Material Handling EventsPerformance Analysis Group

June 30, 2014

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Material Handling Event ReviewFY 2012 – June 12, 2014

Review Material Handling Events at BNL• How are we doing?

• What types of events have we had?

Review Material Handling Incidents in ORPS Database across the DOE Complexes

• Are BNL events similar?

• Can we learn something to prevent events here at BNL?

Review the DOE Lessons Learned Database

• Based upon our events and DOE events which Lessons Learned

might be most beneficial to share.

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Material Handling Events at BNL FY 2012 – June 12, 2014

Review material handling incident rates

Look at injury rates related to material handling event types

Material Handling Incidents at BNL

During this time period there were 56 material handling related events

3 became ORPS

While Q4 FY13 was the highest quarter; overall our rate is low in FY 2014

Bracket Falls from Overhead Crane Trolley (SC3)

Cylinder Strikes Employee

(SC2)

Bucket of Ice Melt Falls nearly Striking Employee(SC3)

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BNL Material Handling Event Type & Injury Rate

Strains & Overexertion is the most frequent outcome for material handling incidents

Overall injury rate for material handling incidents is 63%

This rate may be inflated as low level incidents without injury may not be reported

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Material Handling Events ORPS Analysis FY 2012 – June 12, 2014

Looking for common themes across DOE sites

Provide general recommendations for

consideration

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MethodDeveloped trending codes and evaluated DOE Complex Events: General Equipment Type

• Forklift, dolly/cart/rolling equipment stand/skate, manual, hand truck, hydraulic lift/lift table, truck/trailer, vice…

Injury/No Injury General Activity

• Transport, lifting/lowering, loading/unloading, positioning, manual lifting, inspection

Consequence• Load slipped/dropped, Equipment tipped, Mechanical failure, Strains &

overexertion, Contact with overhead item, Work delay Initiation

• Load shifted/unbalance/not secured, load shifted/unbalanced, material not secure, unaware of surface/surroundings, mechanical failure, manual lift, overload, design change, removal of engineering control

Theme• Inadequate procedure/work planning, General equipment knowledge, Exceeding

equipment load capacity, Mechanical failure, Failure or missing engineering controls, Ergonomics, Underestimating weight of materials

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What are the consequences of material handling events in the DOE Complex?

Are there Injuries?

21 or about 66% of material handling issues involved a slipped/dropped load

17 or 53% resulted in injuries

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What equipment is being used when a slipped/dropped event occurs and are there

related injuries?

Many different types of equipment are involved with slipped/dropped loads Likelihood of injury appears to increase if equipment requires manual

involvement.9

What activity is occurring when a load is slipped/dropped?

Happened most frequently during load transport (57%) About 58% of drops during transport were initiated by issues with

surfaces/surroundings

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Common Themes Noted in the DOE Complex

During manual and machine assisted lifts it is important to accurately determine the weight, positioning and ergonomics of the load in order to select the proper equipment/method for movement.

Ensure that personnel utilizing machinery (forklifts, cranes, hoists, lifts, etc.) are trained and qualified in the use of such equipment and limitations.

Activities involving transport and machinery which involve manual assistance should require additional precautions and work planning especially relating to working surfaces and surroundings since the likelihood of injury is higher.

During work planning additional attention should be directed toward working surfaces and obstacles and its impact on equipment stability.

When possible items should always be properly secured during transport and care should be taken to observe any changes in load stability before any attempt to release the load.

Special care should be given to engage engineering controls when available and ensure they are working as intended. Work planning should consider consequences if engineering controls fail or mechanical failure occurs.

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Comparison of DOE Complex Events andBNL ORPS Events

All three BNL ORPS events involved a slipped/dropped load

• Two of the three ORPS events involved unloading

• One involved lifting

• Surfaces and surroundings played a role in the most severe

material handling event – Cylinder Strikes Employee (SC-2)

Manual lifting increases the likelihood of strains and overexertion.

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Lessons Learned Review

DOE Complex Lessons Learned (2012-2014)• 34 related to material handling

- 2 contributed by BNL

BNL Lessons Learned Database (2012-2014)• 13 related to material handling

- 8 authored by BNL

- 5 shared from the DOE Complex

Many Lessons Learned reviewed shared the same themes and issues revealed in the event analysis

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Recommendations

Communicate to employees the common themes identified and engage them for their experiences, perspectives and possible solutions

Combine LL materials and generate 2- 4 targeted LL to cover themes identified

• Use a sub-team to review material from both LL sources relevant to these themes

• Sub-team should include personnel who perform material handling

Review current practices using work observations and procedure validation

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Questions or Comments?

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