AITA Forklift Safety Week 2012 Presentations

Mr. Steve Stewart
• Licence is not necessarily
evidence of competence.
• WHS legislation……
• Part 4.5 High risk work
• Work Health and Safety Act
• Work Health and Safety
Regulation 2011
• Think not about how much
training will have cost you if
your employee subsequently
• Think about how much will it
cost you if you do not train
them - and they stay………….
Part 3.2 General workplace management
Division 1Information, training and instruction
39 Provision of information, training and instruction
This clause applies for the purposes of section 19 of the Act to
a person conducting a business or undertaking.
The person must ensure that information, training and
instruction provided to a worker is suitable and adequate having
regard to:
(a) the nature of the work carried out by the worker, and
(b) the nature of the risks associated with the work at the time the
information, training or instruction is provided, and
(c) the control measures implemented.
The person must ensure, so far as is reasonably
practicable, that the information, training and instruction provided
under this clause is provided in a way that is readily understandable
by any person to whom it is provided.
• Proper use of plant and
• (1) The person with management or control of
plant at a workplace must take all reasonable
steps to ensure that plant is used only for the
purpose for which it was designed, unless the
person has determined that the proposed use
does not increase the risk to health or safety.
• Maximum penalty:
• (a) in the case of an individual—
—$6,000, or (b)
in the case of a body corporate—
• 215.
• The person must ensure that the
plant does not collide with
pedestrians or other powered
mobile plant.
• Maximum penalty: (a) in the
case of an individual—
or (b)
in the case of a body
203 Management of risks to
health and safety
•A person with management or
control of plant at a workplace
must manage risks to health and
safety associated with plant, in
accordance with Part 3.1. Note.
WHS Act—
—section 21 (see
clause 9).
Types of training
1. Required licences (HRW etc)
2. Qualifications (Nationally
Recognised Training).
3. General training in specific
Types of training
1. Required licences (HRW etc)
2. Qualifications (Nationally
Recognised Training).
3. General training in specific
WHS Act Def:
• plant includes:
– (a) any machinery, equipment,
appliance, container, implement
and tool, and
– (b) any component of any of
those things, and
– (c) anything fitted or connected
to any of those things.
• High Risk Work Licence - LF
• forklift truck, in Schedules 3 and 4,
means a powered industrial truck
equipped with lifting media made up
of a mast and an elevating load
carriage to which is attached a pair
of fork arms or other arms that can
be raised 900mm or more above the
ground, but does not include a
pedestrian-operated truck or a pallet
• High Risk Work Licence - LO
• order-picking forklift truck, in
Schedules 3 and 4, means a forklift
truck where the operator's controls
are incorporated with the lifting
media and elevate with the lifting
Current Licence System
• No ‘Log Book’ system.
• Must be conducted by an
• Formal training to the
approved course (UoC) is
– TLILIC2001A - Licence to operate a forklift
– TLILIC2002A – Licence to operate an order picking
• Does that cover every forklift
type then?
• Type
• Brand
• Specifications
• Mast height
• Capacity
• Load handling attachments
• Safety features
• Control types
• And then there is the
peripheral skills and
knowledge required!
• Most of these will fall into the
ITEM 3 - General training in
specific competences
• Operator elevated equipment.
– Emergency lowering options
– Fall Arrest Equipment
– Emergency Descent
– Rescue procedure
• Forklift Re-fueling safety.
– LPG cylinder change
– LPG cylinder refill
– Fuel storage safety
• Battery electric forklift.
– Battery charging safety
– Battery changing safety
Non – licence equipment
Pallet jacks
Pallet movers
Walkie Stackers
Tow motors
Low level order pickers
Anything under the plant def!
Hierarchy of controls
Personal protective equipment
Hierachy of Controls
• Remember that training is
considered an administrative
• Should include assessment.
• Must be used in conjunction
with a suite of higher level
Contextualised delivery
• An RTO can encompass
required site specific skills in
training programmes.
• Benefit of having training
conducted on-site.
Transport and Logistics
• Most Units of Competence are
contained in TLI10 Training
• Qualification Level: Certificate
• TLIPC110 Certificate I in Transport and
Logistics (Pathways)
• TLI10410c - Certificate I in Transport and
Logistics (Rail Operations)
• TLI11310 - Certificate I in Logistics
• TLI11210 - Certificate I in Warehousing
Thank you
Traffic Management
Traffic Management Plans
Traffic Management Plans
Do we need a
Traffic Management Plan?
According to WorkSafe Victoria, Forklifts
cause more workplace deaths and injuries
than any other piece of equipment.
More than half the people killed in forkliftrelated incidents in the last 10 years have
been pedestrians.
Even when forklifts are travelling at low
speeds they can crush pedestrians causing
serious injury.
Where to Start?
There are numerous publications in each
State and Territory designed to help
businesses develop and implement
effective Traffic Management Plans.
Forklift Safety – Reducing the Risks
Guide - Traffic Management & Forklift Safety
Forklift Safety – Reducing the Risk
COP – Traffic Management Construction 2008
Forklift safety case study: Making traffic management systems
Where to Start?
There are numerous publications in each
State and Territory designed to help
businesses develop and implement
effective Traffic Management Plans.
Forklift Safety – Reducing the Risks
Forklifts - Developing a traffic management plan
Guide - Traffic Management & Forklift Safety
ACT, SA, NT, TAS, WA, Comcare
Forklift Safety – Reducing the risks
AS2359.2 (Draft) Operation
Appendix A – Traffic Management Plans
Where to Start?
‘Forklift Safety – Reducing the
Risks’ Has broken down the
process of developing a Traffic
Management Plan into 4 simple
Where to Start?
Legal Considerations
Before you commence your Traffic
Management Plans you MUST consider
the following when developing your plans.
In each State and Territory employers
are responsible for providing:
• a safe work environment
• safe systems of work
• safe and well-maintained machinery
• proper information, training and
Warehouse Design and
Principles of good design are most economically
applied at the start of a project and are more costly
to introduce retrospectively.
There are four primary functions that your
warehouse layout must accommodate:
1. Product storage
2. Inbound operations (including receiving and
3. Outbound operations (including picking and
4. Value-added processes
Barriers/Barricades or bollards are
designed to protect
pedestrians, but also act to
enforce the walkway –
ie keep mobile equipment off and
pedestrians within. Barriers should
be provided along as much of a
dedicated walkway as possible.
Clearly line mark pedestrian walkways, roadways and operating
areas based on speed limits, stopping distances and
efficient workflow.
Minimise the cross flow of traffic, intersections and blind spots
Clearly define areas where powered loadshifting equipment is
used as ‘pedestrian exclusion zones’ and clearly exclude
powered loadshifting equipment from pedestrian
walkways/work areas
Provide line marking for:
- traffic flow markings
- Loadshifting equipment parking
- Driver designated safe areas
- Car parking
- Keep clear zones
- Speed humps
Prominently display clear warning signs in
relevant, well lit areas to remind persons of the
traffic management hazards and requirements.
Signage examples:
• Speed Limit
• Give Way
• Warning Forklifts in Operation
Warning Devices
Proximity sensing systems in their simplest form
can be used to warn of mobile equipment as it
approaches set locations ie doorways, blind spots
and intersections.
Policies and safe work procedures ensure everyone who
works within a workplace where Mobile Equipment
(forklifts) operate understands how to manoeuvre safely
and correctly throughout the facility without causing harm
to themselves or others.
As with your traffic management plan, everyone in your
workplace, including contractors and visitors, must know
your policies and safe work procedures. Again, you could
use induction and training sessions, and post information
at workplace entrances and notice boards.
You should also review these regularly to ensure they
remain appropriate. You should also ensure people are
complying with them.
• Ensure that High Visibility
Clothing is worn by all people
on site within traffic areas.
• Set policies as to appropriate
footwear within the workplace
eg closed-in and/or safety
Mobile Equipment
Safety Features:
Ratchet style locking park brake lever which
cannot be “accidentally” disengaged.
•Low cowl height for better operator vision.
•Wide foot steps and grab bar for easy access
and egress.
•On trucks fitted with Oil Cooled Disc Brakes
(OCDB) the improved boosted master cylinder
requires less pedal effort, reducing operator
•Reverse alarm.
•Speed limiters.
Mobile Equipment
Safety Features:
•Operator Sensing System (OSS) which
– Parking alarm – alarm warning when
operator leaves seat without applying the
park brake.
– Seat belt indicator – warning light
illuminates for 10 secs to remind operator
to fasten seat belt.
– Hydraulic function lockout – all hydraulic
functions are locked out when operator
has vacated the seat.
The development of traffic
management plans require
consultation from employees/key
The process is never simple, in fact it
is quite complex requiring an indepth understanding of your
business and its needs both now and
in the future.
Thank you
Thank you
• A number of ISO standards
published over the past 5 years.
• These include standards for stability,
safety and brakes.
• Australian Standards will be in the
main replaced by ISO standards.
• AS2359-1:1995 Powered industrial trucks –
General requirements.
• AS2359-2:1985 SAA Industrial truck code
Part 2 Operation.
• AS2359-6:1995 Powered industrial trucks –
Safety code.
• Design requirements for industrial trucks
for Australia
• A number of requirements have been moved to
AS2359-6 or other ISO standards i.e. stability,
brakes and electrical.
• This standard is being updated with the
latest version of ISO3691-1:2011 Industrial
trucks — Safety requirements and
verification — Part 1: Self propelled
industrial trucks, other than driverless
trucks, variable –reach trucks and burden –
carrier trucks.
• This standard is design standard that
• Europe and Japan will adopt.
• This standard is special design
requirements for Australia, Japan and
• Will require that interlocked seatbelts be fitted
to counterbalance forklifts with logic.
• Travelling with elevated mast on battery
electric forklifts.
• A number of changes have been included
in the update since it was last updated in
• All users of forklifts should have a copy of
this standard.
• Operators must be trained on the forklift
they are operating.
• Records of training shall be maintained.
• This should include induction/familiarisation
training for new models.
• Only persons who are qualified and are
trained shall be authorised to use a forklift.
• A record of authorised operators shall be
kept and a system implemented to limit
forklift usage to authorised operators.
• Systems now include swipe cards, pin codes
• Operators shall be provided with a record
of authorisation.
• Users of forklifts shall have a safe system of work
in place.
• Use correct forklift the task.
• Daily pre-operator checks.
• Ensure forklift and any attachments that are on the
forklift that it is rated appropriately.
• Forklifts are isolated when operator leaves forklift.
• Unattended forklift defined as operator more
than 8m away from forklift
• Operator restraints (seatbelts) shall be used when
operating counterbalance forklifts.
• Note if a seatbelt is fitted to other forklifts such as a
reach truck they shall be used.
• Mobile phones shall not be used while the forklift
is in motion.
• Operating procedures should be developed for devices
such as scanners, touch screens, terminals etc.
• Internal combustion engine forklifts shall not be
allowed to idle unnecessarily in enclosed or semi
enclosed areas as it may result in an accumulation
of fumes.
• If internal combustion engine trucks are used in poorly
ventilated areas then it is essential that emissions are
• In such situations battery electric forklifts are the
preferred option.
• A traffic management plan which includes forklift
operation shall be in place for the site.
• Pedestrian paths shall be separated from forklift path by
physical barriers where possible.
• Truck loading and unloading areas to be pedestrian free,
this includes truck drivers.
• Speed limits.
• The objective of a TMP is to achieve as far as
practicable, complete physical separation of
mobile plant and people within the work area.
• Due to building codes there are
requirements for drainage. As part of a
“safe operating system” consideration
needs to be given with operating forklifts on
these inclines when loading or unloading
trucks and the impact on stability.
• Turns with the forks elevated should never
occur as a tip over is a possibility.
• Fork tynes shall support 75% of the load.
• A load backrest extension shall be used
when handling loads which are high or
• Where a segmented load is to be carried,
two thirds of the load or top tier of the load
should be supported.
• Recommended that loads should be shrink
• Work platforms are not to be used for
orderpicking or for production or stores
types of activity such as stocktaking.
• Should only be used for special tasks of a short
• Must wear a harness and lanyard.
• A risk assessment shall be carried out
before using a work platform.
• Bulker bag handling attachments considered to be
a jib due to bag being able to swing freely.
• Section now included on container handling.
• When using high level orderpickers now able to
use pedestrian detection systems.
• Loading docks.
• A system shall be in place to ensure no movement of the
truck or trailer when loading or unloading.
Thank you – Break time