2 TIP: Use previous and this slide to choose 3 answers total Using a safety observer (also known as a spotter) inside the exclusion zone to make sure you don t get too close to electric/power lines. Setting up barricades and traffic control to keep the area clear. Placing pedestrian controls (barricades, signs, etc.) to limit the number of people in the area. Moving any obstructions out of the way. Wearing Personal Protective Equipment (PPE) such as high-visibility clothing and non-slip work boots. Setting up adequate lighting in the work area. 40

41 3. Order Picking Remember, you need to read and understand the relevant section you are studying and look for the blue answer/s that will form part of your practice assessment at home. TIP: Anything written in green is used to help clarify information. 41

42 Determining the Weight of the Load You can check the weight of a load a number of ways: Weigh the load. Check for markings on the load. Calculate the weight of the load. Check the weighbridge certificate. 42

43 Reversing a Load Before reversing the order picker: Check warning devices work, check your mirrors, and look over both shoulders. If possible (depending on the location of the controls on the order picker) face the direction of travel and make sure that all warning devices are working properly to warn other workers/personnel who are nearby. 43

44 Travelling with a Load Never travel the order picker while you are raised more than 600mm from the ground. Order picking forklifts may be fitted with sensors or safety switches to prevent any movement while the order picker from travelling while raised. Under no circumstances should you tamper with or interfere with these safety features to allow the order picker to travel while raised. They are fitted for a reason to keep the order picker stable. Always lower the load as close to the ground as possible while travelling for stability. Under 600mm is considered a safe height for travelling with a load on an order picking forklift. Sound your horn before lowering the order picker or travelling while raised. 44

45 Loads That Obscure Vision If the load blocks your view get somebody to direct you and keep an eye out for other people or equipment in the area. Be aware of rear end swing. This can be very dangerous for people nearby. Keep to the left of aisles and roadways for two-way traffic and maintain a safe distance from other vehicles at all times. 45

46 Travelling With a Load Maintain a safe operating speed based on: The size and load type. Worksite policies, procedures and signage. Weather conditions. Ground/floor conditions. If the floor is wet or slippery you should reduce your speed, avoid using ramps or other inclined pathways and proceed with caution. Personnel/workers and other equipment in the area. Forklift technical limitations and capabilities. TIP: 3 answers only 46

47 Monitoring The Load You need to constantly monitor the load movement to ensure that personnel/workers in the area are safe, and that the load and order picker are stable. Avoid travelling on slopes, ramps or inclines. Order picking forklifts are top-heavy and more likely to overturn on an inclined surface. Stick to hard level surfaces while travelling in the order picker. 47

48 Placing A Load Properly If refilling stock into racking or shelves, you need to make sure that: Loads are stacked on a firm level site. Heavy goods are placed at the bottom. The stock does not become unstable due to height. 48

49 Order Picker tip-over Procedure If you lose control of the order picker and it begins to tip sideways: Remain in the order picker. Brace yourself until the order picker is stationary and is safe to exit. DO NOT try to jump from the order picker while it is tipping over. The answer is NO. If using a turret truck type forklift where the controls are operated from a seated position it is important that you wear the seat belt. It will prevent you from falling out in the event of a rollover and in the event of a collision it prevents the operator from being propelled into the forklift structure or out of the forklift. 49

50 Contact With Power Lines If the order picking forklift truck makes contact with electric/power lines you must take action to limit any further exposure to danger. 1. If possible, and without endangering yourself, attempt to break contact with the electric/power lines by moving the order picker clear, lowering the fork arms or moving the mast. Before attempting this it is important to consider that the controls may be electrified. If this is the case, do not touch them. 2. If it is not possible to break contact with the electric/power lines, you should stay on the order picker platform if it is safe to do so. Be careful not to touch any metal parts of the order picker as they may be electrified. Answer: Jump only if unsafe to stay on due to fire or life threatening situation 50

51 Order Picker Malfunction If the platform drops suddenly, or you suspect there is a problem with the brakes, steering or hydraulic system, immediately lower the load and turn off the order picker. Check the order picking forklift for any signs of damage or wear and check hydraulic lines for splits or bulges. Report the fault to an authorised person. 51

52 4. Shutdown Remember, you need to read and understand the relevant section you are studying and look for the blue answer/s that will form part of your practice assessment at home. TIP: Anything written in green is used to help clarify information. 52

53 Parking The Order Picker Always park the order picking forklift on a flat surface out of the way of other traffic. DO NOT park the order picking forklift: On sloping surfaces. Near First Aid stations or emergency showers. Near fire-fighting appliances. Near doorways. On or near pedestrian walkways. Emergency exits. Where it is obstructing other traffic. Next to train tracks (no closer than 2m). TIP: 3 answers required only 53

54 Referring to details for Shutdown Procedure Any other site-specific safety procedures as required to shut down and secure the order picker. You may also refer to the manufacturer s instructions or operator s manual for details of how to properly shut down the order picker. 54

55 Securing The Site Turn the engine off and remove the keys from the ignition to prevent unauthorised movement of the order picker (if applicable). 55

56 Post Operational Checks Why? After you have finished using the forklift, you need to check it to make sure it is ready for the next operator. Attach batteries to a charger if applicable. While being charged batteries can give off explosive gasses so it is important for them to be charged in a well ventilated areas. Do not smoke around a charging battery the fumes could ignite, causing an explosion or a fire. Always charge batteries in a well-ventilated area away from any naked flame. 56

57 Post Operational Checks If you find any fault with the order picker during the inspection: 1.Stop any operation. 2.Tag the forklift put a danger tag on the order picking forklift to stop anybody using it. 3.Record the problem in the logbook or on the inspection checklist. Give as much detail as possible. 4.Report the fault to an authorised person. You may make minor repairs to the order picking forklift if you are competent and authorised to do so. 57

58 5. Calculations Remember, you need to read and understand the relevant section you are studying and look for the blue answer/s that will form part of your practice assessment at home. TIP: Anything written in green is used to help clarify information. 58

59 Calculating Load Weight For example: You need to move a load of cartons that have been stacked on a pallet. There are 6 cartons per layer and 4 layers on the pallet each carton weighs 33kg The pallet is standard size and weighs 15kg To work out how much this load weighs you need to add the total weight of all of the cartons to the weight of the pallet and MUST use only the following formula in every case during your WorkSafe Calculations Assessment Cartons per layer x Amount of layers x Weight of cartons = Load Weight. Load Weight + Pallet Weight = Total Weight Therefore, during assessment your answers will always look like this: Cartons 6 x 4 x 33 = 792kgs (load weight) 792kgs + 15kgs = 807kgs (total weight) 59

60 When am I overloaded? There are several common way in which you could overload your order picker. In this slide, the machines are rated for 2000kg s. Regardless of which vehicle has the correct load centre can any of these vehicles lift a load safely that weighs 2500kgs? Answer is NO. Ask yourself why the correct answer is NO? 60

61 When am I overloaded? Order Picker A is rated at 2000kg at approved load centre 700mm Order Picker B is rated at 2000kg at approved load centre 600mm Order Picker C is rated at 2000kg at approved load centre 500mm If the load to be moved is 1800kg in weight and 1400mm wide, which order picker can legally and safely move the load? Answer is A. Ask yourself why the correct answer is A? 61

62 When am I overloaded? Order Picker A is rated at 2000kg at approved load centre 700mm Order Picker B is rated at 2000kg at approved load centre 600mm Order Picker C is rated at 2000kg at approved load centre 500mm If the load to be moved is 1500kg in weight and 1000mm wide, which order picker can legally and safely move the load? Answer is All. Ask yourself why the correct answer is All? 62

63 Thank you for Participating in your own Learning Things you should do now: Ask a friend or your spouse to test your underpinning knowledge for accuracy, as all questions must be answered correctly; in order to pass the theoretical stages of your Module 1 and 2 written assessments on the day. Remember to bring your [practice] written answer sheets found in Learner Pack 2 (Activity Book) to class. You will have a good opportunity on the course day to revise the correct answers ahead of actual assessments. Inexperienced candidates MUST bring original copy of HRWL log book signed off by senior workplace area supervisor. Please any queries to info@staltariohs.com.au or phone Assessor John Staltari on