Safe Loading & Unloading ALC 2017 · Key Risk Areas – Loading and Unloading Falling Product " Falling product has resulted in multiple fatalities, and serious injuries. " Load dislodged

Safe%Loading%&%Unloading%%(Incl&LUEZ)&

File name: Safe Loading & Unloading.pdf Our Ref: E00540

Mike Robertson MD & Engineering Manager

0425 001 086 [email protected]

Why is the Logistics Industry SO Poor at Safety?

•  Often the Warehousing and Distribution Division is the poor cousin of the business = less focus from management

•  Road transport companies are obsessed with on-road safety

•  “ You can’t stop idiots on the road” •  “ 2/3 of all truck / car accidents are

the car’s fault” •  So Road Transport tends to be

Blind to the fact that >25% of their fatalities are INSIDE their gate (and many more unloading fatalities are in public spaces)

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There&are&2&issues&here&Chain&of&Responsibility&or&WHS?&

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Chain of Responsibility Laws (Compliance & Enforcement act) RMS (RTA) / VicRoads Now the NHVR (from Feb 2014) Apply for “ON Road” Issues Aimed at related parties in the supply chain Typical applications

!  “On Road” offences ! Multiple parties over same breach

Workplace Health & Safety Laws (Formerly OH&S Laws) Workcover / WorkSafe Apply for every workplace but, by Inter Dept Agreements not take lead “On Road” issues Typical applications

! Forklift / traffic Management

! Falling off trailers

! Loading & Unloading injuries

! Runaway Trailers

Another&session!& Today!&

WHS Law says…..

Legislative Requirements A common feature of all legislative requirements is the need to:

"  “Provide a safe place of work”

This is achieved through:

1.   Evaluation of tasks and potential risks

2.   Establishing suitable controls to reduce risks you identified.

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787#“truck#related”#Industrial#Deaths#recorded#in#10#years##

So&how&much&training&have&you&had&in&RISK&ASSESSMENT?&

Key Risk Areas – Loading and Unloading

How do you undertake a quality risk assessment of your Logistics site? Energy method = Best Start point "  Kinetic energy

"  Trucks "  Forklifts "  Cranes

"  Potential energy "  The load – on truck or mobile

equipment "  People at height

"  Electrical energy "  Chemical energy "  Strain Energy "  etc

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Forklift and People Interaction "  Interactions with people and

Mobile Equipment is a major risk.

"  Forklifts have high accelerations, change direction quickly, but provide poor visibility for the driver

"  Forklift operators find it difficult to keep track of pedestrians.

"  Inexperienced pedestrians are unaware of the risk.

"  Experienced pedestrians often become immune to the risk.

Is&the&Park&brake&really&on?&

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Just&how&close&do&you&really&need&to&be?&


People get complacent and WAY TOO Close to Forklifts

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Falling Product "  Falling product has resulted in multiple

fatalities, and serious injuries.

"  Load dislodged by crane or forklift "  Forklifts often push product off the

opposite side.

"  Load falls from the crane or forklift tine.

"  Loads that move in transit can fall when lashings are released, or curtains or container doors are opened.

"  Reality Check! In the human reaction time of ~1.5 seconds, a load falls 11 metres. “Be careful” is not enough!

Falling#building#products#–#Mark#Beilby#Fatality#

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Product moving on crane or forklift "  Even if the product doesn’t fall……

Serious injuries or death are common

"  People crushed

"  Load traversing in

"  Load lowering

"  Load slung off centre

"  Load slides off the tines

"  Domino effect

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People&Falling&off&Trucks&&"  Too&common&for&drivers&or&loaders&

to&fall&from&the&truck&deck&

" Worksafe&Australia&reports&that&between&2009&and&2011&a&full&49%&of&ALL&injuries&due&to&falls&were&truck&drivers&(1540&of&3100&claims)&

" MulYple&fataliYes&and&serious&injuries&have&resulted&

"  There&is&rarely&a&simple&soluYon&

&&

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It#is#simply#irresponsible#&#illegal#to#allow#this#sort#of#behaviour#on#your#sites#


Reversing&Trucks&&"  Reversing%trucks%vs%pedestrians%are&always&

a&hazard&

"  Poor&to&zero&visibility&for&the&driver.&

"  Pedestrians&run&over&

"  Pedestrians&crushed&against&dock.&

"  Finger&docks&even&worse&

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Loading&Docks&&"  Falling%%forkli9s%are&a&killer&

"  Can&be&forkli]&driver&error&

"  Can&be&due&to&truck&moving&

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Truck&moves&during&load/unload&&"  PotenYal&for&vehicles&to&move&part&

way&through&loading&or&unloading&

" MulYple&fataliYes&and&serious&injuries&have&resulted&

"  Vehicle&runaway&with&handbrakes&incorrectly&applied&

"  Vehicles&actually&drive&away&&&&&

The#driver#“knows”#he#can#move#

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Risk Controls – Loading / unloading

Hierarchy of Controls 1.   Eliminate the hazard altogether.

2.   Substitute

3.   Isolate

4.   Engineering

5.   Administrative (SOP)

6.   Personal protective equipment

AIM&FOR&THE&

HIGHER&LEVEL&OF&CONTROL&

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"  Controls must be “fit for purpose”

"  Use quick temporary options to confirm which controls work best

"  Check that the controls selected are robust and likely to have strong compliance

"  Use the hierarchy of controls "  Aim high "  If procedural, they need to

be robust, well trained, and heavily enforced.

EffecYve&control?&

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Exclusion Zones Can’t See – Can’t Load

"  Very important and now minimum controls

"  Separation of people from forklift, crane, and falling loads

"  You can’t stop product falling off tynes, so stop people being in the “Falling Zone”

"  Loading Unloading Exclusion Zone = LUEZ

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Conceptual#LUEZ#You#should#adapt#this#idea#to#suit#your#situaLon#and#risks##

A#green#mat#can#make#a#cheap#and#flexible#driver#zone#


Traffic Management

Question how we can increase the hierarchy of control level "  Define areas that are high risk

"  Physical controls that restrict access of pedestrians into high risk areas.

"  Very important to keep out any through-traffic

"  Minimise loading numbers in the area – people, forklifts

"  Driver removed and kept out unless required for the loading process

LUEZ Should overlap with plant’s overall Traffic Management

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Vehicle Isolation Several potential solutions: "  Isolate driver from vehicle and

loading area (if not required for loading)

"  Isolate forklift from truck where or when driver lashing/unlashing the load

"  Isolate keys

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Prevention of Dock Falls "  If loading docks are present,

consider if docks are right for your business

"  Isolate area when not in use

"  Bollard against falls close to the actual dock area

Prevent Pedestrian/Truck Interactions "  Isolation fencing/gates

"  One way traffic (forward)

"  Overlap with Traffic Management

"  Limit activities allowed in interaction areas

"  Special care at the base of raised docks, and/or where trucks are reversing

"  “Critical” procedures at a minimum eg. 3 m rule between forklifts and people

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Prevention of Falls from Trucks Many causes and many solutions: "  Solutions worth more detailed discussion

"  Eliminate working at height

"  Engineer ways to work safely from the ground or at height

"  PPE and administrative controls


Communications and Coordination Load tasks requiring coordination between people are a concern "  Understand the process

"  Simplify it

"  Minimise the people involved in any task

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Take 5 A basic safety method Transport safety needs a Take 2 philosophy. "  Things are rarely the same or constant in

the logistics environment

"  What is different about today?

"  Take 5….. Take whatever it takes to: "  Stop "  Look "  Plan "  Do

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In Summary

Summary Remember the WHS legislative requirements "  “Provide a safe place of work”

"  Look at the exposed hazards (energy) in a load/unload environment

"  Put in controls

"  Start quickly with simple controls

"  But move rapidly towards controls further up the Hierarchy of Control

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Key Risks

"  Interactions with mobile equipment (forklift / cranes)

"  Product falling off vehicles / tynes during loading

"  People Falling off trucks

Principal Controls

"  Exclusion Zones (LUEZ)

"  3 Metre rule for forklift /pedestrians

"  Traffic Management

"  Eliminate working on trailers

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Documents

Safe Loading & Unloading ALC 2017 · Key Risk Areas – Loading and Unloading Falling Product " Falling product has resulted in multiple fatalities, and serious injuries. " Load dislodged