Safety in the Movement of People and Materials

1
Safety in the Movement of People and Materials

• Lift Trucks
• Conveyors
• Automated Warehouses

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Types of Lift Truck
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Counterbalance Lift Truck
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Reach Truck
5
Rough-terrain Counterbalance
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Telescopic Materials Handler
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Side-loading Lift Truck
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Pedestrian Controlled Lift Truck
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Large Lift Truck
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Lift Truck Hazards

• Collision with people or vulnerable plant
• Overturning
• Items falling from racking or forks
• Explosion from some batteries
• Hot exhaust
• Dangerous parts e.g. chains, drive shafts etc.
• Driving off edges, into pits etc.
• Placing loads onto peoples feet

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Lift Truck Hazards

• Fumes
• Noise
• Whole body vibration
• Load slipping from forks

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Lift Truck Control Measures
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Driver Selection

• Reliable and mature attitude
• Physically mentally fit
• Intelligent
• Over school leaving age
• Not under influence of drink/drugs
• Good vision
• Good hearing

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Driver Training

• Supervisors should receive an appreciation
• Competent Instructor
• Records should be kept
• Test at end of training
• Employees should be given written authorisation
  at end of training
• Refresher training as necessary

15
Work Area

• Separate traffic routes where possible
• Routes should have sufficient width and clearance
  for largest trucks used
• Prevent pedestrians entering lift truck areas
• Eliminate sharp bends or overhead obstructions
  wherever possible
• Where hazards cannot be removed, use clearly
  marked barriers

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Work Area

• Signs, warning devices, mirrors etc.
• Instructions to sound horns and restrict speed
• Flexible doors of transparent material where lift
  trucks have to pass through

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Work Area

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

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Work Area

• Where possible, edges should be fitted with
  barriers

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Work Area

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

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Work Area

• Firm and level surface, ideally concrete or
  similar
• Potholes should not be allowed to develop
• Steep gradients should be avoided
• Adequate lighting
• Trucks should be parked in a secure area
• Keys should be kept in a secure place

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Protecting Pedestrians Operators

• Segregate pedestrians and vehicles

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Protecting Pedestrians Operators

• Clearly mark traffic routes
• Use audible and visual warning devices
• High-visibility clothing may be necessary, as
  well as safety boots and hard hats
• A Roll Over Protection Structure should be fitted
  where there is a risk of overturning and crushing
  operator

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Protecting Pedestrians Operators

• Seat belts may be required
• Falling object protection structures should be
  fitted where there is significant risk of falling
  materials
• Anyone driving a lift truck on a public road
  should comply with road traffic legislation

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The Lift Truck

• Suitable for its intended purpose
• Travel with loads in lowered position
• Do not load beyond SWL (safe working load)
• Dangerous parts should be guarded
• Eliminate ignition sources in battery charging
  areas
• Adequate ventilation to disperse fumes

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Operation of Lift Trucks

• Issue keys only to authorised people
• Lower forks when parked
• Keep to left when operating
• Sound horn at danger spots
• Avoid violent braking or sudden changes in
  direction
• Never travel down slopes with load in front

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Maintenance

• Follow manufacturers recommendations
• Operators should not carry out repairs
• Trucks that are on loan still need to be checked
  and maintained

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Operator Checks

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

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Conveyor Belts
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Conveyor Hazards

• In-running nips
• Entanglement points at rollers
• Contact with moving parts
• Materials falling from conveyor
• Manual Handling/Ergonomics from incorrectly set
  speeds

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Conveyor Controls

• Guard in-running nips

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Conveyor Controls

• Emergency trip wires or stop buttons
• Guard power drives and other dangerous parts
• Nobody allowed to ride on conveyor
• Operatives should be trained and instructed in
  safe use

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Conveyor Controls
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Automated Warehouses Order Picking Machines
(OPMs)
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OPM Hazards

• Overturning e.g. overloading, gradients
• Falls of people, goods or materials
• Trapping of people in mechanisms
• Trapping of people against fixed structures
• People struck by moving OPM
• Failure of platform supporting mechanism
• People stranded on platform due to power failure
• Inadvertent movements e.g. misapplication of
  controls

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OPM Controls

• Only trained and authorised persons
• Comply with SWL
• Tested and examined every 6 months (LOLER)
• Prevent access to dangerous parts e.g. chains,
  mast sections etc.
• Edge protection
• Suitable overhead guards

36
Automated Warehouse Hazards

• Collision between AGVs and people
• Trapping points between AGVs and stationary
  objects or fixed structures
• Inadvertent movement of AGVs
• Collapse of palletised loads
• Collapse of AGV
• Slips on oil from machines

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Automated Warehouse Controls

• Segregate AGVs from pedestrians
• Trip devices on vehicle bumpers
• Sensors on vehicles to slow it to a crawl
• Ensure accurate positioning of AGV at transfer
  points
• Easily accessible emergency stops
• Automatic monitoring of safety system

38
Automated Warehouse Controls

• Audible and visual signals
• Guard dangerous moving parts
• Prevent unauthorised human access
• Pressure sensitive mats
• Interlocked access gates
• Permit systems for maintenance
• Clear warning notices