Powered Industrial Truck/Forklift Operations Standards and Procedures Disaster Cycle Services Standards & Procedures DCS SP DMWT April 2015
Change Log Date Page(s) Section Change Author: Deploy Materials, Workers and Technology Process 2
Table of Contents Change Log... 2 Introduction... 4 Purpose... 4 Relation to Other Documents... 4 Audience... 4 Scope... 4 Definitions... 5 Roles, Responsibilities and Authorities... 5 Procedures... 6 Identify Forklift Operators... 6 Provide Basic Operator Training... 6 Certified Red Cross Forklift Trainers... 7 Revocation of Trainers Certifcations... 7 Perform Pre-Operation Inspection... 8 Operate a Forklift... 8 Follow Forklift Safety Guidelines... 8 Report an Accident... 9 Maintain Charging/Fueling Areas... 9 Charge/Fuel Vehicles... 9 Maintain Eye Wash Stations and Equipment... 10 Maintain Records... 10 Author: Deploy Materials, Workers and Technology Process 3
Introduction Powered Industrial Trucks (PIT) are specialized industrial trucks that the American Red Cross relies on to conduct complex warehouse operations. The most common type of PIT used is the forklift. Occupational Health Safety and Health Administration (OSHA) Standard 29 CFR 1910.178, Powered Industrial Trucks, contains specific guidance and training requirements for the operation of forklifts. It is imperative that all operators are competent and can operate these heavy machines safely. The successful completion of specialized forklift training and evaluation specified in the OSHA standard is mandatory for all Red Cross forklift operators. Purpose The purpose of this document is to describe the process activities, standards, responsibilities and authorities, and control mechanisms for operating a forklift as required by OSHA Standard 29 CFR 1910.178, Powered Industrial Trucks. Relation to Other Documents This document provides Standards and Procedures for safely operating a forklift within Disaster Cycle Services (DCS) Deploy Materials, Workers and Technology Process. This document relates to the Warehouse Operations Standards and Procedures and lists specific details about forklift operations. The job tool Forklift Daily Inspection Checklist accompanies implementation of these standards and procedures. Audience This document applies directly to Red Cross workers within Disaster Cycle Services including the divisions, the regional chapter network, and national headquarters, who operate or maintain forklifts. Scope This document covers specific rules and guidelines that Red Cross workers must follow per OSHA Standard 29 CFR 1910.178, Powered Industrial Trucks. Failure to abide by all standards and procedures listed within this document can result in serious injuries, loss of life, and/or fines. Author: Deploy Materials, Workers and Technology Process 4
Definitions Occupational Safety and Health Administration The Occupational Safety and Health Administration (OSHA) is a federal agency of the United States that regulates workplace safety and health. OSHA Standard 29 CFR 1910.178 specifically covers the laws and rules that govern Powered Industrial Truck/Forklift operations. Powered Industrial Truck A powered industrial truck is any mobile power-propelled truck used to carry, push, pull, lift, stack or tier materials (includes forklift trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines). It does not include compressed air or nonflammable compressed gas-operated industrial trucks. Staging Area Facility (warehouse) or location where material goods are stored or held before distribution in response to disaster events. Roles, Responsibilities and Authorities Staging Area Lead The staging area lead is accountable for all operations that go on within his or her assigned warehouse or facility. The staging area lead or designee is responsible for ensuring that all personnel whose work involves the operation and/or maintenance of forklifts at Red Cross facilities are properly trained and evaluated to ensure proficiency and safe work practices prior to assuming this duty, regardless of previous forklift experience. Staging area leads or designee are also responsible for ensuring that operators are operating forklifts within OSHA standards and for maintaining all documentation required by the Red Cross. Staging area leads will be on site when forklifts arrive and must sign off that they have validated the training and experience of the operator to use a specific forklift and/or any forklift at the staging area. Staging area leads or designee must also provide a site orientation to the operator prior to use. Note: If the staging area lead is not a trainer their forklift operation responsibilities must be performed by someone they appoint as their designee and the designee must be a trainer. Trainers Trainers are individuals who have successfully completed Red Cross training to teach or train others. Trainers are persons who have the knowledge, training, and experience to train operators and evaluate their competence on a forklift. It is recommended to have a trainer at the staging area so in the rare occurrence a volunteer assigned to operate a forklift is not licensed, the trainer can facilitate the Forklift Fundamentals II portion of the Red Cross training after that operator completes the Forklift Fundamentals I portion of the training. This also ensures that someone at the staging area is familiar with forklift operations and all American Red Cross standards on forklift safety. Author: Deploy Materials, Workers and Technology Process 5
Forklift Operator Forklift operators are accountable for adhering to all standards and procedures for operating a forklift. They are responsible for thoroughly completing the Forklift Daily Inspection Checklist and ensuring that the forklift they are operating is fully operational before each shift. Operators must not use any forklift that fails any part of an inspection and must inform their supervisors of any deficiencies upon discovery. Operators shall immediately report any incidents during operation to the staging area lead or designee. Procedures Identify Forklift Operators 1. The staging area lead identifies a need for a forklift operator at a particular location and puts in a request for a forklift operator with Staff Services. Requests should be planned in advance to allow the Resource Mobilization unit to react. 24 hours or more should be allowed when possible. 2. The Resource Mobilization unit receives the request and assigns an operator who is certified and qualified by the Red Cross to operate a forklift. 3. Once the operator arrives at the site, he or she reports immediately to the staging area lead or designee for a brief on current operations and tasks, evaluation, and on-site orientation. 4. The staging area lead or designee validates that the operator is a certified and trained forklift driver, checks for a valid forklift operator driver s license or trains the volunteer to be an operator and walks the operator around the facility for an orientation of potential hazards, obstacles, and rules. a. If the operator does not have a license, the staging area lead or designee can provide the volunteer with an area to take Forklift Fundamentals I and conduct Forklift Fundamentals II upon completion. Once certification is verified, the staging area lead will walk the operator around the facility for an orientation of potential hazards, obstacles, and rules. 5. Operators will not operate any forklift without prior approval from the staging area lead or designee on site. 6. Operators who have not been deployed and/or have not used a forklift for internal Red Cross purposes within a year must take a refresher course. (Note: Workers that have been actively operating a forklift and have credentials that validate that they are under a current certification must provide this certification to the staging area lead or designee to validate their qualifications to operate a forklift). Provide Basic Operator Training 1. Volunteers take Forklift Fundamentals I to gain the basic skills necessary to become forklift operators. 2. Trainees completes the course, pass the final examination and provide that certificate of completion to an approved trainer for the second part of certification: Forklift Fundamentals II. 3. Trainers conduct the hands-on evaluation for prospective operators using the Forklift Operator Evaluation Checklist and the manufacturers operating guidelines for the forklift(s) to which the operator candidate will be assigned. Author: Deploy Materials, Workers and Technology Process 6
4. Volunteers who already have forklift experience can provide proof of licensing and training to a trainer who can evaluate whether they need to take refresher training or additional training. 5. Volunteers can also receive forklift training at a source outside of the Red Cross that meets OSHA compliance. 6. Operators receive evaluations of their performance in the workplace once every three years. 7. Refresher retraining and evaluations are to be completed when an operator is using a forklift in an unsafe manner, is involved in an accident or near-miss incident and/or is using a different type of forklift. Certified Red Cross Forklift Trainers Experienced forklift operators who are identified and approved by their Disaster Capacity Work Group Logistics Lead will be given the opportunity to train others on how to inspect and correctly operate a forklift. Only personnel that are designated and authorized as trainers are permitted to conduct initial and refresher training for forklift operators within Red Cross. Red Cross Forklift Trainers or Forklift Operators must be at least 18 years old, per OSHA. Trainers are experienced forklift operators with a proven safe operating record that have completed a safety training course on the equipment of which they will be training personnel. Trainers can complete a forklift certification course equivalent to the Red Cross Forklift Fundamentals from a source outside Red Cross that meets OSHA compliance. However, they are still required still required to take the Forklift Fundamentals Certified Trainer and Forklift Fundamentals I course. Forklift operators who have completed Forklift Fundamentals I and II and desire to be forklift trainers for the Red Cross must be approved by their Division Capability Workgroup Logistics Lead. Forklift operators must complete a Trainer Qualification Form which must be signed off by a Division Capability Workgroup Logistics Lead or designee and must take the Red Cross Forklift Fundamentals Certified Trainer webinar. These records will be maintained on file at the regional chapter. Upon completion of the Forklift Fundamentals Certified Trainer webinar, the forklift operator will be certified as a Red Cross Forklift Trainer and can facilitate the hands-on portion of the Red Cross Forklift Fundamentals Module II course. Trainers must use the Forklift Daily Inspection Checklist and the Forklift Operator Evaluation Form during the Forklift Fundamentals Module II hands-on portion. They will also have the manufacturer s operating guidelines on hand for the forklifts they are training on. New trainers should always give a copy of their certificate of completion to their regional chapter to maintain. Revocation of Trainers Certifcations Trainers who prove to be grossly negligent can be removed as certified trainers by Division Capability Workgroup Logistics Leads. Division Capability Workgroup Logistics Leads should be aware of trainers who receive complaints from attendees of the trainers class and incidents or safety violations that occur during the hands on training in-addition to- general awareness of trainers. Division Capability Workgroup Logistics Leads should always request complaints or comments be sent to them by email. Division Capability Logistics Leads should make the best decision as to the competence of a trainer and whether they should remain certified. The chapter should keep documentation on the removal of a trainers certification. Author: Deploy Materials, Workers and Technology Process 7
Perform Pre-Operation Inspection Operators document the pre-operation inspection on the Forklift Daily Inspection Checklist after receiving an on-site evaluation from the staging area lead. Operators are to place any forklift that is found to be in need of repair, defective or in any way unsafe out of service. The forklift is tagged to identify the safety issue and the Forklift Daily Inspection Checklist is submitted to the staging area lead or appropriate on duty supervisor/designee. Operators do not perform maintenance on forklifts found to be defective. Operators do not replace or handle batteries at any time. The only exception is charging the battery. Operators may charge a forklift battery at the end of the work shift. If a leased forklift requires any type of maintenance, the operator contacts the owner of the forklift and arranges for either a replacement forklift or for maintenance to be performed prior to forklift being used again. Managers, supervisors and/or their designees ensure forklifts are properly inspected and that forklift safe operating conditions are maintained. Divisions retain Forklift Daily Inspection Checklist for a period of one calendar year following the inspection date if the forklifts are owned or leased for longer than two weeks by the Red Cross. Records are then maintained by the local disaster logistics staff after the close of an operation. Forklift Daily Inspection Checklist for borrowed or temporarily leased forklifts can be discarded after the forklift is returned to the vendor unless an incident occurred during the time the forklift was in Red Cross possession. If an incident occurred, all records on that forklift are retained regardless of when the forklift is returned and those records should be provided to and maintained by the local disaster logistics staff and kept for a period of one calendar year following the incident. Operate a Forklift Forklift operators at Red Cross facilities operate within the manufacturers operating guidelines for the specific forklift at all times. Operators of these forklifts are familiar with these guidelines and have a copy of the operator s manual on hand during operation. Staging area leads ensure that all forklifts loaned from vendors during disaster operations are equipped with a copy of the operator s manual prior to signing for the piece of equipment. Operators utilize forklifts in accordance with manufacturers guidelines as well as warehouse rules and procedures. Failure to obey all rules or operating in excess of the manufacturers guidelines is subject to disciplinary actions in accordance with Red Cross disciplinary action policies. Follow Forklift Safety Guidelines Staging area leads ensure that protective measures are in place while materials are being moved in, out, and around the warehouse to protect employees from the potential hazards of falling materials. Staging area leads ensure that pathways are marked properly (i.e. no pedestrian, no traffic zones) so that pedestrian traffic and forklift traffic do not use the same paths and ultimately avoid the potential hazard of personnel being struck by a forklift in motion. Forklifts that elevate the operator to a height of four feet or greater for the purposes of picking or pulling orders have protective measures in place (personal fall arrest equipment) to protect the employee from falling, and operators of such equipment receive additional training for such equipment in accordance with Red Cross policies and the requirements set forth by OSHA. Author: Deploy Materials, Workers and Technology Process 8
Report an Accident Operators and/or witnesses to an incident involving a forklift should report the incident immediately to the staging area lead or designated supervisor and Staff Wellness on a disaster relief operation. Staging area leads address immediate emergencies and ensure the collection of written statements from all witnesses to the incident. Consideration should always be given to calling 911 when an accident occurs. Any forklift operator involved in an accident in which they are determined to be at fault must not return to operating a forklift until they complete retraining and successfully complete an operator evaluation. Forklift operators involved in an accident while operating such unit may be drug and alcohol tested immediately and results reviewed prior to resuming any task involving the operation of a forklift regardless of fault. Staff Wellness completes an illness and injury report in addition to providing Sedgwick (the Red Cross insurance provider) with the incident report. Sedgwick will contact the responder involved in an accident should medical services be required. Sedgwick can be contacted at 1-800-285-3258 ext 34251 should a responder need to file a claim. Maintain Charging/Fueling Areas Staging area leads designate areas for the fueling or charging of forklifts within their warehouse. Such areas are to be protected from both forklift and normal motor vehicle traffic if outdoors. Areas are marked by use of floor markings or hard barriers to preclude both traffic and storage of materials in the area. All charging and fueling areas are equipped with an ABC rated fire extinguisher and eye wash station (plumbed or wall mounted) or emergency shower within the immediate vicinity of the area. If fossil fuels such as gasoline or diesel fuels are used to fuel a forklift, then the unit is fueled outside of the structure in an area greater than 100 feet from any structure. Forklifts fueled by propane or other compressed gas shall only have cylinder change areas which are well ventilated or outdoors. All gas cylinders are stored in accordance with federal, state and local regulations. Charge/Fuel Vehicles It is highly preferred that propane forklifts be used whenever possible to avoid hazardous occurrences. Authorized and trained operators charge forklift batteries and perform refueling in designated areas only. All personnel follow proper recharging safety procedures outlined in the owner s manual. The operator shuts the forklift off and engages the parking brake. The operator wears personal protective equipment including approved face shield, goggles, apron, and gloves during battery charging and fueling tasks while keeping tools and other metallic objects away from the top of uncovered batteries. Ensure the vent caps are functioning and the battery or compartment cover(s) are open to to dissipate heat as appropriate. NOTE: Pour the acid into the water; water must never be poured into acid. Author: Deploy Materials, Workers and Technology Process 9
Maintain Eye Wash Stations and Equipment An appropriate portable eye wash device containing not less than one gallon of potable water which is readily available and mounted for use should be available in facilities that do not have or require an emergency services section. Maintain Records Documentation of completed training by Red Cross employees is tracked in the Red Cross learning management system. All Forklift Fundamentals Course certificates of completion are maintained on record for the length of the forklift operator s employment or service with the Red Cross. These records are maintained by their respective Division Capability Workgroup Logistics Lead and the learning management system. Author: Deploy Materials, Workers and Technology Process 10
Powered Industrial Truck/Forklift Operations Standards and Procedures 2015 The American National Red Cross Disaster Cycle Services