TRAFFIC MANAGEMENT IN WAREHOUSING. PLAN AND CHECKLIST March making a difference. New South Wales Government

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1 TRAFFIC MANAGEMENT IN WAREHOUSING PLAN AND CHECKLIST March 2009 making a difference New South Wales Government

2 Acknowledgement: This is a NSW Wholesale Industry Reference Group project in partnership with WorkCover NSW. Disclaimer This publication may contain occupational health and safety and workers compensation information. It may include some of your obligations under the various legislations that WorkCover NSW administers. To ensure you comply with your legal obligations you must refer to the appropriate legislation. Information on the latest laws can be checked by visiting the NSW legislation website ( or by contacting the free hotline service on This publication does not represent a comprehensive statement of the law as it applies to particular problems or to individuals or as a substitute for legal advice. You should seek independent legal advice if you need assistance on the application of the law to your situation. WorkCover NSW

3 CONTENTS PAGE INTRODUCTION 2 Traffic Management Plan ChecklIST 4 Loadshifting Equipment 4 Barricades/Barriers/Bollards 6 Layout/Line Marking 7 Signage/Warning Devices 8 Training, Systems, Policies, Procedures 9 Personal Protective Equipment 11 External Traffic Management Requirements 12 Sample Warehouse Traffic Management Action Plan 13 RISK ASSESSMENT MATRIX 14 DEFINITIONS 15 More INFORMATION 17 1

4 INTRODUCTION The consequences of being hit by loadshifting equipment and other vehicles can be serious, resulting in injury or even death. There is a significant cost to the victim, the employer, the victim s family and the community. This Traffic Management Plan Checklist provides guidance to managers and supervisors of small to medium businesses on how to develop, implement and maintain safe systems of work, intended to eliminate or control the risks of collision in a warehousing and/or storage environment. An important part of managing your business is to ensure the health and safety of your employees and other people, such as customers, visitors or tradespeople who visit your workplace. To ensure you fulfil your obligation for a safe workplace, you need to be aware of what can cause harm and then take action to ensure no one is at risk while they are in your workplace. The following questions will help you evaluate how well you are currently managing safety in your workplace: Do you talk with your employees about safety issues? Yes No Do you encourage your employees to report safety problems? Yes No Do you regularly inspect your workplace to identify safety problems? Yes No Do you fix identified problems? Yes No Do you supervise and train employees so that all work is carried out safely? Yes No If you answered no to any of these questions, you may not be meeting all of your obligations under the Occupational Health and Safety Act 2000 (the OHS Act). Even if you answered yes to all these questions, this Traffic Management Plan Checklist will help you to systematically identify the traffic management safety risks in your workplace and take the necessary steps to make your workplace safer. When using the Traffic Management Plan Checklist, it is important to involve your employees, as they are the people most affected by safety issues and can help to identify the best safety solutions. Involving your workers is one of your obligations under The OHS Act, to consult with your employees on workplace safety issues, including when developing safe work procedures. When you complete the Traffic Management Plan Checklist, it is important to determine how often it needs to be reviewed. As a guide, it is a good idea to review the Traffic Management Plan Checklist at least once a year. However, you may also need to review the Traffic Management Plan Checklist if there are changes to your workplace that may impact on safety, eg when new equipment is introduced into the workplace, in situations where plant/ processes are modified and during seasonal peak periods. 2

5 By completing this Traffic Management Plan Checklist, identifying and controlling any problem areas and reviewing it regularly, you will be well on your way to meeting your legal obligations to provide a safe and secure workplace. Instructions Simply tick Yes or No to each question and add any comments you consider appropriate. If the question does not apply to your workplace, tick N/A. If you tick No to any question you will need to take action to rectify the issue. An action plan template is provided in this Traffic Management Plan Checklist and may be used to map the necessary steps required to make your workplace safer. For more information or assistance, go to or contact the WorkCover Assistance Service on

6 TRAFFIC MANAGEMENT PLAN CHECKLIST Date checklist completed: / / Date checklist to be reviewed (if not reviewed earlier due to a change to the workplace): / / Name(s) of person(s) who completed checklist: Title: Name(s) of person(s) who completed checklist: Title: 1. LOADSHIFTING EQUIPMENT Issue YES NO N/A POSSIBLE Control Measure Action to be taken 1.1 Is a forklift required for this job? 1.2 Have you studied the loadshifting equipment and pedestrian movement in the workplace to identify the risk of collision with a pedestrian? 1.2a Have you implemented control measures to address the risks identified in the above study? 1.2b Have you implemented appropriate measures to monitor the effectiveness of the controls? substitute forklift with more pedestrian friendly loadshifting equipment (eg pallet jacks, walker stackers) if the above is not practicable, design the workplace to eliminate the need for pedestrian access in the vicinity of a forklift. study the loadshifting equipment and pedestrian movement in the workplace identify the potential for collisions with loadshifting equipment and pedestrians, columns, racking and other vehicles. mark No Go for exclusion zones for both pedestrians and powered loadshifting equipment based on pedestrian and equipment movements, braking distance, stability and loads being handled change layout change equipment. ensure there is an appropriate level of supervision provided to see control implemented ensure there are appropriate arrangements in place so that incidents and near misses are reported ensure arrangements are in place to modify controls where necessary based on feedback from incident and near miss reports. 4

7 1. LOADSHIFTING EQUIPMENT (CONTINUED) Issue YES NO N/A POSSIBLE Control Measure Action to be taken 1.3 Have you determined parking areas for loadshifting equipment? ensure loadshifting equipment has its own clearly marked parking and/ or recharging areas design work processes so that no loadshifting equipment is required to park on pedestrian walkways. 1.4 Are daily pre-operational checks being completed for these components? falling object protection brakes seat belts (where fitted) lights warning devices steering tyres controls horn mast and hydraulics chains hand brake load capacity plate Notes 5

8 2. BARRICADES/BARRIERS/BOLLARDS Issue YES NO N/A POSSIBLE Control Measure Action to be taken 2.1 Are physical separation structures installed to keep pedestrians out of loadshifting areas? (they may be essentially visual in nature or only strong enough to resist accidental actions by the pedestrian) enclose designated loadshifting equipment operating areas with physical barriers to prevent pedestrian access if employees work within loadshifting equipment operating areas eg desks, counters, goods dispatch areas or workstations: relocate them away from traffic areas erect physical barriers to protect such areas, eg steel railings. 2.2 Are pedestrian crossings clearly marked? 2.3 Are adequate bollards and safety railings being used to reduce the risk of vehicle and pedestrian collision in the battery charging area and waste bin work zones? 2.4 Do entry and exit points to the building protect pedestrians from being struck by vehicles? clearly designate pedestrian crossings by installing inward opening pedestrian gates as a calming device to ensure people stop and look before crossing have right of way procedures in place and enforced, clearly indicating who must give way pedestrian crossings on the pavement. clearly delineate the battery charging area for electric loadshifting equipment by installing adequate bollards/ safety railings separate access paths for vehicles and pedestrians, eg vehicles access from the end and pedestrians from the side barricading and markings to match ensure clear visibility around waste bin areas to avoid pedestrians stepping out into traffic from blind spots install barriers/bollards to protect other vulnerable equipment, pits or places where employees work. install barriers or bollards at the entry and exit points of the building to prevent pedestrians walking into the path of oncoming vehicles where buildings or walkways open directly onto roadways or traffic zones, erect permanent barriers to ensure pedestrians do not step into the path of passing vehicles use bollards/barriers to prevent vehicles obstructing emergency exits. 6

9 3. LAYOUT/LINE MARKING Issue YES NO N/A POSSIBLE Control Measure Action to be taken 3.1 Is there an effective workplace layout to separate pedestrian and powered loadshifting equipment traffic? 3.2 Is there effective line marking to separate pedestrian and powered loadshifting equipment traffic? clearly line mark pedestrian walkways, roadways and loadshifting equipment operating areas based on speed limits, stopping distances and efficient workflow minimise the cross flow of traffic, intersections and blind spots line mark customer pick-up parking areas make sure customer pick-up parking areas are positioned close to pedestrian walkways and provide access without crossing driveways or loading dock vehicle paths clearly define areas where powered loadshifting equipment is used as pedestrian exclusion zones and clearly exclude powered loadshifting equipment from pedestrian walkways/work areas use line markings and/or marker posts in docking areas to indicate distances from dock, ie 1 metre increments advising driver of proximity to dock, reducing the need for assistance reversing provide line marking for: traffic flow markings loadshifting equipment parking driver designated safe areas car parking keep clear zones lane numbering where multiple docks exist speed humps. 7

10 4. SIGNAGE/WARNING DEVICES Issue YES NO N/A POSSIBLE Control Measure Action to be taken 4.1 Is there adequate lighting and visibility to minimise the risk of collision? install eye ball convex mirrors to provide clear visibility of approaching loadshifting equipment and/ or pedestrians all loadshifting equipment to carry high visibility and/or reflective markings pedestrians within vehicle access areas to wear high visibility clothing or vests provide additional lighting. 4.2 Is there clear warning of loadshifting equipment hazards? loadshifting equipment have fitted and maintained reversing beepers and/or flashing lights clearly mark such things as cabling or ducting with high visibility materials have signs conforming to the Australian Standard AS1319 Safety Signs for the Occupational Environment prominently display clear warning signs in relevant, well lit areas to remind persons of the traffic management hazards and requirements. Signage examples: Pedestrians Prohibited Loadshifting Equipment Operating Area Loadshifting Equipment Prohibited Pedestrian Safety Zone Beware loadshifting equipment operating within the area Vehicles must give way to pedestrians or a priority or right of way procedure that applies to pedestrian crossings. 8

11 5. TRAINING, SYSTEMS, POLICIES, PROCEDURES Issue YES NO N/A POSSIBLE Control Measure Action to be taken 5.1 Are operators adequately trained and licensed where required? make sure operators are adequately trained and competent, even for machines that do not require a Certificate of Competency do NOT allow other people (eg visitors, delivery drivers, etc) to operate machinery without assessing their competency and sighting relevant Certificates of Competency make sure learner operators are properly supervised and complete logbooks induct operators into the operation of new plant have operation manuals for plant available for operators to read keep copies of loadshifting operators Certificates of Competency. 5.2 Have employees undergone a site safety induction prior to being permitted to use loadshifting equipment? 5.3 Are safe work procedures in place for operators of loadshifting equipment? conduct a work environment induction conduct a traffic management site induction. Consult with staff and consider incorporating the following into your safe work procedures: pre-use inspection procedures to check for obvious defects means to ensure loads do not exceed the capacity of the equipment loadshifting equipment key control procedures to ensure only competent operators use the equipment loadshifting equipment to cease work if pedestrians enter a pedestrian exclusion zone loadshifting equipment operators to keep the tynes as close to the floor as practical when travelling and operating within the site loadshifting equipment operators to ensure that their load (mast) has appropriate rearward tilt prior to moving pallet/stock and not travel with tynes extended loadshifting equipment operators should lower their loads before turning in the direction of travel 9

12 5. TRAINING, SYSTEMS, POLICIES, PROCEDURES (CONTINUED) Issue YES NO N/A POSSIBLE Control Measure Action to be taken 5.3 Are safe work procedures in place for operators of loadshifting equipment? (cont) sound loadshifting equipment s horn (warning device) when crossing intersections, pedestrian walkways and access and egress points for pedestrians no loadshifting equipment is to be used to move or shunt another piece of equipment no tampering or modifying of loadshifting equipment by staff Out of Service / Danger tag system clearly understood and carried out by loadshifting operators ensure operators of loadshifting equipment travel in reverse if the load obstructs their view. 5.4 Have procedures and training on traffic management been given to employees and any visitors to the workplace? 5.5 Have you clearly identified pedestrian walkways and traffic directions? 5.6 Are external delivery drivers aware of your site s traffic safety procedures? ensure pedestrians are aware of traffic management rules, including not walking behind loadshifting equipment when in operation and staying on designated walkways and pedestrian areas ensure all contractors and visitors working on site receive induction regarding traffic management and are signed in ensure non-inducted visitors are supervised at all times when walking through the site monitor and assess employee s compliance with the traffic management procedures. develop a site plan clearly identifying pedestrian walkways and traffic directions review the site plan regularly (at least annually), have it dated and signed off by the OHS Committee/ Representative and Site Manager. develop a truck docking procedure to ensure delivery trucks engage trailer braking, chocks and parking brakes at all times during unloading ensure risks of drive-offs during loading and unloading are minimised (eg driver not permitted to stay inside vehicle while being loaded/ unloaded or ignition key put on a hook inside the dock). 10

13 6. PERSONAL PROTECTIVE EQUIPMENT Issue YES NO N/A POSSIBLE Control Measure Action to be taken 6.1 Do pedestrians and drivers (internal and external) wear high visibility clothing in traffic areas? provide high visibility clothing that meets the Australian Standard AS/NZS 4602 Visibility Safety Garments and is appropriate for their specific use day or night ensure pedestrians and delivery drivers wear high visibility clothing (day or night) in traffic areas provide high visibility clothing (eg vests) for visitors or other employees accessing traffic areas from other areas of the workplace, eg office staff entering warehouses. 6.2 Do you have a policy regarding appropriate footwear in the workplace? write a policy regarding appropriate footwear in the workplace and clearly define the term Appropriate Footwear for each area of the workplace ensure persons accessing vehicle areas wear closed-in and/or safety footwear. Notes 11

14 7. EXTERNAL TRAFFIC MANAGEMENT REQUIREMENTS Issue YES NO N/A POSSIBLE Control Measure Action to be taken 7.1 Do you have external controlled speed limits in place for trucks, customer s or visitor s vehicles to the site? install traffic-calming devices to reduce the speed of vehicles, especially when approaching pedestrian or loadshifting equipment operating zones eg boom gates and self closing gates. 7.2 Have you provided safe access and egress to and from your site for pedestrians? provide line markings, signage and barriers for safe pedestrian walkways. 7.3 For common areas where pedestrians and vehicles are required to operate within the same area, have you provided adequate safety control measures? provide line markings on the ground to indicate appropriate parking lanes, driver safe zones and walkways for drivers of vehicles being loaded and unloaded clearly define safety zones protected by bollards/barriers so that drivers or unloading crew can supervise unloading at a safe distance from loadshifting equipment and falling loads. Notes 12

15 SAMPLE WAREHOUSE TRAFFIC MANAGEMENT ACTION PLAN Action Required Priority Person Responsible Est Completion Date Completed by Signature/Date Comments 1. Re-do line marking of all pedestrian walkways M. Brown January 2009 Check all pedestrian walkway areas within the warehouse 13

16 RISK ASSESSMENT MATRIX HOW DANGEROUS IS THE HAZARD YOU HAVE IDENTIFIED? FOR EACH HAZARD THINK ABOUT THE FOLLOWING: WORKCOVER HAZPAK MATRIX HOW LIKELY IS IT TO HAPPEN? HOW BAD IS IT LIKELY TO BE? VERY LIKELY: Could happen at any time ++ LIKELY: Could happen some time + UNLIKELY: Could happen, but very rarely VERY UNLIKELY: Could happen, but probably never will Kill or cause permanent disability or ill health Long term illness or serious injury!!! ical attention and several days off work!! First aid needed! The numbers show how important it is to do something. 1 top priority: immediate action required 6 low priority: take action when possible. Example Hazard: Plate glass door at foot of steps Judge severity: Someone falling down the steps could smash through the glass and be very seriously injured. So it is a!!! hazard. (Look in the second row of numbers.) Judge likelihood: This could easily happen at any time. So it is ++ very likely. (Look in the first column of numbers.) Second row, first column is priority number 1. So it is extremely important to fix this hazard soon. 14

17 DEFINITIONS WHOLESALE TRAFFIC MANAGEMENT Traffic Control Bollards, Barriers, Railings and Barricades A physical barrier installed to separate pedestrians or property from loadshifting equipment and other vehicles. Competent Person A person who has acquired through training, qualification or experience, or a combination of them, the knowledge and skills to carry out that task. Personal Protective Equipment (PPE) Safety devices or safeguards worn by workers to protect against environmental hazards. PPE includes such items as helmets, safety goggles, hearing protectors, face shields, sun screens, respirators, harnesses and lanyards, arm guards, smocks, gloves, high visibility clothing and safety boots. Plant Any machinery, equipment (including scaffold), appliance, implement or tool and any component or fitting thereof or accessory thereto. Risk Assessment A process that estimates the effects or consequences of hazardous events on people, property and the environment. The process would consider the likelihood of occurrence and the severity of the consequences. Safe Work Method Statement or Job Safety Analysis A statement that: describes how work is to be carried out identifies the work activities assessed as having safety risks identifies the safety risks describes the control measures that will be applied to the work activities, and includes a description of the equipment used in the work, the standards or codes to be complied with, the qualifications of the personnel doing the work and the training required to do the work. 15

18 Scheduled Work Scheduled Work is defined in the Occupational Health and Safety Regulation 2001, Part 9.1, Clause 266 and includes some types of cranes and loadshifting equipment used in warehouses. Pedestrian A person travelling on foot. Loadshifting Equipment plant designed to lift and/or move loads Powered: eg motorised pallet mover/jack, forklift truck, walk-behind forklift, stock picker/ order picker, overhead crane, vehicle mounted crane Manual: eg manual pallet jack, trolley, wheeled pallet. Dock Any area designated for the physical receipt and/or despatch of goods. Delivery Vehicle Any vehicle delivering or picking up items from a workplace (eg bicycle, motorcycle, car, van, ute, truck etc). Safety Zone Designated work area protected by a physical barrier separating pedestrians and loadshifting equipment. Certificate of Competency Certification determining competency to operate specific machinery, which is scheduled under Clause 266 of the Occupational Health and Safety Regulation 2001 (eg specified types of forklift, crane, hoist etc). Also commonly called a Ticket or a Licence. Site Plan Building and perimeter layout detailing the flow of work processes and all necessary movements of people, loadshifting equipment, vehicles, material and equipment of different types. Traffic-calming Devices Methods used to bring traffic movement to a momentary halt or reduce the speed of vehicles eg boom gates, self closing gates, speed humps, chicanes. 16

19 MORE INFORMATION GUIDE TO OBTAINING MORE INFORMATION WorkCover NSW Phone: WorkCover NSW publications are available on the WorkCover website or by calling the Publications Hotline on Some useful publications are: Making your forklift work for you Forklift Truck: National Certificate of Competency Plant Guide 2001 OHS Legislation Occupational Health and Safety Act 2000 Occupational Health and Safety Regulation Australian Standards Standards Australia Phone: Australian Standards are available from SAI Global or phone WorkSafe VIC Forklift Safety Reducing the Risk ACT WorkCover A Guide to Forklift Safety July Worksafe WA Guidance Note Safe Movement of Vehicles at Workplaces Shop, Distributive and Allied Employees Association (NSW Branch) InfoSheet8 Working with Forklifts Safety-Engineer.com Forklift Safety by Design 17

20 Health & Safety Executive UK Improving the Safety of Workers in the Vicinity of Mobile Plant Workplace Transport Safety Monash University Accident Research Centre (MUARC) Forklift Trucks and Severe Injuries: Priorities for Prevention Notes 18

21 Notes 19

22 Notes 20

23

24 Catalogue No. WC05856 WorkCover Publications Hotline WorkCover NSW Donnison Street Gosford NSW 2250 Locked Bag 2906 Lisarow NSW 2252 WorkCover Assistance Service Website ISBN Copyright WorkCover NSW 0209

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