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A TRAINING FOR THE METALWORKING INDUSTRIES

SAFE OPERATION OF FORKLIFT. A TRAINING FOR THE METALWORKING INDUSTRIES. Table of Contents. Introduction Risk management on forklift Common forklift hazards Route plan Training for forklift operators Pre-operation checks Load assessments Common safe practices

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A TRAINING FOR THE METALWORKING INDUSTRIES

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  1. SAFE OPERATION OF FORKLIFT • A TRAINING FOR THE • METALWORKING INDUSTRIES

  2. Table of Contents • Introduction • Risk management on forklift • Common forklift hazards • Route plan • Training for forklift operators • Pre-operation checks • Load assessments • Common safe practices • Forklift traffic control

  3. Introduction • Forklift can be hazardous if not handled properly • Forklift accidents can cause serious injury, death, property and product damage • This poses a serious problem • for everyone • Accidents can be prevented if risk assessment and safe work procedures (SWP) are followed. Picture source: http://www.thompsonandjohnson.com/images/accident1.jpg

  4. Forklift Fatalities in Singapore Source: Ministry of Manpower

  5. Potential Forklift Accidents Picture source: http://marbella.to/humour/sep00/forklift.jpg

  6. Potential Forklift Accidents Picture source: http://www.facelift.co.uk/images/roguesgallery/forklift_no-no1.jpg

  7. Forklift Accidents Picture source: http://siri.uvm.edu/graphics/Industrial_Operations/Forklift_accident.gif

  8. Forklift Accidents Picture source: http://www.jicosh.gr.jp/english/cases/cases/case105.gif

  9. Forklift Accidents Picture source: European Industrial Gases Association

  10. Risk Management on Operation of Forklift • Required to manage risks under WSH (risk management) regulations • Assess the risk • Take all reasonably practical steps • Eliminate any risks

  11. Risk Management on Operation of Forklift • Step 1: Identification of hazard Picture source: http://www.safetyworld.com/images/101.gif

  12. Common Forklift Hazards • Overloading • Unsafe stacking • Speeding • Raised forks • Unauthorized operation of forklift • Untrained forklift operators Picture source: http://www.iqsdirectory.com/info/fork-lift-trucks/images/fork2.jpg

  13. Common Forklift Hazards • Lifting of persons on forks • Pedestrians and forklifts moving in the same place • Travelling on slope • Obstruction in the path e.g. overhead, blind corners • Poor ground conditions e.g. slippery, uneven, potholes

  14. Common Forklift Hazards Source: Ministry of Manpower • Body/limbs caught in moving parts of the forklift • Falling loads • Poor condition tyres e.g. without thread markings • Electric Shock (Battery operated forklift) Picture source: http://www.cdc.gov/niosh/face/images/96nj062.jpg

  15. Common Forklift Hazards • Pedestrians and forklift moving in same place Picture source: http://www.safetyworld.com/images/67.gif

  16. Common Forklift Hazards • Forklift traveling on slope Picture source: http://www.sandhillquilting.com/images/M-16-SYS-8436-L.jpg

  17. Common Forklift Hazards • Poor ground conditions Picture source: http://eternitycaptured.com/blog/wp-content/uploads/2007/04/bigstockphoto_Road_Cracks_And_Potholes_606173.jpg

  18. Common Forklift Hazards • Worn out tyres Picture source: http://www.riverina.coop/depts/Realestate/Other/forsale_auctions/whybro/RIMG2040.JPG

  19. Common Forklift Hazards • Unsecured load Picture source: http://www.locknpop.com/images/img_fork.gif

  20. Common Forklift Hazards • Electric shock from battery Picture source: http://www.ubuyme.com/img_prod/679/pic1.jpg

  21. Common Forklift Hazards • Lifting Persons on Forks Picture source: http://www.ttt-services.co.uk/Healthandsaftey/forklift_web.jpgc

  22. Risk Management on Operation of Forklift • Step 2: Assess the risk • Dependent on severity of risk and likelihood of hazards occurring • severity X likelihood = risk level • Risk Level = Low, Moderate or High

  23. Risk Management on Operation of Forklift Severity Minor Moderate Major Likelihood Remote Low Low Medium Occasional Low Medium High Frequent Medium High High

  24. Risk Management on Operation of Forklift • Step 3: Select Measures to Control and Reduce Risk • Based on hierarchy of hazards control • 1st – Remove the hazard (E.g. Forklift operations route separated from workers) • 2nd – Guard the remaining hazards (E.g. Erect physical protective barriers)

  25. Risk Management on Operation of Forklift HIERARCHY OF HAZARDS CONTROL

  26. 1st Remove the Hazards – Forklift Route Planning Picture source: http://maaw.info/images/Figure8-10.gif

  27. Route Plan • Efficient workplace layout/plan • Floors and surfaces in good condition • Fixtures which are clearly visible • Forklift operating and pedestrian paths identified and clearly marked • Designated maintenance, parking and battery charging areas

  28. Forklift Operation Separated from Worker Area Forklift operation area Picture source: Hi Tech Coatings, Inc

  29. Allocated Goods Area Goods sitting area Picture source: Hi Tech Coatings, Inc

  30. Designated Battery and Parking Area Forklift battery charging and parking area Picture source: Hi Tech Coatings, Inc

  31. 2nd Guard the Remaining Hazards: Protective Barriers Brightly coloured barriers Picture source: Hi Tech Coatings, Inc

  32. Risk Management on Operation of Forklift • 3rd – Mitigate impact of hazard (E.g. Operator to wear an seat belt) Source: Ministry of Manpower

  33. Risk Management on Operation of Forklift • Risk assessment to be done for every forklift tasks • To identify the risk and control measures • Establish safe work procedures (SWP) • Inform staff of SWP • Staff to follow SWP Source: Ministry of Manpower

  34. Risk Management on Operation of Forklift • Forklift Safe Work Procedures (SWP) • Forklift Training • Pre-Operation Check • Load Assessment • Common Safe Practice • Traffic Control Source: Ministry of Manpower

  35. Forklift Training • Under Factories (Safety Training Courses) Order, all forklift operators shall undergo a Forklift Drivers’ Training Course • Conducted by a MOM Accredited Training Provider • Consists of 1-day theory course • And 4 or 2 days practical course

  36. Why Conduct Forklift Training • Ensure forklift drivers are competent • To train driver in basic forklift operation • To provide knowledge of safe operating practices for forklift Picture source: http://www.crowndfw.com/training.html

  37. Why Conduct Pre-operation Checks? • Ensure efficient and safe operation of forklifts • Prevent workplace injuries • To remove inefficient forklift practices

  38. Under WSHAC Forklift Checklist, Pre-operation Checks Includes: • Tyres and wheels • Forks/attachments • Chains, cables and hoses • Safety devices (e.g. seat belts, warning devices, rear mirror and etc.) • Leaks • Hour meter • Battery/LPG system • Battery connector • Guards • Structural damage

  39. Pre-operation Checks 1 Source : http://www.thefabricator.com/Images/96/forklift-truck-diagram.jpg

  40. Pre-operation Checks 2 – Propane Forklift Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif

  41. Pre-operation Checks 3 – Electric Forklift Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif

  42. Pre-operation Checks 4 – Yard Forklift Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif

  43. Forklift Load Assessments 1 • Forklift can only handle loads within rated capacity • Follow forklift manufacturer’s load chart Forklift Model Length of fork Picture source : http://gmesupply.com/images/product_desc_images/forklifts/load-chart.jpg

  44. Forklift Load Assessments 1 • When attachments are used, the total weight of the load and attachment must not exceed the lifting capacity Picture source : http://www.kinggroup.com.au

  45. Forklift Load Assessments 1 • Don’t increase the capacity of the forklift using personnel as additional counterweights Picture source : http://www.staugustinelighthouse.com/blog/forklift.jpg

  46. Forklift Load Assessments 2 • Only handle stable or safely arranged loads • Care to be taken when handling extra long or high load • When loads can’t be centered, the forklift should be operated with caution Picture source: http://www.baileypottery.com Source: CP 101: 2004 Code of practice for safe use of powered counterbalanced forklifts

  47. Load Assessments – Weighing the Load Picture source: http://www.weighing-systems.com/TechnologyCentre/forkliftweigh.html

  48. Load Assessments – Weight at Centre of Gravity Forklift Picture source: http://www.morsemfgco.com/images/forklift_sm.gif

  49. Load Assessments – Weight at Centre of Gravity Picture source: http://www.rentrain.com/resources/fork_21.gif

  50. Load Assessments – Weight at Centre of Gravity Picture source: http://www.ccohs.ca/images/J05-2.gif

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