1. Safety in the Movement of People and Materials Lift Trucks Conveyors Automated Warehouses

2. Types of Lift Truck

3. Counterbalance Lift Truck

4. Reach Truck

5. Rough-terrain Counterbalance

6. Telescopic Materials Handler

7. Side-loading Lift Truck

8. Pedestrian Controlled Lift Truck

9. Large Lift Truck

10. Lift Truck Hazards n Collision with people or vulnerable plant n Overturning n Items falling from racking or forks n Explosion from some batteries n Hot exhaust n Dangerous parts e.g. chains, drive shafts etc. n Driving off edges, into pits etc. n Placing loads onto peoples feet

11. Lift Truck Hazards n Fumes n Noise n Whole body vibration n Load slipping from forks

12. Lift Truck Control Measures

13. Driver Selection n Reliable and mature attitude n Physically & mentally fit n Intelligent n Over school leaving age n Not under influence of drink/drugs n Good vision n Good hearing

14. Driver Training n Supervisors should receive an appreciation n Competent Instructor n Records should be kept n Test at end of training n Employees should be given written authorisation at end of training n Refresher training as necessary

15. Work Area n Separate traffic routes where possible n Routes should have sufficient width and clearance for largest trucks used n Prevent pedestrians entering lift truck areas n Eliminate sharp bends or overhead obstructions wherever possible n Where hazards cannot be removed, use clearly marked barriers

16. Work Area n Signs, warning devices, mirrors etc. n Instructions to sound horns and restrict speed n Flexible doors of transparent material where lift trucks have to pass through

17. Work Area n Edges of loading bays, excavations & pits should be clearly marked

18. Work Area n Where possible, edges should be fitted with barriers

19. Work Area n Operating areas should be as free as possible of obstructions, but supports, columns, pipework, racking or other plant may need to be protected by special impact barriers

20. Work Area n Firm and level surface, ideally concrete or similar n Potholes should not be allowed to develop n Steep gradients should be avoided n Adequate lighting n Trucks should be parked in a secure area n Keys should be kept in a secure place

21. Protecting Pedestrians & Operators n Segregate pedestrians and vehicles

22. Protecting Pedestrians & Operators n Clearly mark traffic routes n Use audible and visual warning devices n High-visibility clothing may be necessary, as well as safety boots and hard hats n A Roll Over Protection Structure should be fitted where there is a risk of overturning and crushing operator

23. Protecting Pedestrians & Operators n Seat belts may be required n Falling object protection structures should be fitted where there is significant risk of falling materials n Anyone driving a lift truck on a public road should comply with road traffic legislation

24. The Lift Truck n Suitable for its intended purpose n Travel with loads in lowered position n Do not load beyond SWL (safe working load) n Dangerous parts should be guarded n Eliminate ignition sources in battery charging areas n Adequate ventilation to disperse fumes

25. Operation of Lift Trucks n Issue keys only to authorised people n Lower forks when parked n Keep to left when operating n Sound horn at danger spots n Avoid violent braking or sudden changes in direction n Never travel down slopes with load in front

26. Maintenance n Follow manufacturers recommendations n Operators should not carry out repairs n Trucks that are on loan still need to be checked and maintained

27. Operator Checks n At beginning of each shift, operator should check the following and report any defects to his supervisor: –Tyre pressure and damage; –Steering and brakes; –Fuel, water and oil levels; –Battery levels; –Masts and hydraulics; –All controls; –Horns and other warning systems; and –Lights & mirrors

28. Conveyor Belts

29. Conveyor Hazards n In-running nips n Entanglement points at rollers n Contact with moving parts n Materials falling from conveyor n Manual Handling/Ergonomics from incorrectly set speeds

30. Conveyor Controls n Guard in-running nips

31. Conveyor Controls n Emergency trip wires or stop buttons n Guard power drives and other dangerous parts n Nobody allowed to ride on conveyor n Operatives should be trained and instructed in safe use

32. Conveyor Controls

33. Automated Warehouses & Order Picking Machines (OPMs)

34. OPM Hazards n Overturning e.g. overloading, gradients n Falls of people, goods or materials n Trapping of people in mechanisms n Trapping of people against fixed structures n People struck by moving OPM n Failure of platform supporting mechanism n People stranded on platform due to power failure n Inadvertent movements e.g. misapplication of controls

35. OPM Controls n Only trained and authorised persons n Comply with SWL n Tested and examined every 6 months (LOLER) n Prevent access to dangerous parts e.g. chains, mast sections etc. n Edge protection n Suitable overhead guards

36. Automated Warehouse Hazards n Collision between AGVs and people n Trapping points between AGVs and stationary objects or fixed structures n Inadvertent movement of AGVs n Collapse of palletised loads n Collapse of AGV n Slips on oil from machines

37. Automated Warehouse Controls n Segregate AGVs from pedestrians n Trip devices on vehicle bumpers n Sensors on vehicles to slow it to a crawl n Ensure accurate positioning of AGV at transfer points n Easily accessible emergency stops n Automatic monitoring of safety system

38. Automated Warehouse Controls n Audible and visual signals n Guard dangerous moving parts n Prevent unauthorised human access n Pressure sensitive mats n Interlocked access gates n Permit systems for maintenance n Clear warning notices