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Parcels Sortation with Conveyors
Safety compliance and supporting documentation
Ken House Tel: 07713653072 – email: [email protected]
02/05/16
This is a synopsis of the safety documentation applicable to the deployment of conveyors to be used with parcel sortation. Due to the size of this file I have only placed the main documents in this synopsis. It is a requirement of the SAC1 and Risk Assessment that site assessments must be completed prior to any new equipment being deployed, supported by local risk assessments and consultation with local CWU representatives.
The documents within this pack are electronic copies, all master documents with signatures are held by the originators on site. Should you need to review these please contact Edinburgh MC – [email protected] Continuous Improvement Lead.
Mail preperation frame safety documentation within this document.
Work Equipment Change Safety Assessment (WECSA) ……………….…………1 Safety Assessment SAC1………………………………………………………………………………….2 Safe Systems of Work………………………………………………………………………………………3 Ergonomic Screening ……………………………………………………………………………………… 4 Ergonomics Review (Edinburgh) ……………………………………………………………………..5 Ergonomics Review (Manchester) ……………………………………………………………………6 Operating Manual ……………..……………………………………………………………………………..7 Technical Drawings…………………………………………………………………………………………..8 Layout……………………………………………………………………………………………………………….9 Job Element Sheets …………………………………………………………………………………….10
ANNEX: 1…………………………………………………………………………………………………………………………….
Additional supporting document (not included in this report)
Terms of reference (TOR)……………………………………………………………………………………..11 Joint working review……………………………………………………………………………………………..12 Industrial engineering report………………………………………………………………………………..13
1
Work Equipment Change Safety Assessment Template Owner: S. White Version: 4.0 Date: Nov 2012
WORK EQUIPMENT CHANGE SAFETY ASSESSMENT
Section 1 CHANGE SAFETY ASSESSMENT Work Equipment Title CONVEYORS BY Beumer Work Equipment Photograph Work Equipment Group RM 5M CONVEYOR SYSTEM
Work Equipment Intended Use To convey mail items for sortation into Alps and Hoods
Explanation of change To alleviate the manual handling experience whilst doing the sortation operation
Deployment Date Trial Begins July 2014 Project Manager (contact details)
Martyn Dundas
NATIONAL GEOGRAPHY (name)
UNIT (name)
Work equipment area of use NORTH Edinburgh MC
Section 2 PROHIBITED CHANGE ACTIVITY Will the change impact on any of the following: Yes/No (Yes) (No) Work Equipment Guarding (Primarily machinery guarding) NO If ‘Yes’ STOP do not
progress. Only complete the modification with the
authorisation of the Subject Matter Expert
(SME) Advice on identifying SME’s is
available in the guidance document to this process
If ‘No’ Progress to
Step 3
Computers or VDU’s, including all software & hardware NO Electrical Systems and any power supplies NO Machinery Controls NO Address Interpretation Systems NO Safety Systems such as interlocks, emergency stops, signs NO Machines under warranty NO Introducing substances to machinery hazardous to health NO Lifts and lifting equipment inc mechanical handling equipment NO Road vehicles NO
Section 3 CHANGE - JUSTIFICATION Description of change activity and improvement opportunity
To enable operators to comfortably sort flats and letters into different perstop trays. This will remove the likelihood of any manual handling injury whilst performing this process.
Monitoring Period used to justify the need for Change? From: To: Yes/No Target Benefit? Achieved Y/N? Benefits from the Work Equipment Change Activity
Safety? YES Nil injuries from manual handling Legal? YES SSOW in conjunction with HASAW
1974
Financial? YES Efficiency improvement Quality? YES Sortation process won’t have as many
errors
Performance? YES Modern approach to performing the task to a high standard
Equipment Availability? NO Other? (Describe) NO
During a trial the benefits of any change must be monitored for 90 days. This will prove the effectiveness of the change so it can be horizontally expanded outside the initiating unit or show if the change needs to be reversed. Is the change reversible? (It must be possible to return the work equipment to its original state)
YES Explain: The conveyors can be removed from the unit
Section 4 CHANGE - ACTIVITY What change activity is involved? Yes/No (Yes) (No) New Work Equipment, whether purchased, hired, or leased, even on a temporary basis
YES
2
Work Equipment Change Safety Assessment Template Owner: S. White Version: 4.0 Date: Nov 2012
Modification to Work Equipment even on a temporary basis (As defined in the guidance document)
NO If any option is
‘Yes’ progress with the Work
Equipment Change Safety Assessment
If all options are ‘No’ there is no need to progress with the Work Equipment Change Safety Assessment
Replacement of a component where the replacement isn’t like-for-like
NO
Change of use for the Work Equipment
NO
Significant change of workplace layout due to relocation of fixed Work Equipment or mechanised equipment
NO
Change of environmental in which the equipment is designed to operate
NO
Section 5 CHANGE - SIGNIFICANCE Indicate all that apply and complete all relevant assessments Yes? If Yes
Powered Work Equipment
Which is new or the change impacts on the safety systems, controls, powered elements or it’s sufficiently close to the powered elements/moving parts to constitute a significant risk.
YES Step 6 (1) Applies
Which is not new and the change does not impact on the safety systems, controls, powered elements or it isn’t sufficiently close to the powered elements/moving parts to constitute a significant risk.
NO Step 6 (3) Applies
Non-Powered Work Equipment with moving parts Exclusion, (see Note**)
Which is new or the change impacts on the safety systems, controls, moving parts or it’s sufficiently close to the moving parts to constitute a significant risk.
NO Step 6 (2) Applies
Which is not new and the change does not impact on the safety systems, controls, moving parts or it isn’t sufficiently close to the moving parts to constitute a significant risk.
NO Step 6 (4) Applies
Non-Powered Work Equipment with no moving parts Inclusion (see Note**) NO Step 6 (5) Applies Lifts & Lifting Work Equipment (LOLER assessments are likely for some of the above) Prohibited Changed contact SME
NO Step 6 (6) Applies
Ergonomic Task Activities (Ergonomic task activities are likely to apply in most cases) YES Step 6 (7) Applies Note** Work equipment, where the only moving parts are wheels used to move that work equipment from one static location to another and where those wheels are then locked in place.
Section 6 CHANGE – ASSESSMENT TYPE Change Significance Assessment
Required By Whom Complete
Appendix 1 Powered Work Equipment which is new or
the change impacts on the safety systems, controls, powered elements/moving parts or it’s sufficiently close to the powered elements to constitute a significant risk.
PUWER Assessment.
(Nationally) Head of Engineering Safety (Geographical/Functional/Local) Geographical/Functional Director Safety Appoints an assessor
2
2 Non-Powered Work Equipment with moving parts which is new or the change impacts on the safety systems, controls, moving parts or it’s sufficiently close to the moving parts to constitute a significant risk. Exclusion, see Note**
(Nationally) Head of Logistics & Facilities Management Safety (Geographical/Functional/Local) Geographical/Functional Director Safety Appoints an assessor
NOTE: PUWER Assessment: Before making this modification is the machine/work equipment of standard configuration &/or up to current specification
Yes / No If ‘No’ STOP until such time as the machine or work
equipment has been brought up to current specification
If ‘Yes’ Progress YES
3 Powered Work Equipment which is not new and the change does not impact on the safety systems, controls, powered elements/moving parts or it isn’t sufficiently close to the powered elements to constitute a significant risk.
Screening Assessment
To determine if a
PUWER
Project Manager or Operational Line Manager
1
4 Non-Powered Work Equipment with moving parts which is not new and the change does
3
Work Equipment Change Safety Assessment Template Owner: S. White Version: 4.0 Date: Nov 2012
not impact on the safety systems, controls, moving parts or it isn’t sufficiently close to the moving parts to constitute a significant risk. Exclusion, see Note **
assessment and/or Ergonomic
assessment is required
If in doubt how to proceed seek advice from the local
Safety Team
5 Non-Powered Work Equipment with no moving parts (New or existing) Inclusion, see Note **
Section 6 cont. CHANGE – ASSESSMENT TYPE 6 Lifts and Lifting Work Equipment
Lift Operations & Lifting Equipment
Assessment
Head of Logistics & Facilities Management Safety appoints a Technical Assessor or Safety
Advisor
3
7 Work Equipment used to manually lift, carry, transport or hold loads or that needs to be manually handle
Ergonomic Screening
Assessment
Project Manager, Operational Line Manager or Technical Assessor or Safety Advisor
4
Section 7 CHANGE – IMPACT The intention is that each item of work equipment will have a Work Equipment Change Safety Assessment to assess if it is intrinsically safe to use within Operations & Modernisation and a SAC1 (or equivalent) to determine the level of risk that exists from hazards encountered while using the work equipment in task activities in operations. What impact does the change have on the SAC1? Yes/No (Yes) (No) Is the Work Equipment new and will operator task activities be affected by the introduction of the work equipment?
YES Produce a SAC1 to assess task activities
There is no need to produce a SAC1
If the Change is to existing Work Equipment is there the potential for the Change to impact on any task activities associated with the use of the work equipment?
NO Amend the existing SAC1 or create one
if none exists
There is no need to review the
SAC1 List the SAC1 impacted on by the change: 1) SAC1 covering operational use of Work Equipment (where equipment is introduced as a stand alone item) 2) Project SAC1 (when work equipment is introduced as part of a wider project related to a new procedure)
We have 6 separate conveyors, all made to the same specification, that will be used to help with the
smooth sortation of flats and letters and parcels into the correct containers.
Section 8 STAKEHOLDERS LIST ANY INPUT RECEIVED AND FROM WHO Names and contact details
(Where applicable) Date input received
Unit Manager (Unit Level Work Equipment Change) Paul Laidler Safety Lead Kenny Mckean Geographical Director Safety (GDS) Steve Greaves Head of Logistics & Facilities Management Safety National Asset Team (introduction of or change to assets) Head of Engineering Safety Del Roffey Subject Matter Expert (SME) PUWER Assessor Scott Sutherland 03/07/14 LOLER Assessor NOT NEEDED Ergonomic Assessor Corinne Parsons Other (specify) Other (specify) LIST STAKEHOLDERS SUPPLYING INPUT &/or BEING CONSULTED (For National, Geographical & Unit Level Work Equipment Change)
Names and contact details (Where applicable)
Date consulted &/or input received
UNITE (National) UNITE (Local or Geographical) Alex Sayers 03/07/14
4
Work Equipment Change Safety Assessment Template Owner: S. White Version: 4.0 Date: Nov 2012
CWU (National) CWU (Local of Geographical) (Ops &/or Engineering) Mark Hugall / Ian Robson Other (specify)
Section 9 WORK EQUIPMENT CHANGE SAFETY ASSESSMENT I can confirm that I have the appropriate level of competency, in terms of knowledge and experience of completing other assessments, to allow me to sign off this Work Equipment Change Safety Assessment. I can confirm that on completion of the assessment and associated specialist assessments that provided all outstanding actions are completed and no significant risks are identified and still outstanding that this work equipment is fit for purpose and the intended use to which it will be put within the Business, and that the user of the work equipment or persons who may be affected by its use have been safeguarded from any risks Name Date Signature Project Manager or Operational Line Manager (Not valid unless signed)
Martyn Dundas 03/07/14
Project Managers should: • Sign the Work Equipment Change Safety Assessment in all case and retain a copy of it and all appendices • Forward copies as appropriate:
Local Projects - The Unit Manager Geographical Projects - The Geographical Director Safety National Projects - Head of Logistics & Facilities Management Safety (Non-Powered Equipment) - Head of Engineering Safety (Powered Equipment) - SME (For change specific to areas of Prohibited Change)
PROCESS CONCURRENCE NATIONAL DEPLOYMENTS & CHANGE involving PUWER & LOLER
Name Date Signature Head of Logistics & FM Safety
(Non-Powered)
OR Name Date Signature Head of Engineering Safety
(Powered)
GEOGRAPHICAL or FUNCTIONAL or UNIT DEPLOYMENTS & CHANGE involving PUWER & LOLER (Powered & Non Powered) Name Date Signature
Geographical Director Safety PROHIBITED CHANGE ACTIVITY or SME DEPLOYMENTS & CHANGE involving PUWER & LOLER
& / OR Name Date Signature Subject Matter Expert (SME)
POWERED WORK EQUIPMENT & LIFT WORK EQUIPMENT DEPLOYMENTS & CHANGE Name Date Signature Assets Supply Chain Manager
(Where it is applicable the Process Concurrence is not valid unless signed by at least one of the above)
WORK EQUIPMENT CHANGE SAFETY ASSESSMENT APPENDICIES 1. Work Equipment
Screening Assessment Work Equipment
Screening Assessmen
2. PUWER Assessment (Powered
Equipment)
For Powered Equipment Technical Assessors should
use the PUWER Assessment Tool provided by Engineering
2. PUWER Assessment (Non-
Powered Equipment)
For Non Powered Equipment Technical Assessors or Safety
Advisor should use this PUWER
3. LOLER Assessment
LOLER Assessment v1.2
5
Work Equipment Change Safety Assessment Template Owner: S. White Version: 4.0 Date: Nov 2012
Assessment
PUWER Assessment v1.6
4. Ergonomic Screening
Assessment Ergonomic Screening Assessment v1.2
(All assessments must be signed and attached where they are required )
SAC1 Template: Template Owner: S. White Version: 4.3 Date: July 2013
SAFETY ASSESSMENT & CONCURRENCE (SAC1)
Project/Programme/Product Title
Cut and Tip Conveyors Task or Work Equipment Photograph
Project/Programme/Product Description
Installation and use of Incline and/or Horizontal Conveyors
Deliver, install, use and maintain c100 conveyor systems into 22 mail centres. To provide further systems on an on-going case by case basis
Proposed Schedule, Timescales
Deployment Start: 22 April 2015 Deployment Finish: 26 June 2015 (est) Additional timescales on a case by case basis
Project Lead (Contact Details)
Murray Cook (Business Case Owner) 07702 678200
NATIONAL (SMS 8.1) REGIONAL (SMS 8.2) UNIT (SMS 8.3)
SAC1 Level X
LIST SAFETY INPUT(s) REQUIRED (indicate if applies)
Y/N CATEGORY NAME & CONTACT DETAILS
GROUP SAFETY RISK IMPROVEMENT MANAGER Y 8.1 Joanna Hosking NATIONALLY APPOINTED SAFETY LEAD N 8.1 PROGRAMMES DIRECTOR/MANAGER (as applicable) Y 8.1 Warren Cabot SENIOR SAFETY PROFESIONNAL N 8.1, 8.2 or 8.3 PROJECT SAFETY LEAD N 8.2 or 8.3 PROGRAMMES MANAGER N 8.2 SAFETY ADVISOR N 8.3 PROJECT MANAGER (If different from Project Lead) Y 8.1 & 8.2 & 8.3 Ray Pipe 07703 404378 SUBJECT MATTER EXPERT - Conveyors Y 8.1 Craig Dowe 07587 657236 PROPERTY & FACILITIES (SAFETY TEAM) N As appropriate ENGINEERING (SAFETY TEAM) Y As appropriate Del Roffey/Pete McGowan LOGISTICS (SAFETY TEAM) – (VEHICLES) N As appropriate ASSETS (SAFETY TEAM) N As appropriate ERGONOMIST As appropriate NOTE: This equipment has
been ergonomically assessed prior to national deployment
STAKEHOLDER CONSULTATION Y/N STAGE NAME & CONTACT DETAILS Is consultation necessary with the CWU
Y 8.1 Consultation conducted and agreed with Terry Pullinger through National Steering
Group. Via Francis
Terry Pullinger
SAC1 Template: Template Owner: S. White Version: 4.2 Date: July 2013
Williams/Murray Cook
Is consultation necessary with Unite CMA
Y Martyn Bunn [email protected]
Is consultation necessary with any other stakeholder?
N
LIST ADVICE OBTAINED Y/N STAGE NAME & CONTACT DETAILS HEALTH & SAFETY EXECUTIVE N As appropriate ENVIRONMENTAL HEALTH OFFICER N As appropriate FIRE AUTHORITY N As appropriate OTHER? N As appropriate OTHER? N As appropriate
CONSTRUCTION, DESIGN & MANAGEMENT YES / NO
Does CDM apply to the project? No If ‘Yes’ is the project notifiable to the HSE? No LIST REQUIRED SAFETY INPUT Y/N STAGE NAME & CONTACT DETAILS Strategic CDM Co-ordinator As appropriate N/A Local CDM Co-ordinator As appropriate N/A
SAC
1 T
empl
ate:
T
empl
ate
Ow
ner:
S. W
hite
V
ersi
on: 4
.2
Dat
e: Ju
ly 2
013
STEP
1
INIT
IAL
RISK
ASS
ESSM
ENT
List
bel
ow ta
sks
or w
ork
equi
pmen
t inv
olve
d &
the
haza
rds
asso
ciate
d w
ith th
em &
thos
e pe
ople
affe
cted
, list
all
exis
ting
cont
rols
& r
ate
the
leve
l of r
isk.
Use
sep
arat
e as
sess
men
t se
ctio
ns fo
r ea
ch ta
sk o
r w
ork
equi
pmen
t & a
dd m
ore
asse
ssm
ent s
ectio
ns a
nd e
xpan
ding
as
need
ed. I
f any
risk
s ar
e to
lera
ble
or a
bove
, mov
e to
Ste
p 2
Risk
Con
trol
.
Task
or
Wor
k Eq
uipm
ent
Iden
tifie
d H
azar
ds
Asso
ciate
d Ri
sk
Peop
le
Affe
cted
Ex
istin
g Co
ntro
l(s)
Risk
Ass
essm
ent
Out
com
e Se
e M
atrix
Li
kelih
ood
Seve
rity
Tota
l Co
nvey
or
enab
ling
wor
ks
and
inst
alla
tion.
Build
ing
& El
ectr
ical
Wor
ks.
Wor
king
with
tool
s,
Wor
king
at h
eigh
t In
corr
ect u
se o
f too
ls
Poor
man
ual h
andl
ing
Vario
us in
jurie
s as
a
resu
lt of
the
task
s be
ing
unde
rtak
en fo
r th
e pr
ojec
t.
Cont
ract
ors
RoM
EC –
Pro
vide
d W
ELLs
do
cum
ent d
efin
ing
gene
ric
proc
edur
e of
und
erta
king
wor
ks.
Site
sur
vey
visi
ts u
nder
take
n pr
ior
to c
omm
encin
g an
y w
orks
to
asc
erta
in lo
cal s
pecif
ic
cons
ider
atio
ns,
Conv
eyor
inst
alle
r (B
eum
er) –
Ri
sk A
sses
smen
t and
Met
hod
Stat
emen
ts (R
AMS)
pro
vide
d an
d is
sued
to n
omin
ated
per
son
at
each
site
.
1 4
4 To
lera
ble
Conv
eyor
M
ovem
ent
Mov
es v
ia F
LT &
Pal
let
Truc
k Ve
hicl
e &
pede
stria
n co
llisi
ons
Cont
ract
ors,
em
ploy
ees,
vi
sito
rs a
nd
cust
omer
s
Only
Beu
mer
per
mitt
ed to
re
mov
e co
nvey
ors
from
del
iver
y ve
hicl
es a
nd m
ove
into
fina
l po
sitio
n w
ithin
eac
h m
ail c
entr
e.
RAM
S do
cum
ents
pro
vide
d by
Be
umer
. Pro
ject
team
hav
e co
pies
of p
erso
ns tr
aine
d to
use
FL
Ts. A
ll co
nvey
ors
have
whe
els
to a
void
use
of l
iftin
g eq
uipm
ent
and
man
ual h
andl
ing
task
s w
hen
mov
ing
conv
eyor
s w
ithin
Mai
l Ce
ntre
and
into
fina
l pos
ition
. W
heel
s w
ill b
e re
mov
ed p
rior
to
fixin
g co
nvey
ors
to fl
oor
1 3
3 Ad
equa
tely
co
ntro
lled
Oper
atin
g th
e Po
or m
anua
l han
dlin
g M
uscu
losk
elet
al in
jurie
s U
nit s
taff
/ Cu
rren
t man
ual h
andl
ing
2 4
8 M
oder
ate
SAC
1 T
empl
ate:
T
empl
ate
Ow
ner:
S. W
hite
V
ersi
on: 4
.2
Dat
e: Ju
ly 2
013
conv
eyor
– to
pr
oces
s bu
ndle
s of
lette
rs a
nd
parc
els.
Cont
ract
ors/
Ro
MEC
Au
tom
atio
n
trai
ning
but
doe
s no
t inc
lude
this
co
nvey
or.
Man
ual H
andl
ing
SSOW
Op
erat
ing
the
conv
eyor
D
efec
tive
Mac
hine
, m
ovin
g pa
rts,
sha
rp
edge
s or
jagg
ed m
etal
ed
ges
Mus
culo
skel
etal
, str
ikin
g,
draw
n in
and
cut
s in
jurie
s
Empl
oyee
s an
d m
anag
ers
All c
onve
yors
hav
e au
dite
d pr
e-de
liver
y ch
ecks
at f
acto
ry. A
ll co
nvey
ors
have
com
mis
sion
ing
chec
ks a
nd fu
rthe
r ch
ecks
mad
e as
par
t of f
orm
al h
ando
ver.
All
conv
eyor
s el
ectr
ically
test
ed
prio
r to
firs
t use
, nip
gua
rd g
aps
chec
ked,
all
guar
ds a
re c
heck
ed
for
secu
rity,
saf
ety
and
mon
itorin
g de
vice
s ar
e ch
ecke
d (E
/Sto
ps).
SME
has
unde
rtak
en
Mac
hine
ry D
irect
ive
com
plia
nce
chec
ks a
s pa
rt o
f Reg
ulat
ion
10
and
11 o
f PU
WER
98. O
pera
ting
inst
ruct
ions
hav
e be
en p
rovi
ded
and
oper
ator
trai
ning
ses
sion(
s)
will
be
prov
ided
at e
ach
inst
alla
tion
site
. Nam
ed a
nd
trai
ned
deta
ils w
ill b
e pr
ovid
ed.
Loca
l PU
WER
ass
esso
r to
un
dert
ake
and
com
plet
e PU
WER
as
sess
men
t at e
ach
inst
alla
tion.
Gu
idan
ce w
ill b
e av
aila
ble
from
th
e SM
E
2 4
8 M
oder
ate
(d
ue to
fin
al
PUW
ER
asse
ssm
ent a
ctiv
ity)
Mai
ntai
ning
the
conv
eyor
M
aint
enan
ce
proc
edur
es
Mus
culo
skel
etal
, str
ikin
g,
draw
n in
and
cut
s in
jurie
s
Mai
nten
ance
En
gine
ers
Mai
nten
ance
pro
cedu
res
have
be
en p
rovi
ded
and
cont
aine
d w
ithin
the
Mai
nten
ance
Man
ual.
A te
chni
cal t
rain
ing
cour
se w
ill
be p
rovi
ded
at e
ach
site
1 4
4 To
lera
ble
Mai
ntai
ning
the
Def
ectiv
e M
achi
ne,
Mus
culo
skel
etal
, str
ikin
g,
Mai
nten
ance
Al
l con
veyo
rs h
ave
audi
ted
pre-
2 4
8 M
oder
ate
SAC
1 T
empl
ate:
T
empl
ate
Ow
ner:
S. W
hite
V
ersi
on: 4
.2
Dat
e: Ju
ly 2
013
conv
eyor
m
ovin
g pa
rts,
sha
rp
edge
s or
jagg
ed m
etal
ed
ges
draw
n in
and
cut
s in
jurie
s En
gine
ers
deliv
ery
chec
ks a
t fac
tory
. All
conv
eyor
s ha
ve c
omm
issi
onin
g ch
ecks
and
furt
her
chec
ks m
ade
as p
art o
f for
mal
han
dove
r. Al
l co
nvey
ors
elec
trica
lly te
sted
pr
ior
to fi
rst u
se, n
ip g
uard
gap
s ch
ecke
d, a
ll gu
ards
are
che
cked
fo
r se
curit
y, s
afet
y an
d m
onito
ring
devi
ces
are
chec
ked
(E/S
tops
). SM
E ha
s un
dert
aken
M
achi
nery
Dire
ctiv
e co
mpl
ianc
e ch
ecks
as
part
of R
egul
atio
n 10
an
d 11
of P
UW
ER98
. Ope
ratin
g in
stru
ctio
ns h
ave
been
pro
vide
d an
d op
erat
or tr
aini
ng s
essio
n(s)
w
ill b
e pr
ovid
ed a
t eac
h in
stal
latio
n si
te. N
amed
and
tr
aine
d de
tails
will
be
prov
ided
. Lo
cal P
UW
ER a
sses
sor
to
unde
rtak
e an
d co
mpl
ete
PUW
ER
asse
ssm
ent a
t eac
h in
stal
latio
n.
Guid
ance
will
be
avai
labl
e fr
om
the
SME
(due
to
final
PU
WER
as
sess
men
t act
ivity
)
Yard
Saf
ety
Mov
emen
t of o
ur
vehi
cles
in th
e ya
rd
whe
re th
e co
ntra
ctor
s ar
e w
orki
ng to
unl
oad
the
conv
eyor
s
Vehi
cle
colli
sion
s w
ith
peop
le M
E lif
ting
equi
pmen
t
Cont
ract
ors
Risk
Ass
essm
ent a
nd M
etho
d St
atem
ents
will
be
prov
ided
by
the
cont
ract
or p
rior
to e
ach
deliv
ery.
Enq
uirie
s w
ill b
e m
ade
for
any
spec
ial r
equi
rem
ents
1 4
4 To
lera
ble
Wor
kpla
ce
Safe
ty
Mov
emen
t of m
achi
nes
thro
ugh
the
wor
kpla
ce
from
the
plat
form
Crus
hing
and
str
ikin
g ag
ains
t inj
urie
s Co
ntra
ctor
s,
empl
oyee
s,
visi
tors
and
cu
stom
ers
Conv
eyor
s ar
e m
oved
on
cast
ers
with
in e
ach
site
to e
limin
ate
use
of m
anua
l han
dlin
g eq
uipm
ent.
Wor
kpla
ce R
isk
Asse
ssm
ent –
W
TLL
to m
ake
staf
f aw
are
of th
e in
stal
latio
n.
3 4
12
Mod
erat
e
SAC
1 T
empl
ate:
T
empl
ate
Ow
ner:
S. W
hite
V
ersi
on: 4
.2
Dat
e: Ju
ly 2
013
Cont
ract
or
cont
rol
Cont
ract
ors
who
are
un
fam
iliar
with
RM
G in
divi
dual
site
saf
ety
polic
y
Step
ping
, str
ikin
g, s
lip,
trip
s, fa
lls o
r m
uscu
losk
elet
al in
jurie
s
Cont
ract
ors
Site
indu
ctio
n in
to th
e w
ork
area
an
d re
mov
al fr
om s
ite if
st
anda
rds
are
brea
ched
1 4
4 To
lera
ble
Fire
Saf
ety
Erec
tion
of te
mpo
rary
fe
ncin
g in
the
area
w
here
the
conv
eyor
s w
ill b
e in
stal
led
Rest
ricte
d ac
cess
, egr
ess
entr
ance
and
rou
tes
or
wal
kway
s to
fire
exi
ts
Cont
ract
ors,
em
ploy
ees,
vi
sito
rs a
nd
cust
omer
s
Fire
Ris
k As
sess
men
t. Pr
emis
es F
ire E
vacu
atio
n Pl
ans
(PFE
P)
Pers
onal
Em
erge
ncy
Evac
uatio
n Pl
ans
(PEE
P)
3 4
12
Mod
erat
e
Noi
se
Incr
ease
d le
vels
of
nois
e in
the
wor
k ar
ea
Shor
t or
long
term
he
arin
g de
fect
s du
e to
th
e ex
posu
re to
the
nois
e le
vels
Empl
oyee
s an
d m
anag
ers
From
the
man
ufac
ture
rs d
etai
ls
the
nois
e m
easu
red
at th
e op
erat
or p
ositi
ons
on th
e in
clin
e an
d ho
rizon
tal c
onve
yors
is
44dB
whe
n in
nor
mal
run
ning
, D
urin
g th
e st
art s
ound
er a
nd
whe
n an
em
erge
ncy
stop
is
depr
esse
d th
e no
ise
mea
sure
men
t at o
pera
tor
posi
tions
has
bee
n m
easu
red
at
76dB
. Alth
ough
by
desi
gn th
e co
nvey
ors
are
rela
tivel
y qu
iete
it
is u
nkno
wn
if th
is w
ill h
ave
a cu
mul
ativ
e ef
fect
in it
’s fin
al
inst
alle
d lo
catio
n
3 3
9 M
oder
ate
Wor
k Eq
uipm
ent
New
mac
hine
s no
t ad
ded
to th
e cu
rren
t W
ork
Equi
pmen
t Ris
k As
sess
men
t
Inju
ries
as a
res
ult o
f the
us
e of
the
mac
hine
Em
ploy
ees
and
man
ager
s
Wor
k Eq
uipm
ent R
isk
Asse
ssm
ent
3 3
9 M
oder
ate
ST
EP 2
RI
SK C
ON
TRO
L Li
st a
ll ta
sks
or w
ork
equi
pmen
t rat
ed in
Ste
p 1
as to
lera
ble
or a
bove
. Ide
ntify
& r
ecor
d th
e ad
ditio
nal c
ontr
ol m
easu
res
nece
ssar
y to
ens
ure
risks
are
rem
oved
or
redu
ced
to a
n ac
cept
able
leve
l. On
the
assu
mpt
ion
thes
e ris
k co
ntro
ls w
ill b
e in
trod
uced
com
plet
e th
e ris
k as
sess
men
t ass
essin
g th
eir
impa
ct o
n th
e ris
k ra
ting.
Whe
re a
ny a
dditi
onal
con
trol
s ar
e pr
opos
ed b
ut c
anno
t be
imm
edia
tely
impl
emen
ted
add
them
at S
tep
5. W
here
nec
essa
ry o
btai
n ad
vice
from
the
Safe
ty L
ead
to th
e pr
ojec
t. Us
e se
para
te a
sses
smen
t sec
tions
for
SAC
1 T
empl
ate:
T
empl
ate
Ow
ner:
S. W
hite
V
ersi
on: 4
.2
Dat
e: Ju
ly 2
013
each
task
or
wor
k eq
uipm
ent &
add
mor
e as
sess
men
t sec
tions
and
exp
and
as n
eces
sary
.
Task
or
Wor
k Eq
uipm
ent
Out
com
e Se
e St
ep1
Addi
tiona
l Con
trol
Mea
sure
s Co
mpl
etio
n D
ate
By W
hom
Co
mpl
eted
Ye
s?
Risk
Ass
essm
ent
Out
com
e Se
e M
atrix
Li
kelih
ood
Seve
rity
Tota
l 1.
Ope
ratin
g th
e Co
nvey
or
Mod
erat
e In
itial
trai
ning
will
be
prov
ided
by
the
cont
ract
or p
rior
to fi
rst u
se u
sing
oper
atio
nal
and
tech
nica
l man
uals
. For
on-
goin
g tr
aini
ng
crea
te a
trai
ning
pac
kage
to e
nsur
e al
l em
ploy
ees
and
man
ager
s ar
e co
mpe
tent
to
use
the
conv
eyor
. Exi
stin
g do
cum
enta
tion
coul
d be
use
d fo
r th
is if
requ
ired.
Er
gom
ic as
sess
men
t of c
onve
yors
with
reg
ard
to c
uttin
g &
tippi
ng, h
andl
ing
and
sort
atio
n of
pa
rcel
s an
d m
ail i
tem
s in
to c
onta
iner
s su
ch a
s Yo
rks
& M
ini-
York
s.
SSOW
for
oper
atio
n of
con
veyo
r in
corp
orat
ing
the
reco
mm
neda
tions
in th
e Er
gono
mic
Asse
ssm
ent.
At d
ate
of fi
rst
use
and
will
be
ong
oing
m
ovin
g fo
rwar
d 19
/02/
2015
27
/11/
2015
Firs
t use
-
Cont
ract
or
(Beu
mer
) On
goin
g –W
PC
Corin
ne
Pars
ons
Ken
Hou
se
Each
site
to
conf
irm.
Yes
1 4
4 To
lera
ble
Mod
erat
e PU
WER
ass
essm
ent t
o be
con
duct
ed o
n th
e m
achi
ne to
ens
ure
it m
eets
the
requ
irem
ents
of
the
Mac
hine
Dire
ctiv
e an
d as
socia
ted
stan
dard
s
Each
site
to
advi
se d
ate
whe
n co
mpl
eted
Loca
l PU
WER
as
sess
or w
ith
guid
ance
from
SM
E Cr
aig
Dow
e if
req’
d
Each
site
to
conf
irm
whe
n co
mpl
eted
1 4
4 To
lera
ble
2. M
aint
aini
ng
the
conv
eyor
M
oder
ate
Initi
al tr
aini
ng w
ill b
e pr
ovid
ed b
y th
e co
ntra
ctor
prio
r to
firs
t use
. For
on-
goin
g tr
aini
ng c
reat
e a
trai
ning
pac
kage
to e
nsur
e al
l m
aint
aine
rs a
re c
ompe
tent
to m
aint
ain
and
use
the
conv
eyor
. Pro
vide
, us
ing
oper
atio
nal
and
tech
nica
l tra
inin
g m
anua
ls.
Each
site
to
advi
se d
ate
whe
n co
mpl
eted
Firs
t use
–
Cont
ract
or
(Beu
mer
) On
goin
g -
ETC
Each
site
to
conf
irm
whe
n co
mpl
eted
1 3
3 Ad
equa
tely
Co
ntro
lled
SAC
1 T
empl
ate:
T
empl
ate
Ow
ner:
S. W
hite
V
ersi
on: 4
.2
Dat
e: Ju
ly 2
013
3. Y
ard
Safe
ty
Mod
erat
e
Unlo
adin
g of
the
conv
eyor
s to
be
in a
n ar
ea
whe
re th
ere
are
eith
er n
o or
res
trict
ed v
ehicl
e m
ovem
ents
and
pre
fera
bly
durin
g th
e qu
iete
st
time
of th
e op
erat
ion.
Re
view
the
Yard
Risk
Ass
essm
ent
Each
site
to
advi
se d
ate
whe
n co
mpl
eted
Betw
een,
pr
ojec
t m
anag
er,
nom
inat
ed s
ite
cont
act a
nd
Cont
ract
or
(Beu
mer
)
Each
site
to
conf
irm
whe
n co
mpl
eted
1 4
4 To
lera
ble
4.
Wor
kpla
ce
Safe
ty
Mod
erat
e Re
view
the
Wor
kpla
ce R
isk A
sses
smen
t to
ensu
re th
e lo
catio
n of
the
mac
hine
s ar
e co
nsid
ered
Each
site
to
advi
se w
hen
com
plet
ed
Site
pro
ject
le
ad,
Regi
onal
SH
E ad
vise
r
(CW
U Sa
fety
Re
p)
(saf
ety
rep)
Each
site
to
conf
irm
whe
n co
mpl
eted
1 4
4 To
lera
ble
6. F
ire S
afet
y M
oder
ate
Revi
ew th
e fu
ll fir
e ris
k as
sess
men
t to
capt
ure
the
new
ly in
stal
led
mac
hine
s an
d th
e as
socia
ted
fire
emer
genc
y te
sts
and
evac
uatio
ns.
Each
site
to
advi
se d
ate
whe
n co
mpl
eted
Site
pro
ject
le
ad,
Regi
onal
SH
E ad
vise
r
(CW
U Sa
fety
Re
p)
(saf
ety
rep)
Rep)
(s
afet
y re
p)
Each
site
to
conf
irm
whe
n do
ne
1 4
4 To
lera
ble
7. N
oise
M
oder
ate
Prev
ious
site
spe
cific
nois
e ris
k as
sess
men
ts
shou
ld b
e re
view
ed to
asc
erta
in if
follo
win
g th
e in
trod
uctio
n of
the
conv
eyor
s m
ay ti
p th
e ba
lanc
e of
exc
eedi
ng a
ny n
oise
thre
shol
ds fo
r th
at a
rea
SHE
to a
dvise
da
te w
hen
com
plet
ed
Regi
onal
SH
E ad
vise
r
(CW
U) S
afet
y Re
p)
SHE
to
advi
se w
hen
done
1 3
Ad
equa
tely
Co
ntro
lled
8. W
ork
Equi
pmen
t M
oder
ate
Add
the
new
equ
ipm
ent t
o th
e w
ork
equi
pmen
t list
and
ass
ess.
Pas
s as
set d
etai
ls
on to
AD
ST
PEM
to a
dd
date
whe
n co
mpl
eted
(PEM
) SM
E Cr
aig
Dow
e
PEM
to
advi
se w
hen
done
1 3
3 Ad
equa
tely
Co
ntro
lled
SAC
1 T
empl
ate:
T
empl
ate
Ow
ner:
S. W
hite
V
ersi
on: 4
.2
Dat
e: Ju
ly 2
013
U
se th
e Ri
sk M
atrix
in S
MS
2.1
Risk
Man
agem
ent S
tand
ard
to a
sses
s th
e ta
sk o
r w
ork
equi
pmen
t in
all s
ectio
ns a
bove
.
Over
all A
sses
smen
t W
hen
the
addi
tiona
l con
trol
mea
sure
s ar
e id
entif
ied
prog
ress
with
the
risk
asse
ssm
ent b
ased
on
the
new
info
rmat
ion.
Al
l tho
se a
sses
sed
as A
dequ
atel
y Co
ntro
lled
or T
oler
able
Go
to S
tep
5 An
y th
at a
re a
sses
sed
as M
oder
ate
or a
bove
Go
to S
tep
3
STEP
3
DET
AILE
D R
ISK
ASSE
SSM
ENT
List
all
task
s or
wor
k eq
uipm
ent r
ated
as
mod
erat
e or
abo
ve in
Ste
p 2
in th
e D
etai
led
Asse
ssm
ent s
ectio
n be
low
, whe
re th
e ad
ditio
nal c
ontr
ols
intr
oduc
ed o
r in
tend
ed fo
r in
trod
uctio
n in
Ste
p 2
cann
ot c
ontr
ol th
e ris
ks to
at l
east
an
adeq
uate
leve
l. It
is e
ssen
tial a
t thi
s po
int t
hat t
he S
afet
y Le
ad fo
r th
e pr
ojec
t is
cons
ulte
d. W
ith th
eir
assi
stan
ce id
entif
y w
hich
of t
he a
dditi
onal
det
aile
d ris
k as
sess
men
ts a
re r
equi
red.
The
se a
sses
smen
ts s
houl
d be
use
d to
iden
tify
and
reco
rd a
ny s
pecif
ic co
ntro
l mea
sure
s th
e te
chni
cal s
afet
y sp
ecia
list
com
plet
ing
the
asse
ssm
ent f
eels
are
nec
essa
ry to
ens
ure
risks
are
rem
oved
or
redu
ced
to a
n ac
cept
able
leve
l. W
here
pos
sibl
e ad
ditio
nal c
ontr
ols
shou
ld b
e im
plem
ente
d st
raig
ht
away
. Whe
re a
dditi
onal
con
trol
s ar
e pr
opos
ed b
ut n
ot y
et im
plem
ente
d ad
d th
em a
t Ste
p 5.
Add
mor
e as
sess
men
t sec
tions
and
exp
and
as n
eces
sary
to r
ecor
d yo
ur fi
ndin
gs.
POSS
IBLE
DET
AILE
D R
ISK
ASSE
SSM
ENTS
1
Wor
k Eq
uipm
ent C
hang
e Sa
fety
Ass
essm
ent (
Man
dato
ry fo
r al
l cha
nge
to w
ork
equi
pmen
t) 7
Det
aile
d Re
desi
gn A
sses
smen
t (Fu
ndam
enta
l cha
nge
to th
e pr
ojec
t/pro
cess
) 2
Ergo
nom
ic As
sess
men
t 8
Haz
ard
& Op
erab
ility
Ass
essm
ent/S
tudy
(HAZ
OP)
3 CD
M A
sses
smen
t 9
Epid
emio
logi
cal A
sses
smen
t 4
Prop
erty
& F
acili
ties
Stru
ctur
al A
sses
smen
t (Fu
ndam
enta
l cha
nge
in b
uild
ing
stru
ctur
e)
10
Hea
lth e
ffect
s As
sess
men
t/Stu
dy/S
urve
illan
ce
5 Ya
rd r
isk A
sses
smen
t 11
N
oise
Ass
essm
ents
6
Fire
Sur
vey
and/
or F
ire r
isk A
sses
smen
t 12
Ot
her
Asse
ssm
ent -
spe
cify
Ta
sk o
r W
ork
Equi
pmen
t O
utco
me
See
Step
2
Det
aile
d Ri
sk A
sses
smen
ts
Com
plet
ion
Dat
e By
Who
m
Com
plet
ed
Yes?
Ri
sk A
sses
smen
t O
utco
me
See
Mat
rix
Like
lihoo
d Se
verit
y To
tal
Ta
sk o
r W
ork
Equi
pmen
t O
utco
me
See
Step
2
Det
aile
d Ri
sk A
sses
smen
ts
Com
plet
ion
Dat
e By
Who
m
Com
plet
ed
Yes?
Ri
sk A
sses
smen
t O
utco
me
See
Mat
rix
Like
lihoo
d Se
verit
y To
tal
Use
the
Risk
Mat
rix in
SM
S 2.
1 Ri
sk M
anag
emen
t Sta
ndar
d to
ass
ess
the
task
or
wor
k eq
uipm
ent.
SAC
1 T
empl
ate:
T
empl
ate
Ow
ner:
S. W
hite
V
ersi
on: 4
.2
Dat
e: Ju
ly 2
013
STEP
4
RESI
DU
AL R
ISKS
If
ther
e ar
e an
y re
sidu
al r
isks
mod
erat
e or
abo
ve a
fter
step
3, t
ake
the
follo
win
g ac
tion:
RESI
DU
AL R
ISK
ACTI
ON
S FO
R RI
SKS
ABO
VE M
OD
ERAT
E YE
S N
O
1. S
afet
y Le
ad to
esc
alat
e al
l risk
s m
oder
ate
or a
bove
for
advi
ce o
n a
way
forw
ard
to th
e Gr
oup
Safe
ty R
isk Im
prov
emen
t Man
ager
(8.1
) or
the
mos
t Sen
ior
Safe
ty
Prof
essi
onal
in th
e Bu
sine
ss U
nit (
ex. O
pera
tions
& M
oder
nisa
tion)
, Reg
ion,
Log
istic
s or
Sup
port
Fun
ctio
n (8
.2/3
)
2. S
afet
y Le
ad ta
kes
appr
opria
te c
ours
e of
act
ion
havi
ng e
scal
ated
the
issue
s:
a) A
bort
the
Proj
ect -
Do
not p
rogr
ess
b) A
bort
the
Proj
ect -
See
king
an
alte
rnat
ive
prod
uct/s
ervi
ce s
olut
ion,
then
sta
rt th
e Sa
fety
Ass
essm
ent &
Con
curr
ence
pro
cess
aga
in
c) R
evie
w s
teps
1 to
3. I
nclu
de a
dditi
onal
pro
posa
ls s
ugge
sted
by
the
Grou
p Sa
fety
Risk
Impr
ovem
ent M
anag
er (8
.1) o
r th
e Se
nior
Saf
ety
Prof
essi
onal
im
plem
entin
g th
e ad
ditio
nal c
ontr
ols
iden
tifie
d du
ring
the
revi
ew o
f the
pro
cess
. Whe
re c
ontr
ols
cann
ot b
e im
plem
ente
d im
med
iate
ly –
go
to S
tep
5 an
d ad
d to
the
conc
urre
nce
actio
ns.
ST
EP 5
CO
NCU
RREN
CE A
CTIO
N P
LAN
Re
cord
from
Ste
p 2
‘Ris
k Co
ntro
ls’ a
ny o
utst
andi
ng a
ctio
ns th
at s
till n
eed
to b
e im
plem
ente
d an
d an
y ad
ditio
nal r
isk c
ontr
ols
from
Ste
p 3
‘Det
aile
d Ri
sk A
sses
smen
t’ or
Ste
p 4
‘Res
idua
l Risk
s’ th
at a
re o
utst
andi
ng. R
espo
nsib
ility
and
tim
esca
les
for
com
plet
ion
shou
ld a
lso
be d
eter
min
ed. T
hese
are
par
t of t
he c
ondi
tions
of c
oncu
rren
ce. I
t is
impo
rtan
t to
reco
rd a
ny a
ctio
ns in
this
sect
ion
that
are
ess
entia
l to
the
proj
ect b
ut w
hich
can
not b
e de
ploy
ed b
efor
e sig
n of
f of t
his
proc
ess,
as
such
they
will
bec
ome
conc
urre
nt a
ctio
ns.
CON
CURR
ENCE
ACT
ION
Co
mpl
etio
n D
ate
By W
hom
Co
mpl
eted
? Y/
N
PUW
ER a
sses
smen
t to
be c
ondu
cted
on
the
mac
hine
to e
nsur
e it
mee
ts th
e re
quire
men
ts o
f the
Mac
hine
Dire
ctiv
e an
d as
socia
ted
stan
dard
s As
and
whe
n fo
r ea
ch
inst
alla
tion
Loca
l PU
WER
as
sess
or w
ith
guid
ance
from
Cr
aig
Dow
e if
reqd
Revi
ew th
e W
orkp
lace
Risk
Ass
essm
ent t
o en
sure
the
loca
tion
of th
e m
achi
nes
are
cons
ider
ed.
As a
nd w
hen
for
each
in
stal
latio
n
Site
lead
, re
gion
al S
HE
advi
sor,
loca
l sa
fety
rep
Revi
ew th
e fu
ll fir
e ris
k as
sess
men
t to
capt
ure
the
new
ly in
stal
led
mac
hine
s an
d th
e as
socia
ted
fire
emer
genc
y te
sts
and
evac
uatio
ns.
As a
nd w
hen
for
each
in
stal
latio
n
Site
lead
, re
gion
al S
HE
advi
sor,
loca
l sa
fety
rep
SAC
1 T
empl
ate:
T
empl
ate
Ow
ner:
S. W
hite
V
ersi
on: 4
.2
Dat
e: Ju
ly 2
013
Unde
rtak
e a
Noi
se te
st o
f the
are
a w
here
the
mac
hine
s ar
e lo
cate
d.
Revi
ew th
e N
oise
ris
k as
sess
men
t to
incl
ude
the
new
mac
hine
s If
requ
ired
at
each
site
Si
te le
ad,
regi
onal
SH
E ad
viso
r, lo
cal
safe
ty r
ep
Supp
ortin
g D
ocum
ents
Ass
ocia
ted
with
this
SAC
1
1)
RoM
EC W
ELL
docu
men
t for
ele
ctric
al p
ower
inst
alla
tion
2)
Co
ntra
ctor
Ris
k As
sess
men
t and
Met
hod
Stat
emen
t exa
mpl
e do
cum
enta
tion
for
conv
eyor
del
iver
ies
and
inst
alla
tion
3)
Man
ufac
ture
rs d
esig
n re
sidu
al r
isk a
sses
smen
t
4)
Oper
ator
man
ual
5)
M
aint
enan
ce m
anua
l
6)
Dra
ft SS
oW a
wai
ting
appr
oval
7)
Site
loca
tions
, spe
cifica
tion
and
num
ber
of c
onve
yors
at e
ach
type
(as
of 0
1/M
ay/2
015)
8)
Stan
dard
use
doc
umen
ts (K
en H
ouse
to p
rovi
de)
STEP
6
SAFE
TY R
ECOM
MEN
DAT
ION
By
sig
ning
bel
ow y
ou a
gree
that
one
of t
he b
elow
sta
tem
ents
app
lies
to y
ou, t
here
fore
del
ete
the
stat
emen
ts th
at d
o no
t app
ly
I am
sat
isfie
d in
rel
atio
n to
the
Prog
ram
me,
Pro
ject
or
Prod
uct d
eplo
ymen
t, in
clud
ing
in r
elat
ion
to h
azar
ds d
urin
g th
e op
erat
iona
l use
of w
ork
equi
pmen
t whe
re a
pplic
able
that
1.
Th
ere
are
no s
afet
y ris
ks fo
r m
y ar
ea o
f res
pons
ibili
ty. I
am
abl
e to
rec
omm
end
it fo
r fin
al s
afet
y co
ncur
renc
e.
2.
The
safe
ty r
isks
for
my
area
of r
espo
nsib
ility
are
ade
quat
ely
cont
rolle
d or
hav
e be
en r
educ
ed to
a to
lera
ble
risk.
I am
abl
e to
rec
omm
end
it fo
r fin
al s
afet
y co
ncur
renc
e.
3.
The
safe
ty r
isks
for
my
area
of r
espo
nsib
ility
hav
e be
en id
entif
ied
and
whi
le th
e co
ncur
renc
e ac
tions
hav
e no
t yet
bee
n de
ploy
ed, t
hey
have
bee
n re
cord
ed fo
r im
plem
enta
tion
via
the
Safe
ty M
anag
emen
t Pla
n or
the
Safe
ty A
sses
smen
t Con
curr
ence
Que
stio
ns &
Act
ions
doc
umen
t. I a
m a
ble
to r
ecom
men
d it
for
final
con
curr
ence
on
the
unde
rsta
ndin
g th
ese
actio
ns a
re c
ompl
eted
bef
ore
the
proj
ect i
s de
ploy
ed a
nd th
e ha
ndov
er c
ompl
eted
at U
nit l
evel
. CA
TEGO
RY (8
.1),
CATE
GORY
(8.2
) & C
ATEG
ORY
(8.3
) W
hich
App
ly**
N
AME
SIGN
ATU
RE
DAT
E N
ATIO
NAL
LY A
PPOI
NTE
D S
AFET
Y LE
AD
SEN
IOR
SAFE
TY P
ROFE
SIO
NN
AL (W
here
not
fina
l sig
nato
ry)
PROJ
ECT
SAFE
TY L
EAD
SA
FETY
AD
VISO
R (W
here
not
fina
l sig
nato
ry
PROJ
ECT
MAN
AGER
(If d
iffer
ent f
rom
Pro
ject
Lea
d)
3 Ra
y Pi
pe
Ray
Pipe
01
/05/
2015
SU
BJEC
T M
ATTE
R EX
PERT
– C
onve
yors
3
Crai
g D
owe
Crai
g Do
we
12/0
5/20
15
PROP
ERTY
& F
ACIL
ITIE
S (S
AFET
Y TE
AM)
N/A
CDM
CO-
ORD
INAT
OR
N/A
SAC
1 T
empl
ate:
T
empl
ate
Ow
ner:
S. W
hite
V
ersi
on: 4
.2
Dat
e: Ju
ly 2
013
ENGI
NEE
RIN
G (S
AFET
Y TE
AM)
3 D
el R
offe
y
M
AIN
TEN
ANCE
N
/A
LO
GIST
ICS
(SAF
ETY
TEAM
) – (V
EHIC
LES)
N
/A
AS
SETS
(SAF
ETY
TEAM
) N
/A
ER
GON
OMIS
T N
/A
STEP
7
FIN
AL S
AFET
Y CO
NCU
RREN
CE
By s
igni
ng b
elow
you
agr
ee th
at y
ou a
re s
atisf
ied
the
prog
ram
me/
proj
ect/p
rodu
ct h
as r
ecei
ved
adeq
uate
saf
ety
cons
ider
atio
ns a
nd th
at y
ou a
re p
repa
red
to g
ive
final
saf
ety
conc
urre
nce
on th
e un
ders
tand
ing
that
any
act
ions
in th
is do
cum
ent o
r th
e Sa
fety
Man
agem
ent P
lan
or th
e Sa
fety
Con
curr
ence
Gat
eway
Que
stio
ns &
Act
ions
doc
umen
t are
co
mpl
eted
bef
ore
final
dep
loym
ent o
f and
the
mov
emen
t of t
he p
rogr
amm
e/pr
ojec
t/pro
duct
s an
d an
y as
socia
ted
wor
k eq
uipm
ent t
o bu
sine
ss a
s us
ual t
he.
CATE
GORY
1 S
AFET
Y CO
NCU
RREN
CE (8
.1 o
nly)
N
AME
SIGN
ATU
RE
DAT
E GR
OUP
SAFE
TY R
ISK
IMPR
OVEM
ENT
MAN
AGER
Jo
anna
Hos
king
JH
oskin
g 18
/05/
2015
An
d as
Re
view
ed o
n 19
/11/
2015
. PR
OGRA
MM
ES D
IREC
TOR
/ MAN
AGER
(as
appl
icabl
e)
War
ren
Cabo
t
CA
TEGO
RY 2
SAF
ETY
CON
CURR
ENCE
(8.2
onl
y)
NAM
E SI
GNAT
URE
D
ATE
SEN
IOR
SAFE
TY P
ROFE
SIO
NN
AL
PR
OGRA
MM
ES M
ANAG
ER
CA
TEGO
RY 3
SAF
ETY
CON
CURR
ENCE
(8.3
onl
y)
NAM
E SI
GNAT
URE
D
ATE
SAFE
TY A
DVI
SOR
N
OTE
: For
fina
l sig
n of
f on
Uni
t Lev
el (8
.3) p
roje
cts
refe
r to
the
Safe
ty H
ando
ver
Com
plia
nce
Cert
ifica
te
RISK
MAT
RIX
SAC
1 T
empl
ate:
T
empl
ate
Ow
ner:
S. W
hite
V
ersi
on: 4
.2
Dat
e: Ju
ly 2
013
Safe System of Work Template: Template Owner: S. White Version: 1.3 Date: Feb 2013
ROYAL MAIL GROUP RISK MANAGEMENT
SAFE SYSTEM OF WORK (Appendix 2)
This SSOW provides sufficient INFORMATION and INSTRUCTION to allow managers to control safety risks identified during risk assessments. It is used by work area managers to inform and instruct operators, at induction and refresher training events, how a task they are involved in or work equipment they are using can be completed / used safely. A record should be retained to show that this information and instruction has been shared with those employees affected.
Task / Work Equipment Description
Generic Task / Work Equipment (SSOW Title) Cut & Tip Powered Conveyor
Associated Risk Assessment SAC1 National Cut & Tip Conveyor SSOW Version No V1.3
WHAT RISKS ARE CONTROLLED BY THIS SAFE SYSTEM OF WORK
(As identified in the task risk assessment or SAC1 process, show the risks identified and the controls that have been introduced. For example, pedestrian/vehicle collisions controlled by the provision of a designated & protected walkway. Identified Risk Risk Rating (ref. SMS2.1 Risk Matrix) Control
Operating the conveyor
Tolerable Following initial installation and equipment deployment: National project lead to ensure training is provided on site and delivered to the workplace coaches. On-going training to be delivered by a competent Workplace Coach using safe systems detailed in this document.
INSTRUCTIONS
(How to carry out the task &/or use the work equipment safely - including the Don’t and Do written instructions)
Safe System of Work Template: Template Owner: S. White Version: 1.3 Date: Feb 2013
Cut and Tip Conveyors This safe system of work must be followed at all times and consolidates advice given in operator training and operations manuals. Any problems should be reported to your line manager immediately. It is the legal responsibility of every employee at work: • to take reasonable care for the health and safety of themselves and others who may be affected by
their acts or omissions
• To report defective or faulty equipment immediately.
Before use Check workstation for defects and report defects to your line manager. The work area around any machine must be kept tidy. Check that there are no trailing cables All covers and/or guards must be in place and undamaged. You must be familiar with the location and operation of all machine controls.
General DO inform your manager of any medical condition which may affect your ability to perform your work, or if you are pregnant. DO follow operating instructions. DO keep hands clear of any moving parts.
DO be aware of hypodermic needles, sharp objects and leaking or suspicious packages. DO make sure your path is clear before you lift, carry or push a load.
Manual Handling:
pping Bags
WARNING: Only authorised personnel are allowed to open and access the control panel, power point trip switch panel and disconnect the power lead from the power point. DO NOT attempt to open the control panel cover. DO NOT attempt to access the power point trip switch. DO NOT attempt to disconnect the power lead from the power point. DO NOT plug personal electrical equipment into the blue or red power socket
x
To avoid repetitive actions when tipping mail bags, operators must be rotated at regular intervals.
x
Safe System of Work Template: Template Owner: S. White Version: 1.3 Date: Feb 2013
Assess the weight of the bag. Inform your manager if bag is overweight. (If considered overweight, cut seal and break down contents without lifting bag.) Use the proper equipment to cut the bag tie (e.g. official scissors). Dispose of the string, label ties and seals in a bin. Use correct lifting and handling methods to lift the bag. Lift bag onto work surface in one movement. When the bag is on the surface, feed mail out of the bag by hand before lifting to fully empty. Lifting should be no higher than shoulder height. Check bag is empty and place in appropriate empty bag storage container. Discard any damaged bags. Avoid lifting and tipping bags in one movement.
DO lift full trays from the rear of the workstation using established manual handling techniques. DO fill Yorks using the “Slide and Stack” technique. DO manually lift empty grey Totes. DO NOT over stretch or overstrain arm muscles while tipping a bag. DO NOT leave bags loose on the floor.
Incline Conveyor DO operate an emergency stop button in case of emergency DO operate an emergency stop button when attempting to retrieve jammed mail, even if the machine has already stopped. DO secure, completely cover or remove all loose jewellery and loose clothing, and tie back long hair before operating any machine.
DO NOT use this equipment unless you have been fully trained. DO NOT attempt to start or interfere in any way with any machine which is under maintenance control or displaying a “machine under maintenance” sign. DO NOT tamper with electrical or mechanical equipment/remove safety covers/guards. DO NOT attempt to insert, extract, touch any component, or attempt to remove any jammed item of mail from a moving part of a machine. DO NOT start the machine until you are sure no one is working on it. DO NOT reset an emergency stop until the fault has been cleared. DO NOT use personal stereos when operating this machine. DO NOT lean, touch, stand, walk, or lie on any conveyor belt. DO NOT make unauthorised or unsafe repairs to the conveyor DO NOT overload conveyor belt or load above side height of conveyor. DO NOT throw strings, label ties, or seals on the floor.
Flat Bed Conveyor
DO operate an emergency stop button in case of emergency DO operate an emergency stop button when attempting to retrieve jammed mail, even if the machine has already stopped. DO secure, completely cover or remove all loose jewellery and loose clothing, and tie back long hair before operating any machine.
DO NOT use this equipment unless you have been fully trained. DO NOT attempt to start or interfere in any way with any machine which is under maintenance control or displaying a “machine under maintenance” sign. DO NOT tamper with electrical or mechanical equipment/remove safety covers/guards. DO NOT attempt to insert, extract, touch any component, or attempt to remove any jammed item of mail from a moving part of a machine.
Safe System of Work Template: Template Owner: S. White Version: 1.3 Date: Feb 2013
DO NOT start the machine until you are sure no one is working on it. DO NOT reset an emergency stop until the fault has been cleared. DO NOT use personal stereos when operating this machine. DO NOT lean, touch, stand, walk, or lie on any conveyor belt. DO NOT make unauthorised or unsafe repairs to the conveyor DO NOT overload conveyor belt or load above side height of conveyor. DO NOT throw strings, label ties, or seals on the floor.
Conveyor Safety Phrase Label DO make sure you are aware of the Safety Phrase label which is has been affixed to the side of the incline conveyor above the main control panel
Before use:
Mandatory Pre-use Checks
Safe System of Work Template: Template Owner: S. White Version: 1.3 Date: Feb 2013
P1. Before Use: P1.1 Carry out a visual check of the conveyors general condition. Are there any protruding,
sharp, jagged edges? Has the conveyor received
any impact damage i.e. are the covers damaged?
Is the belt free from damaged and visible wear?
Is there visible damage to the emergency stop buttons?
P2. (Machine not running) Emergency Stop button check: P2.1 There are up to eight emergency stop buttons located on the conveyor
P2.2 Engage the emergency stops by depressing the buttons. P2.3 Release the emergency stop by turning the button anti-clockwise.
Machine Operation: P3. Machine Start-up procedure:
P3.1 (On the control panel) Turn the control power switch clockwise into the vertical position.
P1.1
The equipment must not be used if faults or damage are identified. Report all defects to your line
manager immediately.
P2.1
P2.2 P2.3
Head Strike hazard Be aware of the protruding
emergency stop buttons when accessing the control panel or
picking up mail items from the floor.
P3.1 Control Panel
Check to ensure the people are clear of the conveyor prior and during the completion of the machine start-up procedure.
Safe System of Work Template: Template Owner: S. White Version: 1.3 Date: Feb 2013
P4. Machine Start-up procedure: P4.1 With the red light now illuminated: P4.2 Press the reset button and hold for 5 seconds. P4.3 Amber light now illuminates. P4.4 Press the start button. P4.5 The first Warning sounds with a single beep and Amber light illuminates. P4.6 Continuing to keep start button pressed, second warning alarm sounds, the green light illuminates and the conveyor belt starts.
Emergency stop & start-up procedure:
P5. Emergency Stop: P5.1 Immediately press the nearest emergency stop button. The conveyor will now stop.
P6. Emergency stop restart procedure:
P6.1 Release the emergency stop button. Continual alarm sounds. P6.2 Press the reset button and hold for 5 seconds P6.3 Amber light now illuminates P6.4 Press the start button, alarm sounds once. Keeping the start button pressed the alarm sounds twice. P6.5 The green light now illuminates and the conveyor belt starts.
Bag tipping to the conveyor:
P4.1 P4.2 P4.3
P4.4 P4.5 P4.6
P5.1
Before starting this process ensure the reason for the emergency stop
has been safely resolved and if needed checked by an engineer or
other competent person.
P6.1 P6.2 P6.3
P6.4 P6.5
Safe System of Work Template: Template Owner: S. White Version: 1.3 Date: Feb 2013
P7. Loading the Hopper: P7.1 Use correct lifting and handling methods to remove the bag from the York container. Rest the bag on the front of the Hopper When the bag is on the surface, empty or feed mail out of the bag by hand before lifting to fully empty. Lifting should be no higher than shoulder height. Store the empty bag in a suitable receptacle.
Flat Bed Conveyor P8. Working with the Conveyor: Position 2. P8.1. Extract the appropriate mail items as they pass on the conveyor and sort to the associated container.
P7.1
DO NOT overload the conveyor belt
Bag tipping must only be carried out at the front of the
incline conveyor. DO NOT tip bags over the sides
of the conveyor
Warning! Watch out for sharps!
Warning! watch out for sharps
P8.1
Safe System of Work Template: Template Owner: S. White Version: 1.3 Date: Feb 2013
P9. Conveyor Sensor: P9.1. Sensors are located at the end of the conveyor to prevent mail items falling form the belt. As mail items pass the sensors, the belt will automatically stop. The belt will again re-start once the mail item blocking the sensor is removed.
P9.2. Through local management procedures the sensor can be disabled on the control panel by use of a key switch
P9.3. Where the end of the conveyor has a no “Bump Bar” under no circumstances must a container be placed at the end of the conveyor and the sensor “MUST “be enabled and the key switched to the “ON” position.
P9.4. Where the end of the conveyor has a “Bump Bar” the sensor can be enabled or disabled through the local management procedure.
GENERAL INFORMATION
(Anything specific to the task &/or work equipment) All operators must have received suitable and sufficient manual handling lifting and handling training. Link to 2:15 Manual Handling:
P9.1
Warning! If sensor is disabled items
will travel off the end of the belt. Ensure a suitable mini sleeved York container is in
place.
P9.2
NO container allowed at end of conveyor!
Container allowed at end of conveyor!
Safe System of Work Template: Template Owner: S. White Version: 1.3 Date: Feb 2013
https://portal.royalmailgroup.com/sites/A402/Risk/Forms/Manual.aspx
COMPETENCY (Beyond the training received from this SSOW list any other training that is required)
Training Format (Course/Certificated/Qualification) Following initial installation and equipment deployment: National project lead to ensure training is provided on site and delivered to the workplace coaches. Manual Handling training
Theory and practical with the equipment. WTLL based with practical demonstration.
PERSONAL PROTECTIVE EQUIPMENT
(This PPE is to be provided & used, as specified, by people undertaking this task &/or using this work equipment) Item Ordering details Comments
N/A
SAFETY SIGNAGE
(The below Safety Signage is to be displayed, as specified, in the workplace where this SSOW applies) Item Ordering details Comments N/A
All of the above controls will, if implemented effectively, reduce the safety risks associated with this task &/or work equipment to an ACCEPTABLE level and as such will be ‘Adequately Controlled’.
SSOW AUTHORISATION
Name Signed Date Author Ray Pipe
07/09/2015
Safety Support (where applicable)
I have authorised this SSOW for deployment Safety Authorisation: (As defined in Levels of Authority Appendix 4)
Peter McGowan
11/09/2015
On deployment in the Work Area a copy of the SSOW should be retained for reference
SSOW LOCAL ARRANGEMENTS
SSOW Title
Region
Unit (Where applicable to individual Unit)
Safe System of Work Template: Template Owner: S. White Version: 1.3 Date: Feb 2013
(For use where a Unit Manager wants to add local arrangements to a Group or Business Unit SSOW)
While the SSOW provides sufficient INFORMATION and INSTRUCTION to allow managers to control safety risks for a specific task &/or item of work equipment it is possible that local circumstances within a Unit could introduce additional risks. Where local risk assessment indicates this to be the case LOCAL ARRANGEMENTS could be prepared help to remove or reduce the additional risks to an acceptable level. This additional INFORMATION and INSTRUCTION must be used within the Unit(s) affected to inform and instruct those employees affected. It should also be used at induction and refresher training events to inform employees how a task they are involved in can be completed safely &/or how work equipment they are using can be used safely. Any training or briefing using the SSOW should be recorded to show where the additional information and instruction has been given.
NOTE: Local amendments to a SSOW cannot be less stringent than the national version.
LOCALISATION
Locally Identified Risk
Risk Rating (ref. SMS2.1 Risk Matrix)
Control
LOCAL SIGN OFF
Signature
Date
Local Author
Safety Authorisation: (As defined in Levels of Authority set out in
the Standard) Peter McGowan
11/09/2015
1
Ergonomic Assessment Template Owner: S. White Version: 2.0 Date: May 2013
Ergonomic Screening Assessment (Appendix 4) Work Equipment Title Incline conveyors Work equipment photograph Serial Number/identification mark
Work Equipment Group Conveyors Work Equipment Details
Project Manager (contact details)
Martyn Dundas
NOTE: This is a preliminary assessment which may lead to a more detailed ergonomic assessment depending upon the answers to the following questions. If any of the answers to the questions below are No remedial action or a more detailed assessment will be required. Contact Jane Dillon or Corinne Parsons if you need help to complete the assessment. Reference should be made to the illustrations Fig 1, Fig 2, Fig 3 when answering these questions
1 For this equipment ……. Yes No N/A If No state what remedial action
required Detailed assessment
required Y/N 1.1 Is the equipment less than 16kg
total weight? If yes go to Question 1.2, if no go to Question 1.3
No
1.2 Will suitable handles be provided for lifting and carrying the equipment?
1.3 If the equipment exceeds 16kg total weight will alternative means of transporting be provided? (wheels for example)
N/A
1.4 Are all visual aids/instructions that form part of the equipment clear and easy to understand?
Yes
1.5 Is the working space where this equipment is likely to be used adequate i.e. unlikely to be congested or cramped?
Yes
2 For this equipments intended use (so
far as can be ascertained) ……. Yes No N/A If No state what remedial action
required Detailed assessment
required Y/N 2.1 Will all the lifting tasks be within the
HSE guideline figures, (see Fig 1)? Yes
2.2 Will all the lifting tasks be repeated 7 times/min or less frequently?
No No remedial required as it is parcels being lifted (not large parcels)
2.3 Will all the forces required to keep a load in motion require little effort (e.g. be less than 7kg)?
Yes
2.4 Will all the forces required to initiate movement easy to exert (e.g less than 15kg)?
Yes
2.5 Will all the pushing forces required be exerted with hands between knuckle and shoulder height?
Yes
2.6 Will all forces or items lifted whilst seated be less than 5kg?
N/A
2
Ergonomic Assessment Template Owner: S. White Version: 2.0 Date: May 2013
2.7 Will any items to be carried in the hands weigh less than 10kg and need carrying for less than 1 minute at time?
Yes
2.8 Can all lifting and handling tasks be carried out without twisting or bending?
Yes
2.9 Are all tasks completed within the Golden Zone, (AA or A on Fig 3)?
No There are two low volume selections which are situated beside and slightly behind the operators. There is no remedy required
N
2.10 Will shorter or taller people find reaching or seeing to complete task elements involving this equipment easy?
Yes
2.11 Are work surface heights appropriate? (e.g. around 700mm for seated work, 950 – 1000mm for standing work; reduced to accommodate items placed on work surface or use of tools. Bag tipping heights below 500 mm)
Yes
2.12 Are all movements likely as part of using this equipment Low or Medium risk 2 on the Muri chart, (see Fig 2, ignore walking)
Yes
2.13 Are all postures on the Muri chart scoring Medium or High held for less than 1 minute at a time or repeated less than 7 times/min, (see Fig 2, Ignore walking)?
Yes
2.14 Can suitable time be allowed in any task using this equipment for rest and recovery?
Yes
2.15 Can suitable seats be provided for all tasks that can be done seated?
N/A
2.16 Where this equipment is used for tasks lasting longer than one hour and cannot be done seated will provision been made to allow sitting down during breaks?
Yes
ERGONOMIC ASSESSMENT
I can confirm that I have the appropriate level of competency, in terms of knowledge and experience of completing other assessments, to allow me to sign off this preliminary Ergonomic assessment. I can confirm that on completion of the assessment and any remedial actions that are identified as necessary and no significant risks are identified and still outstanding then this work equipment is fit for purpose and the intended use to which it will be put within the Business as far as its ergonomic impact is concerned, and that the user of the work equipment or persons who may be affected by its use have been safeguarded from any risks. NOTE: If remedial actions highlighted in the remedial action column indicate that a more detailed Ergonomic assessment report is required then the ergonomists Jane Dillon or Corinne Parsons should be contacted for advice. Work Equipment Title (as per page one)
Incline Conveyors Assessment date:
10/11/2015
Assessor name (Not valid unless signed)
Martyn Dundas Assessor signature (not valid unless signed)
Martyn Dundas
The assessors must retain a copy of this Ergonomic assessment and forward a copy to the Project Manager if the assessor and the project manager aren’t one and the same person.
3
Ergonomic Assessment Template Owner: S. White Version: 2.0 Date: May 2013
End of ERGONOMIC Assessment
Fig 1: HSE Lifting and Handling Guideline Figures
Fig 2: Muri Chart
4
Ergonomic Assessment Template Owner: S. White Version: 2.0 Date: May 2013
5
Ergonomic Assessment Template Owner: S. White Version: 2.0 Date: May 2013
Fig 3: Golden Zone
900
1150
1400
1700 C
Motorola Finger Scanner Initial Ergonomics Assessment – Version Creation Date: 19/06/14
Royal Mail is a trading name of Royal Mail Group Ltd. Registered number 4138203. Registered in England and Wales. Registered office: 100 Victoria Embankment, London, EC4Y 0HQ
WCM Parcel conveyors ergonomics assessment
19th February 2015
Corinne Parsons
Lead Ergonomist
SHE Technical Support, Ergonomics
07738 311368
Motorola Finger Scanner Initial Ergonomics Assessment – Version Creation Date: 19/06/14 – Page 2 of 9
Contents
1.0 Introduction .......................................................................................................................................... 3
Assessment .................................................................................................................................................. 4
Home Counties North .......................................................................................................................... 4
Edinburgh ................................................................................................................................................ 5
Assessment of Repetative Work ......................................................................................................... 7
Conclusions .................................................................................................................................................. 8
Motorola Finger Scanner Initial Ergonomics Assessment – Version Creation Date: 19/06/14 – Page 3 of 9
1.0 Introduction An ergonomics assessment of the parcel conveyors in use at Home Counties North (HCN) and Edinburgh was carried out at the request of Ken House, National Workplace Organisation Deployment Lead, as part of the evaluation of the national WCM parcel conveyor trial.
This assessment should be read in conjunction with the Ergonomics Screening assessment which was carried out at the start of the conveyor project.
WCM conveyor Ergo Screening Assessmen
Three points on the screening assessment were identified as requiring a more detailed ergonomics assessment during the trials:-
2 For this equipments intended use (so far as can be ascertained) …….
Yes No N/A If No state what remedial action required
Detailed assessment required Y/N
2.2 Will all the lifting tasks be repeated 7 times/min or less frequently?
N Parcel sorting activities for small parcels. Manual handling risk will be low provided throwing distances are minimised and provision is made to walk round with any heavy or difficult parcels
Assessment during trial
2.9 Are all tasks completed within the Golden Zone, (AA or A on Fig 3)?
N Parcels will be thrown into mini-yorks, layouts may vary at different centres but should not exceed 1 deep if across a conveyor or 2 deep elsewhere. Space should be allowed to walk round to place any items that are too flimsy, heavy or awkward to throw easily.
Review during trial
2.13 Are all postures on the Muri chart scoring Medium or High held for less than 1 minute at a time or repeated less than 7 times/min, (see Fig 2, Ignore walking)?
N Depends on sorting layout. Parcel sorting frequency will be greater than 7times/min, parcels thrown over a distance or difficult parcels to throw will result in arm posture at or above shoulder height
Review during trial
A visit was made to Edinburgh and HCN Mail Centres to observe the operation during the trials and to discuss the working methods with the operators.
Motorola Finger Scanner Initial Ergonomics Assessment – Version Creation Date: 19/06/14 – Page 4 of 9
Assessment The conveyors in use at the two mail centres are similar. Both have the benefit of a low level tipping hopper, rising conveyor and working belt at a good working height for standing work. The belts differ in that the one at HCN is 60cm wide and the one at Edinburgh is 50cm wide.
The layouts of containers and working methods differ at the two mail centres. Both have one person tipping into the hopper and two people sorting from the conveyor into mini-yorks or full sized Yorks with ALP sleeves. At HCN the staff work on both sides of the conveyor and at Edinburgh the staff work on one side and the containers are positioned on the other.
Home Counties North The conveyors are used for all primary parcel traffic except for the large parcels which are sorted in a separate bullring. Both parcel bags and parcels in ALP sleeves are tipped into the hopper.
Home Counties North set up
There are 8 selections around the end of the conveyor in mini-Yorks which are shared between the two staff working on the belt. In addition there are 3 full sizes Yorks for foreign, second class and a local selection. There is an additional mini-York on each side for mis-sorts
Three of the selections on each side and the mis-sorts are within easy reach of the individual on that side. The majority of selections are well outside the golden zone and it is necessary to throw the parcels. For the furthest containers the throwing distance is in
Motorola Finger Scanner Initial Ergonomics Assessment – Version Creation Date: 19/06/14 – Page 5 of 9
excess of 2m causing the arms to be raised above the shoulder height to throw at times. This arrangement exceeds the recommendation in the ergonomics screening assessment for mini-yorks to be only one deep if on the opposite side of the conveyor or two deep if on the same side. As there are two people, one on each side of the conveyor, anything that would be difficult to throw, or for the furthest selections could be sorted by the person on the same side of the conveyor. All selections can readily be walked to with items that are particularly difficult to handle. During the observations occasional parcels missed and landed on the floor.
Sorting to closer selections
Sorting to more distant selections
Edinburgh The conveyor at Edinburgh was 500mm wide and the containers were arranged on the far side of the conveyor. The conveyor was used for Horizon and PPI parcels. Collection parcels were processed separately due to the need to cancel the stamps. There were 11 containers altogether including 5 roads, local selections, Glasgow and foreign selections. For First Class parcels mini-Yorks were used for the roads and the local parcels and full sized Yorks were used for the other selections. For Second Class parcels full sized Yorks were used for all selections.
Motorola Finger Scanner Initial Ergonomics Assessment – Version Creation Date: 19/06/14 – Page 6 of 9
First class set up Second class set up
The conveyor was easy to sort across due to being relatively narrow. Although the reach is slightly outside the golden zone it was a comfortable distance to sort parcels without the need to throw them. The working method was for two people to work on the belt and for parcels for the selections at the far end of the belt to be left on the conveyor for the second person to sort.
It was easy to sort parcels into the full sized sleeves with the front open but it was harder to sort over the top of the closed sleeves as this requires sorting items above shoulder height, increasing the strain on the shoulders and arms. It was easy to reach across the conveyor to sequentially close the containers. This should be the normal practice rather than unnecessarily sorting all parcels over the top of the sleeve as was observed during the visit.
The operators using the conveyor at the time of the visit preferred this to their previous method of working. The low level tipping hopper was seen as a particular benefit. The main concern raised was the tendency for parcels to fall off the side, particularly if there was a big batch of slippery poly-wrapped items coming up the conveyor together. The main point at which the parcels fell off was the interface between the rising conveyor and the flat sorting conveyor. A slightly higher side rail at this point may help but should not extend onto the working area as this will get in the way of elbows when sorting. In addition it may be necessary for the individual working at the first position to move parcels that may fall first. Using a wider conveyor may reduce the number of parcels which fall off but this would have the disadvantage of increasing the risk of sorting across the conveyor by placing all selections further outside the golden zone and so is not recommended.
Motorola Finger Scanner Initial Ergonomics Assessment – Version Creation Date: 19/06/14 – Page 7 of 9
Parcels surge Parcels fallen off conveyor
Several concerns were raised about the conveyor itself:-
• Temperamental to start • Tearing of the uplift conveyor belt which was not considered strong enough material • Vulnerability of the sensor to damage from parcels and it was suggested that this
should have a cage to protect it from damage.
Sensor
Assessment of Repetative Work The actions carried out for both the HCN and Edinburgh layout were analysed and an assessment of the risk from repetative work was carried out using the Health & Safety Excecutive ART tool. The tool takes into consideration the postures of the hands, wrists, arms, trunk and neck; the repetativeness, task duration and forces. The results are given in the table below for the two layouts.
HSE ART tool .pdf
Motorola Finger Scanner Initial Ergonomics Assessment – Version Creation Date: 19/06/14 – Page 8 of 9
Risk factor HCN Edinburgh
Score Score A1 Arm movements 3 3 A2 Repetition 3 3 B Force 1 0 C1 Head/Neck posture 2 1 C2 Back posture 0 0 C3 Arm posture 2 1 C4 Wrist posture 1 0 C5 Hand/finger grip 1 1 D1 Breaks (between 1 and 2 hours between breaks)
2 2
D2 Work pace 0 0 D3 Other factors 0 0 Task score 15 11 D4 Duration multiplier 1 (all shift)
0.75 (up to 4 hours) 1 (all shift)
0.75 (up to 4 hours) Exposure score full shift 15 11 Exposure score full shift 11.25 8.25 Psychosocial and other risk indicators
Not identified, site dependant
Not identified, site dependant
The results show that the risk from repetitive work is higher for the HCN layout than for the Edinburgh layout for First Class mail. If carried out for a whole shift the HCN layout would pose a medium risk of injury for repetitive work, Edinburgh would pose a low risk. For the Second Class layout at Edinburgh, with full sized York sleeves, the risk would increase to medium if the sleeves were closed during the whole sorting process.
Conclusions • The introduction of a parcel conveyor with a low level tipping hopper, rising conveyor
and good working height sorting belt reduces the risk from manual handling compared to tipping parcel bags into a mini-York/ALT or onto a table.
• The Edinburgh layout has shorter sorting distances and so poses a lower risk of injury from repetitive work than the HCN layout.
Motorola Finger Scanner Initial Ergonomics Assessment – Version Creation Date: 19/06/14 – Page 9 of 9
• Both layouts are designed for two sorters to work together and so risks can be minimised by the individual closest to the selection sorting the parcels rather than throwing them over long distances.
• Where full sized Yorks are used the sleeves should be closed as the container fills rather than closing them at the start of the sorting process. This prevents unnecessarily sorting above shoulder height and which increases the risk of injury.
1
Tipping from York Sleeve to Parcel Conveyor Ergonomics Assessment
17th April 2016
David Annett
Chartered Ergonomist
Ergotherapy
www.ergotherapy.co.uk
07957 542341
2
Introduction
An ergonomic review of tipping parcels from York Sleeves into an ascending conveyor was requested by Ken House, National Workplace Organisation Deployment Lead. The operation was observed on the early shift at Manchester Mail Centre and took place on 5th April 2016. Operators and managers were interviewed and video was taken for postural analysis. Mark Connolly (Shift Manager) and Mathew Bullen (WCM Champion) were present during the visit.
Loading the belt with Parcels from the York Sleeve
Background
Manual parcel processing is now a large part of the Royal Mail Operation. Many parcels are sorted from York Sleeves into other York Sleeves in a Bullring. The hopper and ascending belt were originally designed for bag tipping, but has been used with York Sleeves for the last 6 months at Manchester. This provides sorters with a continuous stream of parcels presented at a good working height. This work area was assessed by Dr Corinne Parsons in February 2015 at Edinburgh and Home Counties North (HCN) but focussed on the sorting operation, with alternative layouts of containers. In these offices one person was tipping and two people were sorting from the belt.
3
Assessment
The operation observed in Manchester was different from the offices in the previous report; as there were four operators sorting from the belt rather than two. This appeared to put more pressure on the person tipping the parcels onto the belt, as they were expected by the managers to get through 15 Yorks an hour in order to cost-in the manpower of the operation. Some of the operators felt they were being put under pressure to work faster than their natural pace in order to meet these goals. The CWU representative Graham Booth felt that staff were being put under undue pressure to achieve these goals.
Several operators were observed loading the belts and they were generally able to keep a good posture, minimising bending and twisting. The York Sleeve self-levelling system generally works well to minimise bending, but there will always be times when a heavier item is in the bottom so the base does not raise sufficiently. Operators were generally good at positioning the York close to the hopper and angled such to minimise twisting.
The type/size of parcel made a significant difference to the speed of the operation – larger parcels tended to be lifted with 2 hands and can be sorted quite quickly, so it was harder to keep up. With small items, many could be grabbed at a time and they took longer to sort, so it was easier to keep up. A new working method introduced by the WCM champion is to have a second York available with small items, so that they can alternate with a few handfuls of these to slow down the sorters so it is easier to keep up. This appeared to work well with the limited amount of time it was observed.
The tipper role was rotated every hour with other tasks in the work area, although some staff liked the task and were not always rotated. Taking the empty York away and fetching a full York gives the tipper a break from the repetitive work, but if they are away from the belt for too long the belt empties and the sorters may be standing waiting for work which can put more stress on the tipper and manager. This can vary depending on the quality of portering.
Risks were increased when:
• Operators did not apply the brake of the York so it moved away from them if they leant into the York.
• Items were thrown longer distances to fill in gaps higher up the belt. (Some operators walked down the side of the belt to do this, but this took up time).
• The York was not placed close to the belt which could introduce more twisting when loading.
• Pressure on manager/tipper if the belt was seen to be empty or the closest sorters were standing waiting for work.
• Staff are not rotated to another task after an hour.
4
Assessment of Repetitive work The actions carried out were analysed and an assessment of the risk from repetative work was carried out using the Health & Safety Excecutive ART tool. The tool takes into consideration the postures of the hands, wrists, arms, trunk and neck; the repetativeness, task duration and forces. The results are given in the table below for Manchester where there are four people sorting. An estimate has also been given for the risk when only 2 people are sorting assuming they will not be required to load the belt as quickly. Hence lower figures for the frequency of arm movements, repetitions and work pace.
Risk factor 4 people sorting Estimate for 2 people sorting
Score Score A1 Arm movements 5 3 A2 Repetition 6 3 B Force 1 1 C1 Head/Neck posture 1 1 C2 Back posture 1 1 C3 Arm posture 2 2 C4 Wrist posture 1 1 C5 Hand/finger grip 1 1 D1 Breaks (between 1 and 2 hours between breaks)
2 2
D2 Work pace 1 0 D3 Other factors 0 0 Task score 21 15 D4 Duration multiplier 1 (all shift)
0.75 (up to 4 hours) 1 (all shift)
0.75 (up to 4 hours) Exposure score full shift 21 15 Exposure score half shift 15.75 11.25 Psychosocial and other risk indicators
Under pressure, but site dependant
Less time pressure?
Risk Levels
Exposure score
Proposed exposure level Action
0–11 Low Consider individual circumstances
12–21 Medium Further investigation required
22 or more High Further investigation required urgently
5
Conclusion
If the task of loading the belt from a York Sleeve is undertaken at a steady rate (less than 20 lifts per minute) then it is considered a low risk if undertaken for half shift or (low)medium risk if undertaken for a full shift. This assumes that the York is placed close to the belt to minimise twisting and the York brake is applied.
If the task is undertaken at a faster pace – over 20 lifts per minute then it is rated as a medium risk for a half shift and full shift, although the full shift is very close to the high risk category. Psychosocial indicators at Manchester suggested there was pressure on managers and operators to maintain a high work rate to achieve emptying 15 Yorks per hour.
Handling rates at Manchester varied between 16-30 lifts per minute, so further investigation is recommended. This could include the following:
i. Review other offices using this system to check perceived pressure and handling rates.
ii. Consider using fewer sorters to reduce the pressure on the tipper (2 or 3). iii. Review in more detail if having a second York with smaller items, to top up the belt,
reduces the handling rates.
6
Pictures
Increased risk when throwing items to empty gaps higher up the belt (left). Walking along the belt to drop them higher up takes more time (right).
Placing the York too far from the Belt can lead to more twisting of the torso.
The conveyor sides are relatively low, so if sometimes items may fall over the side they have to be picked off the floor.
Layout for when two Yorks are used, so the operator can alternate between left and right handed.
This operator preferred to work from one side.
Operating Instructions
Incline Conveyor and 4m Horizontal Conveyor for
Operator Instructions
for Cut and Tip conveyors
TITLE:
DO NOT SCALE DRAWIN
DATESIGNATURENAME
DEBUR AND BREAK SHARP EDGES
FINISH:UNLESS OTHERWISE SPECIFIED:DIMENSIONS ARE IN MILLIMETERSSURFACE FINISH:TOLERANCES: LINEAR: ANGULAR:
DRAWN
1
Table of contents About this document Information about this document 3 Warning signs in this document 4
Safety Basic safety instructions 5 Intended use 5 Incorrect use 5 Specialists 5 Dangers 6 Malfunctioning during operation 6 Interfaces to other devices 6 Operating modes 7 Position of Key Components 8
Start up and operation Initial start-up 9 Operation 9 Procedure for accidents or malfunctioning 9 Operational Procedures 10 Troubleshooting 12 Daily Checks 14
Risk assessment 15 Certificate of Conformity 16 APPENDIX A – Print out procedures 17
2
Information about the operating instructions Contents - These operating instructions contain important details and information about the
various operating phases of the conveyor: • Transport, assembly and start-up • Safe operation, required maintenance, remedy of possible faults • Spare parts, supplementary accessories
Product affiliation - The operating instructions describe the finished conveyor at the time of initial delivery.
Supplementary to these operating instructions, special contractual agreements and technical documents apply for special conveyor versions and additional appliances.
- These operating instructions are an integral part of the conveyor - To ensure trouble-free and safe operation as well as the settlement of any warranty claims,
always read these operating instructions first and observe all the information contained herein. - Keep these operating instructions close to the conveyor. - Always give the operating instructions to each subsequent owner or user.
Beumer Group UK shall not accept liability for any damages or malfunctioning caused by non-adherence to these operating instructions.
- Please contact Beumer Group UK if you have any further questions after reading these operating instruc-tions.
BEUMER House, 9 Cartwright Court, Cartwright Way, Bardon HillLE67 1UE LeicestershireUnited Kingdom
Phone: 01530 4412 97Fax: 01530 8157 17E-Mail: [email protected]
RM Office:
System:
Belt width Horiz. Length
Serial no Inc
Serial no Horiz
Date of Install: Engineer:
RHSLHS
Electrical Pass: Y/N
CONVEYOR IDENTIFICATION
3
Warning signs in this document
The warning signs in this document provide information about dangers which may arise during conveyor operation. The relevant warning signs are displayed in the "safety" section.
There are three types of warning signs:
• DANGER • WARNING • CAUTION
Signal word Meaning Consequences of non-adherence
DANGER warns of an imminent death or serious injuries. danger WARNING warns of a possible death or serious injuries are danger possible. CAUTION warns of a possibly
dangerous situation slight injuries are possible.
4
Safety
Basic safety instructions
The conveyor was state of the art and generally safe to operate at the time of delivery; however dangers may still arise during utilization: • Danger of death or personal injury to operators and others • Adverse effects on the conveyor and other areas
Non-adherence to the information in these operating instructions can result in life
threatening injuries! - Read these operating instructions carefully and adhere to the information contained herein to ensure safe conveyor operation.
Intended use
The conveyor is intended for use in mail sort environments and should only be applied to transport goods, such as, parcels or letters.
The conveyor is intended for certain application areas only and its defined capacity limits must not be exceeded during operation. Maximum loading is 50kg/m, over loading may cause product to fall off the conveyors
Any other use without prior consultation with Beumer Group UK is not recom-mended. Operating conditions which deviate from those specified require Beumer Group UK to agree that the changes are safe.
Users should not carry out alterations or modifications without agreeing such changes with Beumer Group UK.
Incorrect use
The conveyor is not intended for transporting people. Beumer Group UK or Conveyortek take no responsibility if the conveyor is not used as originally intended.
Specialists
Specialists are personnel who have the knowledge to read and understand the operating instructions and the ability to carry out work professionally while observingnational regulations.
5
Safety
Dangers This section provides information about various dangers and damages which may occur when operating the conveyor. - Do not climb on the conveyor during operation. - Only carry out maintenance and repair work once the machine has been de-energized and measures have been taken to ensure that it cannot be started accidentally.
- Organise additional safety measures for passageways and to stop people reaching into the moving conveyor.
- Protective covers and housings should only be removed by a competent person carry out maintenance work. All covers and housing must be refitted before the system can be handed back for operational use. - Regularly inspect safety equipment. - No unauthorised access into electrical enclosures or guarding. - Loose clothing could get caught in the conveyor. - Jewelry, such as necklaces or bracelets may get caught in the conveyor. - Long hair could also get caught in the conveyor.. - Always remove materials and objects which are not required from the work environment area to avoid trip hazards.
Malfunctioning during operation
- Regularly inspect the conveyor for visible damage. - Stop the device immediately and ensure that it cannot be started accidentally
in the event of: Smoke, unusual noises, trapped or broken goods, defective support stands, side guides or accessory appliances.
- A specialist must locate the source and remedy the fault before the conveyor can be used again.
Interfaces to other devices
Danger zones can arise when integrating the conveyor into a system. These zones will not be described in these operating instructions and must be analyzed during installation and initial start-up of the respective system. After connecting the conveyor to other conveyors or machines, always check
for new danger zones prior to initial start-up. Especially at the drive roller where cuts, nips and crushing can occur.
6
Safety
Operating modes
Normal mode. Operation when installed at the end customer's site as an individualconveyor or as a conveyor in a system.
Special mode. All operating modes which are required to guarantee and maintain safe and normal operation and listed below.
Special operating mode Explanation Comment
Transport/Storage Loading and unloading, transport and correct storage
Assembly/Initial start-up Installation at the end customer's and execution of a test run
Cleaning Cleaning the outside without removing When de-energized safety equipment
Maintenance/Repairs Maintenance and inspection tasks When de-energized Troubleshooting Trouble shooting during normal operation Fault elimination Eliminating the fault When de-energized Shut-down Removal from the system When de-energized Disposal Removal from the system and disassembly When de-energiz
The conveyors are fitted with Emergency Stop devices which are monitored to ensure the system
comes to a safe stop when activated or if the safety circuit has a fault
7
8
Start-up and operation Initial start-up
The conveyor has been factory tested. The belt adjustment or the belt tension is factory set and does not usually have to be altered.
Wear correct PPE
- If goods become trapped isolate the conveyor and only if easy and safe to do so remove the itemIf not easy to do so then call Engineering
Procedure for accidents or malfunctioning
- Stop the conveyor system and ensure that the isolator is switched off. - In case of an accident: Use the site accident procedure. - Inform your supervisor.
- Only restart the conveyor after it has been deemed safe and released by your supervisor
9
NORMAL OPERATIONAL PROCEEDURE
CONTROL CABINET
Normal Working
a) Ensure the main isolator is switched on on the control cabinet. b) If red lamp with buzzer sounds continuously an emergency stop is depressed c) Check that the sensor is clear d) On the control panel press the blue reset button for 5 seconds until a constant amber light shows on
the beacon e) Press and hold the start button for 3 seconds, this will show a flashing amber light on the beacon and
sound an intermittent buzzer for 3 f) During the sounding of the buzzer and flashing beacon the operator should check that colleagues are
clear of the conveyor. Releasing the button will prevent the conveyor from starting g) When the signal ends the conveyor will start automatically and is ready for operational us h) The conveyors will continue to run with a constant green light until the sensor beam is broken, upon
which an intermittent amber light will be displayed i) To stop the conveyor press the stop button, the green light will flash to indicate
"operator stop". To start again press start button and the conveyor will start again without warning
RESETBUTTON
STARTBUTTON
POWER ONINDICATOR
STOPBUTTON
SENSORON/OFF
RED
AMBER
GREEN
MAIN ISOLATOR
10
The system will fall into sleep mode if:-
a) On a green flashing light it is left idle for more than 5 mins and require starting again b) On an amber flashing light or constant green light with no activity for more than 2 hours and will
require starting again
EMERGENCY STOP In the case of an emergency one of the 4 E stop buttons on the four corners of the incline conveyor or 2 on the horizontal conveyor operator side must be pressed. Doing this will initiate a continuous buzzer as well as a constant red light on the beacon. To re-start use the following procedure:- a) Reset the E stop b) On the control panel press the blue reset button until amber light shows c) Press and hold the start button for 3 seconds, this will sound an intermittent buzzer and flashing amber light on the beacon for 3 seconds d) During the sounding of the buzzer and flashing beacon the operator should check that colleagues are clear of the conveyor. Releasing the button will prevent the conveyor from starting e) When the signal ends the conveyor will start automatically and is ready for operational use f) The conveyors will continue to run with a constant green light until the sensor beam is broken, upon which an intermittent amber light will be displayed g) To stop the conveyor press the stop button, the green light will flash to indicate "operator stop". To start again press start button and the conveyor will start again without warning
This conveyor should only be used by trained operatives
CONVEYORS SHOULD NOT BE OVER LOADED
MAXIMUM LOAD 50Kg/M
11
Troubleshooting
In case of malfunctioning
Operators are only allowed to eliminate faults which are clearly related to an operator error! The danger zones at the conveyor are covered by guards and protective equipment. - Stop the device immediately and ensure that it cannot be started
accidentally. - Remove the conveyed material. - Always make sure that nobody can be injured before restarting the conveyor. - Dispose of any leaked gear oil correctly. If necessary, a specialist must replace the geared motor.
12
DAILY CHECKS
Part Entire conveyor
Interval
Weekly Monthly
Task/ Inspection General visual inspection Check screwed connections
Required work Report if necessary Report if necessary
Rollers Monthly Listen for noise development
Report if necessary
Belts Daily Check the straight running Check for damage
Report if necessary Report if necessary
Visible cables E Stops Trapped items
Daily Daily Daily
Check for damage General Visual Inspection Check for damage Check that they work Remove if safe to do so
Report if necessary
Report if necessary Report if necessary
Report if necessary Report if necessary
LIGHT STATUS SOUNDER
CONSTANT YES
CONSTANT YES
CONSTANT NO
FLASHING YES
FLASHING NO
FLASHING NO
3 PULSES AFTER PULSES
8 PULSES AFTER PULSES MOTOR OVERHEAT CALL AN ENGINEER
BEACON LIGHT
TROUBLESHOOTING WARNINGS
CAUSE ACTION
STOP BUTTON PRESSED
INTERNAL OR SUPPLY FAILURE
RESET ESTOP AND FOLLOW START
PROCEEDURE
PRESS AND HOLD START BUTTON
NONE REQUIRED
CALL AN ENGINEER
REMOVE ITEM BLOCKING SENSOR,
CONVEYOR WILL START
PRESS START BUTTON
CALL AN ENGINEER
ESTOP DEPRESSED
SYSTEM HAS BEEN RESET
SYSTEM IS RUNNING
FAILURE IN SAFETY SYSTEM
SENSOR HAS BEEN COVERED
13
troubleshooting table
DAILY CHECKS
Part Entire conveyor
Interval
Weekly Monthly
Task/ Inspection General visual inspection Check screwed connections
Required work Report if necessary Report if necessary
Rollers Monthly Listen for noise development
Report if necessary
Belts Daily Check the straight running Check for damage
Report if necessary Report if necessary
Visible cables E Stops Trapped items
Daily Daily Daily
Check for damage General Visual Inspection Check for damage Check that they work Remove if safe to do so
Report if necessary
Report if necessary Report if necessary
Report if necessary Report if necessary
14
OP
ERA
TOR
HEA
D D
RU
M IN
RU
NN
ING
NIP
PO
INT
32
6H
EAD
DR
UM
IS C
OM
PLE
TELY
EN
CLO
SED
BEL
T C
OM
PLE
TELY
CO
VER
S TH
E H
EAD
DR
UM
WIT
H
FIN
GER
GU
AR
DS
AT
EAC
H S
IDE
HEA
D D
RU
M IS
CO
MP
LETE
LY E
NC
LOSE
D W
ITH
INTE
RN
AL
MO
TOR
AN
D
BEA
RIN
GS
WH
EN R
UN
NIN
G O
R R
EAD
Y TO
RU
N T
HE
GR
EEN
LIG
HT
IS L
IT O
N T
HE
LIG
HTI
NG
STA
CK
32
6P
USH
BU
TTO
N V
ERSI
ON
- O
NC
E ST
AR
TED
CO
NV
EYO
R R
UN
S
CO
NTI
NU
OU
SLY
IF L
EFT
RU
NN
ING
TH
E P
LC W
ILL
SWIT
CH
TH
E C
ON
VEY
OR
OFF
AFT
ER A
SET
TIM
E
PV
C B
ELT
IS A
NTI
STA
TIC
FA
BR
IC B
AC
KED
GR
IP F
AC
E B
ELT
GEN
ERA
L R
UN
NIN
GO
PER
ATO
RA
CC
IDEN
TAL
STA
RT
UP
32
6FO
OT
PED
AL
VER
SIO
N -
OP
ERA
TOR
CO
NTR
OLS
STA
RT
UP
IF L
EFT
IDLE
FO
R G
REA
TER
TH
AN
5 M
INS
THE
CO
NV
EYO
R
NEE
DS
TO B
E R
ESET
AN
D R
ESTA
RTE
D
CO
NTR
OL
CA
BIN
ET C
AN
NO
T B
E O
PEN
ED U
NLE
SS IS
OLA
TED
FIR
ST. S
HO
ULD
ON
LY B
E O
PEN
ED B
Y TR
AIN
ED E
NG
INEE
RS
GEN
ERA
L R
UN
NIN
GO
PER
ATO
RST
ATI
C S
HO
CK
32
6
ALL
EX
TRA
NEO
US
CO
ND
UC
TIV
E P
AR
TS A
RE
ELEC
TRIC
ALL
Y
BO
ND
ED B
Y N
ATU
RE
OF
THE
BU
ILD
TO
EN
SUR
E TH
ERE
IS N
O
PO
TEN
TIA
L D
IFFE
REN
CE
BET
WEE
N P
AR
TS
INC
LIN
E C
ON
VEY
OR
IS F
ULL
Y EA
RTH
ED
MO
TOR
RA
TED
TO
DO
MO
RE
BU
T H
AV
E B
UIL
T IN
A S
AFE
TY F
AC
TOR
GEN
ERA
L R
UN
NIN
GO
PER
ATO
REL
ECTR
IC S
HO
CK
42
8IN
CLI
NE
CO
NV
EYO
R IS
FU
LLY
EAR
THED
ON
LY E
XTE
RN
AL
CA
BLE
S A
RE
TO F
OO
T P
EDA
L (I
F FI
TTED
)
AN
D M
AIN
S FE
ED
EXIS
TIN
G P
RO
CES
S W
ITH
IN R
OYA
L M
AIL
IS O
F A
SIM
ILA
R N
ATU
RE
VIE
WED
AN
D R
EPLI
CA
TED
TIP
PIN
G M
AIL
BA
GS
OP
ERA
TOR
MO
TOR
OV
ERH
EATI
NG
21
2P
LC IS
PR
OG
RA
MM
ED T
O C
UT
PO
WER
AN
D S
END
WA
RN
ING
MES
SAG
ES I
F M
OTO
R O
VER
LOA
DED
CO
NV
EYO
R L
OA
DED
AN
D R
AN
WIT
H 1
50
KG
S LO
AD
BEF
OR
E D
ISP
ATC
H
THE
TAIL
DR
UM
SIT
S IN
SID
E C
ON
VEY
OR
STR
UC
TUR
E C
OM
PLE
TE W
ITH
INTE
RN
AL
BEA
RIN
GS
TIP
PIN
G M
AIL
BA
GS
OP
ERA
TOR
MA
NU
AL
HA
ND
LIN
G IN
JUR
IES
32
6C
ON
VEY
OR
IS F
ITTE
D W
ITH
TW
O L
EVEL
S FO
R E
MP
TYIN
G M
AIL
BA
GS
WH
EN T
OP
SH
ELF
IS R
EMO
VED
IT R
EVEA
LS A
LO
WER
SHEL
F TH
AT
STIL
L C
OV
ERS
THE
TAIL
DR
UM
BEL
T IS
SET
AT
BO
TTO
M O
F 1
50
MM
WEL
L A
ND
OU
T O
F G
ENER
AL
AC
CES
S FO
R
THE
MO
ST P
AR
T. T
HER
E IS
A V
ISU
AL
AN
D A
CO
UST
IC W
AR
NIN
G O
N S
TAR
T U
P
CO
MP
LETE
WIT
H 1
0 S
EC D
ELA
Y
TIP
PIN
G M
AIL
BA
GS
OP
ERA
TOR
TAIL
DR
UM
INR
UN
NIN
G N
IP P
OIN
T3
26
TAIL
DR
UM
IS C
OM
PLE
TELY
EN
CLO
SED
BEL
T C
OM
PLE
TELY
CO
VER
S TH
E TA
IL D
RU
M W
HIC
H IS
LOC
ATE
D B
EHIN
D T
WO
CO
VER
S
BEF
OR
E M
OV
ING
FR
OM
SIT
E TO
SIT
E A
GEN
ERA
L C
HEC
K O
F A
LL B
OLT
S
SHO
ULD
BE
CA
RR
IED
OU
T
OP
ERA
TIO
NC
LEA
RIN
G M
AIL
OP
ERA
TOR
CA
UG
HT
IN B
ELT
42
8A
LL IN
RU
NN
ING
NIP
S A
RE
BU
ILT
TO E
N6
19
BEL
T IS
CO
MP
LETE
LY C
OV
ERED
IN A
PA
RT
FRO
M P
HYS
ICA
L
WO
RK
ING
AR
EA
CO
NV
EYO
R C
AN
BE
MO
VED
AR
OU
ND
BY
MEA
NS
OF
PA
LLET
PLA
CED
UN
DER
HO
RIZ
ON
TAL
FRA
MEW
OR
K
TRA
NSP
OR
TATI
ON
PA
RTS
LO
OSE
NIN
G3
26
ALL
BO
LTS
& F
IXIN
GS
FAC
TOR
YCH
ECK
ED B
EFO
RE
DIS
PA
TCH
A
LL B
OLT
S U
SED
WIT
H S
PR
ING
WA
SHER
S TO
PR
EVEN
T
LOO
SEN
ING
GEN
ERA
L C
OM
MEN
TS
GEN
ERA
LTR
AN
SPO
RTA
TIO
NTI
PP
ING
OV
ER4
28
SUP
PLI
ED S
TRA
PP
ED O
N P
UR
PO
SE B
UIL
T P
ALL
ETS
CA
N B
E M
OV
ED B
Y FO
RK
TR
UC
K O
R P
ALL
ET T
RU
CK
AR
OU
ND
SIT
E
RIS
K A
SSES
MEN
T
AR
EAP
RO
CES
S P
ERSO
N A
T R
ISK
HA
ZAR
D
SEV
P
RO
BR
ISK
CO
NTR
OL
MEA
SUR
ESA
DD
ITIO
NA
L C
ON
TRO
L M
EASU
RES
RIS
K A
NA
LYSI
S
SEV
ERIT
Y 1.
NO
RIS
K
2. L
OW
RIS
K 3
. MED
IUM
RIS
K
4. M
AJO
R IN
JU
RY
5. H
IGH
RIS
K
PR
OB
AB
ILIT
Y 1.
IMP
RO
BA
BA
LE
2. R
EMO
TE R
ISK
3
. PO
SSIB
LE
4. P
RO
BA
BLE
5.
LIK
ELY
RIS
K =
SEV
ERIT
Y X
PR
OB
AB
ILIT
Y: R
ISK
RA
TIN
G L
OW
1-1
0 M
EDIU
M 1
1-1
5 H
IGH
15
-25
GEN
ERA
L
ENG
INEE
R
CA
UG
HT
IN B
ELT
4
1
4
DIR
T C
OV
ERS
CA
N B
E R
EMO
VED
FR
OM
UN
DER
SID
E
WIT
HO
UT
REV
EALL
ING
AN
Y H
AZA
RD
S
CO
VER
S M
AD
E O
F C
LEA
R P
OLY
CA
RB
ON
ATE
TO
ALL
OW
A V
ISU
AL
INSP
ECTI
ON
BEF
OR
E R
EMO
VIN
G
ISO
LATE
PO
WER
AN
D L
OC
K O
UT
WIT
H P
ERSO
NA
L LO
CK
BEF
OR
E ST
AR
Ple
ase n
ote
this
is a
desig
n R
isk A
ssessm
ent
and s
hould
be u
sed in c
onju
nction w
ith a
site
specific
ris
k a
ssessm
ent
SEVERITY
1. MINOR INJURY
2. LOST TIME INCIDENT
3. +3 DAYS OFF
4. MAJOR INJURY
FATALITY
PROBABILITY
1. IMPROBABLE
2.REMOTE RISK
3. POSSIBLE
4. PROBABLE
5. LIKELY
RISK = SEVERITY X PROBABILITY RISK RATING: LOW: 1 -10 MEDIUM: 11-15 HIGH:15-25
RISK ANALYSIS
15
CERT. of CONFORMITY
16
START UP PROCEEDURE
ONLY NAMED AND TRAINED OPERATORS SHOULD USE THESE CONVEYORS
OPERATORS SHOULD FAMILIARISE THEMSELVES WITH THE RM HEALTH AND SAFETY LABEL
BEFORE USING
1) TURN ON MAIN ISOLATOR
2) THERE WILL BE AN INITIAL START UP SOUND AND THE POWER INDICATOR LIGHT
WILL LIGHT UP
3) ENSURE THAT ALL OPERATORS ARE CLEAR OF MOVING PARTS
4) PRESS AND HOLD THE BLUE RESET BUTTON FOR 5 SECONDS UNTIL THE AMBER LIGHT STAYS
ON
5) PRESS AND HOLD THE START BUTTON FOR 3 SECONDS – THE AMBER LIGHT WILL FLASH AND
THE SIREN WILL SOUND
6) T HE CONVEYORS WILL START TO MOVE
7) SENSOR –
A. IF THE PEC IS SWITCHED OFF THE CONVEYORS WILL RUN CONTINUOUSLY
B. IF THE PEC IS SWITCHED ON THE CONVEYORS WILL RUN UNTIL THE SENSOR BEAM IS
BLOCKED
LIGHT BEACON
CONTROL CABINET
17
CONVEYOR START UP TROUBLE SHOOTING
1) Power indicator not lit
- Check isolator on panel is on
- Check that the main supply isolator is on
- If both on and no power indicator light call an engineer
2) Red light stays lit and steady audible warning
- An Estop is depressed
- Reset Estop and start again
3) Amber light continues to flash and audible warning
- Sensor at end of horizontal is covered
- Unblock sensor and start again
REFER TO MANUAL FOR ADDITIONAL DETAILS
LIGHT STATUS SOUNDER
CONSTANT YES
CONSTANT YES
CONSTANT NO
FLASHING YES
FLASHING NO
FLASHING NO
3 PULSES AFTER PULSES
8 PULSES AFTER PULSES MOTOR OVERHEAT CALL AN ENGINEER
BEACON LIGHT
TROUBLESHOOTING WARNINGS
CAUSE ACTION
STOP BUTTON PRESSED
INTERNAL OR SUPPLY FAILURE
RESET ESTOP AND FOLLOW START
PROCEEDURE
PRESS AND HOLD START BUTTON
NONE REQUIRED
CALL AN ENGINEER
REMOVE ITEM BLOCKING SENSOR,
CONVEYOR WILL START
PRESS START BUTTON
CALL AN ENGINEER
ESTOP DEPRESSED
SYSTEM HAS BEEN RESET
SYSTEM IS RUNNING
FAILURE IN SAFETY SYSTEM
SENSOR HAS BEEN COVERED
18
861
9
900 759
861
9
600x
600
0 ho
rizW
EIG
HT:
A3
SHEE
T 1 O
F 1
SCA
LE:1
:25
DW
G N
O.
TITLE
:
REVI
SIO
ND
O N
OT
SCA
LE D
RAW
ING
MA
TERI
AL:
DA
TESI
GN
ATU
REN
AM
E
DEB
UR A
ND
BR
EAK
SHA
RP
EDG
ES
FINIS
H:UN
LESS
OTH
ERW
ISE
SPEC
IFIE
D:
DIM
ENSI
ON
S A
RE IN
MILL
IMET
ERS
SURF
AC
E FI
NIS
H:TO
LERA
NC
ES:
LIN
EAR:
A
NG
ULA
R:
Q.A
MFG
APP
V'D
CHK
'D
DRA
WN
1C P
arce
ls L
ayou
t with
use
of C
onve
yor 5
Met
er B
elt (
Bag
Tip)
Issu
ed b
y: K
en H
ouse
D
ate:
10/
11/2
015
Issu
es N
o: 3
Sh
eet 1
of 1
: Not
to s
cale
Belt
leng
th: 5
Met
ers
M
axim
um N
o of
ope
rato
rs: 4
M
inim
um N
o of
ope
rato
rs: 2
M
axim
um N
o of
sel
ectio
ns: 1
3
5m
2.6m
Op 1
Op
2
Tip
Open
/ asid
e
15.5
5m
6.52m
Def
ects
/ In
corr
ect S
trea
m
Dupl
icat
e
Ensu
re th
at m
otor
are
not
cov
ered
by
sleev
es
Oper
ator
1 z
one
to s
ort.
Item
s no
t to
be s
orte
d to
Op
2 zo
ne.
Issu
ed b
y: K
en H
ouse
D
ate:
10/
11/2
015
Issu
es N
o: 3
Sh
eet 1
of 1
: Not
to s
cale
Belt
leng
th: 5
Met
ers
M
axim
um N
o of
ope
rato
rs: 4
M
inim
um N
o of
ope
rato
rs: 2
M
axim
um N
o of
sel
ectio
ns: 1
3
5m
2.6m
Sort
So
rt
Tip
Open
/ asid
e
15.5
5m
6.52m
Def
ects
/ In
corr
ect S
trea
m
2C P
arce
ls L
ayou
t with
use
of C
onve
yor 5
Met
er B
elt (
Bag
Tip)
Dupl
icat
e
Ensu
re th
at m
otor
are
not
cov
ered
by
sleev
es
Oper
ator
1 z
one
to s
ort.
Item
s no
t to
be s
orte
d to
Op
2 zo
ne.
Issu
ed b
y: K
en H
ouse
D
ate:
25/
04/2
016
Issu
es N
o: 1
Sh
eet 1
of 1
: Not
to s
cale
Belt
leng
th: 5
Met
ers
M
axim
um N
o of
ope
rato
rs: 3
M
inim
um N
o of
ope
rato
rs: 2
M
axim
um N
o of
sel
ectio
ns: 1
3
5m
2.6m
Sort
So
rt
Tip
15.5
5m
6.52m
Def
ects
/ In
corr
ect S
trea
m
Prim
ary
Parc
els
Layo
ut w
ith u
se o
f Con
veyo
r 5 M
eter
Bel
t (fr
om fu
ll Sl
eeve
s)
= Du
plic
ate
Ensu
re th
at m
otor
are
not
cov
ered
by
sleev
es
Oper
ator
1 z
one
to s
ort.
Item
s no
t to
be s
orte
d to
Op
2 zo
ne.
If w
ork
is m
ovin
g di
rect
ly to
sec
onda
ry ro
ads
whe
n so
rted
, So
rtat
ion
shou
ld b
e in
to m
ini s
leev
es.
If st
orin
g to
wor
k pl
an s
orta
tion
is in
to fu
ll sl
eeve
s.
Test weight by moving the bag.
Be aware of overweight bags.
Max bag weight 11 kg. Report over
weight bags to your line manager.
Lift the bag onto the hopper ledge.
Remember to use both hands and bend your knees, not your
back.
Check the label to ensure you have
the correct stream.
Re distribute missorted bags.
Cut the tie.Place discarded tie and label in
correct bin.
Tip the bag contents into the
hopper.
Do not bend down to retrieve
debris from hopper.
Check bag is empty of all mail.
Fold and place bag onto the correct york.
Issued by: Verified by: JES Ref:Ken House
Maximum Minimum1 1
Manning Levels Version 1:0 Date 21/04/2105
JOB ELEMENT SHEET
INCLINE CONVEYOR CUT AND TIP
Process Step Key Point
Compliance… Incline Cut and Tip
= CRITICAL STEP SAFETY WARNING =
Pick up one parcel from the belt. If the item has a bar code
scan the item.
Ensure that the scanner has registered
the item.
If the parcels has
stamps on them check that they are canceled.
Cancel all stamps before sorting to
selection.
Now look for the
onward post code.If no post code place to one side, so post code can be found. DO not
guess destination.
Sort the item to the correct selection. Mini sleeve or full sleeve
only.
If the selection is not on your side of the
belt, pass to the operator next to you. DO NOT throw across
each other
If the red sleeves needs to be fastened this can be done if the belt if it
is 500mm wide.
If the belt is over 500mm wide, then the
Logistics operator should fasten the
sleeve.
Allow logistics team to move all full containers.
Logistics team will then replace with an empty
container
Issued by: Verified by: JES Ref:Ken House
Maximum Minimum2 1
Manning Levels Version 1:0 Date 18/01/2106
JOB ELEMENT SHEET
CONVEYOR - PARCEL SORTING
Process Step Key Point
Compliance… Conveyor Sorting
= CRITICAL STEP SAFETY WARNING =
