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Gi forklift and material handling 2015

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This is a general industry forklift ppt that I use in the OSHA 10 hour classes.

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Gi forklift and material handling 2015

  1. 1. Material Handling Safety johnanewquist@gmail.com Draft 7 11 2015
  2. 2. July 2015
  3. 3. January 2015 • Kevin Voyles was killed in a GA factory by falling marble slabs.
  4. 4. Feb 2014 • Two men were killed in an industrial accident at a granite company facility in San Francisco • Two men were trapped after at least one large slab of granite fell on them as they unloaded a container truck,
  5. 5. Dec 2013 • Todd L. Wolf, 51, was operating the forklift as it was being unloaded from a trailer. • When the forklift tipped, it crushed the man beneath it.
  6. 6. Dec 2013 • $281 Million award • Osorio was driving a Heckmann tractor-trailer on FM 133 in TX and the drive shaft broke off from under the truck. • The part plowed through the windshield of a pickup that Aguilar was a passenger in • The lawsuit alleged that the drive shaft broke because the defendants did not properly maintain the tractor-trailer.
  7. 7. Nov 2013 Cont
  8. 8. Nov 2013 cont
  9. 9. May 2015 • Federal OSHA does not specifically require employers to equip forklifts with portable fire extinguishers. • However, if the manufacturer equips its forklifts with fire extinguishers, the employer must maintain the extinguishers • Also, the Liquefied Petroleum Gas standard 2006 edition addresses their use in Chapter 9, which states that where either the "authority having jurisdiction" or the end user requires an industrial truck to be equipped with a portable extinguisher • The NFPA standard also says that industrial trucks can only be equipped with portable extinguishers if operators have been trained in their safe operation and use.
  10. 10. July 2013 • Billy Johnston, 48, was killed in an industrial accident in West Allis was lowering a 24,000 pound dust collector when a chain broke. He was either hit in the head by the chain and thrown 30 feet from the piece of equipment, or he hit his head as a result of the fall
  11. 11. July 2013 • Rack on the right • Slid forks in • Tilted forks up • Heard a pop • Stuck hand in to see if product damaged • Rack back bar had popped loose trapping arm
  12. 12. July 2013 • $82,600 • An unapproved C-clamp slid off a 2,600-pound press brake ram as it was lifted, causing the ram to fall to the ground and pin the worker pinning him to the ground and resulting in amputation at the knee.
  13. 13. May 2013 • Workers were lifting a bag of processed powdered chemicals. • The bag, which weighed 3,675 pounds, was hoisted by several straps designed to bear the load. • During the operation, one of the straps failed, causing the bag to drop. • A worker’s arm and head were wedged underneath the bag while others worked to free him.
  14. 14. Dekalb accident 1997 • Protect sling from sharp surfaces • Employees were positioning a 22,000 pound generator with the use of a truck-mounted crane and four synthetic web slings. • While the employees were moving the generator, the slings contacted a steel purlin and were cut. • The generator fell and rolled onto the employees. • Employee #1 suffered fatal internal injuries. • Employee #2 suffered back injuries and was hospitalized. • Photo is an example
  15. 15. Struck By OSHA Reg 5
  16. 16. 2010 Accident Causation Factors • 37 struck by falling object or load • 34 struck by forklift • 28 falls: includes 10 pallet, platform or forks, 8 forklift went off dock, 1 ejected from forklift, 5 fall from load lifted, 1 fall through hole, 1 order picker platform, 2 mezzanine • 27 crushed or caught in Forklift/load and an object • 14 Forklift overturned • 8 caught in amputation • 5 burns / fire • 3 CO, 1 Ammonia • Type of forklift not included due many not identifying the type.
  17. 17. Falls • Getting on a pallet has lead to many deaths and is not acceptable. • Employees use what is available.
  18. 18. Struck-by • What should be done? • Many foot crushing by people too close. • How close is too close?’
  19. 19. Struck By • Loads falling off kill people. • Loads improperly stored kill people. • What can be done?
  20. 20. Struck-by • What should be done when backing out?
  21. 21. May 2014
  22. 22. Overturned • Curbs • Seat belts • Excessive weight lifted
  23. 23. Certification Initially Every 3 years Near Miss
  24. 24. Evaluation Date of Certification Operator’s name Trainer’s Name
  25. 25. Training • For classroom training element, the employer may demonstrate the employee's successful completion by a written or oral test or other appropriate means, such as an evaluation by the instructor.
  26. 26. Refresher Training • Observe the powered industrial truck operator during normal operations to determine if the operator is performing safely, and • Ask pertinent questions to ensure that the operator has the knowledge or experience needed to operate a truck safely.
  27. 27. Is a Forklift a Crane? • Slings use • Qualified rigger? • What can go wrong?
  28. 28. Pushing Loads • Operators were allowed to “bulldoze” double high pallets • Issues are obstructed view
  29. 29. Accidents – Forklift Leaves Dock • November 1, 2000 • An employee was driving a forklift truck in reverse. She backed off of the receiving dock and was pinned under the forklift. Operator was not wearing seatbelt and the forklift didn't have a overhead guard.
  30. 30. Caught in • Several under rack caught in fatalities • Driving into fixed object • Body part outside frame of forklift
  31. 31. Seatbelts • Seatbelts prevent the operator from being pinned by the truck or overhead guard.
  32. 32. Inspection • Barrel lifter with no capacity plate • Don’t forget unapproved attachments that overload the attachment
  33. 33. Fire / Burns • Event Date: 08/13/2010 • Employee was operating a forklift at the time of the accident. • The employee positioned the forklift to remove a tote of scrap paper. • The forklift struck an overhead pipe containing toluene. The employee and the forklift were dowsed in toluene. • The employee pulled the equipment forward and then reverse the lift moving back under the stream of toluene. • Once past the toluene stream, the employee stopped the equipment and climbed to a mezzanine to cut off the supply of toluene. • The employee then remounted the forklift and drove to the locker rooms to access the shower. • The toluene ignited from an unknown source prior to the employee leaving the lift seat. • Both the employee and the lift were badly burned. • 61 M Fatality
  34. 34. Truck Unloading • Is there a procedure?
  35. 35. Mar 2014 • Cedar Rapids IA • Jacob B. "Jake" Harper, 28, died Friday after steel pipes slipped off of a trailer, struck him and caused fatal injuries
  36. 36. Lockout or Guarding? • The person who works on the forklift must know the OSHA lockout standards. • Forks can come down unexpectedly during servicing. • Any body part can be cut or crushed if caught in a scissor point. • Forklift maintenance fatalities – employees get caught underneath because a jack fails, or crushed between mast and frame of truck because they didn’t block it
  37. 37. Forklift Amputation Hazard • The mast has open gears and scissor points.
  38. 38. Fork Lift Platforms • 5(a)(1) under ANSI/ASME B56.1- 2000 • No screen on right.
  39. 39. Forklift Platforms • Good Platform must be guardrails • Secureable • Screen at forklift side
  40. 40. Slabs • Several death happening when lifting large flat objects
  41. 41. Operation • Reverse travel if operator cannot see in front • Seat belts • Traffic control if in road
  42. 42. Maintenance • When working on any vehicle/forklift, cribbing or blocking needs to be performed in case of hydraulic failure.
  43. 43. Riding on Forks • Not allowed
  44. 44. Sample Safety Rules • Follow Manufacturer’s instructions and OSHA regulations. • Use ANSI B56 standards on forklifts if you cannot get the manufacturer’s rules..
  45. 45. Safety Rules • Follow Warning Labels. • Only trained personnel can operate the lifts. • A trained person must inspect the machine before each shift. • And many more!
  46. 46. Training • Hands on training is necessary. An forklift lift is not a car. • The worker should be able to demonstrate all predicted uses of the lift and compliance with manufacturers instructions.
  47. 47. Cautions • Watch for any holes. These will flip some forklift. • These should be identified in advanced and plans to prevent a forklift from going into one is necessary.
  48. 48. Electrical • 1/12/1999 • An employee was operating a side loader, loading and unloading rail car containers in a terminal yard. • A 7200-volt overhead power line ran nearby, about 8.8 meters above the ground. • The mast on the loader reached up to about 9.1 meters. • The employee brought the mast of the loader into contact with the power line. • Three employees at the site were electrocuted
  49. 49. Emergency Response • What is your plan?
  50. 50. Struck By • How can this be avoided?
  51. 51. Fire • Cylinder gases ignited by forklift. • What can be done?
  52. 52. Inspections Why is this inspection form weak?
  53. 53. Inspections • Before daily use using manufacturer’s guidelines • Check all working components and safety device. • Address all leakage of fluids. • Search for defective hydraulic/pneumatic cables. • Look for electrical tape as quickfix that is not acceptable.
  54. 54. Forklift Inspections • Overhead guard improperly welded
  55. 55. Inspection • Labels
  56. 56. Inspection • Load Extension Backrest
  57. 57. Inspection • How much wear is acceptable?
  58. 58. Forklift Inspection • Broken Fiberglass Housing is a laceration Hazard
  59. 59. Inspection • Leaking Hydraulic Fluid
  60. 60. Carbon Monoxide 0222 HCOOHC xx  Perfect World: Real World: xxxxx HCNOCOOHCONOHC  2222
  61. 61. Acute Exposure • Headache • Nausea • Weakness • Irritability • Unconsciousness • Chest Pain
  62. 62. Chronic Exposure • Headache • Lassitude • Dizziness • Anorexia • Ataxia
  63. 63. Best Practice and Required in MN • General industry: Minnesota Rules § 5205.0116 Carbon Monoxide Monitoring • The employer shall monitor environmental exposure of employees to carbon monoxide whenever internal combustion engine powered industrial trucks are operated indoors to ensure that carbon monoxide levels do not exceed those given in Code of Federal Regulations, Title 29, section 1910.1000, Table Z-1-A. • The air monitoring shall be done at least quarterly and represent exposures during a day of highest usage in the areas where employee carbon monoxide exposure is most likely. • Subpart 2. Tailpipe exhaust gas analysis. The employer shall ensure that powered industrial truck engine exhaust gases do not contain more than one percent carbon monoxide for propane fueled trucks or two percent carbon monoxide for gasoline fueled measured at idle and at three-fourths throttle during final engine tuning in a regular maintenance program.
  64. 64. Exposure Limits • OSHA 50 ppm 8-hour Time Weighted Average (TWA) • NIOSH 35 ppm 8-hour TWA • 200 ppm Ceiling by NIOSH • ACGIH Threshold Limit Value is 25 ppm 8-hour TWA; 40-hour work week
  65. 65. PPM CO Time Symptoms 200 2-3 hours Headache, fatigue, nausea 400 1-2 hours Symptoms intensify. Life threatening after 3 hours. 800 45 minutes Dizziness, nausea, convulsions. Death after 2-3 hours. 1600 20 minutes Dizziness, nausea, convulsions. Death within 1 hour.
  66. 66. ACGIH Recommendations • Limit CO concentration to 1% or less for propane fueled trucks • Limit CO concentration to 2% or less for gasoline fueled trucks.
  67. 67. Prevention of CO Poisoning • Maintain equipment in good working order • Provide periodic tune-ups for forklifts to ensure that they run “lean” • Periodic CO analysis of exhaust gases to determine emission concentrations • Provide adequate ventilation • Install CO monitors
  68. 68. Forklift Exhaust • No Violation. • This forklift emits low level of CO.
  69. 69. Storage • What is the problem and solution?
  70. 70. Storage • No Violation. • Material stored properly in racks.
  71. 71. Storage • Cylinders must be secured from falling down.
  72. 72. Material Handling • Rack was hit by forklift and tagged out and pallets removed.
  73. 73. Material Handling • No Violation • Aisle properly marked • Clean lanes
  74. 74. Aisles Not Marked
  75. 75. Struck By • No Violation. • Corner marked so forklift operation can see around corner.
  76. 76. Raised Dump Truck Bed • Event Date: 01/05/2010 • Employee # 1 was attempting to lower the bed of a detached dump trailer which had become stuck in the upright position. • The employee was working in between the trailer bed and frame when the bed fell crushing the employee. • Employee # 2 who assisted employee # 1 but was standing outside the caught between area was also struck by the falling trailer bed but sustained only minor injuries. • 34 M Fatality Use physical stops to hold up in case of failure.
  77. 77. Semi-trailers • Two fatals getting caught between truck and object. • Trailer often is not level causing load to roll off • Load straps release improperly stacked loads.
  78. 78. Skid Steer • Two fatals from being struck by moving Skidsteer • One death from caught in frame and bucket arm • Aug 2013 Matthew Mallett was riding in the skid loader driven by his great-aunt, Gail Henderson, 49, when he fell out.
  79. 79. Jan 2014 • 43-year-old Ronald L. Meier, of Maria Stein, Ohio, was working on a skid loader when the bucket fell, pinning him between the loader and the bucket
  80. 80.  Lock-Out Tag-Out Considerations: 1. Review requirements for the individual crane. 2. Integrate lock out and maintenance requirements. 3. Ensure training in adequate for level of maintenance. 4. Ensure written programs are established and reviewed. 5. Carefully select lockout devices, ask the manufacturer for recommendations. 6. Do not necessarily assume devices are interchangeable between different types of cranes. REVIEW THE MANUFACTURERS SPECIFIC INSPECTION REQUIREMENTS! LOCKED OUT This Lock/Tag may only be removed by NAME: __________ DEPT : __________ COMPLETION DATE: ___________ TIME: ____________ DON’T OPERATE DANGER
  81. 81. 2 TON ACME CRANE ALWAYS CHECK LOAD RATING 10 TON 10 TON CAP. 10 TON CAPACITY KNOW THE RATED LOAD OF THE CRANE BASICS OF CRANE SAFETYBASICS OF CRANE SAFETY
  82. 82. BASICS OF CRANE SAFETY 5 TON ALWAYS ENSURE THE LIFTING DEVICE AND ALL SUPPORTING COMPONENTS ARE RATED FOR THE LOAD TO BE LIFTED! 2 TON 10 TON LOAD KNOW THE RATED LOAD OF THE CRANE BASICS OF CRANE SAFETY
  83. 83. BASICS OF CRANE SAFETY NEVER ALLOW A COWORKER BETWEEN A FIXED OBJECT AND A LOAD! ACME CRANE 2 TON DANGER WORKING CRANES BASICS OF CRANE SAFETY
  84. 84. BASICS OF CRANE SAFETY 2 TON ACME CRANE ALWAYS POSITION LIFTING DEVICE DIRECTLY OVER LOAD BEFORE LIFTING! THINK BEFORE YOU LIFT BASICS OF CRANE SAFETY
  85. 85. BASICS OF CRANE SAFETY DISSIPATE ALL HAZARDOUS ENERGY DANGER HIGH VOLTAGE Always Ensure Energy Sources Are Dissipated Before Initiating Any Maintenance Activity. 2 TON ACME CRANE BASICS OF CRANE SAFETY
  86. 86. Accident • 5/6/08 • No bridge stops for pendant controlled crane • Crane ran off rails and the lifting device and crane hit employee •
  87. 87. Accident • 03/19/2008 • Bridge Crane employee was servicing bridge crane and fell approximately 58 feet.
  88. 88. Accident • 12/20/2007 • One of the four man ground crew working with a mobile underhung bridge crane got too close to the wheel of the crane and was ran over.
  89. 89. Accident • March 14, 2008 • A 1,868 pound plate fell from the C-clamp and onto the employee. • These devices must be designed and rated for lifting steel plates.
  90. 90. Accident • Tuscaloosa AL • “Where passageways or walkways were provided, obstructions were so placed that the safety of personnel was jeopardized by movements of cranes,” • “employee was using a crane to move a sheet of steel to the hot bed when one of the wheels of the crane's floor rail system ran over Korey Ryan's foot.” Typical rail gantry crane
  91. 91. Quiz • How often does a forklift driver have to be re- evaluated/certified? __________ • OSHA’s limit for Carbon Monoxide in an 8 hour shift is ____ ppm.
  92. 92. Summary • Training • Job Hazard Analysis • Written procedures • Manufacturer rules • Inspections
  93. 93. Questions?
  94. 94. Further • This ppt was prepared by John Newquist as a preliminary aid for people required to evaluate aerial lifts. • Thanks to Misette Kobler, Janet S., for corrections and suggestions. • This is not an official OSHA publication. Those will be on the OSHA.gov website. • Newquist.john@dol.gov is my email if you see any errors. This is just a draft as of the cover date. • 312-353-5977

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