FORKLIFT SAFETY PROCEDURE

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1 FORKLIFT SAFETY PROCEDURE AS/NZS 4801 OHSAS OHS20309 SAI Global August 2013 TABLE OF CONTENTS 1. PURPOSE SCOPE ABBREVIATIONS DEFINITIONS FORKLIFT TRUCK QUALIFIED INSTRUCTOR FORKLIFT OPERATOR AUTHORITY TO DRIVE MAST RATED CAPACITY TOOLBOX MEETING SPECIFIC RESPONSIBILITIES HEAD OF ACADEMIC/ADMINISTRATIVE UNIT STAFF MEMBER IN CHARGE (ORGANISER) SUPERVISORS/MANAGERS INDIVIDUALS (STAFF, STUDENTS, VOLUNTEERS)/FORKLIFT TRUCK OPERATORS FORKLIFT TRUCK LICENCING AND TRAINING LICENSING TRAINING WITHOUT A CURRENT LICENSE TRAINING BY INTERNAL OR EXTERNAL PROVIDERS AUTHORITY TO DRIVE TRAINING RECORDS CONTRACTORS AND HIRED FORKLIFT TRUCKS CONTRACTORS HIRED FORKLIFT TRUCKS ON MONASH UNIVERSITY PREMISES FORKLIFT TRUCK ATTACHMENTS JIBS/EXTENSIONS/SIDE SHIFT DEVICES/DRUM HOLDERS PLATFORMS MAINTAINANCE OF FORKLIFT TRUCKS DAILY CHECKS (PRE-OPERATIONAL AND OPERATIONAL) ISOLATION OF FAULTY FORKLIFT TRUCKS BI-ANNUAL OPERATIONAL MANAGERS/SUPERVISORS WORKPLACE INSPECTION LOAD CAPACITIES PLACARDING MOVEMENT OF LOADS UNBALANCED OR OBSCURED LOADS SAFE OPERATION OF FORKLIFTS SEATBELTS AND ENTRY PERSONAL PROTECTIVE EQUIPMENT PASSENGERS TRAFFIC MANAGEMENT FORKLIFT TRUCK TRAFFIC MANAGEMENT MAPS TRAVEL ON GAZETTED ROADS PEDESTRIAN EXCLUSION... 8 Page 1 of 10

2 12.4 SAFETY DRIVER ZONES INCIDENT REPORTING FORKLIFT COLLISIONS WITH STRUCTURES RECORDS TOOLS REFERENCES LEGISLATION MONASH UNIVERSITY OHS DOCUMENTS AUSTRALIAN AND INTERNATIONAL STANDARDS OTHER Page 2 of 10

3 1. PURPOSE The purpose of this procedure is to ensure the identification, assessment and control of risks associated with forklift activities in buildings, car parks, service roads and Victorian gazetted roads undertaken at Monash University is carried out in accordance with the requirements of the Occupational Health and Safety Act 2004 (Vic), the Road Safety Act 1986 (Vic) and AS/NZS 4801:2001 Occupational Health & Safety Management Systems specifications with guidance for use and OHSAS 18001:2007 Occupational Health & Safety Management Systems requirements. Forklifts are an essential part of many activities at Monash University. Forklift activities present an increased risk to health and safety as the work carried out is often done in the presence of pedestrians. This procedure highlights the additional risks that may be encountered when working with forklifts and to provide guidance for controlling associated risks. Staff who elect to manage the risks associated with forklift activities in a different manner to that described in this procedure must use practices that provide at least equivalent, or a better, level of safety. 2. SCOPE This procedure applies to all forklift activities at the Australian campuses of Monash University. 3. ABBREVIATIONS FLT OHS OH&S SWMS Forklift truck Occupational health and safety Monash Occupational Health & Safety Safe Work Method Statement 4. DEFINITIONS A comprehensive list of definitions is provided in the Definitions tool. Definitions specific to this procedure are provided below. 4.1 FORKLIFT TRUCK A forklift truck (FLT) is plant that is powered by electric, diesel, petrol or gas. This power operated plant has pronged platforms (tines) that can be raised or lowered for insertion under a load to be lifted or moved. 4.2 QUALIFIED INSTRUCTOR Someone who has been trained and licensed by WorkSafe Victoria, as an appropriate instructor in the use and operation of mobile equipment, namely FLT. 4.3 FORKLIFT OPERATOR An individual that operates and co-ordinates the safe operation of a FLT and holds a valid license to conduct High risk activities (Forklifts) issued by Worksafe Victoria or who is currently being trained to use a FLT. 4.4 AUTHORITY TO DRIVE 4.5 MAST This is the register whereby a manager or supervisor gives an employee permission to drive and operate mobile FLT equipment. The register contains a copy of the current license information including expiry date, training record and the managers/supervisors signature. The template is available in Appendix 1. A support member providing guide ways that permit vertical movement of the carriage. Page 3 of 10

4 4.6 RATED CAPACITY The maximum weight that the FLT is designed to lift as determined by the manufacturer. 4.7 TOOLBOX MEETING A meeting prior to conducting a task to discuss the associated hazards, risks and controls to be implemented prior to a task. This is not a substitute for a Safe Work Method Statement (SWMS). 5. SPECIFIC RESPONSIBILITIES A comprehensive list of OHS responsibilities is provided in the document OHS Roles, Committees and Responsibilities Procedure. A summary of responsibilities with respect to Fork lift truck (FLT) activities is provided below. 5.1 HEAD OF ACADEMIC/ADMINISTRATIVE UNIT It is the responsibility of the head of the unit to ensure that satisfactory provisions for health and safety are made for FLT activities organised by their unit. The head of the academic/administrative unit must institute a system for assessment, approval and review of all FLT activities in compliance with this document. 5.2 STAFF MEMBER IN CHARGE (ORGANISER) The staff member in charge must ensure that the risks associated with FLT activities are managed effectively. To do this they must: identify possible hazards that may be encountered during the activity; assess the risks associated with those hazards; incorporate strategies to minimise the risks to health and safety using the hierarchy of control; ensure that the supervisor/managers actively participate in the risk management process as appropriate. ensure that the responsibilities for health and safety are communicated to all participants. provide appropriate information, instruction and training to all participants. Hazard identification and risk assessment forms, as well as training in their use, are available from OH&S. Many of the hazards likely to be encountered on field activities and appropriate risk controls are discussed in these guidelines. 5.3 SUPERVISORS/MANAGERS Supervisors of FLT activities must: participate in the risk management process as appropriate; ensure operators are licensed through WorkSafe Victoria; ensure that safe working practices are developed and maintained at all times; arrange for participants to be instructed in safe working procedures; ensure that operators are warned about hazards, and how to avoid, eliminate or minimise them; ensure that participants under their control use the safety equipment and isolation mechanisms provided in the correct manner. 5.4 INDIVIDUALS (STAFF, STUDENTS, VOLUNTEERS)/FORKLIFT TRUCK OPERATORS Each staff member, student and volunteer has a moral and legal responsibility for ensuring that his or her work environment is conducive to good occupational health and safety by: reading any notices relating to the FLT activity, attending any toolbox meeting and returning any forms to the staff member in charge; take action to identify potential hazards prior to the start of work; taking action to avoid, eliminate or minimise hazards of which they are aware; Page 4 of 10

5 reporting all hazards, incidents and accidents to the supervisor in charge, safety officer or OHS Consultant/Manager/Advisor; complying with all occupational health and safety instructions; making proper use of all safety devices and personal protective equipment; not wilfully placing at risk the health and safety of any person at the workplace; maintaining dress standards appropriate for the work undertaken. 6. FORKLIFT TRUCK LICENCING AND TRAINING 6.1 LICENSING In accordance with Road Safety Act (1986), a FLT license is mandatory for the operation of a FLT. Licenses to perform high risk work can be obtained through WorkSafe Victoria. 6.2 TRAINING WITHOUT A CURRENT LICENSE However, if an individual is being trained, that person is permitted to operate a FLT without a license until such time that the person is competent enough to be assessed. The person operating the FLT must be in sight and sound of a licensed operator at all times. It is not acceptable that the licensed operator be in the vicinity of the area of operation. It is not deemed acceptable for a person to be in training indefinitely. 6.3 TRAINING BY INTERNAL OR EXTERNAL PROVIDERS Basic and specific job training is required every 2 years Basic training should be carried out by a suitably experienced instructor/s. The basic skills and knowledge required for safe operation should be covered in the training including: pre-operational checks; operational checks; load stability; traffic management If external training is provided during a year to the operator, internal basic training is not required Specific job training and knowledge of the university working environment and use of any special attachment required for the FLT operation Users are required to maintain a logbook of operational use. 6.4 AUTHORITY TO DRIVE Personnel are not allowed to operate a FLT without authorisation from their supervisor or manager via the Authority to Drive register An Authority to Drive register must be completed and records kept with the FLT for the life of the plant. Appendix TRAINING RECORDS FLT drivers are required to maintain a log book of training events including: external training; internal training; changes in workplace FLT environment training; hours of operation A record of forklift qualifications of operators is required to be kept by organisational units Training records are required to be kept for the life of the FLT. Page 5 of 10

6 7. CONTRACTORS AND HIRED FORKLIFT TRUCKS 7.1 CONTRACTORS Contractors on Monash University premises are required to comply with the forklift safety procedure or an industry equivalent. Contractors are also to comply with the document: Contractor OHS management at Monash University. 7.2 HIRED FORKLIFT TRUCKS ON MONASH UNIVERSITY PREMISES All hired forklifts must be mechanically maintained in a safe manner and evidence available upon inspection All hired forklifts should be fitted with safety devices including rotary flashing lights, horn, mirrors, and seatbelt restraint systems, reversing beepers All hired FLT must be placarded with safe working load capacity A SWMS must be completed prior to hiring a FLT to ensure the correct FLT is hired for the proposed job. 8. FORKLIFT TRUCK ATTACHMENTS When an attachment is fitted to a FLT the dynamic and operating characteristics may change, making it necessary to de-rate the FLT capacity and restrict some operating controls. 8.1 JIBS/EXTENSIONS/SIDE SHIFT DEVICES/DRUM HOLDERS 8.2 PLATFORMS Attachments such as side shift devices, jibs and extension forks must have rated capacities and information on the type of FLT that is suitable for use in connection with such attachments. The revised capacity when an attachment is used is to be endorsed on the load plate of the FLT. maintenance work platforms with a meshed in work area securely attached to the forks can be used to raise people performing minor maintenance tasks. platforms should not be used by workers who have not completed the necessary safety training. These platforms should only be attached to a complying designated forklift with a load capacity data plate stating attachments that may be used. To use a forklift with a maintenance work platform it must have tilt levers locked out and restricting hydraulic valves fitted. order picking platforms must have guard rails to prevent falls. If it is possible for a person to extend their body over the guard or step from the platform, then a safety harness should be provided and worn. The harness must be attached to a strong anchor point. Risk assessment should be performed to determine the type of travel restraint system or fall prevention system suited to the activity and workplace environment. before anyone is raised on a forklift, safe work procedures must be in place to ensure they can be rescued if an incident or breakdown occurs. 9. MAINTAINANCE OF FORKLIFT TRUCKS FLT can only be maintained by duly trained and authorised maintainers Each FLT will be the subject of a routine maintenance programme The maintenance will be to the manufacturers recommendations The maintenance of each FLT must be recorded Daily & weekly maintenance checks must be carried out on the FLT There should be a thorough examination and test of the FLT on an annual Page 6 of 10

7 basis. A certificate should be issued by the examiner to the effect that the FLT is safe to use. 9.2 DAILY CHECKS (PRE-OPERATIONAL AND OPERATIONAL) Daily checks are required prior to the first operation of the day Pre-operational and operational checks. Before use, the FLT must be subject to a visual and operational check using the prestart checklist or equivalent. (See section 15: Tools) The pre-start checklist must be completed and signed-off by the first person using the vehicle on a particular day. All problems must be recorded on the pre-start checklist. The specific issue must be recorded on the reverse of the pre-work checklist When the pre-start check has been completed the card is placed into its holder. It is the manager s/supervisors responsibility to ensure that problems noted during the pre-work check are scheduled for repair and that serious problems are repaired before the truck is used again. Pre-start inspection worksheets must be retained and kept for a period of one year for reference and audit purposes in the event of an incident. These should be kept with the FLT. 9.3 ISOLATION OF FAULTY FORKLIFT TRUCKS If a problem is detected, i.e. damaged forks, pins or overhead guard, faulty horn or hand or foot brake, the FLT must not be used. The FLT must be tagged out until the issue is rectified in accordance with the Monash isolation procedures; Procedures for the isolation of machinery/equipment. 9.4 BI-ANNUAL OPERATIONAL MANAGERS/SUPERVISORS WORKPLACE INSPECTION 10. LOAD CAPACITIES A bi-annual FLT operational workplace inspection is required to be carried out to ensure the safe operation and workplace safety controls are effective. The FLT workplace operational workplace inspection template is available in Appendix The bi-annual FLT workplace inspection must be carried out with a minimum of 2 people including the manager and a current licensed forklift operator with a recommendation of including a Health and Safety Representative if one is currently within the Designated Work Group Operational workplace inspections must be recorded and maintained for the life of the FLT to show evidence of safe work practices in the event an incident occurs. Like heavy vehicles, FLT are dangerous and should be considered hazardous when not operated correctly. Even when travelling at low or restricted speeds, FLT have the potential to cause serious injuries, and when fully laden the risk is even greater. 9.1 PLACARDING FLT must be placarded with load capacity ratings and these weights must not be exceeded. Marked weight, a weight gauge or scale can be used to weigh loads and ensure operators do not exceed the FLT capacity at a given load centre MOVEMENT OF LOADS During FLT movements between locations the tines must be lowered as low as possible but not interfere with the operation of the FLT. FLT operators must ensure each load is carried, lowered and set down in Page 7 of 10

8 compliance with the manufacturer s recommendations The mast of the FLT must be tilted rearward during FLT movements UNBALANCED OR OBSCURED LOADS A SWMS or equivalent must be conducted prior to moving an obscured or unbalanced load. Controls such as tie down straps and stabiliser ropes should be considered. Consideration should be given if a FLT is appropriate for the task and this should be reflected in the SWMS. 11. SAFE OPERATION OF FORKLIFTS 11.1 SEATBELTS AND ENTRY All forklifts operated in Monash University should be fitted with a seatbelt restraint device. A properly adjusted seatbelt will keep you safely in the cabin during an overturn. three points of contact should be used when entering and exiting FLT 11.2 PERSONAL PROTECTIVE EQUIPMENT high visibility vests must be worn when operating a FLT steel capped shoes must be worn when operating a FLT 11.3 PASSENGERS Most forklifts are one person vehicles, and unless an additional seat, footrest and seatbelt is available, passengers must not ride on the forklift No person shall ride on the tines of a FLT. 12. TRAFFIC MANAGEMENT A traffic management plan is essential to address the risk associated with FLT use in the university environment. The traffic management plan is required to meet procedural and legal obligations to ensure separation of FLT and pedestrians/workers, therefore reducing the risk associated with FLT injuries FORKLIFT TRUCK TRAFFIC MANAGEMENT MAPS FLT traffic plans should include the following if applicable; o FLT zones o Pedestrian exclusion zones o Safety driver/observer zones o Controls in place i.e. barriers, mirrors, sirens, strobe lights, signage o FLT parking zones 12.2 TRAVEL ON GAZETTED ROADS FLT must not be on a gazetted road unless registered with appropriate Australian authorities. FLT must be accompanied by at least two lollipop operators in high visibility vests at, at least 10m before and after the vehicle during movement on Monash University gazetted roadways as outlined in a SWMS or equivalent PEDESTRIAN EXCLUSION Every attempt should be made to segregate pedestrians/workers from FLT activities. This may be done with the use of permanent exclusion barriers and tensile barriers. Line marking is not considered an appropriate control for pedestrian/worker exclusion SAFETY DRIVER ZONES Driver safety zones are essential to ensure the safety of delivery drivers Delivery driver barrier exclusion Page 8 of 10

9 permanent barriers are required if drivers oversee forklift activities external to the delivery vehicle. permanent barriers must be of a solid construction to ensure penetration of the barrier by the FLT does not occur tensile barriers are not to be used as barrier exclusion for delivery drivers Delivery driver exclusion without barriers 13. INCIDENT REPORTING Drivers that have exited the delivery vehicle must not observe operations of a FLT outside of the vehicle unless they are within a permanent barrier system or a designated waiting area within a building complex. Before commencement of the FLT activity, the staff member in charge must be familiar with the Monash University Procedures for hazard and incident reporting, investigation and recording. All hazards & incidents that cause or have the potential to cause physical or psychological injuries or illnesses or serious property damage must be reported. A hazard and incident report must be used to report all hazards and incidents. The supervisor of the group, the staff member in charge of the FLT activity must undertake an investigation of the incident on site and assist with the completion of the hazard and incident report. A thorough investigation of the immediate and underlying causes of an incident is essential to prevent a recurrence. The results of the investigation following an incident must be incorporated into the next review of the risk assessment of the FLT activity FORKLIFT COLLISIONS WITH STRUCTURES 14. RECORDS unintentional collisions with structures should be considered an incident and reported intentional bumping of objects to aid movement is not considered an incident. Record to be kept by Records To be kept for: Academic/administrative unit FLT daily checklists Biannual operational managers/supervisors workplace inspection 1 year Life of FLT FLT licence details Life of license Maintenance Life of FLT Registration Life of FLT Risk assessments Staff Development Unit OHS training records of training provided by unit including: Attendees Short description of training content OHS training records of training provided by unit including: Attendees Short description of training content 7 years, or for as long as the staff member is employed 3 years or until reviewed 7 years Page 9 of 10

10 15. TOOLS The following tools are associated with this procedure. Forklift pre-start checklist Authority to drive Bi-annual operational managers/supervisors workplace inspection Forklift truck training log book 16. REFERENCES 16.1 LEGISLATION Occupational Health and Safety Act 2004 (Vic) 16.2 MONASH UNIVERSITY OHS DOCUMENTS Monash University documents are available from the Monash Occupational Health & Safety web site (http://www.monash.edu/ohs/). Procedures for the isolation of machinery/equipment Hazard & incident reporting, investigation & recording procedure Contractor management at Monash University Guidelines for the development of safe work instructions Guidelines for the identification of areas requiring hazardous or regulatory signage Guidelines for safe work instructions Topics: Machine and equipment safety, workshop safety Topics: Use of signage for machine and equipment safety Topics: Training in the safe use of machinery and equipment Information Sheet No. 19: Working Outdoors OHS management at Monash University: Structure, functions, roles and responsibilities OHS risk management at Monash University Risk Control Program Equipment safe work instructions OHS records management at Monash University 16.3 AUSTRALIAN AND INTERNATIONAL STANDARDS 16.4 OTHER AS/NZS 4801:2001 Occupational Health & Safety Management Systems specifications with guidance for use. OHSAS 18001:2007 Occupational Health & Safety Management Systems requirements. AS Gas fuel systems for forklifts and industrial systems AS Industrial trucks Inspection and repair of fork arms in service on fork-lift trucks A handbook for workplaces: forklift safety reducing the risk. Edition No.2 february Worksafe Victoria. George Rechnitzer, Tore J. Larsson. (1992) Forklift trucks and severe injuries: Priorities for prevention. August. Developing a traffic management plan. WorkSafe Victoria Page 10 of 10

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