FLTA National Fork Lift Safety Conference 2015

Peter Harvey MBE
Chief Executive
Fork Lift Truck Association
Sponsored by: Media partner:

• Scale of the issue
• Legislation
• What are the FLTA up to?
Fork Lift Truck Safety

Legislation & Guidance

SUMMARY OF L117
• Carry out an effective observation and know what to look for
• Communicate effectively with operators and line managers
• Recognise unsafe practice and behaviour
• Maintain and promote health and safety standards

THE FLTA POSITION ON FORK
LIFT TRUCK SAFETY

ATTITUDE – BEHAVIOUR CAN CHANGE
• Apathy
• Culture
• Ignorance
• Complacency
• Budgets

PRACTICAL SAFETY
• Segregation
• Speed Control
• Training Operators & Managers
• Risk Assessment
• Near Miss Reporting
• Safety Devices
• Engagement – safety gains

LATEST DEVELOPMENTS
• Hazard Perception Test Analysis
• FLTA Safe Site Finalists
• Safer Site Programme
• Good Hire Guide
• Managers & Supervisor Aide Memoire
• Safety Champion
• Fork Lift Watchdog

HOW TO ACHIEVE BETTER SAFETY
• OWNERSHIP
• LEADERSHIP

www.fork-truck.org.uk
Media partner:Sponsored by:

Craig Johnson
Jungheinrich

You never know when danger is just around the corner…
Sponsored by: Media partner::

Fork truck safety is in our DNA
Craig Johnson
23 September 2015

The Jungheinrich ‘Driven by Safety’ Focus
Product. People. Processes.
■ Our theme focuses on product safety, including both
features built-in to the basic design and those added for
specific applications, we have the most experienced,
trained team of people, both being underpinned by a
system of robust processes.

■ A host of safety features as standard
integrated into the truck design
■ €50m annual spend on
Research and Development.
■ Use of innovative technology
The Jungheinrich ‘Drive for Safety’ Product. People. Processes.
Standard safety features

■ Curve Control senses whether the steering
angle going into a corner is too severe for the
truck’s speed and automatically slows the
vehicle down safely.
■ On our Counterbalance truck range, the
counterweight is designed as an integral part
of the back-end and underside of the machine,
giving it a really low Centre of Gravity built-in.
Built-in standard safety features…a couple of examples

■ Personnel Protection Systems - we offer a shape
recognition system which recognises the human form.
■ Red-spot technology, alerts personnel of an
approaching vehicle.
Optional safety features… a couple of examples

■ Key research and development engineers:
− Global market knowledge
− New technology to market
− Strong health, safety and environmental factors
■ Our safety focus shows our factory engineers as
youngsters, who at a young age already have an
advanced awareness of engineering.

■ Strong and robust processes:
− Both for our employees and our suppliers
− Utilising the same high health, safety, environmental
and quality standards
■ We are committed to safety processes and raising
driver training standards.
■ We are currently rolling out new driver training
centres with the aim of offering more than just
standard driver training.

 We have developed for British Gas, forklift
trucks that demarcate between two distinct
processes and operations, both inside and
outside their buildings.
 Each area has preset safe fork lift speeds and
acceleration.

Philip White
Health & Safety Executive

Background
• 40th anniversary of the Health and Safety at Work Act
coming into force
• Much has changed over 40 years
• Fatal incidents, injuries and ill health greatly reduced
• World leader
• Still a long way to go in many areas

A world class system
Fatalities: 651 to 99 employees* (1974 to 2014/15p).
* excludes self-employed
Reported Injuries: 337,000 to 77,000 (1974 to 2011/12).
Ill health cases: fallen by a third (since early 1990’s).
European benchmarks (2011)
UK

RIDDOR – FLT ‘in operation’ (2010/11)
• Fatal injuries –on average 8 deaths per year.
• Annually c. 1,500 non-fatal injuries reported – comprising 400 ‘major’ and
1,100 ‘over-3-day’.
• Just over half (55%) of FLT accidents are ‘struck by vehicle’; 23% = ‘struck
against - whilst travelling inside.
• Just over one-third of non-fatal FLT accidents were in ‘transport and
storage’ industries. Another third in ‘manufacturing’.
• Around 90% of accidents are coded as ‘agent=fork lift truck’, include
‘reach; clamp; or tele-handler’ trucks.

New Strategy for H&S in Great Britain
• A strategy for the whole health and safety system;
• New ways of working with and motivating others;

More straightforward:
more compliance

Fee for Intervention
• Externally lead review and duty holder survey show
there has been an effective FFI implementation.
• Key issues being professionalism - inspectors
provided practical advice which will help improve
health and safety and that the inspection was
conducted in an efficient and effective manner.
• Some interest from some LAs but no consistent
view.

New Government Priorities
• Growth
• Deregulation
• European Union
• Devolution
• Energy
• Developing infrastructure

Deregulation – the new agenda
• The new Agenda is Deregulatory
• £10bn savings to be delivered over the
Parliament
• Business Impact Targets – deregulatory
“budgets” - to be set for Departments
and their Regulators

Greater involvement for all
• Engagement
• Individual drive
• Learning from incidents
• Revised guidance
• Purchase of new equipment
• Maintenance

Training & Engagement
• Do your operatives receive adequate
training?
• Do you encourage refresher training?
• Do you provide a way for employees to
raise concerns about any health and
safety issues?

Occupational health
• Identify risks
• MSDs
• Lifting and handling
• Noise
• Fumes

Leadership
• Creating a H&S culture for everyone to follow.
• Priority given to major risks.
• Board level support.
• Use incidents to learn not blame.

Working Involvement
• Listen to and involve workforce.
• Offer the best training
• Winning hearts and minds, building trust not
dictating rules and creating paperwork.

ANY QUESTIONS?

John Davies
Ibstock Building Products

IBSTOCK BUILDING PRODUCTS
APPROACH TO FLT SAFETY
By John Davies
Director for Health & Safety

Introduction
• Been in the Brick Industry since 1995
• Got into Health & Safety in 2002
• Joined Ibstock Building Products in June 2014
• Ibstock Building Products divested from CRH (Feb 2015)

How do I assess Safety?

So why did FLT safety become a priority?
There were a number of Fatalities in mainland Europe which involved
reversing FLTs.
The Managing Director of CRH Building Products UK wanted the
current FLT Safety reviewed and a strategy to improve FLT safety.

So the Journey began!
In 2007 we contacted FLT manufacturers to look at what Safety
Features were available.
- Reversing bleepers
- Flashing Lights
- Speed reduction
Nothing on the market which actually does what the company was
looking for.

Auto Speed Reduction System
Challenged FLT Manufacturers to develop an Auto Speed Reduction
System.
• Work in reverse
• Identify objects / people at a set distance
• Automatically reduce speed of the FLT to a safe speed (not stop the
FLT)

Auto Speed Reduction System
Soon identified it only worked on hydrostatic forklift trucks.
Started to work with Linde in 2007.

Won Awards

Other controls reviewed
• Reviewed Vehicle / Pedestrian segregation in the UK.

Forklift Training
FLT training using accredited training companies.
But identified that:
- The standard and information varied.
- The course durations varied.
- Driver competence also varied.

Our Actions!
• Agreed what standard training we wanted.
• Held meetings with training providers and went through the standards /
conditions we required.
• Put together an approved training provider list.
• Monitored the training providers and held performance meetings.

Are we satisfied!
Now we have challenged the FLT industry to find the next evolution for
FLT safety!
Jungheinrich have come back with an auto-reversing system which now
distinguishes the human form from objects!!

So your Challenge?

THANK YOU FOR YOUR TIME
Any Questions

Reece Cherry
G’s Fresh Beetroot

Trust | Efficiency | Quality | Expertise | Can do
Harvesting a Fresh Approach

G’s Fast Facts
• £415m turnover (Budget 2015/16)
• 5,000 employees
• Supplying major supermarkets
across the EU and USA
• c. £20m invested p.a.
• 11,737 hectares
• Supplying all major UK retailers
• Established 1952

The G’s Group
• A group of marketing led family farming businesses
• Growing across 11,737 hectares Europe & Africa
Senegal
325 ha
Spain
4,435 ha
Poland
161 ha
Czech
333ha
UK
6,483 ha

Full Vertical Integration
Full Vertical Integration
Plant Raising
Farming
Further Process
& Packing
Sales &
Marketing

G’s Crop Portfolio
Lettuce Spring
Onions
Celery Radish
Tomatoes Citrus
Onions
Garlic Leeks
Beetroot
Asparagus Legumes
Mushrooms
Flowers

Edinburgh
London
Kent
Spring OnionsSussex
Iceberg
Spinach
Romaine
G’s UK Growing Base
Lancashire
(Strategic Partners)
Celery
Iceberg
Warwickshire
Spring Onions
Asparagus
Legumes
Shropshire
Spring Onions
Gloucestershire
Mushrooms
Dorset
Mushrooms
Cambridgeshire
Onions
Celery
Iceberg
Romaine
Gem
Mushrooms
Norfolk Coast
Onions
Spinach
Celery
Iceberg
Romaine
Gem
Norfolk
Onions
Celery
Iceberg
Romaine
Radish
Suffolk
Onions
Living Leaves
Lincolnshire
Organic Veg
Scottish Borders
(Strategic Partners)
Iceberg

Spain
Salads, Citrus & Tomatoes

Czech Republic
Salads, Onions, Flowers

G’s Poland
Salads, Onions, Veg

Major Sources Worldwide
non-G’s growers
Chile &
Argentina
Onions
Florida
Celery
Mexico
Spring Onions
California
Celery
Gem
Iceberg
Israel
Radish
Egypt
Spring Onions
France
Baby LeafSpain & Portugal
Onions & Garlic
Beetroot
Baby Leaf
Leafy
New Zealand
Onions
Morocco
Radish

G’s Group Sales Growth
G’s Group Sales have doubled over the last 10 years
0
50
100
150
200
250
300
350
400
450
90/91
91/92
92/93
93/94
94/95
95/96
96/97
97/98
98/99
99/00
00/01
01/02
02/03
03/04
04/05
05/06
06/07
07/08
08/09
09/10
10/11
11/12
12/13
13/14
14/15
15/16Budget
£millions
G's Fresh Central Europe Farms Spain Prepared Bagged Salads PGS Mushrooms G's USA
• From 2011 G’s Fresh includes: G’s Fresh Mushrooms (formerly PGS)

G’s Group Brand Portfolio

Customer Base
UK &
Ireland
Poland
Czech
Slovakia
Hungary
Slovenia
Turkey
Germany
France
Netherlands
Spain
Sweden
Norway
Denmark
Finland
Switzerland
Austria
Italy
Russia
Belarus
Ukraine
Romania
Baltic States
Opportunity Sales

Innovation & Investment
90 ha of state-of-the-art
Greenhouses
Investment in the UK business is replicated
in Spain & Czech Republic
Laser Land Levelling 24 Row Iceberg
Planter
Infield Rig Packing
Plant Raising
Reservoir Development
Reservoir Development
Mushroom Farm & AD
Plant
Innovation & Investment
Over the last 6 years,
capital investment
by G’s has totalled
over £80m

Senegal
Radish & Spring Onions

Our People
At G’s we believe we have
competitive advantage
versus other produce
companies due to our
investment in:
• Facilities/Hostel
• Training & Development
• Year round employment
through winter working
in Spanish farms
With the weaker pound and rising standards &
opportunities in Eastern Europe, all agricultural
businesses face the challenge of labour supply

Over Familiarity to Risk

We need to talk…

Fixing the obvious…
Our teams were tasked to gather data;
1. Identify workplace transport activity – “What happens there?”
2. What can we make safer now?
Our people started to tell us what they considered was dangerous, and what needed to be changed…
Fork Trucks
- Blue Spot Technology
Site
- Improving traffic and pedestrian routes – changed routes, barriers
- Additional Lighting (and traffic lights)
- Drivers waiting room installed (with toilet)
- Clocking in machine and locker locations
- Signage and gates
- Driver sign in system (multilingual touch screen)
Assisting our People
- Tablets and smart phones data logging and immediate sharing
- Radio communication devices

Orange Area Ownership
1. Supervisor reviews activity and provides the Manager with a list of those
people who require access.
2. Manager reviews list –
• Approves
• Rejects
The approved persons then undergo the advanced awareness training package.

The Awareness program
Understanding the risks
- Injury and fatality data (specific to industry and Workplace transport)
- Videos showing incidents in similar environments
Behaviours
- “Gatherings” in the Orange Area are not permitted
- Mobile phones not to be used in the “Orange Areas”
- Do not approach fork lift trucks from the rear
- “5 metre rule”
- Instructions to drivers – “Hurry up”, or “As fast as you can” must not be used.
• Challenge – all persons can challenge or be challenged
• Encouragement to report unsafe driving

In Reflection…
60% reduction in pedestrian activity
Improved Real-Time Risk Management – we can immediately identify people who
shouldn’t be in the area.
Significantly raised awareness of vehicle dangers
Catalyst for investment – “Stage 2”

Reece Cherry
Email: reece.cherry@gs-fresh.com
Thank you for listening
Please feel free to get in touch

Graham Andrews
Heineken Hereford

THE PERFECT
FORKLIFT EXPERIENCE

HEINEKEN in the UK

Our UK locations
85

The Perfect Fork Lift Experience
In 2013 the Forklift repair costs
for our Hereford Cider were over
A HEINEKEN specification
3.5T Forklift costs
£90,000
£35,000

EXAMPLES OF ISSUES

HEINEKEN have three Core Values that shape how we
do business – Respect, Quality and Enjoyment.
Using these Core Values, The Perfect Fork Lift
Experience was launched which saw FLT ownership
adopted by teams whereby operators became
responsible for the maintenance of their own trucks.

Warehouse Fork Lift Perfect Experience
CLEANING SCHEDULE FLT AUDIT AWARD

Perfect Fork Lift Experience Impact results 2014
The Perfect Difference…..
Project launch week 27

Practical Safety
Panel

Chris Moon
Guest Speaker
@chrismoonmtb

What you don’t know
can hurt you

Why bother with
Health and Safety?

Effects of an accident
The Loading Bay…

All the reasons we can think
of for making a -
Healthy and Safe Culture

Organisational Safety
The actions of an individual
are a function of the
organisation

Why do accidents happen?

1. People take short cuts
2. Complacency
3. Lack of training
4. Time and cost pressure
5. Poor leadership
•Sponsored by: Media partner:

Procedure- attention to detail

Never underestimate
the power of belief

A Psychological Perspective
Perception of risk

Perception
Of Risk
Time

Ownership and Sub-Culture

Where are the risks?

Zero harm is possible-
shoes, coffee and
speeding
What’s acceptable?

Things constantly change
Be aware of ‘creep’

Things I’ll do to be more healthy
www.chrismoon.co.uk @chrismoonmtb

FLTA National Fork Lift Safety Conference 2015

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