powered industrial truck safety - printing industries alliance · powered industrial trucks •each...

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This program will review the OSHA standard that addresses the safety concerns associated with the operation of energized material lifting and moving equipment including fork trucks, lift trucks and clamp trucks.

Powered Industrial Truck Safety

Lift Truck Safety

Printing Industries Alliance 1

Lift Truck Safety1

Today’s Objective

To maintain a maximum awareness of the fundamentals of

lift truck safety2

Lift Truck Safety


Reason why OSHA created this standard

• Over 100 workers are killed each year

• Over 95,000 serious injuries occur annually– Serious injury: one that resulted in a

disability

Over half are pedestrians

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ComplacencyAccounts for 6 out of 10 industrial

accidents. It happens by:

• Not paying attention to what you are doing

• Disregarding safety procedures and rules (It ain’t gonna’ happen to me!)

• Taking short cuts

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Lift Truck Safety


Lift trucks have revolutionized the work

environment

Makes Work EasierSaves Time and Money

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DANGERS

• Powerful

• Heavy

• Require Your Undivided Attention & Respect 6

Lift Truck Safety


Physical Forces that Affect Safety

•Gravity

•Inertia

•Centrifugal Force

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Changing Environment

The working environment can change. Always be on the

lookout for things that weren’t there before.

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Lift Truck Safety


Most common injury to workers in the printing

industryWorkers tripping over pallets can lead to:

• broken bones

• torn ligaments

• concussions

• cuts

• abrasions (scrapes)

• contusions (bruises) 9

Injuries Related to Lifting Equipment

Can be far Worse

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Lift Truck Safety


Unique Characteristics of Powered Industrial Trucks

• Each type of powered industrial truck has its own unique characteristics and some inherent hazards.

• To be effective, training must address the unique characteristics of the type of vehicle, the loads being carried, and the operating environment

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Training Required

• Operator’s manual

• Familiar & comfortable (not complacent)

• Certification– Initial training with road test

• Triennial re-certification

• Retraining if necessary

• Training records on file12

Lift Truck Safety


Certification• The employer shall certify that each

operator has been trained and evaluated as required by the standard.

• Certification shall include:– Name of operator

– Equipment authorized to operate

– Date of classroom training

– Date of road test

– Identity of person performing the training or evaluation (must be a certified trainer)

– Triennial re-certification13

Variety of Styles

• Electric Batteries

• Gasoline

• Diesel

• Propane

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Lift Truck Safety


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Lift Truck Safety


Narrow Aisle Trucks

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Variations of Pallet Jacks

Walkie

Walkie-Rider

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Lift Truck Safety


To maintain a maximum awareness of the fundamentals of

Pallet Jack Safety

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Most Common Injuries Among Walkie Operators &

Pedestrians

Crushing injuries to the

body20

Lift Truck Safety


Differences in Powered Pallet Jacks

• Location of Controls

• Carriage Height

• Touch and Feel of Controls

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Operational Details

Low-lift powered industrial trucks have:

• Three-point suspension system with drive wheel

• Load wheels w/stability casters

• Tiller steering with controls on handle

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Lift Truck Safety


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Lift Truck Safety


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Picking Up a Load

• Approach with pallet arms (forks) lowered, squared and centered to provide good support

• Move under the load as far as possible

• Make sure the load is stable before lifting

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Lift Truck Safety


Picking Up a Load (continued)

• Raise the load slowly and steadily until it’s high enough for good floor clearance (about 4 inches)

• Make sure the pallet arms are supporting the load

• Don’t force the load; stay within the rated capacity (see ID Plate)

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Moving Loads• Go slowly

• Keep load stable

• Inspect pallets

• Stay away from the edge of a dock or ramp

• Set down load-back out slowly

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Lift Truck Safety


Operating on Ramps

• With or without a load going up or down position yourself upgrade of the lift truck so the load will not fall on you or the jack will not run over you.

• Never turn on ramp or slope to

prevent the load from tipping over

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Battery Acid WEAR PROTECTIVE EQUIPMENT

•Goggles•Rubber Gloves•Chemical apron

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Lift Truck Safety


Areas of Concern

• Pre-start safety inspection

• Design considerations

• Lifting the load

• Moving the vehicle

• Setting down the load

• Other safety tips

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Areas of Concern

• Pre-start safety inspection• Design considerations




• Other safety tips32

Lift Truck Safety


Pre-Start Safety InspectionTo be performed on all energized

material lifting equipment

When must a pre-start safety inspection be conducted and why?

• OSHA mandate

• Company requirement“At the beginning of each shift, the truck

must be inspected for any condition that would adversely affect the safe operation of the truck. Where such conditions exist, the truck shall be removed from service.” 33

Who performs the inspection?

Assigned by the companyCertified operator

• assigned individuals

• first on duty

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Lift Truck Safety


PIT Inspection• Performing the inspection is an OSHA

requirement

• Documenting it, is not a requirement

*However*

• Association advice recommends documenting– Validates the inspection took place to:

– OSHA

– Company35

Pre-Start Safety Inspection Log

• Vehicle identification

• Date w/shift

• Inspector

• List of inspected items

• Comments

• Defects reported

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Lift Truck Safety


Failing a Safety Inspection

• Operating a PIT that has failed the inspection is a citable OSHA violation

multiplied many times if an injury results

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Pre-Start Safety InspectionItems needing to be

inspected:• 1 Forklift body, seat and seatbelt

• 2 Tire condition / wheel nuts

• 3 Hydraulic oil level and hoses

• 4 Hoist, tilt and attachment operation

• 5 Forks, mast and hoist chain

• 6 Lights & horn

• 7 Hand and service brake

• 8 Steering

• 9 Correct operation of instruments

• 10 Report oil leaks or unusual noises

• 11 fumes – exhaust

• 12 Identification Plate (ID plate)

Performed only

by certifiedOperators

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Lift Truck Safety


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Pre-Start Safety Inspection• During an inspection you notice an

item that fails the inspection.

What should you do?• Don’t operate the vehicle

• Notify your supervisor

• Don’t try to fix it yourself

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Lift Truck Safety


Pre-Start Safety Inspection

Defects that would put a lift truck out of service.

–Faulty Brakes

–Steering problems

–Hydraulic leaks41

Pre-Start Safety Inspection

• Discuss with supervisor your organization’s policy for when and how to report

defects.

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Lift Truck Safety


OSHA reminders• Such examination shall be made at least

daily.

• Where industrial trucks are used on an around-the-clock basis they shall be examined after each shift.

• Defects when found shall be immediately reported and corrected.

• A record of each inspection must be kept on file.

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Areas of Concern

• Pre-Start Safety Inspection

• Design considerations• Lifting the load



• Other safety tips 44

Lift Truck Safety


Design Affects Safety

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Lift Truck Safety


A

B

C

Vehicle Center ofGravity (Unloaded)

Center of Gravityof Vehicle and Maximum Load(Theoretical)

Stability Triangle

Notes:1. When the vehicle is loaded, the combined center of gravity (CG) shifts toward line B-C.

Theoretically the maximum load will result in the CG at the line B-C. In actual practice, the combined CG should never be at line B-C.

2. The addition of additional counterweight will cause the truck CG to shift toward point A and result in a truck that is less stable laterally. 47

Design Considerations

• What is the best way to check the load capacity of the lift truck? - ID Plate

• What should you do if the load you are going to pick up is heavier than the recommended load capacity? Don’t

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Lift Truck Safety



• The more the center of gravity moves outside the stability triangle, the less stability the lift truck has. True or False?

• Momentum

• Speed

• Centrifugal force

• Height of the load

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Design ConsiderationsThe ID (identification) plate includes information on the capacities and restrictions of lift trucks. Information regarding the maximum load capacity and load center is especially important.

Load height

reduces

lifting capacity

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Lift Truck Safety



What can happen if your load extends past the load center?

• Vehicle can tip over• Causes rear wheels to rise,

making it difficult or impossible to steer and control the vehicle

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Lift Truck Safety



• What are some of the factors that can cause your truck to tip over?– Overloads

– Unstable load

– Load not centered

– Traveling with raised load

– Sudden start or stop

– Sharp turns

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• How close should the forks be to the floor when

traveling?• The forks should be raised only

enough to clear any uneven surfaces about 4-5 inches

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Lift Truck Safety



Driving in reverse is

REQUIRED when your view is obstructed

by the load

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Unique Safety Concerns

• Proximity to workers

• Rear end steering – wide arc

• Operates in close quarters

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Lift Truck Safety


Design Considerations• Operating maneuvers that would violate safe

driving practices.

– Driving too fast around corners

– Driving too close to the side of a ramp or dock

– Driving forward with an obstructed view

– Parking in front of emergency exits or equipment

– Traveling with load more than 4 inches from the floor

– Elevating someone on the forks57


Review the collision situation:

“I had just picked up a load and was traveling very slowly. As I neared a corner, I hit a pipe that was sticking out in the aisle. No one was hurt, but some of the product was damaged. The area was a mess. There was no way I could have avoided the situation”

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Lift Truck Safety


Yes there was…

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By paying attention to what you are doing

and what is going on around you

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Lift Truck Safety


Areas of Concern



• Lifting the load• Moving the vehicle


• Other safety tips61

Lifting the Load

Fork Truck• Space forks as wide as possible

• Level forks a few inches off the floor (easier to level when flat on floor)

• Slowly insert forks into pallet

• Lift load

• Tilt mast to stabilize the load

• Drive to destination 62

Lift Truck Safety


Lifting the LoadClamp Truck

• Ensure roll is clamped properly

• Level the load

• Lift load

• Drive to destination

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Areas of Concern




• Moving the vehicle• Setting down the load


Lift Truck Safety


Moving the Vehicle

• Obey traffic signs & signalsStop signs don’t mean just slow

down

• Keep forks 4-6 inches off the floor

• Scan in all directions

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Lift Truck Safety


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Speed? how fast is too fast?Question: What does OSHA consider a "safe speed" to be, for the operation of a powered industrial truck?

Reply: OSHA does not have specific speed limits set for the safe operation of a powered industrial truck. However, in determining what is a safe speed, OSHA would take a variety of factors into consideration. These factors include, but are not limited to, the type of truck itself, the manufacturer's limitations on the truck, the load being carried, adequate stopping distances, operating surface conditions, pedestrian traffic, and other safety issues. While specific speed limits are not available, OSHA would consider the totality of the circumstances surrounding the operation of the powered industrial truck in determining whether safe travel speeds are practiced at a workplace.

OSHA letter of interpretation: Under all travel conditions the lift truck shall be operated at a speed that will permit it to be brought to a stop in a safe manner.

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Lift Truck Safety


While Driving• Alert others with horn-use it wisely

• At corners & doorways stop and sound horn

• Use fisheye mirrors

• Be careful going around corners

• Rear wheel steering

• Swings in wide arc

• Centrifugal force

• Start and stop gradually

• Work your way up to a safe speed69

Moving a Load

• Position yourself for best visibility then travel facing in that direction

• Move slowly

• Sound the horn to alert others

• At corners & doorways stop and sound horn

• Be extra careful going around corners

• Scan in all directions

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Lift Truck Safety


SAFETY PRACTICES while traveling

Scan:• forward

• to both sides• between racks

• overheadand

Having eyes in the back of your head would be most useful 71

On the Move• Watch for pedestrians

• Stay out of walkways

• Avoid speeding

• Never block exits, access routes or stairways.

• Never block access to fire fighting equipment

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Lift Truck Safety


Areas of Concern





• Setting down the load• Other safety tips

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Setting down the load

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Lift Truck Safety


Setting Down the Load

• With load, drive forward until just short of the drop off point

• Level the load

• Position the load directly over the drop-off point - 12” above

• Lower the forks/roll until load is resting even and solidly

• Back away slowly75

Setting Down Rolls

• Much damage can result by setting down a roll on its edge. A crack in the edge can damage $100s of raw material or more if the substrate has been processed.

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Lift Truck Safety


Racking• With load, drive forward until just short of the rack

• Tilt the mast to a fully upright level position so loads are parallel to the floor

• Raise the load a few inches above the platform of the rack

• Move forward to line up the load with the rack

• Lower the load until it rests firmly on the platform

• Back away slowly

• Constantly monitor the space above the mast

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Lift Truck Safety


Areas of Concern







Working With Trucks and Trailers

• Check floor strength

• Truck brakes engaged

• Block wheels

• Extend bridge plate

• Keep PITs away from the edge of the dock

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Lift Truck Safety


Loading a truck

• Distribute weight evenly

• Light load on top

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Lift Truck Safety


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Operating on Docks

Remember the dock areas are where most material moving equipment

accidents occur. Encourage extra precautions when working on the

docks.

Establish a dock safety program

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Lift Truck Safety


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Lift Truck Safety


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Operating on RampsTo maintain stability going up or down

a ramp forks point:

• Upgrade with load

• Downgrade without load

• To protect a load from falling off or worse, the truck from tipping over:

*Never turn on ramp or slope*88

Lift Truck Safety


Other Mandated

Safety Tips

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Safety Equipment

Types of protective equipment is available in your operating

environment Safety belt Safety glasses/goggles Hard hat Gloves Shoes

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Lift Truck Safety


Common Safety ProceduresWhat safe operating procedures should you follow regardless of the type of lift

truck you operate?– Use protective equipment provided– Travel with forks down– Scan in all directions– Drive in reverse when

vision is obstructed– Match width of forks

to the loadCareful shifting the forks

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Wet Oily or Icy Surfacesare Slippery and can be

DANGEROUS

• Clean up

• Stay away

• Drive slow92

Lift Truck Safety


Refueling or RechargingBattery Acid or Propane

• WEAR PROTECTIVE EQUIPMENT

•Goggles•Rubber Gloves

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EXTREME CAUTIONCombustible and flammable materials & sparks don’t mix

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Lift Truck Safety


Other ideas

• NO horseplay

• NO hitchhiking

• NO elevator without safety

platform

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Lift Truck Safety


REMEMBER

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SEAT BELTRequired to be worn at all

times

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Lift Truck Safety


Safety harness

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drivers are required to slow down, sound the horn, and proceed with caution at cross aisles and other locations….

where vision is obstructed or

conditions dictate100

Lift Truck Safety


ENVIRONMENT• The working environment is

under constant change. Always be on the lookout for things that weren’t there before.

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Summary• Know your equipment and how it works• Perform a daily equipment check• Follow safe work practices• Obey all company safety rules and procedures• Plan out your job in advance• Follow proper loading & unloading procedures • Respect the power of the vehicle• Be aware of your surroundings• Give right of way to pedestrians• Wear PPE when required• Pay Attention-Stay alert 102

Lift Truck Safety


Our presentation of this program is not conclusive.

In the time allotted we attempt to highlight the main topics of the standard as they generally

apply to our industry. For a complete understanding your company needs to review the OSHA standard in its entirety to determine how it

applies to your facility.

The OSHA standards can be found on their website:

www.osha.gov103

Thank you for your attention and stay

safe! 104

powered industrial truck safety - printing industries alliance · powered industrial trucks •each...

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