Download - Emerging Safety Resources for Brewers...• Employee got off forklift to dispense chemicals into a secondary container. • Employee returned to forklift, started driving without fastening

Presented By

Reva Golden & Tony McCrimmonBrewers Association Safety Subcommittee

FORKLIFT SAFETY

Best Management Practice

for the Management of Powered

Industrial Trucks

Brewers Association2

Agenda

• Background

• OSHA and Regulatory Compliance

• Training

• Hazard Assessment

• Developing and Managing a PIT

Program of Your Own

• Lessons Learned

• Summary

To Keep Us From Getting

Hurt• Because An injury or fatality happened

• OSHA regulations written so doesn’t happen again

• OSHA standard provides specifics for:

– Equipment safety

• Design, safety features, user interface

– Safe Operation

• Vehicle stability, travel, loading


Because It Happens

(Official OSHA Report)• Employee was operating a forklift in brewery production area.

• Forklift tines were about 36 inches above the floor.

• Employee got off forklift to dispense chemicals into a secondary container.

• Employee returned to forklift, started driving without fastening seat belt.

• Employee turned head to greet/ make eye contact with a pedestrian.

• Right forklift tine clipped a concrete bollard protecting the roof support.

• Employee was ejected sideways, outside of the forklift.

• The forklift tipped, the roll over protection cage crushed employee’s chest.

• Transported to hospital where employee died from crushing injuries to chest.

https://www.osha.gov/pls/imis/establishment.inspection_detail?id=317229607


Forklift Stats

In 2014:

• 855,900 US forklifts

• 96,785 total forklift injuries

• 11%, or 1 in 9 ?

• 34,900 serious injuries

• 86 forklift related fatalities

• Damage and lost product $$$


96,000 Injury Accidents per Year• Inattentive, Distracted Operator

• Tip-over

• Unstable Load

• Operator Struck Load, Falling Objects

• Elevated employees

• No training/Inexperience

• Overload/Improper Use

• Speeding

• Obstructed View

• Improper Equipment

• Falling From Dock, Platform, or Curb

• Carrying Any Passenger

• Other Employee Struck by Load

• Vehicle Left in Gear

• Falling From Trailer

• Accident During Maintenance



Forklift Stats

Main reasons for forklift accidents?

• Lack of training for lift truck drivers

• Lack of proper training for lift truck drivers

• Lack of training for particular types of forklifts

• Lack of training for particular forklift applications or lifting procedures

within a company

• Incomplete or incompetent completion of daily inspection checklist

• Poor or improper maintenance of the forklift

• Various reasons operator may be under stress.

• Lift truck not equipped with the proper attachments and accessories.

• Excess age or excess use of the forklift


OSHA Compliance

What do I need to know?

29 CFR 1910.178

Powered Industrial Truck

Standard



7 Classes of POWERED INDUSTRIAL TRUCKS

Equipment Selection 29 CFR 1910.178(a)-(c)

• Forklift must be designed to be a forklift

– ANSI B56.1-1969 and UL listed

• Adequate for the job

– Load within capacity specified on data-plate

– Location of load on forks determines capacity

• Compatible with operating environment

– Special considerations for operating around:

grain dust, ammonia, flammables, etc.

– Control of trapped engine exhaust and fumes

– Combining Carbon Dioxide and exhaust


Equipment Selection

29 CFR 1910.178(d)-(e)

• In good condition

– Regular inspection

– Proper maintenance

– Certified modifications and accessories

• Adequate Safety Features

– Overhead Guard, Roll over protective

structures

– Load Backrest Extension

– Seatbelts

– Lights


Accommodating

29 CFR 1910.178(f)-(g)

• Designated parking and storage

– Flat surface

– Doesn’t block aisles, walkways, exits, egress

– Off gases won’t enter building ventilation system

• Fueling or Battery Charging procedures and

storage

– Flammable liquid storage and handling

precautions

– No smoking area

– PPE and eyewash equipment

– Proper spill kit and appropriate spill training


Accommodating

29 CFR 1910.178(h)-(j)

• Lighting in building

– 2 Lumens

• Structural Integrity

– Floors, loading dock plates, trailers

• Is the lift and load too heavy for

the floor?

• Is it weak enough to collapse?


Accommodating

29 CFR 1910.178(k)

• Pedestrian paths

– Avoid collisions with designated

travel paths

– Accompany visitors

– Pedestrian Make eye contact with

Operator

• Ankle Is Struck By Pipe Bundle And Is Fractured

• Crushes Hand In Pallet Truck Accident

• Sustains Fractured Foot When Struck By Forklift

• Is Struck By Forklift And Sustains Fractured Leg

• PIT Operator Struck By Parcel Truck And Injured

• Hospitalized After Truck Runs Over His Foot

• Is Run Over By Forklift And Receives Injuries

• Is Pinned And Killed Under Industrial Truck

• Fractures Leg, Ankle Crushed By Pallet Jack


Must be 18 years or older

29CFR 570.58

• The Fair Labor Standards Act prohibits under 18

years of age from engaging in specified

hazardous occupational activities.

• 29CFR 570.58- Occupations involved in the

operations of power-driven hoisting apparatus

(Order 7), paragraph (a)(5): specifically prohibits

employees under 18 from operating forklifts.


Training

29 CFR 1910.178(l)

• Valid drivers license

• Initial and refresher

– Classroom and hands on

– Before first use of any truck

– If have any incident

– Wreckless operation

• Written performance evaluation every 3 years

• By outside company or internal?

– Certified as Forklift Trainer

– Is honest about operator’s skills


Training

29 CFR 1910.178(l)

• Classroom

• Driver Evaluation Course

• Your Specific Area

• Your Specific Equipment

• Your Specific Tasks


Distance from edges

29 CFR 1910.178 (m)

• Maintain a safe distance from edge of

elevated dock, platform, freight car

• Chock wheels so trailer doesn’t move

• Secure dock plates so don’t move


Maintenance & Inspection

29 CFR 1910.178(q)

• Remember your liability

• Pre-use; before use each day

– What about “your other operator”?

• Annual

• Operator vs Authorized Maintenance

– Define tasks operator can perform

– Define tasks only for qualified

mechanics

– Partner with certified mechanics



Getting Started—

What do I need to do?


Hazard Assessment

• What’s your function?

– Glass, keg, pallet, material handling

– Vessel installation/ construction

• Operational Space

– General production area vs. cooler/warehouse

– Indoors vs. outdoors

– Loading dock/shipping trailers

Hazard Assessment (cont’d)

• Modifications

– Fork extensions or elevated work platform

• Data plate and max loads

– Stability for the intended functions

– Able to reach max heights

• Identifying safety features & limitations

– Tricky controls or human interface



Hazard Sources

• Ramps

• Overhead clearance

– Low ceilings, fire sprinklers, hard-piping,

auger tubing systems

• Uneven ground/rough terrain

– floor drains, damaged grates over drains,

outdoor operations

• Regularly slick/wet floors

Hazard Sources (Cont’d)

• Tight/limited operation space

– Narrow aisles, obstacles

• Limited visibility

– Corners, intersections, building exit or

entry, poor lighting

• Floor load limits

– Elevators, “mezzanine” flooring

– Dock boards, bridge plates, truck floors



Hazard Sources (cont’d)

• Traffic

– Pedestrians, other PITs, cars/parking lot

• Shelving/storage limitations

– can the shelf support the loads

• Other safety hazards


Paperwork and Documentation

Paperwork and Documentation

• Written Program

– Hazard Assessment

• Training Material

– Written Test

– Driving course set up

– Driver Evaluation Criteria

– Attendance Records

• Inspection Logs and Maintenance Logs

– Out of service tags and/or locks

• Wallet Card



Real Life Examples

• Equipment Orientation vs Complete

Safety Training

– Area awareness

• Auger Accident

• Equipment Collisions

– Unsafe operation

• Overall etiquette

• Fork position

• Maxing out truck limits


Real Life Examples

• Used equipment and poor maintenance

– Flip it and Reverse it

– Exhaust Clouds

– Dock Dilemma

• Distracted Driving

• Poor Hazard Assessment

– Grain storage


In Summary - PIT

Managing Forklift Safety

• It is here to help and it is required!

• Know the regs.

• Buy and maintain safe equipment.

• Provide training to your staff.

– Enforce the rules!

• Assess the Hazards

• Don’t make out mistakes!

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Brewery Safety Training

On-Line Brewery Safety Training

https://brewersassociation.litmos.com/self-signup/

Code: 1327

https://brewersassociation.litmos.com/self-signup/

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Questions & Answers

https://www.brewersassociation.org/educational-publications/powered-industrial-trucks/