Pedestrian Walkway Guidance Document

OHS 2

Pedestrian and Vehicle Safety Guideline


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APPROVAL STATUS The AIAG Occupational Health and Safety Steering Committee and designated stakeholders approved this document for publication on 3/17/2004.

Published by: Automotive Industry Action Group

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Phone: (248) 358-3570 Fax: (248) 358-3253

AIAG Copyright and Trademark Notice: The contents of all published materials are copyrighted by the Automotive Industry Action Group unless otherwise indicated. Copyright is not claimed as to any part of an original work prepared by a U.S. or state government officer or employee as part of the persons official duties. All rights are preserved by AIAG, and content may not be altered or disseminated, published, or transferred in part of such content. The information is not to be sold in part or whole to anyone within your organization or to another company. Copyright infringement is a violation of federal law subject to criminal and civil penalties. AIAG and the Automotive Industry Action Group are registered service marks of the Automotive Industry Action Group. 2004 Automotive Industry Action Group

OHS-2 1 Issue: 01 Dated:6/04/04 Replaces: N/A Dated: N/A


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FOREWORD In 2001, the AIAG Occupational Health and Safety Steering Committee established a working group to optimize powered industrial trucks and related systems. The purpose of the Occupational Health / Industrial Truck (OHIT) subcommittee is to improve safety in the automotive working environment by identifying and standardizing best practices relative to industrial trucks and related facilities and equipment.

The work group initially identified a total of eight topics into which these best practices can be classified. They included the following: Pedestrian and Vehicle Safety, Vehicle Specifications, Maintenance, Technical Innovations, Operator Training, Ergonomics, Applications, and Miscellaneous Equipment. It was decided that the Pedestrian and Vehicle Safety topic was the most critical to address from an industry standpoint. The best practices and guidelines relating to this subject have been compiled and published in this document, which can be used by the automotive OEMs and their suppliers.

This Pedestrian and Vehicle Safety Guideline addresses facility layouts, visual displays, and mental attitudes. The facility and visual displays are physical items that assist in making the workplace safer. The mental elements are somewhat more intangible but crucial to maintaining the awareness of and proper emphasis on safety.

The following elements from this Guideline are addressed in more detail:

Facilities - On-site facilities assessments are necessary to identify areas requiring pedestrian/vehicular safety controls. Consistency in marking and separating these areas is a key to improved awareness of and conformance to the guidelines.

Equipment - Equipment specifications have an impact on how readily a vehicle is observed by pedestrians. For example, recent studies have shown that certain paint colors can make a vehicle up to four times more visible to the human eye.

Operators/Pedestrians - Proper training is essential to ensure that safety requirements are clearly understood. This is as important for the pedestrian as for the vehicle operator. Simple conformance to right-of-way and 2-foot rule guidelines can make a difference and must be observed by both parties.

It is important to remember that the Pedestrian and Vehicle Safety Guideline involves a lot more than "simply painting lines on the floor." It is a comprehensive program and, to be effective, it needs the interaction among all of its elements. Embracing these aspects of the guideline has the potential to significantly reduce vehicle and pedestrian accidents.

Changes of this magnitude will not be easy. The major challenges facing us today are the cultural changes needed to impact the mental attitudes of pedestrians and industrial truck operators. It will require a full commitment from top-level leadership through the entire workforce to drive these necessary behavioral changes.



ACKNOWLEDGEMENTS

The following individuals participated in creating this document.

Mike Mnich CVMedia Thomas Jeruzal DaimlerChrysler Corporation Kevin R. Waszak DaimlerChrysler Corporation Gary M. Elliott Delphi Frank Faulisi Federal Mogul Corporation Dennis Graham Ford Motor Company Brad Joseph Ford Motor Company Mark Tepen* Ford Motor Company Max Atteberry General Motors Corporation Bruce Bennett General Motors Corporation Robert R. Fox General Motors Corporation Ron Hackleman General Motors Corporation Frank E. Steinberger* General Motors Corporation Michael Taubitz General Motors Corporation Walter Girardi Girardi Consulting Michael Courson Hyster Company Bob McAdam Industrial Truck Association Ronald Berglund Michigan Manufacturing Technology Center Gary Paris* NACCO Materials Handling Group, Inc. Sean O'Neil St. Onge Company James Brown Toledo Molding & Die, Inc. James Howe UAW Douglas L. Dickinson Yale Materials Handling Corp. James E. Lindman Yale Materials Handling Corp.

* Co-chairs



TABLE OF CONTENTS AIAG PUBLICATIONS............................................................................................................................. 1 EXECUTIVE STATEMENT ..................................................................................................................... 8 GOVERNING CODES AND STANDARDS ............................................................................................ 9 1.0 CONSENSUS GUIDELINES....................................................................................................... 10

1.1 FACILITY ASSESSMENTS ........................................................................................................... 10 1.1.1 Facility Design.................................................................................................................. 10 1.1.2 Powered Industrial-Truck Traffic Flow............................................................................ 11

1.2 FACILITY LAYOUT..................................................................................................................... 12 1.2.1 Pedestrian Walkways ........................................................................................................ 12 1.2.2 Automated Guided Vehicle................................................................................................ 12 1.2.3 Restricted Zones................................................................................................................ 13 1.2.4 Pedestrian Crosswalks...................................................................................................... 14 1.2.5 Pedestrian Barriers........................................................................................................... 15 1.2.6 Intersecting Aisles ............................................................................................................. 15 1.2.7 Mirrors .............................................................................................................................. 16 1.2.8 Traffic Control Signs......................................................................................................... 16 1.2.9 Rail Spur Pit Stairwells..................................................................................................... 16 1.2.10 Safety Guards.................................................................................................................... 17 1.2.11 Open Floor Work Pits ....................................................................................................... 17 1.2.12 Additional Graphic Symbols ............................................................................................. 17

1.3 POWERED INDUSTRIAL-TRUCK APPLICATION .......................................................................... 18 1.4 POWERED INDUSTRIAL-TRUCK OPERATOR .............................................................................. 19 1.5 PEDESTRIAN .............................................................................................................................. 22 1.6 MATERIAL FLOW AND STORAGE .............................................................................................. 24 1.7 INCIDENT TRACKING AND CATEGORIZATION ........................................................................... 24 1.8 FOLLOW-UP TRAINING.............................................................................................................. 25

2.0 SUPPLEMENTAL GUIDELINES............................................................................................... 27 2.1 FACILITY ASSESSMENTS ........................................................................................................... 27 2.2 FACILITY LAYOUT..................................................................................................................... 28

2.2.1 Truck Docks ...................................................................................................................... 28 2.2.2 Railcar Docks.................................................................................................................... 32 2.2.3 Call Marketplace............................................................................................................... 35 2.2.4 Card Marketplace ............................................................................................................. 37 2.2.5 Shared Pedestrian and PMHV Aisles - Minimum Aisle Width Considerations and General Rules of Thumb ................................................................................................................................. 38 2.2.6 Powered Industrial-Truck (non-AGVS) Traffic Aisle Requirements................................. 39 2.2.7 Automatic Guided Vehicle System (AGVS) Traffic Aisle Requirements ........................... 40 2.2.8 In-Plant Trailer Drop-Off Zones....................................................................................... 40 2.2.9 General Aisle Recommendations ...................................................................................... 41

2.3 VISUAL FACTORY (A PLACE FOR EVERYTHING AND EVERYTHING IN ITS PLACE) .................. 43 2.4 POWERED INDUSTRIAL-TRUCK EXAMPLES .............................................................................. 44 2.5 POWERED INDUSTRIAL-TRUCK OPERATOR .............................................................................. 44 2.6 PEDESTRIAN .............................................................................................................................. 45

3.0 APPLICATION VARIABLES ..................................................................................................... 47 3.1 FACILITY ASSESSMENTS ........................................................................................................... 47

4.0 OTHER CONSIDERATIONS...................................................................................................... 48



4.1 FACILITY ASSESSMENTS ........................................................................................................... 48

APPENDIX A........................................................................................................................................... 49 APPENDIX B ........................................................................................................................................... 51 APPENDIX C ........................................................................................................................................... 53 ABOUT AIAG.......................................................................................................................................... 57

PURPOSE STATEMENT ........................................................................................................................... 57 CORE VALUES ....................................................................................................................................... 57 AIAG ORGANIZATION .......................................................................................................................... 57 AIAG PROJECTS.................................................................................................................................... 57

LIST OF FIGURES AND TABLES Figure 1.1 Dedicated Walkway.................................................................................................................... 12 Figure 1.2 Shared Walkway......................................................................................................................... 12 Figure 1.3 - AGV Boundary Path Demarcation.............................................................................................. 13 Figure 1.4 AGV Caution Sign Figure 1.5 AGV Caution Sign............................................................ 13 Figure 1.6 Typical Restricted Zone ............................................................................................................. 14 Figure 1.7 Stop Sign & Stop Box ................................................................................................................ 15 Figure 1.8 Pedestrian Crosswalk Sign (10 x 14 minimum size)............................................................... 15 Figure 1.9 Typical Aisle Intersections ......................................................................................................... 16 Figure 1.10 Open Pit Sign (10 x 14 minimum size)................................................................................. 17 Figure 1.11 3-Point Mounting/Dismounting Decal ..................................................................................... 20 Figure 1.12 2-Foot Rule Decal..................................................................................................................... 21 Figure 2.1 Truck Docks (Shipping/Receiving) ............................................................................................ 29 Figure 2.2 Truck Docks (LCL Docks) ......................................................................................................... 30 Figure 2.3 Truck Docks (Point-Of-Use Docks) ........................................................................................... 31 Figure 2.4 Saw Tooth Docks (Point-Of-Use Docks) ................................................................................... 31 Figure 2.5 Rail Car Docks (One-Sided Load/Unload)................................................................................. 32 Figure 2.6 Rail Car Docks (Two-Sided Load/Unload) ................................................................................ 33 Figure 2.7 Rail Car Docks (One-Sided Load / Unload Each Car) ............................................................... 33 Figure 2.8 - Portable Rail Dock Storage Stand............................................................................................... 35 Figure 2.9 Call Marketplace ........................................................................................................................ 36 Figure 2.10 First In, First Out ...................................................................................................................... 36 Figure 2.11 Blind Corner ............................................................................................................................. 37 Figure 2.12 Card Marketplace ..................................................................................................................... 38 Table 2.2. Minimum Aisle Widths................................................................................................................. 39 Figure 2.13 One-Way Traffic ...................................................................................................................... 39 Figure 2.14 Two-Way Traffic...................................................................................................................... 40 Figure 2.15 Two-Way AGV Traffic Aisle................................................................................................... 40 Figure 2.16 In-Plant Trailer Drop-Off Zones............................................................................................... 41



EXECUTIVE STATEMENT This AIAG publication reflects a consensus of individuals greatly concerned with the safety and health of all pedestrians and powered industrial-truck operators working within a facility. Recognizing that pedestrian and vehicle safety involves more than simply painting lines on the floor, the AIAG has developed guidelines that attack related safety problem areas head on.

These guidelines, though many in number, involve three strategically targeted elements, which are physical facility layout, visual displays, and mental attitude. The physical guideline elements define the facility layout criteriaand are aimed at isolating pedestrian traffic from powered industrial-truck traffic. The visual guideline elements define varying media and aids aimed at making pedestrians and powered industrial-truck operators aware of potentially hazardous situations they may encounter within any facility. Mental elements, although often intangible, are underscored by both the physical and visual guideline elements. The mental elements are not, in and of themselves, specific guidelines but rather attitudes that need to be developed in all pedestrians and powered industrial-truck operators. These mental elements undoubtedly involve cultural changes that must be promoted from top-level management on down.

Therefore, encouraging cultural mindset changes must not only be a main current focus but a continuing focus throughout the future. The mental attitude of every pedestrian and powered industrial truck operator must, hereafter, be in harmony with all regulations and instructions integrated into the pedestrian and vehicle safety program guidelines. The manner in which individuals conducted themselves in the past while traversing a facility is no longer acceptable. With cultural change comes new, innovative ways of thinking and acting - ways that make a workplace environment safer for everyone.



GOVERNING CODES AND STANDARDS This manual for Pedestrian and Vehicle Safety best practices is intended to complement other established regulations and standards. Of the list of regulations and standards provided below, some are included in this document as stated references whereas reference to others is implied. The content of this manual meets or exceeds the requirements of these regulations and standards as applicable. If a subject is not specifically addressed in this best practices manual, please refer to the latest version of the applicable standard for more information.

ANSI MH26.1 Specifications for Industrial Metal Containers ANSI Z535.1-5 Environmental and Facility Safety Signs ANSI/ISEA Safety Apparel Standards ASME B56.1 Safety Standard for Industrial Trucks ASME B56.8 Safety Standard for Personnel and Burden Carriers ASME B56.9 Safety Standard for Industrial Tow Tractors CSA Z96-02 & B335 Canadian Safety Standards for Lift Trucks ISO 15870 Industrial Powered Trucks Safety Signs and Pictorials OSHA 29 CFR 1910.22 Walking/Working Surfaces - General Requirements OSHA 29 CFR 1910.36 Means of Egress - General Requirements OSHA 29 CFR 1910. 36 Means of Egress - Building General OSHA 29 CFR 1910.38 Emergency and Fire Prevention Plans OSHA 29 CFR 1910.144 Safety Color Codes for Marking Physical hazards OSHA 29 CFR 1910.145 Specifications for Accident Prevention Signs and Tags OSHA 29 CFR 1910.178 Powered Industrial Trucks

Notes:

Governing regulations may vary by country (e.g., Mexico, Europe, etc.), which may result in limited, specific changes to the language contained within this document.

1. ANSI American National Standards Institute

2. ISEA International Safety Equipment Association

3. ASME American Society of Mechanical Engineers

4. CSA Canadian Standards Association

5. ISO International Organization for Standardization

6. OSHA Occupational Safety and Health Act

7. AAR - American Association of Railroads



1.0 CONSENSUS GUIDELINES

1.1 Facility Assessments In general, powered industrial trucks, other in-plant powered vehicles, and pedestrian traffic should be separated wherever possible. In areas where this is not possible, added safety controls (physical and visual) should be required to reduce pedestrian risks. It is important to realize that on-site facility assessments are necessary in order to identify those areas requiring pedestrian/vehicular safety controls and to ensure that the process is consistently implemented across all facilities. However, safety controls themselves will not ensure that pedestrian risks are reduced. Effective implementation of the program should include specific training - for both equipment operators and pedestrians - focusing on the proper interpretation of and compliance with these controls.

A detailed facility assessment should focus on 1) High pedestrian traffic areas (e.g., adjacent to offices, cafeterias, locker rooms, employee entrances, etc.) and 2) High powered industrial-truck and/or finished- product traffic areas (e.g., receiving/shipping docks, warehouses and marketplaces (stock storage), pre-delivery areas, etc.). Each facility assessment should be documented by means of field verifications and layout drawings. Documentation should identify problem areas as well as required improvement modifications.

1.1.1 Facility Design

o Aisle widths and color-coded demarcation lines o Personnel access doorway locations o Service doorway locations o Material storage locations (e.g., marketplaces, material warehouse, line side storage, etc.) o Plant floor office locations including personnel access doorways o Individual departmental locations including supervisory locations o Employee service locations (e.g., shop floor entrances, break rooms, cafeterias, canteens, locker

rooms, main entrances for employees and non-employees, medical, parking lot entrances, restrooms, secured accesses for employees and non-employees, etc.)

o Powered industrial-truck repair staging o Shipping dock locations (e.g., loading bays, personnel access doorways, shipping offices, etc.) o Receiving dock locations (e.g., unloading bays, personnel access doorways, shipping offices, etc.) o Stairwell locations o Permanent ladder locations o Drinking fountain locations



1.1.2 Powered Industrial-Truck Traffic Flow

Powered industrial-truck application and traffic flow should be studied in order to identify potential vehicle/pedestrian trouble spots (e.g., congested areas or where near-miss incidents have occurred) within a facility. Particular aspects of powered industrial-truck applications to be studied include but are not limited to the following:

o Load configurations and variation (e.g., pallets; baskets; tiered, long, and/or wide loaded racks; empty racks, etc.).

o Load engagement prior to and while in transit. o Travel speeds laden and unladed. o Fork height while in transit. o Dolly configuration and trailing features. o Observation of powered industrial-truck operating rules and regulations. o Verification of powered industrial-truck alterations or modifications. o Ancillary device use (e.g., reverse light, warning lights, automatic audible alarms, service horn,

truck-mounted mirrors, etc.).

o One-way versus two-way aisle traffic.

1.1.3 Pedestrian Traffic Flow Pedestrian traffic flow should be studied in order to identify potential and/or existing vehicle/pedestrian trouble spots (e.g., congested areas or where near-miss incidents have occurred) within a facility. Particular areas of pedestrian traffic flow to be studied include but are not limited to the following:

o Overall movement of pedestrians throughout the facility. o Pedestrian movement involving individual workstations, work cells, etc. o Pedestrian movement involving main and secondary entrances and exits. o Pedestrian movement involving cafeterias, canteens, break rooms, etc. o Pedestrian movement involving administration facilities connected to production areas. o Pedestrian movement involving designated tour group routes. o Pedestrian movement involving visitors (e.g., all types of contractors, vendors, service people,

tour groups, etc.) and over-the-road truck drivers.

o Pedestrian movement involving receiving and shipping docks. o Pedestrian movements involving off-line finish product areas, including quality control.



1.2 Facility Layout The following elements are to be incorporated into each manufacturing facility in order to create an enhanced visual control system and to increase individual awareness of both personal risk and expected behaviors. These elements should be continually maintained to ensure the success of creating a safer workplace environment for everyone.

1.2.1 Pedestrian Walkways

o Pedestrian walkways should be marked with widths of no less than 3 feet wide, using demarcation stripe widths of 4-inch minimum.

Dedicated pedestrian-only walkway (Fig. 1.1) boundaries are to be striped green (Industry Safety Green or equivalent) with stripe widths of 4-inch minimum.

Figure 1.1 Dedicated Walkway

Shared vehicular and pedestrian aisles (Fig. 1.2) are to include a marked pedestrian aisle/walkway with boundaries striped yellow (Target Yellow or equivalent). Where possible, these pedestrian walkways should be located to the side of the aisle that is farthest from adjacent traffic/activity (e.g., production linefeed areas) and/or to the side that offers the best out-of-the-aisle escape route.

Figure 1.2 Shared Walkway

1.2.2 Automated Guided Vehicle

o AGV path boundary demarcations (Fig. 1.3) should be striped orange (Industry Safety Orange or equivalent) with a stripe width of 4-inch minimum. These boundaries are to be



striped a distance of 18 inches wider than the outside boundary on each side of the AGV or its widest intended load, whichever is greater.

Figure 1.3 - AGV Boundary Path Demarcation

o At all AGV intersections, either one of the following two warning systems should be in place: Install a 360 degree dome mirror/four-way caution sign stating, WATCH FOR AGV

TRAFFIC (Fig. 1.4), located in the middle of the intersection. Install combination warning light/four-way caution sign stating, AGV TRAFFIC

APPROACHING INTERSECTION (Fig. 1.5), located in the middle of the intersection. Either sign should consist of four sides with the proper wording on all four sides and either a 360-degree dome (spherical) mirror or a warning light (1-10 Hz recommended flash rate) suspended from the middle with the lens cover pointing down. The base of the lens cover or dome mirror should be even with the bottom of the sign. The warning sign and light system/mirror should be mounted a maximum of 12 feet above the floor to the bottom of the lens/mirror. The dimension of the sign should be a minimum of 14 inches vertically and 20 inches horizontally. The sign should be visible to all traffic approaching the intersection. The sign must conform to ANSI Z535.2, OSHA 1910.144, and OSHA 1910.145. The light (when used) should be activated a minimum of 20 feet prior to entering the aisle and turned off after the last dolly being transported leaves the intersection; this type and color of warning light should be unique throughout the entire plant for AGVs only.

Figure 1.4 AGV Caution Sign Figure 1.5 AGV Caution Sign

1.2.3 Restricted Zones

o No pedestrian boundaries should be striped with a red line adjacent to the restricted zone (Industry Safety Red or equivalent) accompanied with a second dashed red stripe parallel



to the first painted line, 4 inches to the inside of the restricted zone, with stripe widths of 4-inch minimum (12 inch total width). Danger signs stating, RESTRICTED ZONE - AUTHORIZED PERSONNEL ONLY or VEHICLE AISLE ONLY PEDESTRIANS PROHIBITED are to be posted along all boundaries of restricted zones. (Figure 1.6) Each danger sign should be conspicuously located to gain the attention of a pedestrian about to access the restricted zone. The dimension of the sign should be a minimum of 10 inches vertically and 14 inches horizontally. The sign must conform to ANSI Z535.2, OSHA 1910.144, and OSHA 1910.145. Examples of restricted zones include shipping docks, receiving docks, material storage areas, and AGV pathways where minimum 18inch clearances between AGV/loads and obstructions are not possible. As plant layouts change, the need and locations of restricted zones should be re-evaluated.

Figure 1.6 Typical Restricted Zone

1.2.4 Pedestrian Crosswalks

o When not adjacent to aisle intersections (e.g., for designating pedestrian crossings between or through Trim/Assembly lines or work cells), aisle crosswalk boundaries should be striped yellow with internal crosshatched striping. These crosswalks should be either angled or perpendicular depending upon the existing configuration of the aisle(s).

o For crosswalks adjacent to aisle intersections, crosswalk boundaries should be striped yellow with internal crosshatched striping. These crosswalks should be perpendicular to the aisle being crossed.

o Powered industrial truck stop boxes (Figure 1.7) should be striped in red on either side of a pedestrian crosswalk where appropriate. Inside these red boxes, the word STOP should be painted in white block letters. Where such markings are not feasible due to floor and environmental conditions (e.g., oil, dust, etc.), posted STOP signs (24-inch octagon, aluminum reflective) should be used.



Figure 1.7 Stop Sign & Stop Box

o A suspended caution sign (Figure 1.8) should be installed at the entrance of every pedestrian crosswalk, centered with the crosswalk and even with the inside aisle marker line, displaying the words PEDESTRIAN CROSSWALK on both sides of the sign. When possible, the sign should be located a maximum of 12 feet above the floor to the bottom of the sign. The dimension of the sign should be a minimum of 10 inches vertically and 14 inches horizontally. The sign should be visible to all approaching aisle traffic. The sign must conform to ANSI Z535.2, OSHA 1910.144, and OSHA 1910.145.

Figure 1.8 Pedestrian Crosswalk Sign (10 x 14 minimum size)

1.2.5 Pedestrian Barriers

o Barriers/railings painted Target Yellow should be installed at pedestrian access points to aisles in which powered industrial truck traffic is present (e.g., from stairways, vestibules, offices, canteens, cafeterias, locker rooms, employee entrances, etc.). The purpose of such barriers is to impede forward momentum for pedestrians entering powered industrial-truck traffic aisles or zones. Note: Barriers shall comply with local/state/federal zoning ordinances.

1.2.6 Intersecting Aisles

o Powered industrial-truck intersecting traffic aisle boundary lines should be striped at a 45-degree angle beginning 4 feet from intersecting aisle lines to improve visibility at intersections. (Figure 1.9)



1.2.7 Mirrors

o 360-degree dome (spherical) mirrors and/or convex mirrors (Figure 1.9) are to be installed at powered industrial-truck/pedestrian intersections to enhance visibility. These mirrors should be mounted to facilitate normal line-of-site for pedestrians and powered industrial-truck operators and to clear all obstacles (e.g., mounted at correct angle, not too high, etc.). When possible, mirrors should be mounted a maximum of 12 feet above the floor to the bottom of the dome.

Figure 1.9 Typical Aisle Intersections

1.2.8 Traffic Control Signs

o STOP sign markings or stop boxes (See Fig. 1.7 and 1.9) should be painted on the floor at key aisle intersections where powered industrial-truck and pedestrian traffic is high and/or safety is a concern. Intersection stop sign markings may vary from 1-way to 4-way based on traffic volume, visibility, and material flow patterns. Stop boxes should be located 3 feet back from the corners of the intersection. The stop boxes should be striped in red with the word STOP painted inside the box in white block letters. Where such markings are not feasible due to the floor and environmental conditions (e.g., oil, dust, etc.), posted stop signs (24-inch octagon, aluminum reflective) should be used.

1.2.9 Rail Spur Pit Stairwells

o Rail Spur Pit Stairwells should be closed to unauthorized personnel by means of a chained access. Each stairwell should be equipped with two handrails. A latch chain or gate should be installed at the top and bottom of each stairwell, blocking access by personnel. Red lines should be painted adjacent to existing aisle demarcations indicating the area located between the aisle and the rail



spur pit is a restricted zone. Danger signs should be attached to each chain containing the words RESTRICTED ZONE - AUTHORIZED PERSONNEL ONLY. The dimension of the danger sign should be a minimum of 10 inches vertically and 14 inches horizontally. The danger signs should be mounted a maximum of 55 inches above the floor to the bottom of the sign. The danger sign must conform to ANSI Z535.2, OSHA 1910.144, and OSHA 1910.145.

1.2.10 Safety Guards

o Safety Guards including but not limited to guardrails, posts, suspended clearance bars, etc., should be painted Target Yellow. Overhead clearance bars painted Target Yellow displaying the clearance height (e.g., CAUTION 8 FOOT CLEARANCE) in black lettering should identify low overhead clearances. The bars should be located a minimum of 3 feet from the low overhead clearance, where possible.

1.2.11 Open Floor Work Pits

o Open Floor Work Pits should have danger signs (Figure 1.10) centered along the length of each workstation accessing the pit with the words OPEN PIT - AUTHORIZED PERSONNEL ONLY on both sides. The dimension of the danger sign should be a minimum of 10 inches vertically and 14 inches horizontally. The danger sign should be mounted a maximum of 7 feet above the working surface of the workstation to the bottom of the sign. The danger sign must conform to ANSI Z535.2, OSHA 1910.144, and OSHA 1910.145.

Figure 1.10 Open Pit Sign (10 x 14 minimum size)

1.2.12 Additional Graphic Symbols

o Additional Graphic Symbols should be included in pedestrian walkways (shared/dedicated) and also in restricted no pedestrian zones, with spacing of selected graphics/striping as follows:

One pair of Footprints (decals or stencils) should be located in the center of and parallel to the pedestrian walkway, every 20-30 feet. Shared walkways footprints should be Target Yellow and dedicated walkways Industry Safety Green. Footprints reinforce pedestrian use of a walkway and provide clarity for pedestrians who may be colorblind.

Crosshatch spacing should measure 24 inches, center-to-center of demarcation lines painted Target Yellow.



1.3 Powered Industrial-Truck Application Every powered industrial truck (fork lift trucks, burden carriers, tow tractor, etc.) in operation should meet configuration and specification requirements of ASME, AIAG, Industry, and Company standards. In addition, the following features are recommended to maximize the operator's visibility to recognize potential hazards. They also ensure that the presence of an industrial truck is easily recognized by pedestrians and other industrial-truck operators.

o Every powered industrial-truck main chassis/frame should be painted a high-visibility color.

o Mast/uprights of high-lift powered industrial trucks should be painted flat black, providing non-glaring component surfaces.

o The forward facing vertical edge of the mast/upright of high-lift powered industrial trucks should have a high-visibility stripe along the vertical face of this edge.

o Drivers overhead guards should be painted flat black, providing non-glaring component surfaces.

o All powered industrial trucks (except for Class 3-Electric Motor Hand Trucks or Hand/Rider Trucks) should be equipped with a forward facing headlight(s), which is key switch activated.

o All fork trucks (sit down and stand drive) should be equipped with a rearward facing drive light not to interfere with the operators vision, which is activated when the trucks directional control system is placed in the reverse mode.



1.4 Powered Industrial-Truck Operator Powered industrial-truck operator training teaches operators safe practices when operating around pedestrians. In addition to the operators training, the following safety rules should apply to all powered industrial-truck operators.

o The trucks service horn should be used to warn others nearby of their presence. The service horn should be sounded when approaching pedestrian workstations and when approaching intersections or corners where the visibility is poor.

o When approaching a pedestrian, an operator should sound the service horn, allow safe clearance, and use STOP and GO AHEAD hand signals to communicate who will proceed first.

o An operator should maintain contact with the brake when approaching a pedestrian or intersection.

o Operators should be aware of visual obstructions at intersections and check overhead mirrors for traffic.

o Operators should not allow anyone to ride on or in their vehicle unless there is an approved seat.

o Operators should not operate any powered industrial truck in a designated pedestrian only aisle.

o Operators should avoid creating blind corners and intersections due to staging tall piles of stock at these locations.

o Bar-code-inventory instrumentation should be mounted in locations that do not hinder the operators ability to safely operate/manipulate any of the hand/foot controls within the operators compartment. This equipment should be installed according to the equipment manufacturers recommendations. Instrumentation should not compromise the operators visibility during normal operation (dynamic or static mode). Instrumentation requiring operator input should not be enabled while the powered industrial truck is in motion.

o Cell phone use should not be allowed at any time while operating a powered industrial truck.

o Company radio dispatch systems installed in powered industrial trucks should be used only when the powered industrial truck is brought to a complete stop. All truck controls should be positioned according to the definition of an unattended truck.

o Operators of powered industrial trucks must be aware of passing traffic when they are getting on and off the vehicle and/or working alongside the vehicle. This can be a particular problem when an operator steps out from between tow carts. In order to reduce the potential for these types of incidents, in those operations where two-way traffic (or the potential for passing) exists, it is suggested that all vehicles that tow carts be equipped with some type of cone or other device that provides passing drivers a warning to give clearance.



o When operating a powered industrial truck, an operator should maintain three points of contact

(3-point mounting/dismounting rule) with the truck when mounting or dismounting it. Contact should be made with one hand and two feet or two hands and one foot at all times. (Fig, 1.11) The operators hands should be free of any obstacles (e.g., food, beverage, tools, etc.) during this process. Prior to dismounting, an operator should check to see that the floor is clear of obstacles (e.g., screws, nuts, oils, water, etc.) and that traffic is clear in both directions.

One 3-Point Mounting/Dismounting decal should be installed on all high-lift powered industrial trucks, with and without cab enclosures, as referenced in Fig. 1.11. The decal should be placed on the left front overhead guard support leg, below any grab handle, on the outside of the support leg. If access is from either left or right, an additional decal should be similarly installed to the right support leg.

Figure 1.11 3-Point Mounting/Dismounting Decal



o If you stop your vehicle to talk to a pedestrian, the 2-Foot Rule should be enforced. This rule

requires an operator to maintain a minimum distance of 2 feet (or outstretched arms length) between the vehicle and the pedestrian being communicated with. In the case of a high-lift powered industrial truck, the load engaging means should be completely lowered, the directional control placed in neutral, and the power supply to either motor or engine turned off before the pedestrian is allowed closer than two feet to the vehicle. For all other powered industrial trucks, the directional control should be placed in neutral and the power supply to either the motor or engine turned off. An operator may not start the truck until the pedestrian is at least two feet away from the vehicle and is aware that it will be moving. Decals (similar to Fig. 1.12) should be installed on all powered industrial trucks to remind both the operator and pedestrian of this rule. Typical installation details are listed below; however, the size and location of the decals can vary according to local practices.

Four decals (Fig. 1.12) should be installed, one on each drivers overhead guard support leg.

The line separating the two pictures should be positioned on the outside corner of each support.

One picture should face the interior of the operators compartment. The second picture should face the exterior of the truck. The picture locations are intended to remind both operator and pedestrian.

The decals should be installed at a height range of 60-74 inches above the ground, measured to the center of the decal.

If the powered industrial truck is equipped with a cab enclosure, the decal should be cut, placing one picture in each of the required locations.

Figure 1.12 2-Foot Rule Decal



o Operators should wear high visibility safety vests in all designated powered industrial-truck

traffic areas, restricted zones, and any other congested areas as determined by each facility assessment. Examples might include shipping/receiving docks, cafeteria perimeters, battery charging/changing areas, security gate personnel entrances, etc.

o The Right-Of-Way policy is key to maximizing the effectiveness of the cultural change mentioned in the Executive Statement. Under the Pedestrian and Vehicle Safety Guideline, pedestrians should be instructed that they possess the "right-of-way" only when they are in the pedestrian walkway or an identified crosswalk. When entering or traveling in walkways and crosswalks, pedestrians should be alert to vehicle traffic. When encountering vehicle traffic, the pedestrian should establish eye contact and use verbal or hand signal communication with the operator to determine who will proceed first. The powered industrial- truck operator is still ultimately responsible for the safe operation of the vehicle in the working environment and must be instructed according to current training requirements.

1.5 Pedestrian A pedestrian is any person who is not within the normal operating position on any powered industrial truck. More specifically, a pedestrian may be a co-worker, a company employee visiting from another company location, all outside visitors (e.g., all types of contractors, vendors, service people, tour groups, etc.), and over-the-road truck drivers. All pedestrians should receive on-site training in vehicle/pedestrian safety to ensure compliance with the requirements set forth in this section. Additionally, pedestrian training should consist of but not be limited to the following instructions:

o Pedestrians should walk within designated pedestrian walkways only (e.g., shared walkways yellow and dedicated walkways green).

o Pedestrians should not walk more than two abreast in any pedestrian walkway.

o Pedestrians should watch for powered industrial trucks that may be approaching from behind or on either side.

o Pedestrians should STOP and LOOK when a powered industrial-truck operator is sounding the trucks service horn. They should make eye contact with the operator and use STOPandGO AHEAD hand signals to communicate to the operator who will proceed first.

o Pedestrians should stop until they are sure the powered industrial truck operator sees them when they are in each others path of travel.

o Pedestrians should use STOP and GO AHEAD hand signals to communicate to powered industrial-truck operators who will proceed first.

o Pedestrians should use caution when approaching an intersection or entering a vehicle traffic area and should obey traffic control signs.

o Pedestrians should maintain a distance of 2 feet (or outstretched arms length) from any powered industrial truck in operation. (Fig. 1.12)



o The Right-Of-Way policy is key to maximizing the effectiveness of the cultural change

mentioned in the Executive Statement. Under the Pedestrian and Vehicle Safety Guideline, pedestrians should be instructed that they possess the "right-of-way" only when they are in the pedestrian walkway or an identified crosswalk. When entering or traveling in walkways and crosswalks, pedestrians should be alert to vehicle traffic. When encountering vehicle traffic, the pedestrian should establish eye contact and use verbal or hand signal communication with the operator to determine who will proceed first. The mindset of the pedestrian needs to reflect similar behaviors used on public sidewalks along city streets. This process places the responsibility of personal safety directly upon the pedestrian. Pedestrians use this skill-set in their daily lives away from company property and it should be a relatively easy lesson to portray.

o Pedestrians should be aware of visual obstructions at intersections and check overhead dome/convex mirrors for traffic before proceeding.

o Pedestrians should be alert to changing workplace conditions such as water/oil on the floor.

o Pedestrians should cross at designated crossings, when available. Otherwise, before crossing an aisle or other area where powered industrial trucks are operating, pedestrians should STOP and LOOK in both directions. Cross only if it is safe to do so. Always assume that powered industrial trucks have the right of way. When in doubt, insist that the powered industrial-truck operator go on ahead, and then cross.

o Pedestrians should wear high-visibility fluorescent green safety vests in all designated, powered industrial-truck traffic areas, restricted zones, and any other congested areas as determined by each facility assessment. Examples might include shipping/receiving docks, cafeteria perimeters, battery changing areas, personnel security gate entrances, etc. Additionally, the following guidelines apply:

At local plant discretion, operators of powered industrial trucks in designated areas should wear a high-visibility vest.

At local plant discretion, all company and outside visitors may be required to wear high-visibility vests at all times while in the plant.

High-visibility vests should be worn as the exterior garment (e.g., on top of coats, sweaters, and other clothing).

A local plant control system should be set up to administer high-visibility vests.

o Pedestrians should never climb over or go under pedestrian barriers. Where pedestrian barriers are not available, stop, check aisle traffic, and then proceed with caution.

o Pedestrians should never enter aisle ways, which are blind spots for powered industrial-truck operators (e.g., through racks, blind corners, etc.).

o Pedestrians should never enter posted powered industrial-truck aisles dedicated for truck traffic only.

o Pedestrians should never walk/jump over open floor work pits.



o Pedestrians should never enter rail car spur pits unless authorized.

o Pedestrians should never take short cuts through designated material storage locations, warehouse areas, or stock racks. Powered industrial-truck operators cannot anticipate such acts and may not be able to stop in time.

1.6 Material Flow and Storage Good material handling practices involve proper transport and storage of material. General guidelines addressing the safe flow and storage of material include but are not limited to the following:

o Material transported by powered industrial trucks should be secured and stable.

o Material should be transported at speeds that enable the powered industrial-truck operator to bring the truck/load to a safe stop. Operators should slow down and proceed with caution when traversing floor conveyors, ramps, dock boards, and bridge plate.

o Material stored at all line side workstation areas that is stacked more than 4feet high should have some type of guard (e.g., wire/synthetic mesh or screen) on the workstation side to prevent accidental falling of any stored material.

o Material should not be stored within the demarcation lines of any aisle or walkway.

o Powered industrial trucks should not be used to push material along any aisle way or storage area.

1.7 Incident Tracking and Categorization Incident tracking and categorization is aimed at identifying incident particulars in order to prevent similar occurrences in the future. The more complete the information gathering process, the more beneficial the collected data will be. Collected data can be analyzed and plotted in chart format to determine where trouble spots exist as well as where progress has been made. The following list of chart titles by category provides a uniform, consistent means by which to track ongoing events involving the Pedestrian and Vehicles Safety Program.

o Chart #1 - Powered Industrial Truck and Dock Incident Severity - By Category Fatal Death is result of incident. Serious Lost time at work is result of incident. Minor No lost time as result of incident. Near-Miss Incident did not result in personal injury or property damage.

o Chart #2 - Equipment Type Involved in Incidents By Truck Classification Class 1 Electric Motor, Sit-down Rider, Counter-Balanced Truck. Class 2 Electric Motor Narrow Aisle Truck (Stand Up). Class 3 Electric Motor Hand Truck or Hand/Rider Truck. Class 4 Internal Combustion Engine Truck (Solid Tire).



Class 5 - Internal Combustion Engine Truck (Pneumatic Tire). Class 6 Electric and Internal Combustion Engine Tow Tractors. Class 7 Rough Terrain Forklift Truck (Pneumatic Tire). Personnel and Burden Carrier. Other

o Chart #3 - Pedestrian Severity By Category Same categories as Chart #1

o Chart #4 - Equipment Involved in Serious/Fatal Pedestrian Incidents Same categories as Chart #2

o Chart #5 - Dock/Hi-way Trailer Related Incident Severity By Category Same categories as Chart #1

o Chart #6 - Industrial Truck Incident Types By Category Pedestrian Struck Collision with Another Industrial Truck Loss of Load or Materials Collision with Fixed Object Other

o Chart #7 - Equipment Involved in Pedestrian Incidents By Category Same categories as Chart #2

o Chart #8 - Pedestrian Location in Industrial Truck Incidents By Category In Work Cell or Break Area Already in Aisle Entering Aisle Standing Next to Truck Cutting Through Area Other

o Chart #9 - Incidents by Division Chart for Pedestrians Chart for all Types

o Chart #10 - Incidents by Month 1 Chart for Pedestrians 1 Chart for all Types

Appendix A provides a sample industrial vehicle incident report.

1.8 Follow-Up Training During the course of powered industrial-truck operation, it may be determined that follow-up operator training is required. Based on company policy, OSHA 1910.178, and ASME B56 requirements, follow-up training must be required when:



o The operator has been observed to operate the vehicle in an unsafe manner. The observation may

be made by anyone.

o The operator has been involved in an accident. The accident may be reported by anyone.

o The operator has been involved in a near-miss incident. The incident may be reported by anyone.

o The operator has received an evaluation that reveals that the operator is not operating the truck safely.

o A condition in the workplace changes in a manner that could affect safe operation of the powered industrial truck.

o The operator is assigned to a powered industrial truck with operating functions not provided in previous operator training.

o The existing powered industrial truck in operation has been modified.

The amount and duration of follow-up training will be case specific. The objective of the training is to ensure that the operator has the knowledge and skills needed to operate a particular powered industrial truck safely. The training should also be followed by an evaluation of the operator to verify that the stated objective has been achieved.

Additionally, based on similar incidents described above, there may be occasions where pedestrians need follow-up training. If this is the case, the pedestrian(s) should be instructed in a manner consistent with that of a powered industrial-truck operator. Similarly, a post-evaluation of the pedestrian training should be required.



2.0 SUPPLEMENTAL GUIDELINES

2.1 Facility Assessments Benchmarks for designing the optimum plant layout include but are not limited to the following guidelines:

o Design for optimum pedestrian aisle space and crosswalks. Completely segregate pedestrian from powered industrial truck traffic wherever possible.

o Locate drinking fountains away from active aisles. o Do not store any material within 8 feet of aisle intersections, thus improving visibility of the

approaching intersection.

o Use 360-degree dome mirrors or convex mirrors at blind/congested intersections. o Locate all personnel access doors away from the main aisles for powered industrial-truck traffic.

Access from doors should not lead immediately into an aisle.

o Wherever possible, dedicate aisles as material flow traffic aisles only. o Identify space at dock locations as non-pedestrian areas only. o Define tool operator space with an escape path and protection from equipment encroachment. o Identify potential problem areas and mark them with signs, paint, or cross-hatching to alert

powered-equipment operators and pedestrians of potential hazard areas (e.g., use stop signs, foot paths on floor, flashing light at intersections, etc.).

o Provide safe clearance between pedestrians and powered overhead equipment (e.g., conveyors, etc).

o Provide railings around corners and high pedestrian areas to protect from trailing dollies being towed. Ensure that railings do not result in tripping hazards.

o Provide dedicated zones for dolly drop-off. o Provide adequate lighting for existing working conditions. o Provide windows on each corner of all inter-plant offices located at aisle intersections to

eliminate blind corners.

o Dedicate one personnel access door for over-the-road truck drivers to enter/exit. Access should lead directly to and from Shipping and Receiving offices. The personnel access door should be located close to the respective offices to eliminate drivers walking across loading/unloading bays. Install information signs instructing drivers to proceed to holding areas (canteen, break room, waiting room, etc.) until summoned.

o To accommodate the safe passage of over-the-road drivers from their tractors to the designated entrance/exit, marked pedestrian walkways should be installed. One shared pedestrian walkway



should be centrally located between every two docking stations, perpendicular to the dock and extending a minimum of 12 feet forward of the longest tractor-trailer servicing the dock. This walkway should intersect with the main shared walkway installed parallel to the dock stations and leading to the designated access area. Additional outside lighting may be required to ensure that the walkways are appropriately illuminated for safe passage of the drivers. Footprints (decal/stencil) may be installed to assist drivers. Demarcation lines and footprints should be painted Target Yellow.

o Stairs located near powered industrial-truck traffic aisles and descending from elevated floor levels should exit pedestrians parallel to the aisle, never perpendicular.

o Locate information signs at busy intersections, along congested aisles and walkways, at main and secondary entrances to a facility, and in other strategic areas. These signs should show a picture of a powered industrial truck accompanied with the wording CAUTION-Watch for Powered Industrial-Truck Traffic.

o Locate information signs stating Place No Stock in areas where storage of such material will create blind spots.

o Wherever possible, provide aisles that can safely support two-way traffic and a separate pedestrian aisle (twice the width of the maximum load handled + 18 inches load-to-load clearance + a 3-foot pedestrian walkway). Aisle demarcation lines should be painted in accordance with the mandatory requirements of Section 1.2.

o Fire extinguishers and related fire-fighting equipment should be mounted to the inside of vertical structural support columns and not directly on the column adjacent to powered industrial-truck traffic aisles.

o Picnic tables, rest areas, vending machines, etc., should be located away from powered industrial- truck traffic aisles. If this is not possible, protective guards/barriers should be installed as needed.

o Eliminate pedestrian flow shortcuts in production line areas. Design to prevent pedestrians from cutting though production lines and into main powered industrial traffic aisles.

o Use skywalk and/or subway pedestrian walkways that remove pedestrian traffic from the main production floor areas.

2.2 Facility Layout The intention of the following additional guidelines is to identify best practices for designing facility layouts in conjunction with new model planning. These guidelines will result in greater productivity through improved material flow and help promote separation of powered industrial-truck and pedestrian traffic.

2.2.1 Truck Docks

o The truck dock apron and aisles that are used to service the truck unloading process should be classified as "Authorized Personnel Only" and marked as such, according to the Pedestrian and Vehicle Safety Guideline. (Figure 2.1)



Figure 2.1 Truck Docks (Shipping/Receiving)

The term "Apron" refers to the interior area from the face of the dock plate to the edge of the plant perimeter aisle and extending 10 feet (3.0m) past the edge of the first and last docks. The apron is used for maneuvering equipment and material, and for staging trailer strings and containers. (Figure 2.1)

o The minimum aisle width for aisles servicing the truck dock apron is two times the widest load handled, plus 3 feet (0.9m).

o The minimum overhead clearance is 18 feet (5.5m) throughout the dock apron and 12 feet (3.6m) overhead clearance in adjacent aisles.

o The use of automated restraints requires an integrated sequence of controls. o Facilities for over-the-road truck drivers and the shipping office should be provided so that non-

company personnel are contained.

o The dock apron should contain no building columns. o The minimum spacing between docks is 15 feet (4.6m), center to center. o All docks and dock equipment should conform to AIAG standards. o For docks where full-length in-plant trailer trains are to be used, the distance from the dock face

to the opposite side of the apron should be: [8 feet (2.4m) dock plate, plus15 feet (4.6m)



maneuvering zone, plus planned string length, plus 8 feet (2.4m) tractor hookup area]. (Figure 2.2)

Figure 2.2 Truck Docks (LCL Docks)

o Point-of-use docks should not unload directly into the building perimeter aisle. The dock area should be isolated from other traffic and marked as such according to the Pedestrian and Vehicle Safety Guideline. The minimum depth of the unloading area is 35 feet (10.7m) from the dock face to the perimeter aisle [8 feet (2.4m) dock plate, 27 feet (8.2m) apron].



Figure 2.3 Truck Docks (Point-Of-Use Docks)

Handling of exceptionally large containers will require additional depth

o Saw-tooth docks should conform to the same guidelines as those set for standard truck docks described above. The apron depth is to be measured along a perpendicular line from the dock plate to the edge of the plant perimeter aisle. Dock spacing, center to center, should be taken parallel to the docks. (Figure 2.4)

Figure 2.4 Saw Tooth Docks (Point-Of-Use Docks)



2.2.2 Railcar Docks

o To minimize travel distances and in-plant congestion, a rail spur should be located as close as possible to point-of-use/storage of the production components received in the railcars.

o The rail dock apron is the interior area, which extends from the edge of the rail well to the edge of the main plant aisle parallel to the rail spur. The apron should be a minimum of 20 feet (6.1m) wide [2 feet (0.6m) clear, plus 18 feet (5.5m) maneuvering zone], although a wider apron may be required if the rack length is greater than 108 inches (2.7m) (e.g., 1-piece body side racks). Included in the 20 foot (6.1m) apron is a 2-foot (0.6m) wide line-of-sight clearance at the edge of the depressed well for visually checking railcars before they exit the plant. The perimeter of the rail dock opening should be painted in yellow with a minimum 4-inch (10.2cm) stripe, in accordance with the Pedestrian and Vehicle Safety Guideline. The apron is used to safely maneuver powered industrial trucks and for the temporary staging of racks and in-plant trailer strings. This dedicated space supports rail load and unload operations without congesting or restricting the main plant pedestrian and material flow. No full or empty containers should be stored on the apron. (Figures 2.5, 2.6, and 2.7)

Figure 2.5 Rail Car Docks (One-Sided Load/Unload)



Figure 2.6 Rail Car Docks (Two-Sided Load/Unload)

Figure 2.7 Rail Car Docks (One-Sided Load / Unload Each Car)

o Aisles next to rail dock aprons should be 21 feet (6.4m) wide, which includes a shared 3-foot (0.9m) pedestrian aisle. The location of the pedestrian aisle is to be identified by the plant based on actual powered industrial-truck and pedestrian flow in the area. (Figures 2.5, 2.6, and 2.7)

o The rail dock apron should be an open area, with no columns that may restrict maneuvering of powered industrial trucks.



o Overhead clearances in the dock apron area should be 20 feet (6.1m) minimum with no overhead

restrictions.

o No unloading/reloading of a railcar can be done by traveling through the doors of another railcar.

o The rail dock apron and aisles that are used to service the rail unloading should be classified as "Authorized Personnel Only" and marked as such according to the Pedestrian and Vehicle Safety Guideline. (Figures 2.5, 2.6, and 2.7)

o No employee facilities (e.g., offices, cribs, etc.) or building entrances should be located on the rail dock apron to minimize pedestrian traffic.

o Material should not be warehoused on the rail dock. Temporary staging of racks is allowed to support railcar loading and unloading.

o Rail spur crossover bridges should be aligned with plant aisles. Bridges should be a maximum of 500 feet (152.4m) apart and their location must not compromise the efficiency of the railcar unloading facilities. Crossover bridge location should be reviewed for congestion issues, which may be alleviated by the addition of incremental bridges. Bridge width should reflect the width of the parallel cross aisle. (Figures 2.5, 2.6, and 2.7)

o For rail docks serviced by AGVs, more space may be required on the apron to accommodate incremental drop zones.

o Portable rail dock plates should be stored on a stand (a place for every part) when not in use. (Figure 2.8)



Figure 2.8 - Portable Rail Dock Storage Stand

o Rail spot spacing of 100 feet (30.5m) is required for a typical car length of 86 feet (26.2m), and 74 feet (22.6m) is required for 60-foot (18.3m) cars.

o Access to outside staging areas should be located at the end of the rail spur to allow empty containers to be shuttled in and out from an outdoor staging area with minimum congestion and travel.

o All rail facilities must be compliant with AAR or other applicable standards.

2.2.3 Call Marketplace

o Perimeter aisles should support material storage areas. (Figure 2.9)

o Aisles internal to the marketplaces should be off limits to non-authorized personnel and indicated as such, according to the Pedestrian and Vehicle Safety Guideline. (Figure 2.9)

o A drop zone should be provided if materials are transported to or from the marketplace by tow train. The size of a drop zone should be based on the internal logistics plan. (Figure 2.9)

o Storage lanes and drop zones should be identified by painted lines on the floor. (Figures 2.9 and 2.10)



Figure 2.9 Call Marketplace

Figure 2.10 First In, First Out



o An overflow area should be located near the marketplace and identified accordingly. (Figures 2.9

and 2.10)

o Materials within 8 feet (2.4m) of an aisle intersection used by pedestrians should be stored no higher than 4 feet (1.2m) to preserve visibility for equipment and personnel in the area. Where blind intersections exist, an overhead domed mirror should be provided. (Figure 2.11)

Figure 2.11 Blind Corner

o The marketplace should be strategically located near its point-of-use for the maximum efficiency of material flow.

2.2.4 Card Marketplace

o Aisles internal to the marketplaces should be off limits to non-authorized personnel and identified as such, according to the Pedestrian and Vehicle Safety Guideline. (Figure 2.12)

o Materials within 8 feet (2.4m) of an aisle intersection used by pedestrians should be stored no higher than 4 feet (1.2m) to preserve visibility for equipment and personnel in the area. Where blind intersections exist, an overhead domed mirror should be provided. (Figure 2.11)

o Painted lines on the floor should identify Drop Zones, using the standards defined in the Pedestrian and Vehicle Safety Guideline.

o A drop zone should be provided if materials are transported to the marketplace by tow train. The size of the drop zone should be based on the internal logistics plan.

o The marketplace should be located as close as possible to a receiving location.



Figure 2.12 Card Marketplace

o An overflow area should be located near the marketplace and identified accordingly.

Properly designed aisles facilitate the safe movement of people, materials, and equipment. Staging or storing containers in the aisle is explicitly prohibited. Plant aisle widths are influenced by the pedestrian flow, the width of containers, and the size and maneuvering capability of powered industrial trucks. Because of the variables in the products manufactured in different plants, precise standards for aisle sizes cannot be established. However, below are general guidelines and determinants that should be considered when developing aisle sizes.

2.2.5 Shared Pedestrian and PMHV Aisles - Minimum Aisle Width Considerations and General Rules of Thumb

o Aisles of adequate width should be provided for efficient material handling operations. Note that 3-foot dedicated pedestrian aisles and in-plant trailer drop-off zones are incremental to these numbers.



Table 2.2. Minimum Aisle Widths

Assembly / Machining Body shop Stamping

Aisles along building perimeter wall 15 feet (4.6m) 15 feet (4.6m) 20 ft. (6.1m)

Cross aisles and storage areas 12 feet (3.7m) 15 feet (4.6m) 15 feet (4.6m)

Service aisles 8 feet (2.4m) 8 feet (2.4m) 8 feet (2.4m)

2.2.6 Powered Industrial-Truck (non-AGVS) Traffic Aisle Requirements

o One-way Powered Industrial-Truck Traffic - widest load handled or powered industrial truck, whichever is greater, plus 3 feet (0.9m) [18 inches (0.5m) clear on either side of load]. (Figure 2.13)

Figure 2.13 One-Way Traffic

o Two-way Powered Industrial-Truck Traffic - two times the widest load handled or powered industrial truck, whichever is greater, plus a 3-foot (0.9m) [18 inches (45.7cm) clearance on either side of the load]. (Figure 2.14)



Figure 2.14 Two-Way Traffic

2.2.7 Automatic Guided Vehicle System (AGVS) Traffic Aisle Requirements

o Two-way AGVS Traffic - two times the widest load handled or width of AGV, whichever is greater, plus 4.5 feet [18 inches (45.7cm) clear between loads, 18 inches (45.7cm) clear on either side of loads].

o One-way AGVS Traffic - widest load handled or width of AGV, whichever is greater, plus 3 feet (18 inches clear on either side of load).

Figure 2.15 Two-Way AGV Traffic Aisle

2.2.8 In-Plant Trailer Drop-Off Zones

o Drop-off zones should be shown and marked on facility layouts where required.



o As require, drop-off zones should be provided to support the available marketplaces and placed to

facilitate the smooth flow of material.

o Drop-off zones are considered separate and incremental areas and not part of the aisle width. The general guideline for sizing drop-off zones is [number of strings wide time the widest load handled, plus 18 inches (45.7cm)] wide, and [trailer train length including tow tractor, plus 7 foot (2.1m) ramp in and 7 foot (2.1m) ramp out area] long. (Figure 2.16)

Figure 2.16 In-Plant Trailer Drop-Off Zones

o Drop zones cannot be located in aisles.

o Drop zones should be visibly marked.

o Drop zones should remain open/free when not in use.

2.2.9 General Aisle Recommendations

Pedestrians entering the aisle from critical areas, including stairways, vestibules, offices, canteens, cafeterias, locker rooms, restrooms, employee entrances, etc., should enter the aisle moving parallel to aisle traffic. Using barriers such as railings or guardrails may accomplish this. Under no condition should this impede emergency egress from the building.



o For movements of materials greater than 108 inches (2.7m) in length (e.g., truck frames,

fuel/brake tube bundles, headliners, vehicles on skids, body sides, etc.), aisles may need to be wider at intersections or where linefeed materials are delivered. Drop-off zones are considered separate and incremental areas and should not infringe upon the aisle.

o Aisle boundary lines and traffic visuals are to be in conformance with the Pedestrian and Vehicle Safety Guideline.

o Specifically in Assembly and Stamping facilities, all aisles for the movement of materials and pedestrians should be through aisles to decrease the potential for the unsafe movement of material in confined areas.

o Cross aisles should be provided at least every 500 feet (152.4m). Production zones exceeding 500 feet (152.4m) in length (trim lines, etc.) create excessive powered industrial-truck travel.

o Perimeter aisles should be located a minimum of 4 feet (1.2m) away from the wall to permit safe pedestrian access to the aisles and access to emergency fire-fighting equipment (e.g., hoses and extinguishers, mains, plumbing, power boxes, light switches, etc.) that may be located on a perimeter wall. If these items impede pedestrian movement, a shared pedestrian/powered industrial truck aisle may be required locally. (Figure 2.3)

o Service aisles permit egress for mobile service equipment. They are not designated for the movement of materials. Service aisles are typically 8 feet (2.4m) wide but may be wider if needed for service requirements. Service aisles should be marked in conformance with the Pedestrian and Vehicle Safety Guideline.

o Overhead clearance in aisles used for the movement of production materials should be a minimum of 12 feet to allow for the unobstructed movement of trailer trains [1.5 feet (45.7cm) for trailer height, two times the container height of 56 inches (1.4m), 12 inches (30.5cm) clearance]. Where overhead clearance is less than 12 feet (3.7m), bump bars should be in place to denote maximum clearance height.

o Rail crossover bridges are required in instances where rail facilities divide in-plant processes and/or warehouse operations. (Figures 2.5 and 2.6) As a general rule:

A crossover bridge should be provided every 500 feet (152.4m) or less. A crossover bridge should be provided at all main aisle intersections.

o All aisle configurations and widths must conform to applicable national or local standards.



2.3 Visual Factory (A Place for Everything and Everything in its Place) o Follow the Pedestrian and Vehicle Safety Guideline. Establish and identify Pedestrian-only Aisles and Pedestrian/Powered Industrial-Truck

Shared Aisles.

Establish Powered Industrial-Truck only Aisles. Paint aisles according to the color-coding guideline. Use "foot print" decals/stencils to reinforce pedestrian walk aisles. Identify Pedestrian restricted areas with red boundaries and cross-hatching. Use "STOP" signs and painted "STOP" lettering on the floor.

o Use visual Aids throughout the plant to identify and highlight:

Pedestrian Restricted aisles. Pedestrian aisles. Equipment-only aisles. Market Areas (Stock Storage). Equipment storage (e.g., dies, maintenance equipment, production process equipment, scrap

cribs, part containment cribs, etc.).

Safety equipment (e.g., alarms, fire-fighting equipment, water fountains, etc.). Clearly identify pedestrian aisle crossing areas by means of visual aids. Reminder advertising (e.g., placards with pictures of powered industrial trucks indicating

"CAUTION - Watch for Lift Truck Traffic" located at all busy intersections, along aisles, walkways, etc.)

Signs posted at plant entrances warning pedestrians of electric-powered industrial trucks operating silently in the plant.

o Identify vehicle and equipment parking and charging areas, (with yellow markings, department number and powered industrial truck number). Ensure that battery change areas have adequate aisle clearance and are appropriately marked.

o To help increase visibility, it is recommended that all in-plant vehicles operate with headlights on. o Use of dome mirrors is recommended for areas that are congested or have limited visibility. o Yellow blinking lights can be used to warn pedestrians and vehicles to slow down at busy

intersections.

o Safety alert signs at production line crossovers can be used to increase awareness at aisle crossings.



o "No stock" signs should be posted near aisle intersections and in areas where dunnage creates

blind spots.

o Protect walkways with barrier guards where they are adjacent to loading zones or warehousing of racks and dunnage.

o Status boards for inbound truck receiving on docks and material delivery in market areas should be used to convey work status to team members.

o Material Handling Card Part Delivery Routes should be well defined and indicated by painted lines on the floor or posted signs.

o Skid Handling To minimize in-plant travel distance and congestion, truck docks used for

unloading/reloading skid trailers should be located as close as possible to the skidding/deskidding operations. These docks should be segregated from other truck docks.

Unloading/reloading of skid trailers from truck trailers should not take place into an aisle. One bay of the building is required behind skid docks for staging skid trailers.

2.4 Powered Industrial-Truck Examples Fast-charge battery technology can assist in meeting the demands of a two- or three-shift operation. Implementation of this new technology should comply with this Pedestrian and Vehicle Safety Guideline. Fast-charge technology benefits include but are not limited to the following:

o Parallel powered industrial truck charging uses one utility connection, thus reduces charging room space requirements.

o Powered industrial trucks can operate on one battery each for an entire day, thus reducing travel time to and from battery charging rooms as well as downtime battery change-outs and maintenance.

o Fast-charge units can be strategically located throughout a facility, isolating powered industrial trucks to locations where they are used. This reduces the now unnecessary trips through other parts of a facility in order to get to the charging room.

o Pressure-operated battery watering system technology can further assist in meeting the demands of a two- or three-shift operation. Implementation of this technology should comply with this Pedestrian and Vehicle Safety Guideline.

2.5 Powered Industrial-Truck Operator To ensure operator accountability for safely operating a powered industrial truck, the use of a driving record system may be appropriate to monitor accident, near-miss, or other incident data pertinent to the qualification and continued authorization of individual operators to operate such vehicles. Appendix B contains an example of a driving record reporting system. Distractions to powered industrial-truck



operators should be studied and addressed accordingly. Some common operator distractions include but are not limited to the following:

Personal entertainment systems (e.g., walkman radio/cassette tape/CD, etc.) should not be allowed at any time while operating a powered industrial truck.

Smoking tobacco of any kind by the driver is not recommended while he is operating a powered industrial truck. Tobacco use must comply with the local facility work rules.

2.6 Pedestrian Pedestrian training is vital to the success of the Pedestrian and Vehicle Safety Guideline as is powered industrial-truck operator training. All pedestrians gaining access to a production facility using powered industrial trucks should be given a brief training session which includes but is not limited to the foll

Pedestrian Walkway Guidance Document

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Transcript of Pedestrian Walkway Guidance Document