‘
‘
Vehicle Safety
for Material Handling
Joint Health and Safety Training
Implementation Guidelines
Inventory Code: MH001PG
‘
‘
Vehicle Safety for
Material Handling
Implementation Guidelines
Inventory Code: MH001PG
UAW-GM
Vehicle Safety for Material Handling
Materials prepared by the
UAW-GM Center for Human Resources
Health and Safety Department
Copyright © 2009
UAW-GM Center for Human Resources
All Rights Reserved
No material in this book may be copied, reproduced,
or used in any way without written permission.
Implementation Guidelines
Table of Contents
Scope and Application........................................................................................ 1
Introduction.......................................................................................................... 2
Roles and Responsibilities................................................................................. 3
Training Requiremnts and Procedures ............................................................. 4
Reauthorization Training .................................................................................... 8
Pre-operation Inspection .................................................................................. 10
Basic Safety ....................................................................................................... 12
Tasks Covered by These Guidelines ............................................................... 15
Rail Car Safety ................................................................................................... 21
Truck Dock Equipment...................................................................................... 27
Aisle Guidelines................................................................................................. 31
i
UAW-GM
Vehicle Safety for Material Handling
ii
Implementation Guidelines
Scope and Application
This booklet is to provide guidelines for the implementation of the UAW-GM Vehicle Safety for
Material Handling program. The guidelines cover all the tasks and requirements needed to
obtain an operators permit for a powered industrial vehicle, also known as a PIV.
In order to prevent injury and to meet all training requirements the UAW and GM have agreed
to a program that will meet the requirements of the OSHA Standard 1910.178 and in some
cases exceed the OSHA Standard in order to better protect our employees.
The major elements of these guidelines are:
•
Roles and Responsibilities
•
Training Requirements Procedures
•
Supplemental/Refresher Training
•
Pre-operation Inspection and Maintenance
•
Controls and Functions
•
Basic Safety and Refueling
•
Material Handling
•
Railcar Safety
•
Dock Safety
•
Aisle Guidelines
1
UAW-GM
Vehicle Safety for Material Handling
Introduction
The UAW and General Motors have discussed their mutual concerns regarding powered
industrial vehicle safety. The UAW and General Motors agree that a Vehicle Safety for Material
Handling Program needs to be implemented to ensure the safety of all of their employees.
It is the employee’s right and responsibility to receive all required training to follow established
local policies and to seek the advice of local leadership in the event of a situation in which the
employee believes the policy is being violated. All Training must meet both the UAW-GM and
OSHA Standard 1910.178 for requirements and content.
2
Implementation Guidelines
Roles and Responsibilities
It is the responsibility of management to oversee implementation of the Vehicle Safety for
Material Handling program. The Plant Safety Review Board will monitor the implementation of
this program.
The PSRB (Plant Safety Review Board) shall:
•
Review with the Local Joint Health and Safety Committee (LJHSC) the implementation of
this program.
•
Commit adequate resources so that all elements of this program are implemented
The LJHSC (Local Joint Health and Safety Committee) shall:
•
Ensure that all appropriate people receive the required training and refresher training
•
Ensure all PIV’s are included in a proper preventative maintenance schedule.
•
Collect and disseminate information regarding injuries and/or incidents pertaining to this
program to be used for heightening the awareness of all appropriate employees.
Vehicle Operators
•
&RPSOHWHWKHUHTXLUHGHTXLSPHQWVSHFL¿FWUDLQLQJLQFOXGLQJSK\VLFDOH[DPHYDOXDWLRQ
SDVVDZULWWHQRURUDOH[DPDQGSDVVDKDQGVRQWUDLQLQJWKDWLVYHKLFOHVSHFL¿F
•
Maintain a valid operators permit on their person whenever operating a vehicle.
•
Follow all local plant safety policies and driving rules
•
Report any unsafe conditions, near misses, and any incidents to his/her supervisor
immediately.
•
Do not operate a vehicle if your ability is impaired due to health, medication, or other
reasons.
3
UAW-GM
Vehicle Safety for Material Handling
Training Requirements and
Procedures
1. Types of PIV’s
a. Sit down counterbalance
b. Stand up counterbalance
c. Hand walkie (powered hand walkie)
d. Order selector
e. Reach
f. Tugger
g. Burden Carrier
1) PIV’s must only be operated by designated person such as:
a) Operators
b) Maintenance and test personnel
c) Trainees under direct supervision of a designated person in a training
environment (designated person must have a valid operators permit).
2. Authorization Requirements
a. Authorization requirements for frontline supervisors.
1) Supervisors of PIV operators must attend the Vehicle Safety for Material
Handling program following the plants receiving the training from the UAWGM CHR Health and Safety Department.
b. Authorization requirements for PIV operators, prior to being authorized, state a PIV
HPSOR\HHPXVW¿UVW
1) Pass a medical exam.
2) Attend the Vehicle Safety for Material Handling Program.
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4
Implementation Guidelines
4) Pass written or oral exam.
D 7KHZULWWHQRURUDOWHVWPXVWEHVSHFL¿FWRWKHW\SHRIYHKLFOHWKH
employee will operate.
9HKLFOHVSHFL¿FKDQGVRQWUDLQLQJLQDWUDLQLQJHQYLURQPHQW
a. Operational – drive the vehicle forward and reverse through the driving course
demonstrating safe operating procedures.
b. Transporting material – operator must demonstrate safe stacking, transporting, and
storing of materials.
c. Loading hoppers and drop bottom and solid bottom gons (if required) – operator
must load hoppers and solid and drop bottom gons while demonstrating proper safe
operating procedures.
d. Load/unload semi-trailers (if required) – operator must perform inspection of
trailer following safety procedures. Operator must load and unload trailer while
demonstrating safe operating procedures.
e. Load/unload railcars (if required) – operator must inspect, load, and unload railcar
using proper guidelines and safety procedures.
f. Enter/exit elevators (if required) – operator must inspect, enter, and exit elevator with
several loads that vary in weight following all safe operating guidelines.
6. An operator must be issued an operator permit
a. The permit MUST identify what types of vehicles the operator is authorized to
operate.
b. You must renew a permit every three (3) years by passing a medical exam AND a
UHFHUWL¿FDWLRQWUDLQLQJSURJUDP
5
UAW-GM
Vehicle Safety for Material Handling
Sample Permit
Front
Operators Permit
This is to certify
John Doe
is
authorized to operate a sit down
counter balance fork truck.
_______________________________________
Supervisor Signature
Approved
Back
x______________________________________________
Signature
Clock # _________________________________
Date of Issue:
_____________
Date of Expiration: _____________
Restrictions:
None
Corrective Glasses
This permit must be carried by employee during working
hours and presented on demand of safety department or a
member of management and may be revoked for violation
of safety rules.
6
Implementation Guidelines
Supplemental Training
Authorized operators will receive appropriate additional training whenever there is a change
in the local procedure or when new hazards are presented as a result of a change in job
assignments, a change of vehicle, or process with which they may not be familiar. If a change
of vehicle is required, the operator must be authorized to operate that vehicle. If an operator
LVQRWDXWKRUL]HGWRRSHUDWHWKDWVSHFL¿FYHKLFOHKHRUVKHPXVWJRWKURXJKWKHDXWKRUL]DWLRQ
process for that vehicle.
•
Pass a written or oral exam
•
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•
2-7VSHFL¿FWRYHKLFOHW\SHLQDZRUNLQJHQYLURQPHQW
7
UAW-GM
Vehicle Safety for Material Handling
Reauthorization Training
Each operator permit must be renewed every three years. The operator must pass a
UHFHUWL¿FDWLRQH[DPDQGGHPRQVWUDWHWKHVDIHXVHRIHDFKVSHFL¿FYHKLFOHWKH\ZLOOEH
authorized to operate in a training environment. Each employee must also receive a medical
H[DPEHIRUHWKH\FDQEHUHFHUWL¿HGWRRSHUDWHD3,9
Operator permits must be reviewed every three years. The proper procedure for renewing a
permit is as follows:
7KHRSHUDWRUPXVW¿UVWSDVVDPHGLFDOH[DPWKDWFRQVLVWVRIWKHIROORZLQJ
•
Depth perception
•
Vision
•
Reaction timing
•
Hearing
•
Blood pressure
•
Heart and lungs
•
Musculoskeletal
•
EKG (required for age 45 and above)
•
Any addition medical indication sustained from your medical history and/or the
results of your medical examination/evaluation.
•
Operators are entitled to an explanation of all testing to be done as well as an
explanation of all test results.
2. Operator attends PIV Reauthorization Training. The reauthorization training must be
conducted in the following order.
a. Student must perform a proper pre-operation inspection of each vehicle he/she is
to be authorized to operate.
b. Watch only the following PIV Safety Reauthorization DVD modules:
8
•
Permit and Handling
•
Basic Safety
•
Refueling Modules
Implementation Guidelines
c. Review Appendix C of the Vehicle Safety for Material Handling Reference Guide
for the difference in rear end swing between a car and a fork truck.
d. Hands on training of each vehicle the operators are renewing. Operators cannot
add any vehicle to their license in a reauthorization course. If they have not been
SUHYLRXVO\FHUWL¿HGWRRSHUDWHDYHKLFOHWKH\PXVWDWWHQGWKH9HKLFOH6DIHW\IRU
Material Handling for the at-risk-worker to add any additional vehicles to their
license. In order to renew currently licensed vehicles, they must conduct handson training in a training environment to include the following:
1) Operational – drive the vehicle forward and reverse through the driving
course demonstrating safe operating procedures.
2) Transporting material – operator must demonstrate safe stacking,
transporting, and storing of materials.
3) Loading hoppers and drop bottom and solid bottom gons (if required)
– operator must load hoppers and solid and drop bottom gons while
demonstrating proper safe operating procedures.
4) Load/unload semi-trailers (if required) – operator must perform inspection
of trailer following safety procedures. Operator must load and unload
trailer while demonstrating safe operating procedures.
5) Load/unload railcars (if required) – operator must inspect, load, and
unload railcar using proper guidelines and safety procedures.
6) Enter/exit elevators (if required) – operator must inspect, enter, and exit
elevator with several loads that vary in weight following all safe operating
guidelines.
If at anytime an operator fails to meet one of these requirements, they must repeat the training
exercise. If they fail a second time, they must re-attend the full Vehicle Safety for Material
Handling for the at-risk-worker. If an operators permit has expired and is past the six (6) month
grace period, they must also attend the Vehicle Safety for Material Handling At-Risk Work
course again.
9
UAW-GM
Vehicle Safety for Material Handling
Pre-operation Inspection
A pre-operation inspection MUST be preformed on every PIV by the operator during each
shift before being used to determine its condition. The pre-operation inspection must be
documented according to your facilities local policy. If the condition of any part of the PIV
is questionable, the PIV must not be used and must be properly tagged and scheduled for
repair. You must follow all manufacture recommendations when conducting a pre-operation
inspection. See owners manual for these recommendations and the Vehicle Safety for
Material Handling Reference Guide.
When inspecting the mast of a PIV look for:
•
Broken welds
•
Cracked or bent areas
•
Missing or worn stops
When inspecting lift chains and rollers look for:
•
Worn areas
•
Damage
•
Proper lubrication
When inspecting the forks look for:
•
•
•
Cracks or bent forks
Wear
Mismatched or different sized forks
When inspecting the overhead guard look for
•
Broken welds
•
Missing or loose bolts
•
Bent or worn areas
When inspecting the tires look for:
•
•
•
10
Large chunks of missing rubber
Loose rubber on the rim
Missing bolts or missing/loose lug nuts
Implementation Guidelines
When inspecting the steering mechanism look for:
•
Excessive play
•
Bending while turning
Test the accelerator pedal before turning the vehicle on. Depress the accelerator and release.
If it returns to the up position, it is working properly. If it does not, do not operate the vehicle.
Tag it and notify your supervisor. To check the seat break (where applicable), sit on the seat,
turn the vehicle on, and put the vehicle in gear. Rise up off the seat enough to allow the
seat to move forward. You should hear the vehicle shut off. If not, tag the vehicle and notify
your supervisor. To check the parking brake, set the brake and put the vehicle in gear. If the
vehicle moves, tag the vehicle and notify your supervisor.
When inspecting the lift controls, raise the forks up to capacity and let them sit for several
minutes. If they begin to drift down, this indicates a hydraulic leak or malfunction. When
testing the tilt cylinder, if the mast twists or returns unevenly, tag the vehicle and notify your
supervisor.
When inspecting the seat and seat belt:
•
Check the seat for adjustment and make sure it is secure.
•
Be sure the seat belt latches securely.
•
Make sure the belt will extend and retract smoothly.
•
Check the belt for cuts, frays, and tears.
,QVSHFWDOORIWKHYHKLFOHVÀXLGOHYHOVDQGEHVXUHWKH\DUHDWWKHDSSURSULDWHOHYHOV,IDWDQ\
time a vehicle does not pass inspection, tag the vehicle and notify your supervisor.
You must follow all pre-operation inspections recommended by the manufacturer. These
recommendations can be found in the owner’s manual. The UAW-GM policy is every PIV must
have an owner’s manual on the vehicle at all times.
Basic Safety/Material Handling:
Make sure operators follow all the basic safety rules set forth by both UAW-GM and OSHA
Standard 1910.178. No person shall refuel a PIV unless properly trained and they have the
appropriate personal protection equipment. Operators must also follow all basic safety rules
set by your local joint health and safety committee.
When ever you operate a PIV you must do a proper hazard analysis. Make sure to identify
any hazards or obstructions in you path of travel. Remember hazards are three dimensional
±FKHFNWKHÀRRUFHLOLQJDQGZDOOV,GHQWLI\DQ\KD]DUGRXVPDWHULDO\RXPD\EHUHTXLUHGWR
transport or come into contact with. Material Safety Data Sheets must be available for all
materials in the plant.
11
UAW-GM
Vehicle Safety for Material Handling
Basic Safety
Basic Safety
Forks
Adjust the forks before picking up a load. Proper fork adjustment will increase load stability. To
adjust the forks:
5DLVHWKHIRUNVRIIWKHÀRRU
2. Release the fork lock
3. Slide forks in desired direction
4. Lock the fork lock
5. Use caution and beware of pinch points
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Handling the Load
Never raise or lower a load while driving – it will reduce visibility and stability of the vehicle.
'RQRWKDQGOHORRVHRUXQVWDEOHORDGV%HDZDUHRIRYHUKHDGREVWUXFWLRQV%HDZDUHRIÀRRU
FRQGLWLRQVDQGPDNHVXUHWKHUHDUHQRRLOVSLOOVZHWVSRWVRUFUDFNVLQWKHÀRRU%HVXUHWR
leave at least a three vehicle lengths to allow a safe stopping distance.
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•
Keep to the right side of the aisle/road
•
Stop at all intersections
•
2EH\DOOWUDI¿FVLJQV
•
Never allow pedestrians between your vehicle and other objects
•
Always use your horn to alert pedestrians.
12
Implementation Guidelines
When Parking A Vehicle
•
5HVWWKHIRUNVÀDWRQWKHÀRRU
•
Turn the ignition to the off position
•
Set the parking brake
•
Make sure the vehicle is not blocking any aisles or doors.
Material Handling
When doing a hazard analysis, it is the driver’s responsibility to inspect the following areas,
where applicable:
•
Work area
•
Route of travel
•
Visibility check for the following:
•
Hazards and obstructions
•
Overhead and width clearance
•
3HGHVWULDQWUDI¿F
•
Environmental condition
•
Structural capacity
•
Pinch points
•
Equipment under pressure
•
3LWVRUXQHYHQÀRRULQJ
•
Picking up a Load with a Fork Truck
•
13
UAW-GM
Vehicle Safety for Material Handling
Picking Up A Load with A Fork Truck
1. Square the truck with the load.
2. Adjust the forks to the width of the container and drive forward until the forks are under the
load.
3. If there are containers behind the one you are moving, be careful not to insert the forks
beyond the container being picked up.
4. Position the load so it is centered and rests against the carriage of the truck.
/LIWDQGWLOWDQGORDGVRLWFOHDUVWKHÀRRU
Stacking Procedures
1. Square the load and raise it to the proper height for stacking
2. Drive the load into position and line up the stacking pins with the container below.
/RZHUWKHORDGVORZO\LQWRSRVLWLRQ0DNHVXUHDOOWKHSLQV¿WLQWRWKHRSHQLQJVSURYLGHGRQ
the container below.
4. Lower the forks and signal to bystanders.
5. Look in the direction of travel and back out from under the load.
6. Stop and lower the forks to the proper travel height.
Ramps and Inclines
Traveling on a ramp or incline changes the stability of your truck. Following the safety
guidelines listed below will assist in the safe operation of a fork truck on a ramp or an incline.
14
•
Proceed slowly when traveling on a ramp.
•
Always drive with the load upgrade.
•
Have a clear line of vision.
•
/LIWDQGWLOWWKHIRUNVWRFOHDUÀRRUREVWUXFWLRQV
•
Use the horn to signal pedestrians of your approach.
•
Use a signal person if a clear line of vision is impossible.
•
Never turn on a ramp; turning on a ramp reduces fork truck stability.
Implementation Guidelines
Tasks Covered by
These Guidelines
Service/Maintenance
If any part of a PIV does not pass a pre-operation inspection it MUST NOT be used. Tag
the vehicle with a DO NOT USE tag and notify your supervisor to set up maintenance on the
vehicle. The vehicle must remain out of service until service is complete and it passes a preoperation inspection.
Controls and Functions
The controls and functions of every PIV may vary. It is important that the operator know and
understand how they operate. The trainer must demonstrate to all trainees how to properly
operate all controls and functions of a PIV. The trainer must give a demonstration of all hands
on exercises to be performed by the trainees in accordance with OSHA Standard 1910.1778.
If at anytime any of the controls or functions of a PIV are not in proper working order take the
PIV out of service immediately. Tag the PIV for repair and notify the supervisor to schedule
maintenance on the PIV.
Minimum Requirements for
Orange Crush Zones
•
Each facility should evaluate the need for establishing Orange Crush Zones for all material
KDQGOLQJKLJKWUDI¿FDUHDVDVGHWHUPLQHGE\SODQW3HGHVWULDQ9HKLFOH&RPPLWWHHV7KHVH
2UDQJH&UXVK=RQHVZLOOEHLGHQWL¿HGE\YLVLEOHERXQGDULHVDVGHVFULEHGEHORZ
•
$ZULWWHQSURFHGXUHVKDOOEHFUHDWHGWKDWLQFOXGHVWKHVSHFL¿FUHTXLUHPHQWVRIWKLVSUDFWLFH
This procedure shall be reviewed with all employees to ensure understanding (see
page 17 for an example).
15
UAW-GM
Vehicle Safety for Material Handling
•
Each plant must determine the most appropriate method for identifying an Orange Crush
Zone. The most common method is a highly visible (nominally 4-inch wide) orange (GMS
³6DIHW\2UDQJH´RUHTXLYDOHQWVWULSHSDLQWHGRQWKHÀRRUWRLGHQWLI\WKHERXQGDU\RI
each Orange Crush Zone. The orange stripe outlines the perimeter of each designated
zone. Barriers or painted columns may be used in conjunction with the orange stripe or
VHSDUDWHO\WRLGHQWLI\D]RQHSURYLGHGWKHPHWKRGFKRVHQDGHTXDWHO\DQGFOHDUO\LGHQWL¿HV
the zone.
•
Signs shall be prominently placed throughout the area to warn unauthorized persons from
entering an Orange Crush Zone (see page 18 for example signs).
•
Only authorized personnel shall be allowed in an Orange Crush zone,
•
$OOSHUVRQQHOZKRUHFHLYHSHUPLVVLRQWRHQWHUDQ2UDQJH&UXVK]RQHVKDOOEHLGHQWL¿HG
by appropriate highly visible clothing/device, such as a vest, when inside the zone. These
persons shall be instructed on the safety procedures as they apply inside the zone.
•
Implementation of this practice shall be coordinated with the plant Pedestrian Vehicle
Committee.
Plant Options
Communications
The method for communicating the procedures and potential hazards in the zones to
authorized personnel can be determined by the plant.
Enhanced Awareness
•
:DUQLQJV\PEROVRUGHFDOVPD\EHSDLQWHGRQWKHÀRRURUFROXPQV
•
Columns outlining the perimeter of the Orange Crush Zone may be painted orange.
•
Barriers may also be used to enhance awareness.
•
Assigned drivers in Orange Crush Zones may also be required to wear highly visible vest
when inside these zones.
16
Implementation Guidelines
Example — Safety Procedure for Orange Crush Zones
2UDQJH&UXVK=RQHVDUHDUHDVLQWKHSODQWWKDWKDYHKLJKYHKLFOHWUDI¿FDQGSUHVHQWD
VLJQL¿FDQWULVNWRSHGHVWULDQV7KHULVNRIDSHGHVWULDQJHWWLQJDVHULRXVFUXVKLQJLQMXU\LQ
WKHVHDUHDVLVVLJQL¿FDQW$VDUHVXOWRQO\DXWKRUL]HGHPSOR\HHVDUHDOORZHGLQ2UDQJH
Crush Zones.
2. Only authorized personnel are to be inside the perimeter of these areas. Vendor
representatives and non-material plant personnel are required to check in with the material
supervisor or an appointed designee in order to be accompanied inside these areas.
3. The material supervisor or appointed designee will notify all affected material personnel in
the area about the presence and location of any vendor representatives or non-materials
personnel working in the zone.
7KHYHQGRUUHSUHVHQWDWLYHVDUHDOVRUHTXLUHGWRZHDUÀXRUHVFHQWYHVWVZKLOHZRUNLQJLQWKH
plant for greater visibility and recognition by plant personnel.
$OO2UDQJH&UXVK=RQHVZLOOEHRXWOLQHGZLWKDQRUDQJHVWULSHSDLQWHGRQWKHÀRRU
6. The area will also be posted with warning signs.
7. Contact the Safety Department for additional information as needed.
17
UAW-GM
Vehicle Safety for Material Handling
Labels for Orange Crush Zones
WARNING
BEWARE
OF THE...
“ORANGE CRUSH ZONES”
Pedestrians and
Unauthorized Vehicles Are
NOT Permitted in
Banks and on Docks
This Includes
ALL Areas Marked with
Orange Lines.
“Orange Crush” Zones
18
Implementation Guidelines
Equipment Requirements:
•
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performance of any safety device, may only be performed after obtaining written approval
from the vehicle manufacturer and/or lessor.
•
Vehicle nameplates and lift capabilities must be maintained to insure that they are both
legible and visible to the operator. Capacities shall be marked on overhead guards.
•
Fork trucks must be equipped with approved overhead guards.
•
Powered industrial vehicle restraint system (seat belts) – must be worn at all times when
operating a vehicle (when applicable).
•
GMNA Common visibility warning lights will be installed on all newly acquired equipment.
All fork trucks that do not currently have GM Common lighting on their fork trucks should be
equipped with a safety awareness device. It is required that trucks without any awareness
GHYLFHEHUHWUR¿WWHGLQDFFRUGDQFHZLWKWKHVSHFL¿FDWLRQV
•
Mirrors on fork trucks are prohibited, unless equipped from the manufacturer.
Pedestrian Safety Awareness
It is recommended that the following guidelines be covered with all your employees on
an annual basis to provide safety awareness for both pedestrians and mobile equipment
operators, to reduce the possibility of pedestrian / vehicle collisions. This can be accomplished
in a variety of ways, examples might be:
1. Safety contacts
2. Safety talks
3. Department meetings
19
UAW-GM
Vehicle Safety for Material Handling
Guidelines
•
Never assume that a mobile equipment operator can see you.
•
Always use pedestrian walkways when available.
– Lines designate pedestrian walkways.
– When walkways are not designated, always stay to the right.
•
Obey all posted signs:
– Stop signs at intersections.
– “Do Not Enter” signs, dock signs warning pedestrians to stay out. etc.
•
Always STOPDQGORRNIRUWUDI¿FBEFORE entering aisles.
•
Never assume that a vehicle will be brought to a stop.
•
Always rely on your VISION, not your ability to hear.
•
Make eye contact with the mobile equipment operator.
•
Where possible, communicate with the mobile equipment operator (wait for the wave).
•
Keep all parts of your body clear of the mobile equipment at all times.
– Especially if you have been conversing with the driver of a stopped vehicle and he is
departing,
•
Be aware of mobile equipment not only hauling material, but also trailering material.
•
Finally, WALK DEFENSIVELY!
– Stay attentive.
– Always look where you are going.
– Never read material while you are walking.
– Avoid cell phone use in areas of mobile equipment
20
Implementation Guidelines
Rail Car Safety
I. Inspection Prior To Opening or Closing All Rail Car Doors
A. All railcar doors will be visually checked for defects prior to attempting to open or close.
This check is to be done by those trained and authorized to inspect rail car doors. A
B.O.S.S. device/shark cage must be installed before attempting to open any rail car
door. When using a B.O.S.S. device, a minimum of two employees are required at all
times.
1. Door track - bottom
a. Straight and smooth
b. Track- brackets free of damage and all brackets in place
2. Door rollers - bottom
a. Properly mounted on track with bottom retainers free of defects and mounted to
roll freely down the track
3. Door rollers and guides - top
a. Properly engaged, free of defects and aligned to roll freely down the track
4. Top retainer - door-track
a. Straight, free of defects or damage
b. Top safety hangers, if provided, must be engaged and free of defects
5. Door
a. Free of structural damage
b. Ensure guides and components are intact
c. Check for bowed conditions
6. Front and rear stops
a. In place, secure and free of damage.
21
UAW-GM
Vehicle Safety for Material Handling
% 3OXJW\SHGRRUV,QDGGLWLRQWRWKHDERYH,$LQVWUXFWLRQVWKHIROORZLQJVSHFL¿FLWHPV
should be inspected:
7RSFUDQNVLQFOXGLQJWKHFHQWHUVDIHW\FUDQNPXVWEHVXI¿FLHQWO\HQJDJHGWR
support the door when “canmed” out. The cam roller should not be visible, or should
be barely visible below the edge of the channel.
2. Bottom cranks must be straight and damage free. Adjusting screw must be locked
securely.
3. Vertical rods and supports must be straight and damage free.
4. Locking mechanisms must be engaged and damage free.
& 6OLGHUROOLQJW\SHGRRUV,QDGGLWLRQWRWKHDERYH,$LQVWUXFWLRQVWKHIROORZLQJVSHFL¿F
items should be inspected:
1. Door latches must be engaged and damage free
2. Roller mechanism must be damage free. For top hung doors, upper trolled channel
must be secure and damage free.
D. Door pull brackets or mechanical door opening hardware must be secure and damage
free.
II. Car door opening and closing procedure
A. General operating instructions - If the visual check indicates no defects, and the car is
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E\KDQG,IFDUVDUHHTXLSSHGZLWK¿[HGPHFKDQLFDOGRRURSHQHUVWKLVGHYLFHLVWREH
used. Caution should be used during operation to assure that upper and lower slides
and runners maintain their position.
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the car next to the door. The purpose of this inspection is to determine whether there
is any material condition (shifting of load / product) which may make further opening
of the door unsafe.
2. Never take a position during door movement in which you could be struck by a falling
car door. Always have a clear route to safety. Assure that other personnel are clear
before opening, or closing a rail car door.
3. Carefully observe any actions during door movement that indicate the door could
fall.
22
Implementation Guidelines
4. Any damage to hasp and pin area of door locking device or any damage to door that
would cause door to be improperly latched or cause improper securing of security
seals must be so noted and reported to the serving railroad.
B. Unique operating Instructions - various types of doors
1. Slide — rolling doors
a. Doors must be opened initially with door mounted door opener or a pry bar, then
pushed by hand, taking care that the employee opening the door is positioned at
door edge opposite the direction of the travel.
b. Caution - pulling on the door could result in back injury.
2. Plug type door
a. Prior to taking a position in front of this door to unlock or cam it out, substantial is
to be placed in front of the door in the event the door falls. A heavy material rack
or forklift truck properly positioned can provide additional protection should the
door fall.
b. The above does not apply when plug-type doors are opened from track.
c. While unlocking and camping, observe the action of the door. If it appears to drop
down or move out excessively, check the upper and lower crank arms to assure
WKDWWKH\DUHVXI¿FLHQWO\HQJDJHG
d. Using both hands, move the handle back and forth. Then unlock the opening
handle and crank open slowly, checking for material that might be resting against
the door. Handle may be under pressure to spin open, if something inside is
pushing on the door.
e. Once cammed out, the door should then be pushed by hand with the door
positioned ahead of the person opening it, i.e., the person pushing the door
should not be alongside the door, in case it falls.
f. Where possible, plug-type doors can also be opened from inside the car after a
visual inspection from the outside.
23
UAW-GM
Vehicle Safety for Material Handling
3. Camel type doors
a. Prior to taking a position in front of this type door to rotate the center door lift
lever, a shark cage is to be placed in front of the door in the event the door falls.
While raising the door on its trolleys, the action of the door should be observed.
Check the upper guides and secure the center door lift lever in the lift position
before moving the door. Vise-grip pliers or a “c” clamp may be used for this
purpose.
b. Push the door by hand as indicated above.
C. Inoperable car doors:
1. If a door cannot be manually opened by means outlined above in Section II.B, the
railroad should be contacted to open the door. If railroad assistance is not available,
DQGWKHUDLOFDUGRRUPXVWEHRSHQHGLPPHGLDWHO\TXDOL¿HGSODQWSHUVRQQHOPD\
proceed to open the door using the following guidelines.
2. For doors which cannot be manually opened by the means outlined above (see II.B),
and after all prudent steps have been taken to open doors without excessive force,
an approved device may be employed.
a. Mechanical devices should place the operator adjacent to the car wall, but not in
the area of the opening door. Operators, if at all possible, are to work from dock
level and not in the track wells or adjacent to doors as they open.
b. The use of such a device denotes a heavily damaged door and requires that a
member of supervision be present when door opening takes place.
c. In no case should devices be used without being approved by the appropriate
plant personnel
d. Mechanical devices may be used as long as the chains, ropes or cables push or
pull parallel to the movement of the car.
e. These devices should not exceed 3000 pounds of pull or push (force) on the
door. The mechanical device should have automatic cutouts that limit the force
applied.
f. Safety hooks for each application should be approved.
g. Maintenance and inspection of the above devices and their use within the
guidelines of this program are to be approved by appropriate plant personnel.
24
Implementation Guidelines
3. Fork tines are never to be used on rail car doors.
4. Fork trucks with or without an approved attachment are never to be used on plug
type doors due to the ease with-which damage can be done to the cams.
5. Car doors that are not hand operable will be reported and may necessitate being
shipped for repair. (The objective is to eventually have all railroad car doors
maintained for hand opening).
D. Closing of car doors:
1. Doors to he closed prior to the release of a car should again be visually checked for
damage. The reverse methods of opening are recommended for closing all doors.
2. Upon closing of door, the latch and pin device must be properly seated and the
security seal attached in a satisfactory manner. On plug type doors the vertical and
horizontal-locking bars must be engaged. If the latch and pin or locking bars cannot
EHVHFXUHGDQGWKHVHDOSURSHUO\DI¿[HGDQGWKLVFRQGLWLRQZDVQRWQRWHGXSRQ
placement of the car, then it should be reported to appropriate personnel and noted
in the dock supervisors seal book.
E. Railroad assistance:
,QVRPHFDVHVLWPD\EHSUXGHQWWRVHHNWKHDVVLVWDQFHRITXDOL¿HGUDLOURDG
personnel to aid in the opening/closing of railcar doors or the movement of
bulkheads.
2. For example, where the above mentioned cables, chains, etc., are obviously
inadequate for safe opening, the car should be left untouched, and the local rail yard
requested to provide trained personnel to open the car to allow its contents to be
safely removed.
3. Depending on the type and severity of the problems found, the car could be placed
in Bad Order Status to ensure repairs are made prior to further use.
4. The serving railroad or pool operator (origin railroad) is responsible to ensure that
door conditions are corrected.
25
UAW-GM
Vehicle Safety for Material Handling
III. Reporting damage and subsequent action
A. Cars in a damaged/unsafe condition
7KHUDLOURDGLVWREHQRWL¿HGSULRUWRUHOHDVHIURPVKLSSLQJSODQW7KHVZLWFKOLVWPXVW
note the type and location of damage
2. If the car is loaded with return racks or product, this should be included as necessary
LQIRUPDWLRQLQWKHQRWL¿FDWLRQVRWKHFDUFDQEHVSRWWHGXQORDGHGDQGLQVSHFWHGE\
the assigned plant before return to the local railroad for proper maintenance.
3. All incidents of failing railcar doors are to be reported to the plant safety activity.
A written incident report should- also be forwarded to the local railroad for proper
maintenance.
IV. Door maintenance
A. Frequency of maintenance:
1. The plant to which the cars are assigned must arrange for a systematic program to
lubricate the operating mechanism of all doors on assigned railroad cars. Such a
program should be ongoing and must provide for lubrication of all rail car doors in
DFFRUGDQFHZLWKDVVRFLDWLRQRI$PHULFDQ5DLOURDG6SHFL¿FDWLRQVRQDURXWLQHEDVLV
Time between lubrications should not exceed six (6) months.
B. Sliding type doors:
1. The following items must be lubricated:
a. Door tracks
b. Mouse and other stops, latch and hold open devices
c. Lock mechanism
26
Implementation Guidelines
Truck Dock Equipment
Restraint Systems
'H¿QLWLRQ7KHVHare devices utilized to prevent trailers from unexpected movements
away from the dock. There are primarily two major approaches to preventing movement of
trailers, (1) placement of barriers in front of wheels to hold back a trailer (i.e., wheel chocks
– manual or automated); and (2) holding a trailer by a mechanical means that is attached to a
point on the dock. (i.e., ICC bar [RIG] restraint systems, also called “dock locks”).
1. Wheel Chocks - (Method 1)
•
Manual Chocks - While meeting current Federal Government standards, use of manual
chocks presents some special considerations. First, if highway trailer designed chocks
(10”-12” mm, height) are not purchased, they can be easily driven over in a pull-away
situation. Surface conditions (wet, icy, slope, surface material, etc.) can also determine
the overall effectiveness of chocks. Chocks require someone to physically place the
devices in proper position, as they can easily be improperly placed. They also do not
provide communications between dock personnel and truckers, and they can be easily
damaged, misplaced or stolen, Because of the above issues, these devices are the
least effective method of restraining a trailer,
If manual chocks are the primary means of restraint, the local facility should
review their SOP’s covering the restraint procedure. Topics to be considered
might be:
•
Chock placement responsibility
•
Performance monitoring
•
Near miss reporting systems are in place and monitored
2. Automated Wheel Chocks - These are devices that restrain the trailer by holding the
wheels in place. They are normally moved into position by a system utilizing hydraulics
RUDLUSUHVVXUH7KH\FDQEHVXUIDFHPRXQWHGWRWKHÀRRUSLWPRXQWHGLQWRWKHÀRRURU
incorporated into a truck leveler. Issues involved in these systems again are the chock
height, exposure to weather, and maintenance. Note: Interpretation from OSHA allows for
only one wheel to be restrained by these type systems.
27
UAW-GM
Vehicle Safety for Material Handling
3. “ICC Bar Restraint” also called “Rear Impact-Guard “(RIG) or “Dock Lock” (Method 2)
(System whereby the trailer is held by the restraint to the dock from movement.) By design,
some hold back systems are more effective than others. These systems utilize the I.C.C.
bar to hold the trailer, they are dependent on trailers having their bars in good condition
and at proper heights, and they also cannot differentiate between an I.C.C. bar and any
other device under the truck, i.e., license plate. During some type of loading conditions,
it is possible that the locking system can lose contact and thus allow the trailer to move
away from the dock. Including these systems in the facility preventative maintenance (PM)
program is strongly recommended because of the safety systems involved and required for
proper operation.
Other Dock Safety Equipment
Nose Jacks – These devices are utilized to prevent trailers from tipping over or collapsing in
case of landing gear failure. Jacks, have historically been used in pairs; one at each corner
of the trailer at the nose end. With today’s trailers, nose jacks used under the front corners
must be carefully placed to insure that they do not line up with access holes used for repairs
on trailers. Using two jacks also requires careful adjustment of height. Both jacks must be
adjusted to the same height (Slight contact is recommended but within 1” is required)
Recently, a larger and differently designed jack has been introduced. This new jack is designed
WREHXVHGE\SODFLQJLWXQGHUWKHIURQWFHQWHU¿IWKZKHHODUHDRQDWUDLOHU7KLVMDFNKDV
a large horizontal bar across its top and also requires careful placement on the trailer, both
in location (centered) and height (see above). A single jack should not be used if there is an
observed threat of trailer dolly wheel failure and collapse. In this case, jacks should be used in
pairs.
Trailer Levelers (Truck Levelers) – Because of the many different trailer heights, many
docks require a device to adjust the height of the trailer to the dock. This is an important safety
feature because moving a load across an uneven surface can cause an unsafe bouncing of the
material on the forks, or cause the fork trucks operation to be unsafe. Also loading or unloading
RIWUDLOHUVXSWRWKHUHDUGRRUFDQEHGLI¿FXOWRULPSRVVLEOHLIWKHWUDLOHULVVLJQL¿FDQWO\ORZHUWKDQ
WKHGRFN$GGLWLRQDOO\PRUHDQGPRUHDLUULGHWUDLOHUVDUHEHFRPLQJSDUWRIWKHH[SHFWHGÀHHW
and truck levelers ease the acceptance of this type highway trailer,
* Do not use ICC or RIG bar restraint with truck leveler. Use wheel based restraint.
28
Implementation Guidelines
Dock Levelers
There are two basic designs of dock levelers:
1. Mechanical Docklevelers – (spring activated) These devices require someone to
physically pull a chain, walk on the dock board and thus by the person applying their weight
cause the dock leveler board to go down and make contact with the trailers rear edge.
Advantage is lower price and little effect by weather. Disadvantages are springs require
adjustment; they can bounce when driven over, simulating an effect similar to a speed
bump, thereby causing ergonomic problems for the fork driver. Note: This type leveler has
QREDUULHUOLSZKLFKLQWKHVWRUHGSRVLWLRQFDQDFWDVDQDERYHGRFNVDIHW\EDIÀHUDQG
stop fork trucks from driving off the end of dock when no trailer is in position. There are no
electronic interlocks to the restraint system and therefore no safety lights to inform the fork
truck driver or truck driver of truck loading status. Maintenance requirements are greater
than hydraulic docklevelers. Hold-down and spring adjustments required periodically. This
type of leveler would not be recommended at an automotive facility.
2. Hydraulic Docklevelers – The standard automotive practice is a hinged-lip platform,
powered by a self-contained electro-hydraulic pump and motor to raise the platform and
extend the lip. Recommended dock leveler lip for all automotive applications includes
a stored position above dock (5” min. height) lip barrier. This system is interlocked
electronically to the restraint system and safety lights inform the fork truck driver or
truck driver of truck loading status. The hydraulic leveler limits platform free-fall to 3” or
less. The hydraulic leveler automatically returns to dock level and restores to safe cross
WUDI¿FSRVLWLRQ7KLVV\VWHPUHTXLUHVORZPDLQWHQDQFH7KLVW\SHRIOHYHOHUZRXOGEH
recommended at an automotive facility.
Note: When considering dock levelers, correct calculations must be given to the weight of
loads and frequency of use to be carried across the leveler boards. Not factoring the weights
and frequency to be carried by these systems can affect safety and the frequency/seriousness
of repairs. In addition, the proper width, length and slope of these devices can affect loading/
unloading practices.
29
UAW-GM
Vehicle Safety for Material Handling
Integrated Electrical Systems
(Combination Control Panels)
The best practice for controlling the components at a truck dock requires an Integrated Dock
Optimization and Control System (IDOCS). This system controls all or some of the following:
GRFNGRRUGRFNOHYHOHUWUDLOHUUHVWUDLQWWUXFNOHYHOHULQÀDWDEOHGRFNVKHOWHUGRFNGRRUKHDWHU
and dock light.
Additionally, this type control panel is intended to do the following:
A. To provide for the safe operation of multiple interdependent pieces of dock equipment
by controlling the sequence of operations.
% 7RIDFLOLWDWHWKHHI¿FLHQWRSHUDWLRQDQGPDLQWHQDQFHRIDOOFRPSRQHQWVRIWKHGRFN
system by the use of a single-point function for operation station, disconnect, electrical
lockout, diagnostic troubleshooting.
C. To protect the dock equipment, the building and trailers from damage due to operator
error.
D. To consolidate the clutter of panels and disconnects for multiple pieces of dock
equipment from multiple manufactures into a single panel.
E. To provide an integrated set of electrical control drawings with a common numbering
scheme to automotive standards.
F. To provide a single 3-phase power feed to the dock, and provide a single transformer for
those devices requiring a 110-volt power feed.
Role of the PC&L Dock Supervisor
Understand the operation of all the above types of equipment that is utilized in your facility. If
unsure about their operation or functioning, get training on their use. Review the condition of
WKLVHTXLSPHQWRQDUHJXODUEDVLVDQGUHSRUWDQ\GH¿FLHQFLHVLPPHGLDWHO\)LQDOO\EHVXUHWKDW
your employees do not take shortcuts and use this equipment properly.
30
Implementation Guidelines
Aisle Guidelines
1.
Avoid setting up an operation were an operator must change elevations throughout
normal cycle.
$YRLGKDYLQJWHDPURRPVYHQGLQJDUHDVRI¿FHVDQGEDWKURRPVH[LWLQJLQWRDQDLVOH
If this cannot be avoided clearly mark entrances/exists. The use of directional posts to
restrict immediate entrance into the aisle should be used.
2I¿FHVSRUWDEOHVKRXOGQRWEHSODFHGDWLQWHUVHFWLRQVWRDYRLGFUHDWLQJEOLQGVSRWV
4.
Avoid placing personal locker on aisle ways.
$YRLGSODFLQJWDOOHTXLSPHQWRUFDELQHWVQHDU¿QDOOLQHGULYHRIIWKDWZRXOGUHVWULFWFDU
truck driver’s view.
6.
Computer terminals should not be placed where users are exposed to vehicles.
5DLOGRFNVVKRXOGEHIUHHIURPRI¿FHVEUHDNDUHDVDQGFULEVWRPLQLPL]HSHGHVWULDQ
WUDI¿F
&ULEORFDWLRQVVKRXOGEHVXFKWKDWIUHTXHQWHPSOR\HHXVHGRHVQRWFRQÀLFWZLWKKLJK
YHKLFOHWUDI¿F
9.
Avoid creating dead end aisles.
10. Aisle stripes should be a minimum of 4” (plant safety and/or material must approve for
deviation).
11. Aisle width is measured from outside to outside of aisle line (stripe).
12. Minimum overhead clearance for aisles and across rapid transfers is 12’0”, preferred
15’0” (plant safety and material must approve for deviation).
13. Where possible, consider pedestrian only aisles and vehicle only aisles.
14. A pedestrian aisle should be provided to all functional areas of the plant including
FDIHWHULDVDQGDGPLQLVWUDWLRQRI¿FHV
15. A 7’0” minimum vertical distance should be maintained to provide clearance over
pedestrian aisles.
$RQHZD\WUDI¿FDLVOHVKRXOGQRWEHOHVVWKDQ¶´ZLGHUWKDQWKHZLGHVWFRQWDLQHUYHKLFOH
LISRVVLEOHWU\WRDYRLGFUHDWLQJDRQHZD\WUDI¿FDLVOH
31
UAW-GM
Vehicle Safety for Material Handling
$WZRZD\WUDI¿FDLVOHVKRXOGQRWEHOHVVWKDQ¶´ZLGHUWKDQWZLFHWKHZLGWKRIWKHZLGHVW
container/vehicle.
•
Material must be stored so as not to create an overhang into aisles which might
LQWHUIHUHZLWKYHKLFOHWUDI¿F
•
All walkways, aisles, and passageways shall be kept clear of material and in good
repair, with no obstruction across or in aisles that could create a hazard.
•
Good visibility must be maintained at corners of aisle intersections with tiers of
FRQWDLQHUVVHWEDFNRUORZHQRXJKVRWKHWUXFNGULYHUFDQVHHRWKHUWUDI¿FZLWKRXWKLV
WUXFNRUORDGLQIULQJLQJLQWRLQWHUVHFWLRQVRUDLVOHVRIFURVVWUDI¿F6HHDOVR8$:
GM Storage and Stacking Guidelines)
– Where possible, corners should be diagonal (45°) corner to prevent stacking up
to edge or corner.
32
•
Each facility must work through their Plant Safety Review Board (PSRB) to establish
a pedestrian safety process to reduce exposures to pedestrian/vehicle collisions.
•
:KHUHDQDLVOHLVXVHGIRUHPHUJHQF\H[LWRUIRUDFFHVVLQJ¿UH¿JKWLQJHTXLSPHQW
the aisle shall be kept clear with no obstruction (required).
•
Aisle widths must comply with OSHA or applicable state/local regulations (required)
and any additional regulation set forth by the plants local joint health and safety
committee.