Trainee Workbook. Licensing Course. Order Picker Forklift. Trainee Workbook. Participant Name: TLILIC2002 Trainee Workbook

Transcription

1 Participant Name: Order Picker Forklift Licensing Course Trainee Workbook Trainee Workbook Version 1.1 TLILIC2002 Trainee Workbook

2 Table of Contents Training Services 4 You Pty Ltd trading as Raise Training What this Trainee Workbook is about... 3 Introduction to high risk work licensing... 4 Objectives and Principles... 4 Training and Assessment Requirements WHS and High Risk Work Licensing... 5 Application Requirements... 5 Training Requirements... 5 Prepare for hazards... 7 Assess the risk (risk assessment)... 9 Hierarchy of Hazard Control Personal Protective Equipment (PPE) Identify workplace hazards Common workplace hazards Workplace communication Check the forklift Visual checks Checking data plates and signs Controls Pre-operational checks Starting the forklift correctly Post-start operational checks Testing the forklift & recording and reporting faults Plan the move Identifying appropriate communication methods Assessing the weight of the load Move the load Stay alert Shut down and secure the forklift Parking the forklift Securing the forklift Disclaimer: All care has been taken to ensure this workbook is accurate. Training Services 4 You Pty Ltd takes no responsibility for any loss or damage resulting from any inaccuracies or omissions. Also, this workbook does not foreshadow nor take responsibility for future changes to government laws, regulations and guidelines. It is imperative that people using this workbook, source relevant manufacturer s documentation and adhere to company, site and statutory procedures and requirements. The images used in this workbook are for illustrative purposes only. Training Services 4 You Pty Ltd trading as RAISE Training Page 2 of 35

3 What this Trainee Workbook is about Training Services 4 You Pty Ltd trading as Raise Training This trainee workbook is about the skills and knowledge required to operate an order picking forklift, including preparing for hazards, checking the forklift, planning for a move, moving a load, shutting down and securing the forklift. Persons achieving competence in this unit will need to fulfil all of the relevant state WHS regulatory requirements concerning the safe operation of order picking forklifts. Successful completion of this course leads to a licence being issued. The Elements of Competency from the unit TLILIC2002 Licence to operate an order picking forklift truck covered in this trainee Workbook are listed below. - Plan work - Conduct routine checks - Shift load - Shut down and secure forklift truck This unit of competency is from the Transport and Logistics Training Package (TLI). This Trainee Workbook provides general information and advice on the safe operation of an order picking forklift truck. Always read the operator s manual to understand the limitations of the forklift and equipment you are using. RAISE Training recognises the importance of quality training as an underpinning principle in providing skilled workers, and that the most effective form of training is a combination of informal and formal training methods. Use the instruction and information supplied to you by your trainer to gain and demonstrate a satisfactory* level of skill and general knowledge. If you wish you may access additional resources for the purposes of further development or studying for the licensing assessment. It is your responsibility as the trainee to practice and study as required to ensure that your level of competence in both the theory and performance components is satisfactory prior to any form of testing. Workbook Tasks Throughout this workbook, you will be required to perform certain tasks relating to the area of study and used to re-enforce your learning. These points will be highlighted by the following icons: Discussion Points These tasks will help you to understand the underpinning knowledge and will help you to think for yourself and discuss viewpoints with other trainees as well as your trainer. Activities At the end of each element, you will be able to review the content by completing these tasks. The activities help to determine if you understand the information covered and can be completed by yourself or as a group. * a level of skill/knowledge that would be satisfactory to pass a WHSQ Licence Assessment. Training Services 4 You Pty Ltd trading as RAISE Training Page 3 of 35

4 Introduction to high risk work licensing Training Services 4 You Pty Ltd trading as Raise Training The new national system is based on the National Standard for Licensing Persons Performing High Risk Work. The National Standard requires training and assessment to be undertaken by a Registered Training Organisation (RTO) under the Australian Quality Training Framework (AQTF). Objectives and Principles The objectives of this National Standard are: - to ensure that persons have the skills and knowledge to perform high risk work in a safe manner; and - to facilitate the operation of a nationally uniform and efficient licensing system for persons engaged in high risk work. Licenses issued in accordance with this National Standard will be recognised in Australian States and Territories to promote the portability of skills and the free movement of labour across State and Territory borders. This National Standard provides a national policy approach for authorising the performance of high risk work and promoting safety standards relating to high risk work. Training and Assessment Requirements Training and assessment for this course must be delivered under the supervision of, or in partnership with, an RTO in accordance with the AQTF. Training and assessment must show evidence of: - structured training - practical training experience, and - an assessment of the trainee s* competency Before being booked into a WHSQ Licence Assessment, trainees must demonstrate to the RTO Course Facilitator that they have achieved the required competencies to have their skills and knowledge assessed against the relevant unit(s) of competency. Recognition of a trainee s prior learning may exempt a person from undertaking all or part of the training but must demonstrate that the person s equivalent qualifications and prior learning are relevant to the competency. Part of a person s learning may include on the job training and experience. This should be demonstrated through the completion of a training logbook which is used to keep track of workplace training. A person is not allowed to perform HRW if they are not competent to do so (whether you hold a HRW license or not). If a person does not have a HRW license however, they must have been formally assessed by an RTO and operate under the direct supervision by a qualified license holder, for training purposes only. Once the course has been successfully completed, the RTO Trainer/Assessor will complete a assessment documentation which is used to demonstrate engagement in a recognised course of training to a WHSQ Assessor. * Under WHS Regulations, a trainee is a person who is receiving formal training and informal learning in a class of HRW. Training Services 4 You Pty Ltd trading as RAISE Training Page 4 of 35

5 WHS and High Risk Work Licensing Training Services 4 You Pty Ltd trading as Raise Training Under Workplace Health and Safety law, an employer must provide a workplace that is safe and without risk to health. They must provide instruction, training and supervision for their employees to work safely and must do so in a way that is easy for employees to understand. An employer must never allow a person to perform HRW if they know that person is not competent to do so. Otherwise, they will also be responsible for putting others at risk and can be severely penalised. Application Requirements A person must not operate a forklift truck unless the person holds a LF Class HRW licence, unless: 1) A person is enrolled in a course with a Registered Training Organisation (RTO) for the licence required (formal training); AND 2) Being supervised at a workplace by a person who is licensed to carry out the high risk work (informal training). In order to obtain an LO Class forklift licence, an individual must enrol in a formal course of study with a Registered Training Organisation (RTO). Once enrolled in a formal course of training and whilst undergoing either formal or informal learning, the individual is considered a trainee under WHS law. All course participants MUST: 1. Be able to speak and/or understand the English language; and 2. Accept the requirements of the course and assessment process. Training Requirements Persons wishing to apply for a LO Class HRW licence must be assessed by an accredited WHSQ assessor in affiliation with a Registered Training Organisation (RTO). Before the licence assessment can take place applicants MUST: 1. Be at least 18 years old; 2. Be a resident of Queensland; 3. Provide at least 100 points of identification; 4. Not currently hold an equivalent licence; 5. Provide evidence of engagement in a recognised course of training; and 6. Provide evidence that they have achieved the required competencies. An assessment for an HRW licence involves both a knowledge and performance assessments and an assignment (or calculations assessment) conducted by the accredited WHSQ assessor. Training Services 4 You Pty Ltd trading as RAISE Training Page 5 of 35

6 Workplace Health and Safety Queensland (WHSQ) Licensing Assessment This assessment requires applicant to undertake a theory exam, a calculations exam, demonstrate an equipment/site inspection and carry out practical tasks as requested by the WHSQ accredited assessor. On successful completion of the assessment, the Workplace Health and Safety Queensland (WHSQ) Assessor will issue you with an Assessment Summary (AS1). You must submit your application within 60 days from the date of assessment, if you fail to do so the Assessment Summary (AS1) issued by the assessor will expire and you will be required to complete the entire assessment again. You must submit your licence application at an Australia Post outlet only and it must have passport photo facilities. A fee is payable to Australia Post for the licence card which is nationally recognised. If you submitted your application within the 60 day period and have not received your photo license in time, you are still licensed (the payment receipt from Australia Post is your proof of this). You will receive your licence, however, this can take some time depending on holiday shutdowns and how many applications are being processed by Workplace Health and Safety Queensland (WHSQ). Your Assessment Summary (AS1), is valid as proof of qualification until you receive your photo licence card. If you are really concerned you can ring Workplace Health and Safety Queensland (WHSQ) on (have your Assessment Summary and Australia Post receipt with you when you ring them). You will need to renew your HRW licence every five (5) years. If you do not renew your licence within 12 months from the date it expires, you won t be able to renew your licence. Instead, you will need to get new licence by completing a course with an RTO and applying for a new licence. Should you be required to provide written evidence of competency to your employer before commencing high risk work, you can show your employer your HRW licence. Alternatively, you can show your employer that you have enrolled with an RTO and are training to get your licence. Responsibilities It is the responsibility of a HRW licence holder to follow safe operating procedures at all times and to ensure the safety of others in the workplace. Failure to do so can result in the persons HRW licence being cancelled, suspended or being refused to have it renewed. If a HRW licence holder is no longer competent to do the work they hold the licence for (e.g. have not performed work for a number of years and have forgotten), then they should not perform that work and seek further training should they wish to continue. Activity 1 - WHS and High Risk Work Licensing Complete questions 1-6 of a theory assessment. the Activities Workbook Training Services 4 You Pty Ltd trading as RAISE Training Page 6 of 35

7 Section 1 Prepare for hazards Section outline Areas covered in this section are: identify workplace hazards and apply appropriate control measures Training Services 4 You Pty Ltd trading as RAISE Training Page 7 of 35

8 Performance Criteria 1.1, 1.2 and 3.2 Identifying Workplace Hazards A hazard is anything that can hurt you or others while you work. You need to know (identify) workplace hazards before you start work. Look for hazards. Look above you, look around you, and check the ground below you. Hazard Control Measures Hazard control measures are actions you take to control or prevent a danger that can injure (hurt) you or others. Set up hazard controls before you start a task. The hierarchy of controls tells you the steps to take in order to reduce the danger from hazards. A risk is the chance of a hazard injuring a person. The most important aspect of forklift driving is safety. As a forklift driver you must be aware that there are always people working around you and if there was an accident they may be injured. It would be a terrible burden to have on your conscience that your workmate was injured by an accident that you could have prevented. Forklift safety has a very high profile in Australia. These accidents can be prevented only if companies and individuals realise the implications of these accidents and take steps to prevent them from happening. The best method for preventing workplace injuries is to identify hazards, assess the risk of the hazard occurring and apply appropriate control methods. This section of your trainee workbook will look closer at this objective. Hazard A hazard is anything that can harm you or others while you work Risk A risk is the chance of a hazard injuring or hurting a person. In other words, what is the chance of the hazard hurting you? Control A control is what you can do to stop the hazard from hurting or killing you Training Services 4 You Pty Ltd trading as RAISE Training Page 8 of 35

9 Assess the risk (risk assessment) You need to identify (know) the worksite s hazard before you start work. Look for hazards. When you find a hazard, you need to work out two things: 1. How dangerous is the hazard? 2. How likely (risky) is it that the hazard will hurt someone? For example, you find a very dangerous hazard but the risk of it hurting someone is low. Because the danger is high, you need to find a way to control it. Use the risk assessment and control form example below and the hierarchy of hazard control to help you. Talk to workmates or OHS people to work out the best way to reduce the risk. Risk Assessment - Putting it all together Here is an example of a risk assessment and control form. You may use something similar at your workplace to help with risk management. You can find out more about risk management in the Workplace Health and Safety codes of practice. Assess the risk What does assess the risk mean? It means: what are the odds a hazard will injure or hurt you? For example, is there a high or low risk a hazard will hurt or injure you? If the risk is high, talk to OHS reps to work out the best way to use hierarchy of hazard control to remove or control the risk. Training Services 4 You Pty Ltd trading as RAISE Training Page 9 of 35

10 Hierarchy of Hazard Control Training Services 4 You Pty Ltd trading as Raise Training The Hierarchy of hazard control shows the steps you can take to control hazards in your work area. The table below shows the six steps in order from best choice of control to the last choice. You can use these hazard controls together to reduce the risk of harm to yourself and others. Elimination is always the safest option but may not always be practical, while PPE is seen as a last line of defence if other measures fail. A driver must use the safest and most practical control measure or combination of control measures possible. Hazard Control Description Example 1 Elimination If you can, try to remove or get rid of the hazard. 2 Substitution If you are unable to remove the hazard, use something else. 3 Isolation Keep the hazard separate. Stop other people getting near the hazard. 4 Engineering control measures 5 Administrative practices 6 Personal Protective Equipment (PPE) Use plant and equipment to lower the risk of damage or harm. Use safe work practices to reduce the risk of damage or harm. Wear safety clothing and equipment to control a hazard. These are the least useful way to control hazards. Make sure the PPE is right for you and the company has trained you in how to use it. Set up pedestrian exclusion zones. Use a spotter to warn forklift drivers when people are nearby. Q22 (13) Put up barriers or fencing to stop people getting near the hazard. Or put a time restriction in place. This means people can only go into the area at a set time. Use lights, reverse beeper and horns to warn people nearby. Pedestrian exclusion zones marked on the floor and beware of forklift signs. Pedestrians wear hi-vis clothes so forklift drivers can see them more easily. When a potential hazard is identified by a driver, there may already be control measures in place. If this is the case the driver must ensure the control measures that are in place are appropriate for the hazard identified. Personal Protective Equipment (PPE) The best time to ensure your safety equipment is safe to use is before starting any type of work. You must wear a safety harness at all times when operating an order picking forklift. It is important to have a safety harness with a fall arrest system because it can stop the operator from falling out in the event of a tip over and stops the operator from being thrown out of the forklift in the event of a collision. Training Services 4 You Pty Ltd trading as RAISE Training Page 10 of 35

11 Identify workplace hazards A hazard is anything that can hurt you or others while you work. You need to know (identify) workplace hazards before you start work. Look for hazards. Look above you, look around you, and check the ground below you. Zones to check for hazards: Above head height Power line Buildings Trees Bridges Clearance height Other obstructions Other overhead services Ground to eye height Other equipment Machines People/pedestrians Blind corners Things in the path of travel Enclosed area Dimly lit areas Other obstructions Facilities Ground level (and below) The surface is strong enough to support the weight of the forklift and load There are trenches or recently backfilled trenches Spills or wet surfaces Debris/rubbish Underground services Surface condition The surface that an order picker forklift operates on should be hard and level. This is because order picking forklifts are top heavy and may overturn on slopes. Discussion Points What workplace hazards have you identified? Training Services 4 You Pty Ltd trading as RAISE Training Page 11 of 35

12 Common workplace hazards Too dark Rear end swing Pedestrians Weather Hazardous material Working from heights Overhead services Powerlines Pedestrians Pedestrian access should be restricted by ensuring that the area being used by the order picking forklift is secured to prevent pedestrian access. If it is not practicable to fence off the area, you should use witches hats, flashing lights, warning signs or other personnel to assist. Hazardous Material There are a number of common material around the workplace that can potentially be harmful. For example, batteries should be charged in a well ventilated area because when they are under charge they give off gases which may explode. Too dark When working at night or in darkened areas, you MUST have adequate lighting across the entire working area so that the forklift can safely conduct its operations. Rear End Swing The rapid sideways movement at the rear of the forklift truck creates a hazard for pedestrians and other workers. Weather Forklift operations should take additional precautions under extreme conditions such as bad weather conditions, heavy wind etc. For example, if you are operating in bad weather conditions, the surface is wet or slippery, you should reduce your speed and proceed with caution. Workplace communication The first and most important step in reducing the likelihood of an accident is hazard identification. This means identifying all workplace situations or events that could cause injury or illness. There are many methods which are useful for identifying hazards, including communicating with others. Below is a list of the types of people who you can consult with about workplace hazards before starting any type of work Q19 (7.1): Safety officers Supervisors Managers Colleagues OHS Committee members Health and Safety Representatives It is very important to talk with others before starting work, especially on a new job, because every workplace has its own specific hazards and you need to make sure that any workplace policies and procedures are being followed. Activity 2 - Prepare for hazards Complete questions 7-22 of a theory Activities assessment. Workbook Training Services 4 You Pty Ltd trading as RAISE Training Page 12 of 35

13 Section 2 Check the forklift Section outline Areas covered in this section are: Visually inspect the forklift truck for any damage or defects Conduct a start-up check of the forklift truck Check the operational capability of the forklift truck Describe the correct procedure for reporting defects or damage to the forklift truck Training Services 4 You Pty Ltd trading as RAISE Training Page 13 of 35

14 Performance Criteria 2.1 Visual checks You should always do a visual check of a forklift truck before using it to ensure there are not any problems. A faulty forklift truck can cause injury to yourself and others if you have an accident. Before you use an order picking forklift truck, do a vidual check to make sure there aren t any problems. Before you move any loads, look at the forklift to see if it s in a safe working condition and is right for the job. A faulty forklift could cause an accident and injure or kill you or your workmates. To work safely, check the forklift before you start work. Look for damage or faults with things such as: - Battery - is it charged? - Fluids (oils and water) - Date plate - Is it missing or unreadable? - Hydraulic hoses - any leaks? - Tyres - are they flat? - Any attachments - Mast - Brakes - Warning devices - Lights - Gauges - Steering - Shield - Is it clean? - Rust, lifting paint and cracked welds - Forks and platform - are they in place and properly secured? - Logbook/user manual - is it missing? Repairs and Maintenance Using a forklift may be hazardous if maintenance is neglected or repairs, rebuilds or adjustments are not performed in accordance with the manufacturer s design criteria. Therefore, only a competent person who is authorised by the employer can attempt to make any kind of repairs to a forklift truck. Tyres and Wheels It is important to check the condition of the tyres and wheels of an order picking forklift in order to ensure stability. Things you should be keeping an eye on include: - Making sure there are no large chunks missing from the rubber - That the tires are not worn down too far - That the wear is even - That the tyres and wheels are properly secured. Training Services 4 You Pty Ltd trading as RAISE Training Page 14 of 35

15 Performance Criteria 2.2 Checking data plates and signs Forklift trucks are required to display plates and signs. These may include a data plate, compliance plate, manufacturer s plate and warning decals. You must be able to identify all signs and labels. You should know the order picking forklift s load limits and what it can and cannot do. All signs and labels should be clear enough for you to read. Before you use the forklift, look for: - Data plate - Do not use tag - Warning signs You should know the order picking forklift s load limits and what it can and cannot do. All signs and labels should be clear enough for you to read. The weight limit of your forklift truck is its Rated Capacity and is marked on the forklift s data plate. The Rated Capacity of the forklift truck is measured by the Maximum Load that a forklift truck is designed to carry at a specified Load Height at a specific Load Centre Distance. Drivers must be able to understand the load plate and the conditions of loading at all times. The Load Centre Distance is taken from the vertical face of the loading platform to the load centre of gravity. It is the responsibility of the owner to provide a load plate that displays the lifting capacity of the machine under all lifting conditions. Do not use a forklift truck that does not have a load plate. If the data plate was missing or unreadable, the forklift truck should be tagged out of service and reported to an appropriate person. Training Services 4 You Pty Ltd trading as RAISE Training Page 15 of 35

16 Performance Criteria 2.3 Controls Learning what all of the controls do will help you to operate the forklift truck safely. Know your forklifts controls Different forklifts have different controls. Get to know the position and use of all controls on the order picking forklift. These include: - Emergency power disconnect button - Steering wheel - Steering direction indicator - Parking (dead man s) brake pedal/button - Pallet clamp release pedal - Emergency lower valve - Lights - Horn button - Gauges - Hydraulics - Attachments Training Services 4 You Pty Ltd trading as RAISE Training Page 16 of 35

17 Performance Criteria 2.4 Pre-operational checks Before operating the forklift truck, you should always do a number of pre-operational checks. These checks must be done properly before starting the forklift truck. Before you start the forklift, do a number of pre-start checks. A proper pre-start check means more than just a quick look. You ll find a list of pre-start checks in the user/operator manual. Below are examples of pre-start checks: Emergency lower valve Check safety harness Check access gates Check fluids Check mast and lift system Check pallet clamp pins or other locks Check guards Check forward and reverse travel Training Services 4 You Pty Ltd trading as RAISE Training Page 17 of 35

18 Performance Criteria 2.5 Starting the forklift correctly Before operating the forklift truck, you should always do a number of pre-operational checks. These checks must be done properly before starting the forklift truck. To start the order picking forklift, look in the user/operator manual to find out the right way to start it. Listen for strange noises after you start the forklift. Noises may be a sign that something is wrong with the forklift. If you hear a noise you are unsure of, turn the forklift off and do your pre-start checks again. How to start an order picking forklift 1. Make sure both battery gates are securely in place. 2. Connect the battery to the forklift. Put on the battery side covers. 3. Step into the operator s area and lower both side gates. 4. Put the safety belt around your waist and ensure it fits properly. Then secure the lower end of the tether to your safety belt. Secure the upper end of the tether to the tether bar on the overhead guard. 5. Make sure the emergency power button is up. 6. Turn the machine on. 7. If your forklift has a card start, put your card in the slot on the control panel. 8. Ensure the forklift passes the self-test. 9. Check the battery is charged. 10. Take your left foot off the dead man s brake 11. Use one hand to steer the forklift. Use your other hand to control the travel and lift functions. Training Services 4 You Pty Ltd trading as RAISE Training Page 18 of 35

19 Performance Criteria 2.6 Post-start operational checks You should always do post-start checks after you start the forklift truck to ensure the forklift truck is still safe to use. Once you start the order picking forklift, do some more checks to make sure the forklift is still safe to use. For example: Check controls work smoothly Check safety harness Check access gates Check steering Check the brakes Check lights Check horn Check gauges Check clamp release pedal Check hydraulic hoses Check attachments Check emergency shut off Training Services 4 You Pty Ltd trading as RAISE Training Page 19 of 35

20 Performance Criteria 2.7, 2.8 and 4.5 Testing the forklift & recording and reporting faults You should test all functions of a forklift truck before commencing work. This should include all pedals and controls, brakes and parking brake, lights, horns and reversing beeper as well as any other visible damage or defects. It is very important to record and report any faults you identify during your checks. Equipment may get damaged or someone injured if you do not. Before you start the order picking forklift, test its safety devices to see if they work: These includes: Access gates Safety harness Emergency lower valve Pallet clamp release Dead man s pedal Overhead guard If you find any defects or problems with the forklift, you must follow this procedure: 1. Remove Key 2. Tag Out 3. Record 4. Report Remove the key from the forklift so that it cannot be used Tag out the forklift with a danger tag so no one else can use it. Activity 3 - Check the forklift Record the fault in the logbook. There may be other forms required. Complete questions of a theory Activities assessment. Workbook report the fault to your supervisor, manager or other authorised person. Training Services 4 You Pty Ltd trading as RAISE Training Page 20 of 35

21 Section 3 Plan the move Section outline Areas covered in this section are: Assess the weight of the load to be moved and ensure that the equipment being used is appropriate for the task Inspect the work area and determine appropriate path to travel Describe various communication options Describe the correct response to an unplanned or unsafe situation Training Services 4 You Pty Ltd trading as RAISE Training Page 21 of 35

22 Performance Criteria 1.4 Appropriate path of movement You should always observe the work area before starting a job and plan the path that you will take. This will lower the chance of injury and damage to equipment and property. Check the route you will take the load. This will help prevent accidents. To help avoid an accident, you and other forklift drivers must keep to an agreed path. When you are planning a task such as moving a load there are certain things, other than site hazards, that you should also consider. These things include: Characteristics of the load The size, shape, weight and contents of the load is relevant to how it should be moved. Capacity of the forklift The weight of the load must be within the capacity of the forklift truck being used. Location of task Where is load to be moved? Are there people working in the area? Is there sufficient space? Is it safe to be moved there? Specifics of task Does the load contain dangerous good which should be segregated? What is the size and shape of the load? Can it be moved safely? Equipment required for the task Is the type of equipment to be used suitable for the task? Is there any special training required before it can be used? Availability of equipment Is permission needed before the equipment can be used? Does someone else need to use the equipment or will they need it before the task is completed? Permits required for the task Sometimes only personnel that are issued with a valid work permit may carry out certain work or tasks. Communications (safe and adequate) Appropriate methods that can be used to communicate with other site personnel Access and egress Is the rate or means of entry or exit to a work place. It includes footpaths, corridors, doorways, gates, steps etc. Blind corners A corner that you cannot see around prior to travelling. Commonly the most accident-prone areas within the workplace. Doorways People and other traffic may enter the area through doorways at any time. Low overhead clearance may become an issue. Lighting /illumination Is there adequate lighting available across the entire working area* Training Services 4 You Pty Ltd trading as RAISE Training Page 22 of 35

23 Performance Criteria 1.5 Communication methods It is important to communicate with your workmates when you are on a worksite. There are many methods of communication. You may need to read things like Material Safety Data Sheets (MSDS), Job Safety Analysis worksheets, work permits and written instructions. Identifying appropriate communication methods Communication is a major factor in creating and maintaining a safe and efficient workplace. Different forms of communication are used throughout various work places e.g. verbal, written instructions, listening, signage, hand signals, appropriate work permits, etc... To ensure your workplace is safe and healthy, employers, employees, managers, contractors and visitors must communicate with each other and work together. However, it is not possible to deal directly with every situation that may be found at the workplace. There are some tasks that must be controlled in order to avoid a hazard and cannot be conducted by just anyone in the workplace. Work Permits are used as an extra safety precaution. They inform a worker what they can (and cannot) do and helps worker to understand what their obligations are and what is expected of them. All workers need to have access to emergency procedures. These are commonly found within your immediate work area, centralised filling systems, signage on walls and direct from your Fire Warden or Health and Safety Representative etc. You MUST always obey safety signs in the workplace. An example of some commonly used signs within the workplace are listed below: Fire Sign Danger Sign Emergency Information Sign Regulatory Sign - Mandatory. Regulatory Sign - Restriction If an unsafe incident does occur, it is important to ensure that the right personnel are made aware so that they can control the situation or work to prevent it in the future (i.e. Safety Officer, Supervisor, Managers and/or HSR - Health Safety Representatives). Training Services 4 You Pty Ltd trading as RAISE Training Page 23 of 35

24 Performance Criteria 1.3 and 3.1 Checking the load You should always assess the weight of a load before moving it. Check the data plate to ensure that the forklift can support the load to be moved. Assessing the weight of the load What information is included on the manufacturer s data plate? By law, every forklift is required to have a manufacturer s data plate which has information about attachment details (if one can be fitted). This data plate also includes the following information: maximum safe working load load centre distance maximum lift height make, model and serial number mast tilt (in degrees) tyre type and recommended pressure gross vehicle weight attachment details (if one is fitted) It is important to check the weight of the load before trying to lift it in order to stop overloading and prevent accidents. It is critical that you know the information on the manufacturer s data plate so that you choose the appropriate forklift and attachments needed for safe operation, and the forklift is driven and used within the safe operating capacity. Before you move a load check its weight to see if the forklift can move it. Calculate the weight of the load Check the weight of the load when you plan the job before lifting the load. To find the weight of an unmarked load: - Read the weighbridge certificate, consignment note or other documentation - Look at the load itself or the packaging it comes in - Calculate the weight of the load yourself - Weigh the load Activity 4 - Plan the move Complete questions of a theory assessment. Point of Balance (Fulcrum) The point of balance or fulcrum point of an order picking forklift is located where the tyre closest to the load touches the ground. Training Services 4 You Pty Ltd trading as RAISE Training Page 24 of 35

25 Section 4 Move the load Section outline Areas covered in this section are: The candidate is to operate the forklift truck at a safe speed The candidate is to conduct work safely at heights and use safety equipment correctly The candidate is to move and place loads in a manner that safe and secure Training Services 4 You Pty Ltd trading as RAISE Training Page 25 of 35

26 Performance Criteria 3.3, 3.4 and 3.5 Operating the forklift Always operate a forklift in a safe manner by driving at a safe speed and by following safety procedures. You should always place the load on the forklift in a way that allows the forklift to operate safely and keep stable. Move the load slowly and watch out for hazards such as pedestrians, other equipment etc. Travel at a safe speed When operating an order picking forklift, follow safety rules at all times. Make sure you travel at a speed that an emergency stop (if needed) will not move or make the load unstable. Use the safety equipment Work safely at heights by using safety equipment. Emergency lower valve Emergency lower valve works properly. Use the valve if the forklift stops when it s elevated or if the operator gets sick. Use it to safely lower the operator to the ground. Safety harness Check the compliance date on a tag attached to the harness. The tag shows you when the harness was made and when you should stop using it. Access gate The operator must be located within the control(s) platform at all times when operating the forklift. The gates help keep you within the operator s compartment for greater safety while elevated. The gates are self-closing that slide or open inwards and should be closed at all times when operating the forklift. Pallet clamp release pedal The pallet clamp keeps the pallet in place and stops it from moving. Training Services 4 You Pty Ltd trading as RAISE Training Page 26 of 35

27 Move the load Once you are ready to start moving the load, keep the load safe and stable. Place the load on the forklift in a way that allows the forklift to operate safely and stay stable. Move the load slowly and remember to watch for hazards. If the load is unevenly distributed to the side, then it must be restacked in order to fix the stability of the load. Attachements should be put in and out without touching or scraping the load. Make sure there are no objects or parts of your body sticking out. You are only allowed to carry other passengers when the forklift is specifically designed to carry more than one person. Training Services 4 You Pty Ltd trading as RAISE Training Page 27 of 35

28 Before the load is lifted it must be hard against the platform or operator deck. The load should not move away from the lifting attachments. Should the load not be hard against the heel of the fork arms, the Load Centre Distance will be increased which will reduced the forklift truck s capacity and may reduce the stability. Ensure that you do not raise or lower a load near or over other personnel because this is against safe working procedures and may cause injury or death. Decide whether to go forward or backward. If your view is obstructed, ensure you do the following before moving: - Check pathway is clear - Look over both shoulders, if reversing - Use warning devices such as horn and flashing lights - Use guide, if required Always look in the direction of travel. When reversing, look over both shoulders before moving. Training Services 4 You Pty Ltd trading as RAISE Training Page 28 of 35

29 Lifting attachments or load should not rub on the ground or racks. Training Services 4 You Pty Ltd trading as Raise Training When refillign stock into racking or shelves, you must consider the following when stacking items on top of each other? - Heavy goods must be placed on the bottom - Stack should not become unstable due to height - Loads must be stacked on a firm level surface Travelling height should leave enough floor clearance to move. There are safety devices such as sensors or safety switches that stops the order picking forklift from either travelling at full speed, or travelling at all while the platform is raised more than 600mm above the ground? You are NOT allowed to interfere with these devices to enable it to travel while raised? Training Services 4 You Pty Ltd trading as RAISE Training Page 29 of 35

30 Performance Criteria 3.6 and 3.7 Constant vigilance Dangerous and unexpected events can still occur even though you have carried out all of the required checks. You must always keep alert when moving a load and watch out for things that can go wrong. Stay alert Even though you ve done all of your checks, dangerous and unexpected events can still happen. When you are moving a load, stay alert and watch out for things that could go wrong. Pedestrians/vehicles may expectantly get in your way. Load movement should be constantly monitored to ensure safety to people and load stability Be aware of the factors listed below which can affect lateral stability: - turning at speed - driving over uneven surfaces - an uneven distributed load - driving with a flat or under inflated tyre - driving too fast - travelling with the load raised - braking too hard when turning - side shift not centred - lifting a load on one fork arm - driving sideways across a slope - dragging (snigging) a load sideways with a jib attachment Training Services 4 You Pty Ltd trading as RAISE Training Page 30 of 35

31 The wheels closest to the load of an order picking forklift truck act as a fulcrum with the load on one side and the machine body on the other. If the weight of the load is heavier that the counterweight it will cause longitudinal instability (the forklift will tip). Be aware of the factors listed below which can affect longitudinal instability: - overloading - severe braking - incorrect use of the mast tilt (especially with the load carried at higher level) - load not positioned against the heel of the fork arms Contacting electrical lines - lifting a load with a jib with the mast tilted forward - picking up an over-width load - fitting slipper forks If the forklift comes into contact with electrical service lines take the most appropriate actions listed below: Warn others to stay away and not to touch the forklift - driving with reach extended Try to break contact with the lines by moving the forklift away if safe to do so Stay on the forklift until informed it is safe to exit the machine Report to management, power company and safety regulator Check machine before reuse. Fire or other emergency It is extremely important to have a list of warehouse fire safety procedures for staff to follow. Each staff member should review these frequently. You should hold monthly review meetings. The goal is for warehouse users to be confident about what to do in the event of a warehouse fire emergency. Planning, implementing and educating about warehouse fire safety procedures could save a life. In the event of an emergency, operators may be required to: Alert personnel to the emergency, Communicate the nature of the emergency, Inform personnel of unsafe areas, Provide information to emergency services. In the event of an emergency, you must give way to ALL emergency vehicles.it is important that as an employee, you are aware of the site evacuation plan, meeting point and any other information related to the emergency procedures. Training Services 4 You Pty Ltd trading as RAISE Training Page 31 of 35

32 Overturning forklift In the event of the forklift rolling over sideways, the operators best chance of minimising injury can be achieved by: Remaining in the forklift (do not jump out), Brace yourself and lean away until it is safe. Emergency power disconnect button You may need to cut the power to your forklift because the controls do not respond and the forklift continues to operate, despite your efforts to stop it. Emergency lower valve Activity 5 - Move the load Complete questions of a theory assessment. the Activities Workbook Training Services 4 You Pty Ltd trading as RAISE Training Page 32 of 35

33 Section 5 Shut down and secure the forklift Section outline Areas covered in this section are: Park, shut down and secure the forklift truck appropriately Training Services 4 You Pty Ltd trading as Raise Training Training Services 4 You Pty Ltd trading as RAISE Training Page 33 of 35

34 Performance Criteria 4.1, 4.2, 4.3 and 4.4 Parking and securing the forklift truck You should always park your forklift in a safe area so that it will not get in the way of anything else. Parking the forklift You have finished using the forklift truck. Park it is a safe area so it won t get in the way of anything Ensure the forklift is parked clear of the following. Near doorways May cause injury or prevent access during an emergency. On or near pedestrian walkways May cause injury or force pedestrians to walk into the line of danger. Blind corners Can create a hazard for drivers and pedestrians moving through the workplace. Emergency exits Specifically used for fast escape during an emergency. Never block access. Near first aid stations Do not block access as most injuries require swift attention. Near firefighting appliances Emergency equipment must be easily accessible at all times, do not block access. Refueling stations May be required by other drivers in the workplace, do not block access. On sloping surfaces If it is necessary for the forklift to be parked on a sloping surface then wheel chocks must be used. Training Services 4 You Pty Ltd trading as RAISE Training Page 34 of 35

35 After you have brought the forklift to a halt, it needs to be parked correctly. Check the user/operator s manual to learn the correct shut down procedure (things you should do) for your forklift. 1. Fully lower the forks 2. Put the forklift in NEUTRAL 3. Apply the park brake 4. Adhere to the site specific safety procedures If a forklift must be parkd on an inclined surface, the driver should chock the wheels of the forklift in addition to the above normal parking procedures. The forklift should always be inspected before and after operation. During shutdown the driver must check the forklift for any damage or leaks, ensure it is safe for the next driver and make sure all systems are shutdown correctly. If the driver detects any defects or faults, such as damage or leaks, the driver should remove the keys, place a warning notice on the forklift indicating the forklift must not be used and then report the fault to an authorised person. Securing the forklift Now secure the forklift so someone else cannot use it without permission. Turn the key switch to OFF. Remove the key from the key switch. Remove the (optional) keycard from its slot. To prevent unauthorised use of the forklift the key must be removed and returned to a secure location. Activity 6 - Shut down and secure the forklift Complete questions of a theory assessment. the Activities Workbook Training Services 4 You Pty Ltd trading as RAISE Training Page 35 of 35