MATERIALS HANDLING SAFETY - … · "This program has been created to assist companies that are endeavoring to educate their employees regarding good safety and health practices. The

LEADER'S GUIDE

0360-LDG-E

MATERIALS HANDLING SAFETY

Part of the SAFETY MEETING KIT Video Series

Quality Safety and Health Products, for Today...and Tomorrow

106 Capitola Drive Durham, NC 27713

(P) 919-544-6663 (F) 919-544-5800 Trainingnetwork.com



THE SAFETY MEETING KIT VIDEO SERIES This program is part of the Safety Meeting Kit Video Series. The programs in this series have been created to provide employees with good, basic information on everyday safety and health topics. This series includes programs on the following topics: - Accident Investigation - The ANSI MSDS - Back Safety - Compressed Gas Cylinders - Computer Workstation Safety - Conflict Resolution (Industrial and

Office versions) - Crane Safety (Industrial and

Construction versions) - Driving Safety - Dealing with Drug and Alcohol

Abuse (Employees and Managers/Supervisors versions)

- Electrical Safety - Eye Safety (Industrial and

Construction versions) - Ergonomics (Industrial and Office

versions) - Fall Protection - Fire Extinguishers - Fire Prevention (Healthcare,

Industrial and Office versions) - First Aid (Industrial and

Construction versions) - Hand and Power Tool Safety

(Industrial and Construction versions)

- Hand, Wrist and Finger Safety (Industrial and Construction)

- Hazardous Materials Labels - Hazardous Spill Cleanup - Heat Stress (Industrial and

Construction versions) - Ladder Safety (Industrial and

Construction versions) - Machine Guard Safety - Materials Handling Safety - Office Safety - Rigging Safety (Industrial and

Construction versions) - Safety Audits - Safety Housekeeping and

Accident Prevention - Safety Orientation - Safety Showers and Eye Washes - Sexual Harassment (Employees &

Managers/ Supervisors versions) - Sexual Harassment Investigations - Slips, Trips and Falls - Welding Safety (Industrial and

Construction versions) - Wellness and Fitness - Winter Safety - Workplace Harassment (Industrial

and Office versions) - Workplace Stress - Workplace Violence

Other products in the Safety Meeting Kit line include employee booklets and posters which have been designed specifically to be used with the programs. By combining these three products you have all of the materials you need to promote and conduct a complete safety meeting (for information on booklets and posters contact your local distributor).



WARRANTY/DISCLAIMER "This program has been created to assist companies that are endeavoring to educate their employees regarding good safety and health practices. The information contained in this program is the information available to the producers of the program at the time of its production. All information in this program should be reviewed for accuracy and appropriateness by companies using the program to assure that it conforms to their situation and recommended procedures, as well as to any state, federal or other laws, standards and regulations governing their operations. There is no warranty, expressed or implied, that the information in this program is accurate or appropriate for any particular company's environment."

Copyright 1995 The MARCOM Group, Ltd.



TABLE OF CONTENTS 1 INTRODUCTION TO THE PROGRAM

- Structure and organization - Background - Objectives - Reviewing the program

2 PREPARING FOR THE PRESENTATION

- Structuring the presentation - Setting up the class and classroom

3 CONDUCTING THE SESSION

- The initial steps - Showing the program - Conducting the discussion - Concluding the presentation - Wrapping up the paperwork

4 OUTLINE OF MAJOR POINTS IN THE PROGRAM 5 ACCOMPANYING MATERIALS

- Scheduling and Attendance Form - Quiz - Training Certificate - Employee Training Log



INTRODUCTION TO THE PROGRAM Structure and Organization Information in this program is presented in a definite order, so that employees will see the relationships between the various groups of information and can retain them more easily. The sections in this program include:

- Types of potential hazards.

- Planning a job.

- Personal protective equipment.

- Proper lifting and moving techniques.

- Other ergonomic considerations.

- Hand-trucks, carts and pallet-trucks.

- Mechanical lifting devices. Each of the sections gives an overview of important information in one topic area, providing employees with the basis for understanding how to handle and move various types of materials safely. Background No one wants to be in an accident. That's why employees take so many precautions when they go about their jobs each day. However, many people feel that handling and moving the materials they work with every day is an ordinary task, not something that they really need to be concerned about.



In spite of this perception (or perhaps because of it) there are hundreds of thousands of materials handling accidents every year from small splinters, cuts or scrapes, to crushed fingers, hands and feet... even deaths. Employees need to recognize that materials handling activities can be dangerous. They need to know proper lifting and moving techniques, how to use materials handling equipment safely and what personal protective equipment should be worn with various types of jobs. Objectives To help employees recognize materials handling situations that may be hazardous, and how to deal with these situations safely, this education and training program is designed to present basic information in these areas. Upon completion of the program, employees should be able to:

- Recognize materials handling situations that may be hazardous.

- Know how to plan their materials handling work to avoid accidents and injuries.

- Use good lifting and moving practices.

- Recognize materials handling situations where other ergonomic

considerations come into play.

- Know some of the materials handling equipment that is available to help them with their jobs.

- Know the basics of using simple materials handling equipment

safely.



Reviewing the Program As with any educational program, the presenter should go through the entire program at least once to become familiar with the content and make sure the program is consistent with company policy and directives. An outline of the points in the program is included in this Leader's Guide to help with this task and for general reference. As part of this review process, you should determine how you, as the presenter, will conduct your session. The use of materials such as handouts, charts, etc., that may be available to you needs to be well thought out and integrated into the overall program presentation.



PREPARING FOR THE PRESENTATION Structuring the Presentation In conducting this education session, you should proceed with a friendly and helpful attitude. Remember that the trainees are looking to your experience and knowledge to help them relate to the situations shown in the program. It is important to let the trainees interact with you and each other during the training session. Stimulating conversation within the group is one of the best things you, as the presenter of the program, can do to help everyone get as much as possible from the session. Be alert for comments that could help in this area in future sessions and make note of them. As the presenter, you also should:

- Keep the session related to the topic of materials handling safety.

- Relate discussions to how employees can recognize materials handling situations that may be hazardous, and what they can do to deal with these situations safely.

- Prevent any one person or small group of employees in the session

from doing all the talking.

- Get everyone involved. Ask questions of those who don't participate voluntarily.

- Clarify comments by relating them to the key points in the program.

Use the outline of the major points included in the program, as well as the information included in the quiz, as the basis for answering any questions. If you don't know the answer, say so. Tragic results may occur should you provide incorrect or inaccurate information. Remember, this is a positive program on materials handling safety. Make sure your attitude and words reflect this and that the emphasis is always on providing the information needed by the attendees to improve their ability to work safely.



Setting up the Class and Classroom Remember, there are a number of things that must be done to set up the class as well as the classroom. These fall into several groups of activities, and include:

- Scheduling and Notification - Use the enclosed form to schedule employees into the

session. - Make sure that the session is scheduled so that it fits

into your attendees' work day. - Send out notification of the session well in advance, to

give people enough time to incorporate it into their schedule for that day.

- If possible, post a notification on bulletin boards in the affected employees' areas.

- The Classroom

- Schedule the room well in advance. - Make sure the room can accommodate the expected

number of attendees. - Check it again on the day of the program to make sure

there is no conflict. - Make sure the room can be darkened, and won't create

a glare on the television screen. - Locate the light controls and test them. - Make sure the power for the videotape or DVD player

you are using operates separately from the room light. - See if you can control the room temperature. - Know where the closest restrooms are. - Assure that the room is free from distracting noises. - Make sure emergency exits are marked and known to

the attendees.



- Seating - Make sure everyone can see the screen from their seat. - Make sure everyone can hear both the videotape/DVD

and you (when you speak). - Check to see that seating is such that writing can be

done easily. - Make sure the seating arrangement allows eye contact

between attendees, and between you and attendees.

- Equipment and Materials - Make sure the videotape or DVD player, monitor, and all

appropriate cables and extension cords are available. - Make sure a stand or table is available and is of

appropriate height for all attendees to easily see the monitor.

- If you plan on using a chartpad, blackboard, or other writing board, make sure it is available, easy to see, and you have the proper writing implements.

- Make sure you have 6" x 8" index cards or other materials to be used as name tents for attendees.

- Make sure you have made up a sufficient number of copies of the quiz, as well as any other handouts you are using.

- Final Check

- Make sure equipment is in the room prior to the scheduled session.

- Check to see that the room is set up properly. - Check equipment prior to the presentation to assure

that it works. - Make sure extension cords, etc. are taped down, if need

be, to avoid tripping. - If you are using the videotape version of the program,

run the leader up to the point where the program begins.



CONDUCTING THE SESSION The Initial Steps In conducting the session remember the positive nature of this presentation. Everyone is attending in order to learn more about how to recognize materials handling situations that could be hazardous, and how to work safely in these situations.

- Introduce yourself as the session leader.

- State the title of the program, Materials Handling Safety and the purpose of the session (to learn about how handle materials safely).

- Inform the attendees when there will be breaks (if you plan them) the

location of exits and restrooms and if water, coffee, or other refreshments will be available.

- Make sure all of the attendees have signed in on your scheduling

and attendance sheet. Remember, it is very important to document peoples' attendance at the session.

Once this housekeeping is done, it is time to move to the meat of the session. First, the attendees need to be informed about the objectives of the session (this is where you can use a flip chart or board to list the objectives, which should be done prior to the class starting). This listing should be preceded with some introductory remarks. Your own words are always best, but the remarks should include information such as the following paragraphs:

"No one wants to be in an accident. That is why we take so many precautions. But many of us look at handling and moving the materials that we work with every day as an ordinary task, not something that might be hazardous."

"Yet every year there are thousands of materials handling accidents in facilities just like ours. Which is why we need to learn how to



recognize materials handling situations that could be dangerous, as well as what we need to do to work safely in these situations."

"The program we are going to watch today will give us a good overview of what types of materials handling situations can, in fact, be hazardous. It will also review some of the types of equipment we can use to work in these situations safely, as well as what personal protective equipment should be worn. To make this the most productive session possible we need to look at what we want to accomplish here today (verbally reference the 'Objectives' list from the first section or gesture to the blackboard or chart where you have written them down)."

Once the objectives have been provided, you are ready to show the program. However, you do need to let the attendees know that they will be taking a quiz at the end of the session (if you are using it). It needs to be emphasized that they are not being graded, but that the quiz is being used to see if the session is effectively transmitting information to them in a way they will remember. Showing the Program At this point, you need to introduce the title of the program once again, Materials Handling Safety, darken the lights if necessary, and begin the showing of the program. If you are using the DVD version of the course you have several options as to how you can move through the program and what employees see. T

he DVD menu has two selection bars:

- Play. - Contact Us.



To just play the program from beginning to end, select Play. If you would like information on other programs and products that are available from Training Network you can select Contact Us for information about how to contact us. Conducting the Discussion After the program has been shown, it is time for the group discussion on the information contained in the session. Care must be taken to make sure that the discussion is kept to the general topic of how to handle materials safely. There are several ways to conduct this discussion. These include:

- Calling for questions from the attendees and using these questions as the basis for the discussion.

- Leading the discussion through the points covered in the program

using statements such as: - "One of the sections that we saw in the program

discussed various types of materials handling equipment. What types of equipment are available in our facility?"

- "We saw an interesting sequence discussing the steps that should be taken in order to lift an object safely. Who can review these steps for us?"

You should use the discussion format that you are most comfortable with. The outline of the major points addressed in the program and the questions and answers in the master copies of the quiz can also be very useful as a basis for discussion. Remember, you have allocated a limited amount of time in which this discussion can take place. It is important to blend the attendees' questions and areas of obvious interest with the objective of trying to touch on each major area within the session in the discussion. By touching on each area, the attendees are much more likely to retain the information presented in the session.



Concluding the Presentation Once discussion has concluded, whether naturally or you have had to bring the discussion to a close in order to complete the session within the time allowed, it is time to give the quiz (if you are using it). Again, remind the attendees that the quiz is only meant to help determine how effective the presentation of the information is, and that they will not be graded on it. Let them know that they have approximately five minutes to complete the quiz. At the end of the five minute period, remind the attendees to date and sign their quizzes, and then collect them. The attendees should be thanked for attending the session and reminded of any other sessions in the educational program that they may be attending. They can then be dismissed to return to their normal activities. *(An alternative to this approach is to give the quiz immediately after showing the program, then use a review of the quiz as a basis for your group discussion.) Wrapping Up the Paperwork Before much time has passed, and the subject matter is fresh in your mind, several areas of paperwork must be completed. First, check to make sure that all attendees signed the scheduling and attendance form. Next, make sure that you have a quiz from every attendee, dated and signed. Also, depending upon what you have decided to do, a copy of the attendance sheet and the quiz for each attendee should be either filed in your files, or turned over to the attendee's department manager (or the personnel office) so that this paperwork can be included in their personnel file. The attendees' training logs should also be updated, and each attendee should be given a filled out and signed training certificate, signifying that they have successfully completed the course. Remember, it is always a good idea to document information about employee attendance at these sessions, as well as the fact that the employee has come away from the session with an increased knowledge of how to handle materials safely.



OUTLINE OF MAJOR PROGRAM POINTS The following outline summarizes the major points of information presented in the program. The outline can be used to review the program before conducting a classroom session, as well as in preparing to lead a class discussion about the program.

- There are all types of materials: - Many shapes and sizes. - Raw materials. - Product components. - Inventory. - Finished products.

- All types of people handle these materials.

- Lifting. - Carrying. - Moving.

- Handling materials has its dangers. The two most common materials

handling hazards are: - Forklift accidents. - Lifting injuries.

- Any time you need to move something, start by making a game plan.

- Know your destination. - Determine the best path to follow. - Remove any obstacles.

- Inspect any object before you pick it up.

- Read all labeling. - Look for hazard warnings.

- Determine the best way to grip the object.

- Use handles or hand-holds if they exist. - Watch out for sharp edges, staples and splinters (wear

gloves if necessary).



- Test the load without picking it up. Is it: - Heavy? - Bulky? - Unbalanced?

- If you are sure you can handle the object then you are ready to pick

it up. - Remember there is a right and a wrong way to lift

things.

- Good lifting habits start with an understanding of your body mechanics.

- The spine is made up of small, interlocking bones held together by a delicate network of tendons, ligaments, and cartilage.

- Legs have big, sturdy bones and strong muscles. - Good lifting minimizes the strain on the spine by

maximizing the use of the legs.

- You should know how to use good lifting techniques. - Stand close to the object. - Keep your feet about a shoulder's width apart. - Keep your back straight. - Bend at the knees. - Get a firm grip on the object. - Bring the object close to your body. - Lift the load with your legs (keeping your back straight).

- Some people wear back belts to provide extra support while lifting.

- They don't replace good lifting habits. - Back belts don't make us immune to injuries.

- There are also good carrying techniques that should be used.

- Keep your back straight. - Bend your elbows slightly. - Keep the load close to your body. - Proceed with caution. - Keep your eyes on where you are going. - Don't block the view with what you're carrying.



- Good lifting habits are also important in putting things down. - Keep your back straight. - Keep the load close to your body. - Bend at the knees. - Lower the object straight down. - Watch your fingers.

- Unusually shaped or sized objects require special grips.

- Put one hand high on the side away from you. - Put the other hand low on the side close to you. - Carry sacks and bags over your shoulder or on your hip. - If the object is too awkward or heavy, get help.

- Team lifts require good cooperation.

- Have one person direct what is happening. - Lift, carry and unload together.

- Some situations put too much of an ergonomic strain on the body

and should be avoided, such as: - Twisting or bending at the waist when carrying an object

(pivot your feet and turn the whole body). - Reaching too far or too often (rearrange your materials). - Repetitive motions (take short breaks and stretch). - Overhead lifts (use a step-stool or ladder).

- Never strain to lift something heavy.

- Divide the load into smaller, lighter parts. - Get help.

- Using some type of lifting aid is often the best way to avoid injury.

There are many types: - Hand-trucks. - Carts. - Pallet-jacks. - Others.

- Always inspect any equipment before you use it.

- If something is wrong, report it to your supervisor. - Never try a makeshift fix.



- Two-wheeled lifting aids like hand-trucks work on the lever and fulcrum principle.

- Provides good lifting power. - Positioning the load properly is important.

- To use a hand-truck properly:

- Make sure the load is flush with the back of the truck. - Stack the load no higher than the hand-hold. - Support the top of the load with one hand. - Tilt the truck back with the other hand (you may want to

brace the axle with your foot). - Balance the weight of the load over the wheels.

- How you move the hand-truck is also important.

- Grip the hand-hold firmly, with both hands. - Push, don't pull.

- When you arrive at your destination make a controlled landing.

- Support the load with one hand. - Slowly lower the truck with the other.

- Compressed gas cylinders present a special handling situation.

- Never hand roll cylinders. - Use a special, curved hand-truck. - Secure the cylinder to the truck with a safety chain.

- Four-wheeled lifting aids, such as carts and platform-trucks offer greater stability and carrying capacity.

- Weight is distributed over four points, not just two.

- How you load this equipment is still important. - Distribute the weight evenly. - Don't overstack.



- Moving four-wheeled carts and trucks correctly is important too. - Push rather than pull the truck. - Be aware of traffic in front of you (more weight requires

greater stopping distance). - At your destination, secure the equipment, so it won't

roll away.

- Return carts and other equipment to designated storage areas when not in use.

- Leaving equipment in the wrong location can cause trips or falls.

- Makes it easy for the next user to find the equipment.

- Some jobs require special lifting aids.

- Pallets make it easy to stack and store materials, but need to be moved with a pallet-truck or jack.

- Check the load to make sure it is secure and weight is evenly distributed.

- Carefully insert forks under the pallet. - When the truck is in place make sure front wheels are

on the floor (clear of pallet slats). - Carefully elevate the forks. - Lift the load until all four corners of the pallet are off the

ground.

- Know how to move a pallet-truck correctly. - Push rather than pull whenever possible. - Watch where you are going. - Allow adequate stopping distance. - At your destination, store the pallet in its proper place

(don't block aisle ways or exits). - Watch your toes as you lower the forks.

- When heavy lifting is required, you can often use lifting machines.

- All of them are powerful. - They can be dangerous. - Only use this equipment if you have been properly

trained. 106 Capitola Drive

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- Mechanical scissor-lift tables: - Raise materials to specified heights. - Some tilt to give easier access to materials.

- Hydraulic platforms.

- Raise and lower heavy objects. - Some models can be fastened to the floor.

- Forklifts are one of the most common pieces of materials handling

equipment. They are: - Powerful. - Versatile. - But can be dangerous.

- When using a forklift, check its weight limit to see what it can safely

handle. Then make sure the load: - Has its weight evenly distributed. - It stable and secure. - Its not so high that it obstructs your view while driving.

- Using forklifts with some materials may require special considerations.

- Drums can be moved on a pallet, or with a custom attachment.

- Other containers or materials may require specialized attachments as well.

- When driving a forklift or similar equipment, remember to:

- Keep the load low to the ground. - Put the load in its proper place upon reaching your

destination. - Only stack materials you know are stackable (observe

height restrictions).



* * * SUMMARY * * *

- When handling materials have a game plan. - Know where the load needs to go, and how to get there. - Wear PPE, like gloves and safety shoes, when necessary. - Use good lifting habits. - Ask for help when you need it. - Use lifting aids if necessary. - Pace yourself, don't hurry.



ACCOMPANYING MATERIALS In order to assist you in conducting your session on Materials Handling Safety, we have provided some materials that can be used with this program. These materials have been furnished in master form. This will enable you to copy as many of these forms as you need. If you have colored paper available to you, it is often useful to put each form on a different color. This enables you to easily differentiate between the materials. The materials enclosed with this guide include: Scheduling and Attendance Form This form is provided so you can easily schedule your attendees into each session of the program. It is important that you have each attendee sign-in on the appropriate form, documenting their attendance at the session. Typically, a copy of this form is filed in the employee's personnel folder. Quiz The quiz is normally given after viewing the program. However, if you want an indication of the increase in the attendees' knowledge of how to handle materials safely, you can give the quiz both before and after the program is shown. You can also use the quiz as the basis for class discussion. If you have decided to give the quiz both before and after the attendees view the program, it is often interesting to have the attendees compare their before and after answers as part of the session. Typically, the quiz is filed in the employee's personnel folder.



Training Certificate This form allows you to give each employee their own certificate of completion showing that they have attended the course and taken the quiz. Space is provided to insert the employee's name, the course Instructor and the date of completion. Employee Training Log This log helps you to keep track of when each employee has taken the course, as well as associated courses/training. Space is provided to list pertinent data about the employee, as well as information such as the date the course was taken, and the instructor conducting the course. A copy of this form should be kept in each employee's training or personnel file.



SCHEDULING AND ATTENDANCE FORM


TRAINING SESSION SCHEDULE

ATTENDEE DATE TIME SIGNATURE



QUIZ


Name: Date: 1. What are the two most common materials handling accidents?

Forklift incidents. Slips, trips and falls. Lifting injuries.

2. True or False... Good lifting techniques put more pressure on the spine,

and less on the legs? True False

3. True or False... To correctly pick up an object, bring it as close to your

body as is comfortably possible? True False

4. True or False... When grasping an awkward object put one hand low on

the side away from you and the other hand high on the side close to you? True False

5. When using a lifting aid, such as a hand-truck or cart, should you push or

pull the equipment? Push. Pull.

6. True or False... When driving a forklift, it is best to keep the load as high off

the ground as overhead clearances will allow? True False

7. True or False... When using a hand-truck, it is best to tilt the truck as far

back as possible to spread the weight of the load? True False





QUIZ


PRESENTER'S COPY WITH ANSWERS 1. What are the two most common materials handling accidents?

X Forklift incidents. Slips, trips and falls. X Lifting injuries.

2. True or False... Good lifting techniques put more pressure on the spine,

and less on the legs? True X False

3. True or False... To correctly pick up an object, bring it as close to your

body as is comfortably possible? X True False

4. True or False... When grasping an awkward object put one hand low on

the side away from you and the other hand high on the side close to you? True X False

5. When using a lifting aid, such as a hand-truck or cart, should you push or

pull the equipment? X Push. Pull.

6. True or False... When driving a forklift, it is best to keep the load as high off

the ground as overhead clearances will allow? True X False

7. True or False... When using a hand-truck, it is best to tilt the truck as far

back as possible to spread the weight of the load? True X False



EMPLOYEE TRAINING LOG

MATERIALS HANDLING SAFETY Employee: Employee #: ____ Social Security #: Department: Date of Next Required Training:

DATE

TYPE OF TRAINING

OR COURSE DESCRIPTION LOCATION OF COURSE MATERIALS

INSTRUCTOR'S NAME AND ADDRESS/DEPARTMENT

CERTIFICATION OF TRAINING AND TESTING

(Instructor's Signature)



TRAINING CERTIFICATE

This is to certify that _____________________________________ has

completed the course Materials Handling Safety and has been tested on the

contents of the course, as required. This training, as well as the associated

testing was conducted by ___________________________ and was

completed on _________.

_____________________________ ____________

(course instructor)

(date)

(employee name)

(course instructor)

(date)

Documents

MATERIALS HANDLING SAFETY - … · "This program has been created to assist companies that are endeavoring to educate their employees regarding good safety and health practices. The