POWERED INDUSTRIAL TRUCK SAFETY PROGRAM

Transcription

1 Quality. Integrity. Experience. Electrical Engineers and Contractors Since 1918 Specializing in Design/Build POWERED INDUSTRIAL TRUCK SAFETY PROGRAM Operator Training Certification Accident Investigation W133 N5030 Campbell Drive Menomonee Falls, WI fax Mailing Address P.O. Box 917 Butler, WI Monona Drive Madison WI fax Reviewed 2/1/2010

2 POWERED INDUSTRIAL TRUCK SAFETY PROGRAM PURPOSE The purpose of this program is to ensure the safe operation of Staff Electric s powered industrial trucks. This includes certifying qualified drivers to ensure that Staff s industrial trucks are operated safely. Certifying operators will reduce the potential for bodily injury, product damage and property damage. SCOPE This program applies to all operators of powered industrial trucks. Examples of powered industrial trucks include lift trucks and rough terrain forklifts. The program does not cover aerial lifts, lift platforms and earth moving equipment. RESPONSIBILITIES Ms. Julie LaRose, Director of Safety and Health, has been designated the program coordinator for Staff Electric. Mr. Kevin Voelkel has been designated the hands-on fork lift trainer. The coordinator is responsible for conducting classroom training and evaluating candidates to determine if they qualify to operate a powered industrial truck. The fork lift trainer is responsible for conducting hands- on fork lift training and completing the operational evaluations. Ms. LaRose and Mr. Voelkel have been certified as powered industrial truck trainers by the Wisconsin Industrial Truck Company (WITCO). OPERATOR SELECTION Each operator must have the physical and mental abilities to perform the duties required to safely operate Staff Electric s powered industrial trucks. Powered truck operation will be limited to individuals who have been certified. TRAINING Operator training consists of a combination of classroom instruction and operational evaluation. A. Classroom: The classroom instruction will consist of a lecture, and discussion. Refer to Appendix A for the training outline and materials. Operators must pass a written test with a score of at least 80%. B. Operational Evaluation: After the operators have demonstrated their knowledge of operating powered industrial trucks safely, they will demonstrate their ability to operate a powered industrial truck during an operational evaluation or driving test. A "Driver Evaluation Form will be used for documenting this evaluation. The program coordinator will provide the classroom training and the forklift trainer will conduct the operational evaluation. Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 2

3 Employees that have been trained at another company will still be required to complete Staff s powered industrial truck training program. CERTIFICATION Each operator that has been trained and has demonstrated competency in the performance of the operators duties shall be certified. The operator will be issued a license similar to a driving license indicating his/her certification. A log of trained operators and the type of equipment that they have been certified on will be maintained. REVOCATION OF CERTIFICATION Management may revoke/suspend certification when the operator acts in an unsafe manner as determined by: Accident involving personnel injury or property damage Annual operator s performance evaluation Observations of unsafe driving practices or near misses RETRAINING Retraining shall be conducted so that the employee retains and uses the knowledge, skills and ability needed to operate the powered industrial truck safely. Retraining shall be provided when: 1) There is reason to believe that there has been unsafe operation. 2) An accident or near miss occurs. 3) A performance evaluation indicates the operator is not capable of performing the assigned duties. OPERATORS PERFORMANCE EVALUATION The fork lift trainer will conduct performance evaluations for each new operator. Existing operators will be evaluated every three years. See Appendix C for Staff Electric s forklift operator performance evaluations. Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 3

4 OPERATING STANDARDS General Guidelines 1) Only authorized operators shall be permitted to operate powered industrial trucks. 2) All accidents involving bodily injury, property damage, equipment or material damage must be reported to the foreman or supervisor immediately. 3) Industrial trucks shall not be located such that fire equipment, alarm boxes, emergency equipment, electrical service cabinets or fire exits are obstructed. 4) Industrial trucks shall not be overloaded. The rated capacity of the truck shall not be exceeded at any time. 5) Employees operating lift trucks equipped with seat belts shall wear the seat belt when operating the truck. 6) Lift truck operators are never permitted to carry passengers or riders on their trucks. Riders on lift trucks are subject to injury such as being struck by foreign objects and being thrown off the truck. Riders may also obstruct the operator s view. 7) Employees are not to stand or ride on the forks of a lift truck at any time. 8) It is the operator s responsibility to ensure that no one stands or walks under any elevated portion of the lift truck. 9) When a lift truck is left unattended, the forks must down, controls in neutral, brakes set and power off. A lift truck is unattended when the operator is more than 10 feet away from the vehicle with the vehicle in view or when the operator leaves the vehicle and the vehicle is not in his/her sight. 10) Stunt driving and horseplay are NEVER permitted on fork lift trucks. 11) Employees are to keep legs and feet within the confines of the operator s compartment of lift trucks. 12) Pedestrians have the right of way at all times. 13) When mounting or dismounting the lift truck, always maintain three point contact with the steps and handrails. Do not use the steering wheel or any controls as handholds. 14) Never jump either on or off the lift truck. Never mount or dismount a moving lift truck. Be careful of slippery conditions on platforms, steps and handrails when mounting or dismounting the lift truck. Stock and Equipment Movement 1) Prior to moving a fork lift, the operator must know the location of all equipment and personnel in the area. 2) The reverse warning alarm must be kept in operating condition. Use a signal person when moving the lift truck in congested areas. The signal person and driver must be trained in hand signals to avoid accidents associated with misunderstood signals. 3) When traveling with or without a load, the operator shall keep the forks as low as possible to the ground without dragging the forks. The lift truck must not be in motion while a load is in the raised position except to stack or unstack a load. 4) The lift truck operator is required to travel in reverse if the load being carried obstructs forward view. 5) Lift trucks must be driven at speeds at which the truck can be brought to a stop safely. 6) Lift truck operators must sound their horn when entering, leaving or passing any doorway, or any location where vision is obscured. Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 4

5 7) Lift truck operators must keep to the right when meeting any other lift trucks, and must drive three truck lengths behind when following other trucks. 8) Never carry a maximum load with center more than 24 (60 cm) from the vertical back of the forks. 9) When working with a suspended load, avoid sudden starts, stops and turns. Never drag a load. 10) Prior to truck operation, the worksite should be surveyed to identify specific hazards to raise awareness among lift truck operators. These hazards and control measures should be discussed in the course of toolbox talks. Truck Maintenance and Fueling 1) Handle fuel with care. Always stop the engine before refueling the lift truck. 2) Smoking is not permitted while fueling a lift truck. ACCIDENT INVESTIGATION All accidents involving powered industrial trucks will be investigated. These accidents may involve personnel injury, property damage or both. The purpose of the accident investigation is to identify the root cause of the accident so that corrective action can be implemented to prevent a similar accident from recurring. Corrective action may involve retraining, instituting a physical control (i.e. backup alarm or mirror) or disciplinary action. INSPECTION AND MAINTENANCE A. Pre-Operation Checklist. Industrial trucks will be examined before each use, and will not be operated if the examination shows any condition adversely affecting the safety of the vehicle. On a monthly basis, a pre-operation inspection checklist will be completed to document the condition of the vehicle. The pre-operation inspection checklist is attached in Appendix D. B. Preventative Maintenance. The preventative maintenance program for all powered industrial trucks will be maintained by the shop. Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 5

6 APPENDIX A STAFF ELECTRIC INDUSTRIAL TRUCKS Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 6

7 APPENDIX B INDUSTRIAL TRUCK TRAINING OUTLINE Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 7

8 STAFF ELECTRIC TRAINING PROGRAM OUTLINE I. Introduction a. Introduce trainers b. Format of Training Seminar (OSHA regulations, Video, Quiz, Staff Policy, Test, Hands On Training) c. Lunch II. OSHA s Powered Industrial Truck Standard (CFR ) a. Powered Industrial Truck Definition b. Classes of Commonly Used Powered Industrial Trucks c. Reasons for New Standard d. Training Requirements of New Standard <<Video: Fundamentals of Safe Operation 22 minutes>> II. Quiz III. Truck Related Topics (Julie) a. General components of a forklift truck b. Difference between truck and automobile c. Operating instructions, warnings, and precautions (general guidelines) d. Travel guidelines (steering and maneuvering) e. Proper signaling f. Proper refueling g. Stability of powered industrial trucks h. Lifting guidelines i. Inspection checklists <<Written Test>> IV. Workplace Related Topics - Hands on training (Kevin) a. Components of job site specific lift truck b. Operating controls c. Inspection and maintenance d. Job site specific exposures (toolbox talks) 1. Surface conditions 2. Composition of loads 3. Traffic V. Operator Performance Evaluation (Kevin) Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 8

9 QUIZ BASICS OF FORKLIFT OPERATION 1. Generally, all forklifts have a : ratio of truck weight to the weight of the load they can safely lift. 2. According to OSHA, a safe following distance for one forklift to follow another is truck lengths. 3. always have the right of way. 4. The condition, the condition and the condition of the can affect safe operation of a forklift. 5. When traveling with a load, the forks should be to the without and tilted. 6. Forks should be at least / the length of the load. 7. The capacity of the truck can be found fastest on the. 8. When making a right 90 turn in a warehouse, approach the intersection closer to the side of the aisle. 9. When parking the forklift, the should be touching the floor, controls in, brake set and off. 10. The rear wheel steering of a forklift causes the rear to swing than an automobile. 11. To remove a partially filled L.P. Tank, shut the valve, let the stall, turn the off and then the hose. 12. To lift personnel with a forklift, use a. Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 9

10 1. exceed the capacity of the forklift as it appears on the serial data plate. 14. Load height affects forklift. 15. If you can t see around a load,. 16. When taking a load down a ramp, drive. 17. When going down a ramp empty, drive. 18. Load placement on the, affects the forklift s. 19. A parked truck should not aisles, fire or. 20. reach through an upright to readjust a load. 21. Use the appropriate that best suits the job. 22. and your forklift smoothly. 23. A hourmeter is equivalent to your odometer. 24. Slow down and at cross aisles, sharp corners, ramps, blinds spots, in congested areas or whenever vision is blocked. 25. Approach and cross rail road tracks at a angle, not across. 26. Always keep within the running lines of the forklift. 27. Never approach anyone of a fixed object. 28. is not permitted. 29. Never allow a on the forklift. 30. Gas, diesel and LPG powered trucks produce a colorless, odorless and poisonous gas while running called. 31. According to OSHA, a forklift is unattended when the operator is feet or more away from the vehicle, or the forklift is not in. Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 10

11 WRITTEN TEST FORKLIFT OPERATOR TRAINING John Deere/International Rough Terrain Mitsubishi/ Datson/Clarklift EMPLOYEE NAME JOB SITE DATE SELECT THE MOST CORRECT ANSWER & MARK IT IN THE LEFT COLUMN 1. The most important thing on a safety conscious lift truck operator s mind as he/she goes through their day is: a. Getting ready for his/her next load b. Beating the company record for quick unloading c. Looking out for potential accidents 2. While operating a lift truck, you take responsibility for: a. Only your own safety b. The safety of all co-workers c. All consequences of any accident 3. The conditions that can affect the safe operation of a lift truck is/are: a. The operator s condition b. The truck s condition c. The condition of the load d. All of the above 4. Uneven surfaces, cracks or even small objects lying on the floor can cause: a. A tip over b. Loss of load c. Loss of control d. All of the above 5. What is the general ratio of forklift weight to capacity load weights? a. 1:1 b. 2:1 c. 3:1 d. 4:1 6. Serial data plates provide information on the forklift s: a. Overall width and length dimensions b. Maximum lift height c. Required safety equipment Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 11

12 7. In operating your fork truck, it is important to: a. Listen for unusual noises b. Watch for potential accidents c. Feel the truck s balance d. All of the above 8. A forklift hour meter is equivalent to a car s: a. Oil pressure gauge b. Water temperature light c. Mile odometer 9. When taking a load down a ramp: a. Travel in reverse b. Sound your horn and go forward c. Raise your forks until you can see below the load 10. When lifting personnel you should: a. Use a safety platform b. Use a pallet c. Make sure they are sitting down d. Make sure they are holding onto the lift chains 11. The weight capacity of a lift truck can be found fastest: a. In the operator s manual b. In the service manual c. On the serial data plate d. By calling the dealer 12. When traveling with a load, your forks should be: a. 6 or 8 above the floor b. 10 above the floor c. As close to the floor as possible 13. When parking or leaving the truck unattended, the: a. Controls should be in neutral and parking brake set b. Key turned off and removed c. Fork tips should be flat on the floor d. All of the above 14. When placing a load, it should be: a. Set in the proper position b. Pushed into position c. Pushed into position using the counterweight 15. The forks on a lift truck should be positioned so they: a. Are suited for the pallet size b. Evenly support the load c. All of the above Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 12

13 16. When making a tight left turn going forward: a. Stay in the middle of the aisle b. Keep close to the right side of the aisle c. Keep close to the left side of the aisle 17. Never exceed the capacity of your lift truck: a. Unless you add passengers to the counterweight b. Unless the load is kept lower than 84 c. Under any circumstances 18. On a gas, LP or diesel lift truck, to reverse travel directions, you should: a. Stop b. Slow to 1 MPH c. Do it at any speed, lift truck can handle it d. Do it only when the steer wheels are straight 19. To remove a tank with liquid propane still remaining, you must: a. Shut off valve and let engine run until it dies b. Turn off the key c. Remove L.P. tank coupler and tank d. All of the above 20. In the event of a tip over: a. Attempt to jump clear of the fork lift b. Turn off the engine c. Grip the wheel, brace your feet and stay with the truck 21. A forklift is unlike an automobile for the following reasons: a. Forklifts have a higher center of gravity b. Forklifts require a greater stopping distance c. Forklifts have 2 wheel brakes d. All of the above 22. When mounting or dismounting a forklift face: a. away from the forklift b. toward the forklift c. do it the most comfortable way for you d. jump on/off 23. A forklift operator s performance must be evaluated at least: a. monthly b. yearly c. every two years d. every three years Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 13

14 24. Training on one type of vehicle: a. qualifies the operator for that type of vehicle b. is sufficient for all company forklifts c. should be done every 2 years 25. The pivot point for a forklift is: a. The center of the steering axle b. The base of the forks c. The center of the drive axle hub d. The mid-point of the mast. SELECT THE CORRECT ANSWER CIRCLING T (TRUE) OR F (FALSE) 26. Equipment data plates and decals must be in legible condition. T F 27. It is not the responsibility of the lift operator to protect pedestrians in the work area. T F 28. Never turn on ramps, slopes or inclines. T F 29. Stunt driving is absolutely not permitted. T F 30. When making a turn, it is not necessary to slow down the lift truck. T F 31. You are responsible for reading the operator s manual for any lift truck that you operate. T F 32. All traffic signs and markings must be obeyed. T F 33. The stability triangle shows that an unloaded truck is a safer truck than a truck with a load. T F 34. Operators should always watch overhead clearance for sprinkler lines, process piping, conveyors and other obstacles. T F 35. Your chances for survival in a tip over are better if you stay with the truck on a sit down rider lift truck. T F 36. The higher the load, the more stable a truck will be. T F 37. To adjust a load, it is permissible to reach through the upright. T F 38. Loads should be carried with the mast/upright tilted forward. T F 39. A load should always be positioned back against the fork backrest and centered on the forks. T F 40. When crossing railroad tracks, approach at an angle, hold the steering wheel firmly and cross slowly. T F Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 14

15 41. The overhead guard is a safety device designed to protect the operator from falling objects. T F 42. People may walk or stand under raised forks. T F 43. Forks should be at least 2/3 s the length of the load. T F 44. Smoking is permitted when filling LP tanks or fueling trucks. T F 45. Gas, diesel and L.P. powered trucks produce a colorless, odorless and poisonous gas while running. T F 46. OSHA considers a lift truck to be unattended if the operator is more than 20 feet away. T F 47. It is permissible to travel with forks in the raised position if you don t see pedestrians around. T F 48. An unloaded fork lift is less dangerous than a properly loaded fork lift. T F 49. Liquid propane is lighter than air and will rise to the ceiling. T F 50. For every inch beyond the rated load center, 100 lbs. of capacity is lost. T F 51. Surface conditions, low tire pressure and traveling with a raised load can cause a forklift to tip. T F Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 15

16 APPENDIX C OPERATOR EVALUATION FORM Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 16

17 STAFF ELECTRIC FORKLIFT PERFORMANCE EVALUATION NEW OPERATOR Operator s Name: Date: Lift Truck Evaluated On: Reviewed the Following 1. Operators manual 2. Components of the lift truck 3. Operational controls 4. Start up procedure 5. Parking procedure 6. Proper position of the upright/forks when moving 7. Attachments proper operation 8. Composition of loads 9. Load manipulation/types of loads 10. Picking up a load properly 11. Traveling with a load 12. Placing a load down properly Floor, Rack, Stacking, etc. 13. Trailer loading/unloading 14. Surface conditions/travel speed 15. Pedestrian traffic 16. Operating environment 17. Hazardous locations 18. Ramps/Grades 19. Dock area 20. Fueling Comments Comments or recommendations: Evaluator s Name: Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 17

18 STAFF ELECTRIC FORKLIFT PERFORMANCE EVALUATION Operator s Name: Date: Lift Truck Evaluated On: Circled numbers represents unsatisfactory. 1. Gets familiar with controls prior to moving truck 2. Fails to look around before starting 3. Fails to look to rear before backing up 4. Looks in direction of travel 5. Sounds horn when backing up 6. Sounds horn at blind curves and at intersections 7. Stops and starts smoothly 8. Operates at safe speeds 9. Makes turns with truck in proper position 10. Operates controls smoothly 11. Lowers forks/load when driving 12. Keeps forks from dragging on floor 13. Enters pallet all the way 14. Enters pallet without moving pallet 15. Exits pallet without dragging forks 16. Does not raise load first, then tilt back 17. Does not level load before setting down 18. Moves too far with load elevated 19. Places load properly 20. Hit storage rack, property, truck 21. Parks truck properly (fork tips on ground, controls neutralized, brake on, power off) 22. Operates lift truck with a good attitude Comments Comments or recommendations: Evaluator s Name: Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 18

19 APPENDIX D INSPECTION AND MAINTENANCE Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 19

20 OPERATOR S PRE-OPERATION CHECKLIST (Check before the start of each shift.) Truck Type: Operator: Foreman Date: Hour Meter Reading: Shift: Check Items OK or Explain items needing attention of repairs. Visual Checks Obvious damage Look for leaks Forks Engine crankcase oil level Radiator water level Fuel level Hydraulic sump tank oil level Tire condition Battery connector Head and tail lights Warning lights Fire extinguisher Hour meter Other gauges and instruments Operational Checks Horn Gauges and instruments Steering Service brakes Parking brakes Hydraulic controls Lift chains Unusual smells/sounds Other Notations Staff Electric Co., Inc. Powered Industrial Truck Program (Revised 10/1/2001) 20