Forklift Safety: How to Prevent Distracted Driving and Eliminate Hazards

Presented by:

Chip Darius, MA, OHST, CET, CSHO Safety Priority Consultants, LLC

Thursday, March 12, 2015 1:30 p.m. to 3:00 p.m. Eastern 12:30 p.m. to 2:00 p.m. Central 10:30 a.m. to 12:00 p.m. Pacific

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Forklift Safety: How to Prevent Distracted Driving and Eliminate Hazards Presented by:

Chip Darius, MA, OHST, CET, CSHO Safety Priority Consultants, LLC March 12, 2015

y Forklift safety y OSHA & ANSI standards y Potential hazards & incidents y Operator training programs y Dealing with distractions y Manufacturer’s

recommendations y Policies & procedures y Q&A

y y y y y y y

List applicable OSHA & ANSI standards List typical hazards & incidents Determine training requirements Identify potential distractions Refer to manufacturer’s recommendations Develop policies & procedures Consider contractors

Operator Forklift Immediate  Area Surrounding Environment

y Transport material horizontally y Lift material vertically y Lift people vertically as last option y Tested, rated per ANSI/ITSDF B56.1 / B56.6 y Counterbalanced

y See handout y Class 1 to Class 7 y https://www.osha.gov/SLTC/etools/pit/forklif

t/types/classes.html

y General Industry 

29 CFR 1910.178 y Construction  29 CFR 1926.602 Ö 1910.178 y ANSI B56.1‐1969 incorporated by 

reference (IBR) – see 1910.6 and 1926.6

y B56.1 Safety Standard For Low Lift And High 

Lift Trucks

y B56.6 Safety Standard For Rough Terrain 

Forklift Trucks 

y B56.11.6 Evaluation of Visibility From 

Powered Industrial Trucks

y Operator slip, fall during mount/dismount y Strike against (horizontal) y Strike against (overhead) y Struck by other vehicle y Tip‐over (front, side, rear) y Ejection from ROPS, crush injury y Spearing

y Fire/explosion due to fuel y Unintended pushing/dragging y Struck by falling objects y Structural failure y Entanglement, caught‐on/in/between y Electrical shock y Hazardous atmosphere y Burns from hot parts

y Inspect before use y Work on firm, level surfaces 

‚ Avoid surface hazards (e.g., drop‐offs or  holes, slopes, bumps/ground obstructions,  debris) y Stay 10’ away from power lines y Beware overhead hazards (utilities,  branches, overhangs, threaded rod, etc.) y Operate only in safe weather conditions

y Only if manufacturer

has approved y Only with approved  man basket/platform y Only vertical lift y Properly secured y Always attended y Never tilt mast with personnel raised

Operator Forklift Immediate  Area Surrounding Environment

y 29 CFR 1910.178 y 29 CFR 1926.602(d)

Training 29 CFR 1926.20(b)(4) The employer shall permit only those employees  qualified by training or experience to operate  equipment and machinery. y

29 CFR 1926.20(f)(2) The employer must train each affected employee  in the manner required by the standard, and each  failure to train an employee may be considered a  separate violation.  y

y 1910.178(l)(3)(i)(M)

Any other operating instructions, warnings,  or precautions listed in the operator's manual  for the types of vehicle  that the employee is being trained to operate. y

y Observed unsafe operation y Accident/near miss during forklift use y Evaluation reveals unsafe operation y Assigned to different type of forklift y Change in workplace affects safe operation

Consequences of Inattention

2008 Federal Railroad Administration (FRA)  banned rail employees from using cell phones or  other electronic devices on the job.  y

2009 President Obama Executive Order to  federal employees ‐ no texting while driving  government‐owned vehicles or privately owned  vehicles on official government business. Federal  contractors encouraged to adopt and enforce ban  on texting while driving.  y

y 2009 Federal Aviation Administration (FAA). 

Air carriers to create and enforce policies to  limit cockpit distractions, keep pilots focused  on transporting passengers safely. y 2010 Federal Motor Carrier Safety 

Administration (FMCSA) banned texting for  commercial truck and bus drivers. y 2011 FMCSA banned all hand‐held cell phone  use.

y 2011 Pipeline and Hazardous Materials Safety 

Administration (PHMSA) banned texting on  electronic devices by drivers operating a  motor vehicle containing hazardous materials. 

y 2012 OSHA Distracted Driving Initiative. 

Threatens 5(a)(1) citations if employer  organizes work in a way that makes the  practice a “practical necessity” y 2014 FAA no personal electronics in cockpit 

for personal use.

y Prohibit cell phone use, texting, messaging, 

and other distracting behaviors. y Where technologies must be used, develop 

protocol and train employees on how and  when to use them safely.

y 2‐way Radios/Nextel/PTT y Scanners y Food/drink y Headphones/earbuds y Bright light, loud noise y Interesting activity y Personal electronics/phones/texting y Conversations with pedestrians y Signs, mirrors

y Be an alert pedestrian y Avoid distracted walking y Avoid sudden changes in direction y Don’t run y Don’t distract operators y Stay out of line of travel y Forklifts don’t stop on a dime y Hazards of loose loads y Make eye contact with operator

y Blind corners y People + machines in same path y Push‐through on racks y Congested areas: caf, vending, time clocks y Indoor/outdoor transitions y Multi‐truck operations

y Pressure y Drug/alcohol use y Stunts/horseplay y Inattention y Revealing clothing y Daydreaming y Habits & History y Complacency

y Fatigue, shift rotation, overtime y Sleep deprivation y Concentration/daydreaming y Medication y Illness/injury y Depression y Habits y Sensory perception limitations y Information overload

y Distraction.gov – official US government 

website for distracted driving y December 2012, in US and its territories:

171.3 billion text messages sent per month

171,300,000,000

y Intended use y No modifications without approval y Pride & professionalism y Monitoring, feedback y Avoid “normalization

of deviance”

y Capacity plate y Calculate ‘maximum safe load moment’

5,000 lb. capacity at  24‐inch load center 5,000 x    24 120,000 5,000 24√120,000

y

Do the math on the fly

What capacity at  36‐inch load center? 3,333 36√120,000 At 48‐inch load center? 2,500 48√120,000

y

Consult the chart

y Forklift: only manufacturer‐approved

y Keep on machine y Read them y Know them y Train to them y Review them y ALWAYS follow them

y Use operator manual as procedure guide y AEM equipment‐specific manual y OSHA requirement came from ANSI standard

y Location y Speed y Impact y Geo‐fencing y Utilization y Idle time y Maintenance y Access codes

y Per manufacturer’s manual y Pre‐use each shift y Each new operator y Spot checks y Fly‐by y Maintenance

y Promote worker participation in safety y NOT cash y NOT gambling y Useful and effective y TIME and SPACE

y Safety scores for supervisors y Failure to enforce y Safety management systems y Mastery goals for workers (skills) y Communicated y Clear y Consistent y Understood

y Clear contractor policies y Site orientation y Quick correction y Consistent consequences

y Pedestrian interactions y Overhead clearance y Cup holders y Music systems y Load sizes y Operating environment y Severity of consequences y Classified locations

Operator Forklift Immediate  Area Surrounding Environment

y y y y y y y

List applicable OSHA & ANSI standards List typical hazards & incidents Determine training requirements Identify potential distractions Refer to manufacturer’s recommendations Develop policies & procedures Consider contractors

y Chip Darius, MA, OHST, CET, CSHO y [email protected]

BLR’s Safety Summit: Best Practices & OSHA Compliance for 2015 y All-new program! y Practical guidance for overcoming the latest safety management challenges! y Comprehensive pre-conference workshops! y Esteemed faculty of seasoned safety practitioners and consultants! y And much, much more!

Visit http://safetysummit.blr.com to register today!

Disclaimers *This webinar is designed to provide accurate and authoritative information about the subject matter covered. It is sold with the understanding that the publisher is not engaged in rendering legal, accounting, or other professional services. *This webinar provides general information only and does not constitute legal advice. No attorney-client relationship has been created. If legal advice or other expert assistance is required, the services of a competent professional should be sought. We recommend that you consult with qualified local counsel familiar with your specific situation before taking any action.

Chip Darius Chip Darius is founder and president of Safety Priority Consultants, LLC, established in 2000. In 15 years, the company has provided training and consulting in occupational safety and health, OSHA compliance, and safety management systems for over 750 clients in more than 30 states from coast to coast. He is an experienced litigation consultant and expert witness in safety-related matters. He has also served as safety advisor for the Connecticut Business & Industry Association. Darius is an IVES certified mobile equipment operator trainer for forklifts, aerial boom lifts, and aerial scissor lifts. Chip also holds certifications as an occupational health and safety technologist (OHST), a certified environmental, safety, and health trainer (CET), a certified safety and health official (CSHO), and a forklift safety technician (FST). Darius has been a certified emergency medical technician (EMT) for 35 years. Darius earned BS and MA degrees from the University of Connecticut, where he has also served as adjunct faculty. He is a member of the National Environmental, Safety & Health Training Association (NESHTA), author of three guidebooks, and designer of more than 200 specialized courses in safety and trainer development. He holds certificates from the OSHA Training Institute, National Safety Council, Construction Safety Council, National Fire Protection Association, and others. Darius has presented on-site training, conference presentations, keynotes, and seminar programs in numerous states, Canadian provinces, and foreign countries. He presented at the 2011 National Safety Council Congress in Philadelphia, Pennsylvania. He is presently a committee member for ANSI/ASSE Z490.1: Criteria for Accepted Practices in Safety, Health, and Environmental Training.

Powered Industrial Trucks eTool: Types & Fundamentals - Types: Forklift Classifications

Class Class Class Class Class Class Class

I: Electric Motor Rider Trucks II: Electric Motor Narrow Aisle Trucks III: Electric Motor Hand Trucks or Hand/Rider Trucks IV: Internal Combustion Engine Trucks (Solid/Cushion Tires) V: Internal Combustion Engine Trucks (Pneumatic Tires) VI: Electric and Internal Combustion Engine Tractors VII: Rough Terrain Forklift Trucks

Class I: Electric Motor Rider Trucks The following are examples of Class I powered industrial trucks.  

Lift Code 1: Counterbalanced Rider Type, Stand Up.

Lift Code 4: Three Wheel Electric Trucks, Sit Down.  

Lift Code 5: Counterbalanced Rider, Cushion Tires, Sit Down.

 

 

Lift Code 6: Counterbalanced Rider, Pneumatic or Either Type Tire, Sit Down.

http://www.osha.gov/dcsp/products/etools/pit/forklift/types/classes.html[9/17/2012 8:56:12 PM]

Powered Industrial Trucks eTool: Types & Fundamentals - Types: Forklift Classifications

Class II: Electric Motor Narrow Aisle Trucks The following are examples of Class II powered industrial trucks.  

Lift Code 1: High Lift Straddle.  

Lift Code 2: Order Picker.

Lift Code 3: Reach Type Outrigger.

Lift Code 4: Side Loaders: Platforms.  

Lift Code 4: Side Loaders: High Lift Pallet.

Lift Code 4: Turret Trucks.

Lift Code 6: Low Lift Platform.

Lift Code 6: Low Lift Pallet.

 

http://www.osha.gov/dcsp/products/etools/pit/forklift/types/classes.html[9/17/2012 8:57:14 PM]

Powered Industrial Trucks eTool: Types & Fundamentals - Types: Forklift Classifications

Class III: Electric Motor Hand Trucks or Hand/Rider Trucks The following are examples of Class III powered industrial trucks.  

 

Lift Code 1: Low Lift Platform.

Lift Code 2: Low Lift Walkie Pallet.

  Lift Code 4: Low Lift Walkie/Center Control.

Lift Code 5: Reach Type Outrigger.

Lift Code 6: High Lift Straddle.

Lift Code 6: Single Face Pallet.

Lift Code 6: High Lift Platform.

Lift Code 7: High Lift Counterbalanced.

 

Lift Code 8: Low Lift Walkie/Rider Pallet and End Control.

http://www.osha.gov/dcsp/products/etools/pit/forklift/types/classes.html[9/17/2012 8:58:08 PM]

Lift Code 3: Tractors

 

Powered Industrial Trucks eTool: Types & Fundamentals - Types: Forklift Classifications

Class IV: Internal Combustion Engine Trucks (Solid/Cushion Tires) The following are examples of Class IV powered industrial trucks.  

 

 

Lift Code 3: Fork, Counterbalanced (Cushion Tire).

Class V: Internal Combustion Engine Trucks (Pneumatic Tires) The following are examples of Class V powered industrial trucks.  

 

 

Lift Code 4: Fork, Counterbalanced (Pneumatic Tire).

Class VI: Electric and Internal Combustion Engine Tractors The following are examples of Class VI powered industrial trucks.  

 

 

Lift Code 1: Sit-Down Rider (Draw Bar Pull Over 999 lbs.).

http://www.osha.gov/dcsp/products/etools/pit/forklift/types/classes.html[9/17/2012 8:59:22 PM]

Powered Industrial Trucks eTool: Types & Fundamentals - Types: Forklift Classifications

Class VII: Rough Terrain Forklift Trucks Class VII – Rough terrain forklift is a generic term used to describe forklifts typically intended for use on unimproved natural terrain and disturbed terrain construction sites. However, the term “rough terrain” does not imply that the forklift can be safely operated on every conceivable type of terrain. There are three basic types of rough terrain forklift:

 

This is an example of a ruggedly constructed forklift and is designed to be used primarily outdoors.

Vertical mast type.  

This is an example of a vehicle equipped with a telescoping boom, which enables it to pick and place loads at various distances and lift heights in front of the machine. The ability to reach out in front of the forklift allows the operator flexibility in the placement of a load.

Variable reach type.  

This is an example of a portable self-propelled rough terrain forklift that is typically transported to the job site. It is mounted on a carrier to the back of a truck/trailer and is used to unload heavy items from the truck/trailer at the job site. Note that not all truck/trailer mounted forklifts are rough terrain forklifts.

Truck/trailer mounted.

http://www.osha.gov/dcsp/products/etools/pit/forklift/types/classes.html[9/17/2012 9:00:00 PM]