Safety in the Movement of People and Materials Lift Trucks Conveyors Automated Warehouses

Safety in the Safety in the Movement of People Movement of People

and Materialsand Materials

Lift TrucksLift Trucks

ConveyorsConveyors

Automated WarehousesAutomated Warehouses

Types of Lift TruckTypes of Lift Truck

Counterbalance Lift TruckCounterbalance Lift Truck

Reach TruckReach Truck

Rough-terrain Rough-terrain CounterbalanceCounterbalance

Telescopic Materials Telescopic Materials HandlerHandler

Side-loading Lift TruckSide-loading Lift Truck

Pedestrian Controlled Lift Pedestrian Controlled Lift TruckTruck

Large Lift TruckLarge Lift Truck

Lift Truck HazardsLift Truck Hazards

Collision with people or vulnerable plantCollision with people or vulnerable plant OverturningOverturning Items falling from racking or forksItems falling from racking or forks Explosion from some batteriesExplosion from some batteries Hot exhaustHot exhaust Dangerous parts e.g. chains, drive shafts Dangerous parts e.g. chains, drive shafts

etc.etc. Driving off edges, into pits etc.Driving off edges, into pits etc. Placing loads onto peoples feetPlacing loads onto peoples feet

Lift Truck HazardsLift Truck Hazards

FumesFumes NoiseNoise Whole body vibrationWhole body vibration Load slipping from forksLoad slipping from forks

Lift Truck Control MeasuresLift Truck Control Measures

Driver SelectionDriver Selection

Reliable and mature attitudeReliable and mature attitude Physically & mentally fitPhysically & mentally fit IntelligentIntelligent Over school leaving ageOver school leaving age Not under influence of drink/drugsNot under influence of drink/drugs Good visionGood vision Good hearingGood hearing

Driver TrainingDriver Training

Supervisors should receive an Supervisors should receive an appreciationappreciation

Competent InstructorCompetent Instructor Records should be keptRecords should be kept Test at end of trainingTest at end of training Employees should be given written Employees should be given written

authorisation at end of trainingauthorisation at end of training Refresher training as necessaryRefresher training as necessary

Work AreaWork Area

Separate traffic routes where Separate traffic routes where possiblepossible

Routes should have sufficient width Routes should have sufficient width and clearance for largest trucks usedand clearance for largest trucks used

Prevent pedestrians entering lift Prevent pedestrians entering lift truck areastruck areas

Eliminate sharp bends or overhead Eliminate sharp bends or overhead obstructions wherever possibleobstructions wherever possible

Where hazards cannot be removed, Where hazards cannot be removed, use clearly marked barriersuse clearly marked barriers

Work AreaWork Area

Signs, warning devices, mirrors Signs, warning devices, mirrors etc.etc.

Instructions to sound horns and Instructions to sound horns and restrict speedrestrict speed

Flexible doors of transparent Flexible doors of transparent material where lift trucks have to material where lift trucks have to pass throughpass through

Work AreaWork Area

Edges of loading bays, excavations Edges of loading bays, excavations & pits should be clearly marked& pits should be clearly marked

Work AreaWork Area

Where possible, edges should be Where possible, edges should be fitted with barriersfitted with barriers

Work AreaWork Area

Operating areas should Operating areas should be as free as possible be as free as possible of obstructions, but of obstructions, but supports, columns, supports, columns, pipework, racking or pipework, racking or other plant may need other plant may need to be protected by to be protected by special impact barriersspecial impact barriers

Work AreaWork Area

Firm and level surface, ideally Firm and level surface, ideally concrete or similarconcrete or similar

Potholes should not be allowed to Potholes should not be allowed to developdevelop

Steep gradients should be avoidedSteep gradients should be avoided Adequate lightingAdequate lighting Trucks should be parked in a secure Trucks should be parked in a secure

areaarea Keys should be kept in a secure Keys should be kept in a secure

placeplace

Protecting Pedestrians & Protecting Pedestrians & OperatorsOperators

Segregate pedestrians and Segregate pedestrians and vehiclesvehicles


Clearly mark traffic routesClearly mark traffic routes Use audible and visual warning Use audible and visual warning

devicesdevices High-visibility clothing may be High-visibility clothing may be

necessary, as well as safety boots necessary, as well as safety boots and hard hatsand hard hats

A Roll Over Protection Structure A Roll Over Protection Structure should be fitted where there is a risk should be fitted where there is a risk of overturning and crushing operatorof overturning and crushing operator


Seat belts may be requiredSeat belts may be required Falling object protection structures Falling object protection structures

should be fitted where there is should be fitted where there is significant risk of falling materialssignificant risk of falling materials

Anyone driving a lift truck on a Anyone driving a lift truck on a public road should comply with public road should comply with road traffic legislationroad traffic legislation

The Lift TruckThe Lift Truck

Suitable for its intended purposeSuitable for its intended purpose Travel with loads in lowered positionTravel with loads in lowered position Do not load beyond SWL (safe Do not load beyond SWL (safe

working load)working load) Dangerous parts should be guardedDangerous parts should be guarded Eliminate ignition sources in battery Eliminate ignition sources in battery

charging areascharging areas Adequate ventilation to disperse Adequate ventilation to disperse

fumesfumes

Operation of Lift TrucksOperation of Lift Trucks

Issue keys only to authorised peopleIssue keys only to authorised people Lower forks when parkedLower forks when parked Keep to left when operatingKeep to left when operating Sound horn at danger spotsSound horn at danger spots Avoid violent braking or sudden Avoid violent braking or sudden

changes in directionchanges in direction Never travel down slopes with load Never travel down slopes with load

in frontin front

MaintenanceMaintenance

Follow manufacturers Follow manufacturers recommendationsrecommendations

Operators should not carry out Operators should not carry out repairsrepairs

Trucks that are on loan still need Trucks that are on loan still need to be checked and maintainedto be checked and maintained

Operator ChecksOperator Checks

At beginning of each shift, operator At beginning of each shift, operator should check the following and report should check the following and report any defects to his supervisor:any defects to his supervisor:– Tyre pressure and damage;Tyre pressure and damage;– Steering and brakes;Steering and brakes;– Fuel, water and oil levels;Fuel, water and oil levels;– Battery levels;Battery levels;– Masts and hydraulics;Masts and hydraulics;– All controls;All controls;– Horns and other warning systems; andHorns and other warning systems; and– Lights & mirrorsLights & mirrors

Conveyor BeltsConveyor Belts

Conveyor HazardsConveyor Hazards

In-running nipsIn-running nips Entanglement points at rollersEntanglement points at rollers Contact with moving partsContact with moving parts Materials falling from conveyorMaterials falling from conveyor Manual Handling/Ergonomics from Manual Handling/Ergonomics from

incorrectly set speedsincorrectly set speeds

Conveyor ControlsConveyor Controls

Guard in-running nipsGuard in-running nips


Emergency trip wires or stop Emergency trip wires or stop buttonsbuttons

Guard power drives and other Guard power drives and other dangerous partsdangerous parts

Nobody allowed to ride on conveyorNobody allowed to ride on conveyor Operatives should be trained and Operatives should be trained and

instructed in safe useinstructed in safe use


Automated Warehouses & Automated Warehouses & Order Picking Machines Order Picking Machines

(OPMs)(OPMs)

OPM HazardsOPM Hazards Overturning e.g. overloading, gradientsOverturning e.g. overloading, gradients Falls of people, goods or materialsFalls of people, goods or materials Trapping of people in mechanismsTrapping of people in mechanisms Trapping of people against fixed structuresTrapping of people against fixed structures People struck by moving OPMPeople struck by moving OPM Failure of platform supporting mechanismFailure of platform supporting mechanism People stranded on platform due to power People stranded on platform due to power

failurefailure Inadvertent movements e.g. misapplication of Inadvertent movements e.g. misapplication of

controlscontrols

OPM ControlsOPM Controls

Only trained and authorised personsOnly trained and authorised persons Comply with SWLComply with SWL Tested and examined every 6 Tested and examined every 6

months (LOLER)months (LOLER) Prevent access to dangerous parts Prevent access to dangerous parts

e.g. chains, mast sections etc.e.g. chains, mast sections etc. Edge protectionEdge protection Suitable overhead guardsSuitable overhead guards

Automated Warehouse Automated Warehouse HazardsHazards

Collision between AGVs and peopleCollision between AGVs and people Trapping points between AGVs and Trapping points between AGVs and

stationary objects or fixed structuresstationary objects or fixed structures Inadvertent movement of AGVsInadvertent movement of AGVs Collapse of palletised loadsCollapse of palletised loads Collapse of AGVCollapse of AGV Slips on oil from machinesSlips on oil from machines

Automated Warehouse Automated Warehouse ControlsControls

Segregate AGVs from pedestriansSegregate AGVs from pedestrians Trip devices on vehicle bumpersTrip devices on vehicle bumpers Sensors on vehicles to slow it to a Sensors on vehicles to slow it to a

crawlcrawl Ensure accurate positioning of AGV at Ensure accurate positioning of AGV at

transfer pointstransfer points Easily accessible emergency stopsEasily accessible emergency stops Automatic monitoring of safety systemAutomatic monitoring of safety system

Automated Warehouse Automated Warehouse ControlsControls

Audible and visual signalsAudible and visual signals Guard dangerous moving partsGuard dangerous moving parts Prevent unauthorised human accessPrevent unauthorised human access Pressure sensitive matsPressure sensitive mats Interlocked access gatesInterlocked access gates Permit systems for maintenancePermit systems for maintenance Clear warning noticesClear warning notices

Documents

Safety in the Movement of People and Materials Lift Trucks Conveyors Automated Warehouses