TLIB107C - Check and Assess Operational Capabilities of Equipment - Learner Guide

TLIB107C

MC

Check and assess operational capabilities of equipment

Armstrong’s Driver Education Learner Guide

TLIB107C Check and assess operational capabilities of equipment

© Australian National Training Authority 2003 ADELG1077 Customised and developed by Armstrong’s Driver Education Pty Ltd July 2009


© Australian National Training Authority 2003 Customised and developed by Armstrong’s Driver Education Pty Ltd July 2009 ADELG1077

Contents

What this Learner’s Guide is about ........................................ 5 Planning your learning ........................................................... 6 How you will be assessed ...................................................... 8

Section 1............................................................................................. 9 How do we use and maintain mechanical materials handling equipment? ............................................................................ 9

Additional resources....................................................................... 27

Feedback on activities .................................................................... 29



What this Learner’s Guide is about

This Learner’s Guide is about the skills and knowledge required to check and assess the operational capabilities of equipment in accordance with workplace requirements, including inspecting equipment and work area, checking the operational capability of equipment and its safety devices, identifying and assessing the impact of faults on safety and work requirements, and recording and reporting the results of inspection and testing in accordance with workplace procedures and relevant regulatory requirements.

The Elements of Competency from the unit TLIB107C Check and assess operational capabilities of equipment covered in this Learner’s Guide are listed below.

Inspect equipment and work area

Check equipment operational capability

Identify and assess impact of faults on work requirements

Record and report results of inspection and testing

This unit of competency is from the Transport and Logistics Training Package (TLI07).



Planning your learning

It is important to plan your learning before you start because you may already have some of the knowledge and skills that are covered in this Learner’s Guide. This might be because:

• you have been working in the industry for some time, and/or

• you have already completed training in this area.

Together with your supervisor or trainer use the checklists on the following pages to help you plan your study program. Your answers to the questions in the checklist will help you work out which sections of this Learner’s Guide you need to complete.

This Learner’s Guide is written with the idea that learning is made more relevant when you, the learner, are actually working in the industry. This means that you will have people within the enterprise who can show you things, discuss how things are done and answer any questions you have. Also you can practise what you learn and see how what you learn is applied in the enterprise.

If you are working through this Learner’s Guide and have not yet found a job in the industry, you will need to talk to your trainer about doing work experience or working and learning in some sort of simulated workplace.



Section 1: Safe operation of mechanical materials handling equipment

Are you able to: Yes No

1. outline the requirements for the maintenance of MMHE?

2. complete a pre-‐use check on a range of MMHE?

3. identify, then eliminate any workplace hazards which will affect the safe operation of MMHE?

4. report the results of the inspection correctly?

5. select the correct MMHE for a range of tasks?

6. demonstrate (under supervision) the correct and safe operation of at least three types of MMHE within a workplace situation?



How you will be assessed

Assessment of this Unit of Competency will include observation of real or simulated work processes using workplace procedures and questioning on underpinning knowledge and skills. It must be demonstrated in an actual or simulated work situation under supervision.

You will be required to:

• demonstrate basic maintenance procedures

• inspection of MMHE and work sites

• report the results of the inspection.



Section 1

How do we use and maintain mechanical materials handling equipment?



Section outline

Areas covered in this section

Selecting appropriate equipment for the task

Conducting a pre-‐operation check

Reporting the results of the pre-‐operation check

Using the MMHE equipment to do a variety of tasks

Determining what maintenance needs to be done on the MMHE



Selection of MMHE

There is always more than one way to do the job. This is particularly true when deciding on how to move or shift a load. Some types of MMHE are suited to specific loads but generally loads can be shifted by using different types of MMHE.

When selecting which type of MMHE to use we need to consider the following:

• load:

− What is the load?

− How heavy is the load?

− What shape is the load?

− What types of MMHE are suitable to shift the load?

• environment:

− How much space is available?

− Are there ramps or steps in the travel path?

− Is the ground rough or smooth?

• availability:

− What type of MMHE is available for me to use?

• efficiency:

− What type of MMHE will enable me to shift the load as quickly and safely as possible, with the least amount of effort?

• distance:

− How far do I have to shift the load?



Activity 1: Selection of MMHE

Look at materials handling tasks that need doing in your workplace. List five tasks that require you to use different types of MMHE.

Decide which types of MMHE would be best suited to complete these tasks, and use the activity sheet on the next page.



Task Type of MMHE that you would use

Why would you use this equipment?

There is feedback on this activity at the back of this Learner’s Guide.



Pre-operation safety check

Before using any piece of MMHE it is essential that you conduct a pre-‐operation safety check on both the equipment and the worksite.

This check is to ensure that the equipment is safe to use and the actual worksite is safe to work in.

In relation to the safety check on the equipment:

• the extent of the safety check will be determined by the complexity of the equipment and any OHS regulations placed on the equipment

• there may be a need to complete a checklist to fulfil workplace requirements before using the equipment

• the check is to ensure that there are no faults or damage on the equipment which will make it unsafe to operate.

In relation to the safety check on the worksite:

• this check is to ensure that the worksite ( the path that you will actually be taking when moving the load ) is safe and free from obstacles and safety hazards

• you should inform people who may be working in or near your path

• you should erect barriers and signs to inform other people of any danger (where necessary).



Activity 2: Pre-operational safety check - equipment

Watch your trainer or an experienced person demonstrate a pre-operational safety check on at least three different types of MMHE.

The pre-operational check may include a pre-start check and an operational check, depending upon the type of MMHE being used.

The pre-start check is done before the equipment is started or used. It is to check for faults that can easily be seen; for example, flat tyres, worn slings, wire caught around wheels, etc.

The operational check is done once the equipment is started or before it is used on a job. It is completed to determine if all parts are working properly; for example, brakes, controls, etc.

Whilst the person is performing the pre-operational safety check, ask them to tell you what they are checking so that you can write it down to form a list of the parts that need to be checked. An activity sheet is provided to help you.

Then decide if it is a pre-start check or an operational check and mark on the worksheet accordingly.

Example: Forklift (this example is not complete)

Name of equipment Forklift

Parts checked - Pre start Pre-start Operational

Tyres for damage, pressure ✔

Wheel nut - not missing, tight ✔

Safety cage - damage, not loose ✔

Horn ✔

Park Brake ✔

Steering ✔

etc.

etc.



Name of equipment 1. Forklift

Parts checked Pre-start Operational



Name of equipment 2.


Name of equipment 3.




Activity 3: Check of work area

Ask your supervisor to give you five common workplace tasks involving MMHE. Use these tasks to practise checking the work area for any potential hazards that might exist.

Write down areas that have the potential to cause accidents. Then identify the actions that you would take (or actually took) to eliminate the hazard.

Hazard Action taken

Check out your answers with your trainer and then add any that you may have missed, for future reference.

There is feedback on this activity at the back of this Learner’s Guide.



Reporting of pre-operation check results

Once both the safety check on the equipment and the workplace has been completed, the results need to be reported. Many workplaces have a standard checklist and procedure for reporting. All employees who use that equipment use this standard procedure.

Some workplaces expect you, the employee, to be responsible for this process.

Occupational Health and Safety regulations in some states/territories expect that a pre-‐operational check is done before you use the equipment. The results then need to be recorded and reported. Therefore, it may be your responsibility to do this before using any MMHE.



Activity 4: Develop your own checklist

Find out if your workplace has a standard procedure for conducting the pre-operational check, then recording and reporting the results.

If so, obtain a copy of the relevant documentation for your reference.

If not, then you need to develop your own checklist.

Using the information gathered in the last two activities, develop your own checklist for first checking the equipment and then checking the workplace.

An example copy of a developed checklist can be found in the ‘Additional resources’ section of this Learner’s Guide.

Once completed, show the checklist to your trainer and discuss what you have developed and why you have developed it.



Activity 5: Using the checklist

Using the standard workplace checklist or the checklist that you developed in the previous activity, practise the procedure on a variety of MMHE and tasks. While conducting the checks use your checklist and determine: • How easy is the checklist to use? • Is the layout of the checklist simple? • Could anyone use the checklist? • Does it cover all the necessary requirements? • Do I need to put any other instructions on the checklist?

After trialing the checklist, list any changes that you would recommend and discuss them with your trainer. Make the changes, if necessary. Then report the results of the pre-operational check according to your workplace procedures.

NOTE: Some MMHE requires you be licensed before you use it. If the MMHE that you are going to use falls into this category then you need to be supervised when conducting the operational check.



Operating the MMHE

This part of the unit deals with the operation of MMHE. Care must be taken during this section to ensure that adequate supervision is given to operators using the equipment. Depending on the type of equipment (e.g. Forklift) this may be a lawful requirement.



Activity 6: Using MMHE

During this activity you will be required to practise using at least three different types of MMHE within a workplace situation.

In consultation with your trainer, select at least three different types of MMHE that you can practise using. Your trainer will give you workplace tasks to do using each type of equipment. This may occur over a period of time.

Each time you use the equipment, fill in the logbook given to you in the section titled ‘Assessment tasks’ in this Learner’s Guide.

This activity must be done under supervision according to any workplace or OHS requirements.

This activity allows you to practise using the equipment only. There will be separate assessment exercises that you need to complete.

Once you feel that you are competent in the use of this equipment, approach your trainer and request an assessment. If the type of MMHE requires you to be licensed you will need to be assessed by a ‘registered workplace trainer’ to gain this licence. See your trainer for clarification.



Maintenance of MMHE

All types of mechanical equipment need maintenance. There are two types of maintenance:

• preventative maintenance

• breakdown maintenance.

Breakdown maintenance is when the MMHE equipment breaks down or becomes faulty and cannot be used normally. In this condition it is also probably unsafe to use. Do not use equipment that is faulty or broken. Broken equipment also results in expensive MMHE being taken to a workshop to be fixed.

The problem with this is that:

• it costs money to fix the faults

• workers lose time waiting for equipment to be repaired

• the organisation possibly needs to hire expensive replacement equipment

• the possibility of an accident is increased

• customers orders may not be delivered.

A better way to operate is to have a preventative maintenance program within your workplace. This program is much the same as the preventative maintenance that you do for your car. For example, with your car you:

• check the oil levels regularly

• change the oil

• check the water and other fluid levels and top them up

• check and adjust the tyre pressures

• clean the windscreen

• grease the wheel bearings.

The same type of program needs to be in place with MMHE so that you can prevent the breakdowns before they occur.



Activity 7: Preventative maintenance

By asking the people around your workplace, find out if a preventative maintenance program exists.

If your workplace does have a preventative maintenance program, determine what your role in the program is.

If your workplace does not have a preventative maintenance program then develop your own program.

You can research into what needs to be done by: • looking at manufacturer’s specifications and handbooks • discussing with your trainer • discussing with the maintenance department • comparing it to something known to you - such as a car or

bicycle.

A format that you could use is shown below.

Type of equipment

Maintenance to be done

Daily Weekly Monthly Yearly Date done

28/7/97

Grease wheels x ✔ Hand pallet truck

Check hydraulic ram x ✔

Check water x ✔

Change hydraulic oil x ✔

Grease wheel bearings

x ✔

Forklift

etc.

Clean all grease and oil from rollers

x ✔

Grease bearings x ✔

Oil chains x ✔

Conveyor

etc.

Have an experienced workplace person show you the maintenance procedure on a range of MMHE.



Now practice the maintenance procedures yourself on the MMHE. Remember to fill in any documentation that you have developed or that already exists.



Additional resources



Sample checklist for MMHE - This example is for Forklifts

Pre-start check - outside visual

Pre-start check - inside engine compartment

No leaks or obstructions under Forklift Liquid levels correct - engine oil, hydraulic oil, brake fluid, cooling water, transmission oil

Tyres - not flat, not damaged, wheel nuts not loose, tyre pressure

Fan belt - correct tension

Mast assembly - damage, obstructions, lubrication, chain tension

Battery - water level, connections and security

Forks/attachments - condition, secure, locking pins secure

Battery (electric Forklifts) - sufficient charge, water levels

Load backrest -secure, not damaged Condition - any leaks, damage or obstructions

Hydraulic hoses and couplings - excessive leaking, not damaged

Body damage Operational Check

Safety cage secure Gauges and warning lights - working

Check steering wheels and cylinders Lights - working

Check for any loose wiring Warning signals - revolving light, reverse beeper, indicators

Towing pin secure Horn

Check manufacturer’s data plate Mast controls

Driver compartment - free from obstacles, adjust seat, adjust mirrors

Park brake

Gas - turn on, check fittings secure, check for leaks, check level of gas

Foot brake

Steering

Name: ________________________ Signature ________________ Date _____________



Feedback on activities

The responses provided in this section are suggested responses. Because every workplace is different, your responses may vary according to your specific workplace procedures, the equipment available and the nature of the business.



Activity 1: Selection of MMHE

Example answers

Task Type of MMHE

Why?

Pick a single order of goods. Stock goods onto a pallet for dispatch.

Ride-on pallet truck

Goods can be stacked directly onto the pallet therefore saving time. Ride-on pallet truck moves quicker from one pick location to the next.

Unload a truck containing 10 pallets of goods. The truck is located in a steel scrap yard.

Counterbalance Forklift - solid tyres - correct tonnage

Forklift provides most efficient way to unload pallets from trucks. Counterbalance Forklift with solid tyres selected because reachtruck has small solid wheel and is not suitable for rough ground. Solid tyres prevents punctures from scrap steel.

Pick a customer order of three cases of cigarettes from the small secured store area.

Sack truck Area is small, order is small, sack truck is very manoeuvrable and load not too heavy therefore this would be the most efficient way to pick/carry this load.

Restack a bay of radiator hoses - high level restacking within the warehouse.

Reach truck High level pallet stacking capabilities, manoeuvrable in warehouse aisles.



Activity 6: Pre-operational safety check

Example answers

Name of equipment 1. Forklift (recommended to complete)


No leaks or obstructions under Forklift

Tyres - damage, not flat, loose wheel nuts

Mast assembly - damage, obstructions, chain

Forks/attachments - damage, security

Load backrest - secure, not damaged

Gauges/warning lights

Horn

Warning signals

Hydraulic hoses/couplings

Body damage

Safety cage secure

Mast controls

Foot brake

Park brake

Check manufacturers data plate

Gas - turn on, check for leaks, secure

Check engine compartment - obstructions

Check fluid levels - oil, water, brake fluid, etc.

Steering

Battery - water level, connections



Name of equipment 2. Ride on pallet truck


Controls -forward, reverse

Brakes

Hydraulic controls

No obstructions under truck

Steering

Battery levels - ensure sufficient charge

Wheels - not damaged

Warning lights

Safety lock devices

Name of equipment 3. Hand sack truck


Wheels - not damaged, not flat, bearings

Hand grips not loose

No damage to frame

Check operation to ensure smooth movement

Securing strap - check working



Activity 3: Check work area

Hazard Action taken

rubbish on floor

low doorway

pedestrian crossing

blind corners

slippery floor -cold room

uneven floor

ramp

busy area - people working

intersection

traffic area

stock sticking out into path

remove rubbish

ensure MMHE fits, slow through doorway

slow, sound horn, place signs/barricades

slow, sound horn, warning device

slow, leave longer stopping distance

ensure load stability, strap load, slow

go up /down the correct way, ensure load stability

inform people of your intending action, sound warning device, erect signs or barricades

go slow, sound warning

keep watch out for traffic, give way to traffic, go slow

mark, barricade or restack shelf to ensure it is not sticking out



Activity 7: Preventative maintenance

Sample checklist

Type of equipment

Maintenance to be done

Daily Weekly Monthly Yearly Date

28/7/97

Grease wheels x ✔

Check hydraulic ram x ✔

Hand pallet truck

Check water x

Change hydraulic oil x

Grease wheel bearings

x

etc.

Forklift

Clean all grease and oil from rollers

x

Grease bearings x

Oil chains x

etc.

Conveyor

TLIB107C - Check and Assess Operational Capabilities of Equipment - Learner Guide

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