HOW A FORKLIFT PROGRAM can be both PRACTICAL and EFFECTIVE

Transcription

1 HOW A FORKLIFT PROGRAM can be both PRACTICAL and EFFECTIVE A case study in the design, implementation and maintenance of a basic forklift program for flexible packaging operations FPA Environmental Summit & Safety Conference January 2007

2 THE BASICS OF PROGRAM DESIGN Before any program can be created for a specific facility, an in-depth review of the OSHA standard should be performed. This will ensure that the requirements detailed in the regulation can be incorporated at each point necessary in the program. For purposes of this presentation, however, we will assume that folks have reviewed the forklift standard so we can concentrate on applicability. Where necessary, specific points of the standard will be referenced by number during the presentation.

3 Designing Your Forklift Program OSHA Forklift Standard 29 CFR Your Company Employees Facility Forklift types Other process issues Your Company s Forklift Program

4 But first, a little background on our company Employees 120 manufacturing employees Average tenure is 12 years Bring in New Employees over the course of the year Facility 90,000 square foot facility 2 levels, connected by an internal ramp (8% grade) 100% of forklift traffic is on smooth concrete floor Light to moderate pedestrian traffic Space is tight, so traffic patterns are easily identified Forklift types Standard propane and electric forklift Scissors lift and Bucket lift Electric walk-behind and personal assist vehicle

5 After reviewing the standard, other process-related issues relating to forklifts warranted inclusion in our program: Housekeeping Plant-wide Workstation specific Forklift Attachments Drum Grabber Extra Long Forks Documented Inspections Shiftly or Pre-Trip Thorough Maintenance

6 Initial Program Design How were we going to start? With all of the background issues, requirements and design considerations, it was difficult to find a place to start. The easiest way to start was to concentrate on the four points discussed earlier: Facility Process issues relating to forklifts Forklift Types and condition Employees

7 Program Design Initial Focus We couldn t change the layout of the facility Our process and traffic flow patterns wouldn t change either All of our forklifts were in excellent condition We decided to begin by concentrating our efforts on training (l)

8 Program Design - Trainers How to train everyone? Internal or External trainers? Due to the size of our company and the expense that would be involved if we outsourced, we chose to utilize internal trainers. We had four employees attend a National Safety Council sponsored Forklift train-the-trainer session. These staff were chosen for their extensive experience in forklift driving and their job responsibilities (l)(2)(b)(iii) We had many of our questions answered and left the train-the-trainer session with some takeaways

9 Program Design Training Issues What did we learn from the train-the-trainer session? We received a full set of classroom instruction manuals for new employees that met the majority of the requirements outlined in (l). We received clarification that veteran employees need only an evaluation and not a full classroom training session to be compliant. We also received clarification that we could design our own evaluation course and evaluation form for each forklift type.

10 Program Design Initial Plan Our first plan of attack Identify all employees that need evaluations and set them up on an evaluation schedule. Utilize the given NSC training program as our training program for new employees and select veterans. Design an evaluation course to determine proficiency in accomplishing forklift tasks that are representative to what they would do on a daily basis at our plant. Design an evaluation form that would capture and document all of the requirements that demonstrated onthe-truck proficiency. Do the same for the other forklift types. Incorporate the other issues such as inspections and attachments into the program.

11 Program Implementation Phase 1 Identify Employees: Veteran Employees Must complete the on-the-truck evaluation If they don t pass the evaluation, they must take the classroom course (l)(4) If they ever have a forklift incident, or someone witnesses that employee driving erratically or recklessly, they are required to take the classroom course as a refresher. New Employees Must complete classroom course first AND then pass the on-the-truck evaluation.

12 Implementation Classroom Course Course consists of: Video lessons Scenario-based hypotheticals Workbook retention tests Course emphasizes: OSHA required points found in (l)(3) such as: Pre-shift inspections Operating instructions Truck controls Steering and maneuvering Fork operations Vehicle capacity The Stability Triangle Load manipulation; stacking and unstacking

13 Implementation Evaluation Course We designed an evaluation course to determine proficiency in accomplishing forklift tasks that were representative to what forklift operators would do on a daily basis at our plant. As we took employees through the evaluation course, the trainers utilized talking points to emphasize certain topics and/or issues:

14 GLENROY FORKLIFT EVALUATION COURSE A Pre trip inspection and remove pallet from rack A B stop, turn around to back down ramp C stop, turn around to place pallet on ground D place pallet on ground, back out forks, turn off truck, step away from truck, get back on, pick up pallet, return to base via ramp and finishing dept. E - Return to start via finishing and break room area B C D E

15 Implementation Evaluation Form We designed an evaluation form that would capture and document all of the requirements that demonstrated on-thetruck proficiency. This form also serves as certification to prove the operator was trained and evaluated (m)(6)

16 Implementation other lift types Now that we had completed the program design and implementation for a standard forklift, we needed to extrapolate our protocol for the other powered industrial truck types, such as: Electric Scissors Lift. Electric Bucket Lift Electric Walk-Behind Electric Work-Assist Vehicle (man-lift)

17 Implementation Electric Scissors Lift Then we designed the form First we designed the course

18 Implementation Electric Bucket Lift Then we designed the form First we designed the course

19 Implementation Electric Walk-behind Lift Then we designed the form First we designed the course

20 Implementation Electric Person-Lift Then we designed the form First we designed the course

21 Implementation other issues Other issues we had to deal with Inspections Shiftly pre-trip Thorough maintenance inspections Propane tank changing Train new employees and refresh veterans Teach both classroom and experiential Electric battery charging Proper procedures Potential hazards Forklift attachments Train affected employees on proper utilization Changes to forklift stability

22 Implementation - Inspections Inspections (q)(7) Maintenance Once every 200 hours, each forklift is taken through a documented 22 point-functionality inspection by our maintenance department to make sure that the forklift is in proper operating condition. Shiftly Because our facility runs 24-7, we are required to inspect our forklifts for safe operations before every shift. This presented logistical challenges as well as a possible paperwork nightmare We chose to utilize an electronic inspection method to alleviate the paperwork and be more convenient for the operators.

23 Implementation Propane Tank Changing Propane or LP-Gas Tank Changing (f) We train all new employees with a presentation on propane, it s potential hazards, what PPE to wear when changing, etc. Then we show the new employees where the propane rack is located and walk them through changing a tank.

24 Implementation Electric Battery Charging Electric Battery Charging (g) We train all new employees with a presentation on sealed electric batteries and the potential hazards with the process of recharging the battery. Then we show the new employees where the chargers are located and walk them through the proper charging procedure. We also explain the importance of the close location of the eyewash stations to the chargers in case of emergency.

25 Implementation Forklift Attachments Forklift Attachments (l)(3)(i)(G) We utilize two types of attachments; a drum grabber and fork extensions. We train all new employees with a presentation on each attachment and emphasize: It s proper use and operation Limitations of use how a full load alters the forklift s center of gravity.

26 Program Maintenance After all employees have been trained and evaluated, the program moves into maintenance mode on a three year cycle (l)(4)(iii) Changes are made to the program before the three year retrain date if: New forklift types are added Significant changes are made in traffic patterns or process protocols. An increase in forklift accidents or erratic driving is seen Otherwise, just train new employees as they come on board and schedule evaluations for all veteran employees three years after their initial evaluation.

27 To summarize OSHA Forklift Standard 29 CFR Your Company Employees Facility Forklift types Other process issues Your Company s Forklift Program

28 And finally Any questions?

29 Thanks for listening!!