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1 Safe%Loading%&%Unloading%% (Incl&LUEZ)& File name: Safe Loading & Unloading.pdf Our Ref: E00540 Mike Robertson MD & Engineering Manager
2 Why is the Logistics Industry SO Poor at Safety? Often the Warehousing and Distribution Division is the poor cousin of the business = less focus from management Road transport companies are obsessed with on-road safety You can t stop idiots on the road 2 / 3 of all truck / car accidents are the car s fault So Road Transport tends to be Blind to the fact that >25% of their fatalities are INSIDE their gate (and many more unloading fatalities are in public spaces) 2&
3 There&are&2&issues&here& Chain&of&Responsibility&or&WHS?& Chain of Responsibility Laws (Compliance & Enforcement act) RMS (RTA) / VicRoads Now the NHVR (from Feb 2014) Apply for ON Road Issues Aimed at related parties in the supply chain Typical applications! On Road offences! Multiple parties over same breach Another&session!& Workplace Health & Safety Laws (Formerly OH&S Laws) Workcover / WorkSafe Apply for every workplace but, by Inter Dept Agreements not take lead On Road issues Typical applications! Forklift / traffic Management! Falling off trailers! Loading & Unloading injuries! Runaway Trailers Today!& 3&
4 WHS Law says.. Legislative Requirements A common feature of all legislative requirements is the need to: " Provide a safe place of work This is achieved through: 1. Evaluation of tasks and potential risks 2. Establishing suitable controls to reduce risks you identified. So&how&much&training&have&you& had&in&risk&assessment?& 787# truck#related #Industrial# Deaths#recorded#in#10#years## 4&
5 Key Risk Areas Loading and Unloading How do you undertake a quality risk assessment of your Logistics site? Energy method = Best Start point " Kinetic energy " Trucks " Forklifts " Cranes " Potential energy " The load on truck or mobile equipment " People at height " Electrical energy " Chemical energy " Strain Energy " etc 5&
6 Key Risk Areas Loading and Unloading Forklift and People Interaction " Interactions with people and Mobile Equipment is a major risk. " Forklifts have high accelerations, change direction quickly, but provide poor visibility for the driver Is&the&Park&brake&really&on?& " Forklift operators find it difficult to keep track of pedestrians. " Inexperienced pedestrians are unaware of the risk. " Experienced pedestrians often become immune to the risk. Just&how&close& do&you&really& need&to&be?& 6&
7 Key Risk Areas Loading and Unloading People get complacent and WAY TOO Close to Forklifts 7&
8 Key Risk Areas Loading and Unloading Falling Product " Falling product has resulted in multiple fatalities, and serious injuries. " Load dislodged by crane or forklift " Forklifts often push product off the opposite side. " Load falls from the crane or forklift tine. " Loads that move in transit can fall when lashings are released, or curtains or container doors are opened. " Reality Check! In the human reaction time of ~1.5 seconds, a load falls 11 metres. Be careful is not enough! Falling#building#products# # Mark#Beilby#Fatality# 8&
9 Key Risk Areas Loading and Unloading Product moving on crane or forklift " Even if the product doesn t fall Serious injuries or death are common " People crushed " Load traversing in " Load lowering " Load slung off centre " Load slides off the tines " Domino effect 9&
10 Key Risk Areas Loading and Unloading People&Falling&off&Trucks& & " Too&common&for&drivers&or&loaders& to&fall&from&the&truck&deck& " Worksafe&Australia&reports&that& between&2009&and&2011&a&full&49%& of&all&injuries&due&to&falls&were& truck&drivers&(1540&of&3100&claims)& " MulYple&fataliYes&and&serious& injuries&have&resulted& " There&is&rarely&a&simple&soluYon& & & It#is#simply#irresponsible#&#illegal#to#allow# this#sort#of#behaviour#on#your#sites# 10&
11 Key Risk Areas Loading and Unloading Reversing&Trucks& & " Reversing%trucks%vs%pedestrians%are&always& a&hazard& " Poor&to&zero&visibility&for&the&driver.& " Pedestrians&run&over& " Pedestrians&crushed&against&dock.& " Finger&docks&even&worse& 11&
12 Key Risk Areas Loading and Unloading Loading&Docks& & " Falling%%forkli9s%are&a&killer& " Can&be&forkli]&driver&error& " Can&be&due&to&truck&moving& 12&
13 Key Risk Areas Loading and Unloading Truck&moves&during&load/unload& & " PotenYal&for&vehicles&to&move&part& way&through&loading&or&unloading& The#driver# knows #he#can#move# " MulYple&fataliYes&and&serious& injuries&have&resulted& " Vehicle&runaway&with&handbrakes& incorrectly&applied& " Vehicles&actually&drive&away& & & & & 13&
14 Risk Controls Loading / unloading Hierarchy of Controls 1. Eliminate the hazard altogether. 2. Substitute 3. Isolate 4. Engineering 5. Administrative (SOP) 6. Personal protective equipment AIM&FOR& THE& HIGHER& LEVEL&OF& CONTROL& 14&
15 Risk Controls Loading / unloading " Controls must be fit for purpose " Use quick temporary options to confirm which controls work best " Check that the controls selected are robust and likely to have strong compliance EffecYve&control?& " Use the hierarchy of controls " Aim high " If procedural, they need to be robust, well trained, and heavily enforced. 15&
16 Risk Controls Loading / unloading Exclusion Zones Can t See Can t Load " Very important and now minimum controls " Separation of people from forklift, crane, and falling loads " You can t stop product falling off tynes, so stop people being in the Falling Zone " Loading Unloading Exclusion Zone = LUEZ Conceptual#LUEZ# You#should#adapt#this#idea#to# suit#your#situalon#and#risks## A#green#mat#can# make#a#cheap#and# flexible#driver#zone# 16&
17 Risk Controls Loading / unloading Traffic Management Question how we can increase the hierarchy of control level LUEZ Should overlap with plant s overall Traffic Management " Define areas that are high risk " Physical controls that restrict access of pedestrians into high risk areas. " Very important to keep out any through-traffic " Minimise loading numbers in the area people, forklifts " Driver removed and kept out unless required for the loading process 17&
18 Risk Controls Loading / unloading Vehicle Isolation Several potential solutions: " Isolate driver from vehicle and loading area (if not required for loading) " Isolate forklift from truck where or when driver lashing/ unlashing the load " Isolate keys 18&
19 Risk Controls Loading / unloading Prevent Pedestrian/Truck Interactions " Isolation fencing/gates " One way traffic (forward) " Overlap with Traffic Management " Limit activities allowed in interaction areas " Special care at the base of raised docks, and/or where trucks are reversing " Critical procedures at a minimum eg. 3 m rule between forklifts and people Prevention of Dock Falls " If loading docks are present, consider if docks are right for your business " Isolate area when not in use " Bollard against falls close to the actual dock area 19&
20 Risk Controls Loading / unloading Prevention of Falls from Trucks Many causes and many solutions: " Solutions worth more detailed discussion " Eliminate working at height " Engineer ways to work safely from the ground or at height " PPE and administrative controls 20&
21 Risk Controls Loading / unloading Communications and Coordination Load tasks requiring coordination between people are a concern " Understand the process " Simplify it " Minimise the people involved in any task 21&
22 Risk Controls Loading / unloading Take 5 A basic safety method Transport safety needs a Take 2 philosophy. " Things are rarely the same or constant in the logistics environment " What is different about today? " Take 5.. Take whatever it takes to: " Stop " Look " Plan " Do 22&
23 In Summary Summary Remember the WHS legislative requirements " Provide a safe place of work " Look at the exposed hazards (energy) in a load/unload environment " Put in controls " Start quickly with simple controls Key Risks " Interactions with mobile equipment (forklift / cranes) " Product falling off vehicles / tynes during loading " People Falling off trucks Principal Controls " Exclusion Zones (LUEZ) " 3 Metre rule for forklift /pedestrians " But move rapidly towards controls further up the Hierarchy of Control " Traffic Management " Eliminate working on trailers 23&
24 24&
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