Reva Golden & Tony McCrimmon

Transcription

1 FORKLIFT SAFETY Best Management Practice for the Management of Powered Industrial Trucks Presented By Reva Golden & Tony McCrimmon Safety Subcommittee

2 Agenda Background OSHA and Regulatory Compliance Training Hazard Assessment Developing and Managing a PIT Program of Your Own Lessons Learned Summary 2

3 To Keep Us From Getting Hurt Because An injury or fatality happened OSHA regulations written so doesn t happen again OSHA standard provides specifics for: Equipment safety Design, safety features, user interface Safe Operation Vehicle stability, travel, loading 3

4 Because It Happens (Official OSHA Report) Employee was operating a forklift in brewery production area. Forklift tines were about 36 inches above the floor. Employee got off forklift to dispense chemicals into a secondary container. Employee returned to forklift, started driving without fastening seat belt. Employee turned head to greet/ make eye contact with a pedestrian. Right forklift tine clipped a concrete bollard protecting the roof support. Employee was ejected sideways, outside of the forklift. The forklift tipped, the roll over protection cage crushed employee s chest. Transported to hospital where employee died from crushing injuries to chest. 4

5 Forklift Stats In 2014: 855,900 US forklifts 96,785 total forklift injuries 11%, or 1 in 9? 34,900 serious injuries 86 forklift related fatalities Damage and lost product $$$ 5

6 96,000 Injury Accidents per Year Inattentive, Distracted Operator Tip-over Unstable Load Operator Struck Load, Falling Objects Elevated employees No training/inexperience Overload/Improper Use Speeding Obstructed View Improper Equipment Falling From Dock, Platform, or Curb Carrying Any Passenger Other Employee Struck by Load Vehicle Left in Gear Falling From Trailer Accident During Maintenance 6

7 Forklift Stats 7

8 Main reasons for forklift accidents? Lack of training for lift truck drivers Lack of proper training for lift truck drivers Lack of training for particular types of forklifts Lack of training for particular forklift applications or lifting procedures within a company Incomplete or incompetent completion of daily inspection checklist Poor or improper maintenance of the forklift Various reasons operator may be under stress. Lift truck not equipped with the proper attachments and accessories. Excess age or excess use of the forklift 8

9 OSHA Compliance What do I need to know? 29 CFR Powered Industrial Truck Standard 9

10 7 Classes of POWERED INDUSTRIAL TRUCKS 10

11 Equipment Selection 29 CFR (a)-(c) Forklift must be designed to be a forklift ANSI B and UL listed Adequate for the job Load within capacity specified on data-plate Location of load on forks determines capacity Compatible with operating environment Special considerations for operating around: grain dust, ammonia, flammables, etc. Control of trapped engine exhaust and fumes Combining Carbon Dioxide and exhaust 11

12 Equipment Selection 29 CFR (d)-(e) In good condition Regular inspection Proper maintenance Certified modifications and accessories Adequate Safety Features Overhead Guard, Roll over protective structures Load Backrest Extension Seatbelts Lights 12

13 Accommodating 29 CFR (f)-(g) Designated parking and storage Flat surface Doesn t block aisles, walkways, exits, egress Off gases won t enter building ventilation system Fueling or Battery Charging procedures and storage Flammable liquid storage and handling precautions No smoking area PPE and eyewash equipment Proper spill kit and appropriate spill training 13

14 Accommodating 29 CFR (h)-(j) Lighting in building 2 Lumens Structural Integrity Floors, loading dock plates, trailers Is the lift and load too heavy for the floor? Is it weak enough to collapse? 14

15 Accommodating 29 CFR (k) Pedestrian paths Avoid collisions with designated travel paths Accompany visitors Pedestrian Make eye contact with Operator Ankle Is Struck By Pipe Bundle And Is Fractured Crushes Hand In Pallet Truck Accident Sustains Fractured Foot When Struck By Forklift Is Struck By Forklift And Sustains Fractured Leg PIT Operator Struck By Parcel Truck And Injured Hospitalized After Truck Runs Over His Foot Is Run Over By Forklift And Receives Injuries Is Pinned And Killed Under Industrial Truck Fractures Leg, Ankle Crushed By Pallet Jack 15

16 Must be 18 years or older 29CFR The Fair Labor Standards Act prohibits under 18 years of age from engaging in specified hazardous occupational activities. 29CFR Occupations involved in the operations of power-driven hoisting apparatus (Order 7), paragraph (a)(5): specifically prohibits employees under 18 from operating forklifts. 16

17 Training 29 CFR (l) Valid drivers license Initial and refresher Classroom and hands on Before first use of any truck If have any incident Wreckless operation Written performance evaluation every 3 years By outside company or internal? Certified as Forklift Trainer Is honest about operator s skills 17

18 Training 29 CFR (l) Classroom Driver Evaluation Course Your Specific Area Your Specific Equipment Your Specific Tasks 18

19 Distance from edges 29 CFR (m) Maintain a safe distance from edge of elevated dock, platform, freight car Chock wheels so trailer doesn t move Secure dock plates so don t move 19

20 Remember your liability Pre-use; before use each day Maintenance & Inspection What about your other operator? Annual Operator vs Authorized Maintenance Define tasks operator can perform Define tasks only for qualified mechanics Partner with certified mechanics 29 CFR (q) 20

21 Getting Started What do I need to do? 21

22 Hazard Assessment What s your function? Glass, keg, pallet, material handling Vessel installation/ construction Operational Space General production area vs. cooler/warehouse Indoors vs. outdoors Loading dock/shipping trailers 22

23 Modifications Hazard Assessment (cont d) Fork extensions or elevated work platform Data plate and max loads Stability for the intended functions Able to reach max heights Identifying safety features & limitations Tricky controls or human interface 23

24 Ramps Overhead clearance Hazard Sources Low ceilings, fire sprinklers, hard-piping, auger tubing systems Uneven ground/rough terrain floor drains, damaged grates over drains, outdoor operations Regularly slick/wet floors 24

25 Hazard Sources (Cont d) Tight/limited operation space Narrow aisles, obstacles Limited visibility Corners, intersections, building exit or entry, poor lighting Floor load limits Elevators, mezzanine flooring Dock boards, bridge plates, truck floors 25

26 Hazard Sources (cont d) Traffic Pedestrians, other PITs, cars/parking lot Shelving/storage limitations can the shelf support the loads Other safety hazards 26

27 Paperwork and Documentation 27

28 Paperwork and Documentation Written Program Hazard Assessment Training Material Written Test Driving course set up Driver Evaluation Criteria Attendance Records Inspection Logs and Maintenance Logs Out of service tags and/or locks Wallet Card 28

29 Real Life Examples Equipment Orientation vs Complete Safety Training Area awareness Auger Accident Equipment Collisions Unsafe operation Overall etiquette Fork position Maxing out truck limits 29

30 Real Life Examples Used equipment and poor maintenance Flip it and Reverse it Exhaust Clouds Dock Dilemma Distracted Driving Poor Hazard Assessment Grain storage 30

31 In Summary - PIT Managing Forklift Safety It is here to help and it is required! Know the regs. Buy and maintain safe equipment. Provide training to your staff. Enforce the rules! Assess the Hazards Don t make out mistakes! 31

32 Brewery Safety Training On-Line Brewery Safety Training Code:

33 Questions & Answers 33