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New South Wales Governmentmaking a difference
TRAFFICMANAGEMENTIN WAREHOUSING
PLAN AND CHECKLISTMarch 2009
DisclaimerThis publication may contain occupational health and safety and workers compensation information. It may include some of your obligations under the various legislations that WorkCover NSW administers. To ensure you comply with your legal obligations you must refer to the appropriate legislation.
Information on the latest laws can be checked by visiting the NSW legislation website (www.legislation.nsw.gov.au) or by contacting the free hotline service on 02 9321 3333.
This publication does not represent a comprehensive statement of the law as it applies to particular problems or to individuals or as a substitute for legal advice. You should seek independent legal advice if you need assistance on the application of the law to your situation.
© WorkCover NSW
Acknowledgement: This is a NSW Wholesale Industry Reference Group project in partnership with WorkCover NSW.
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CONTENTS PAGE
INTRODUCTION 2
TRaffIC MaNaGeMeNT PlaN CheCklIST 4
loadshifting equipment 4
Barricades/Barriers/Bollards 6
layout/line Marking 7
Signage/Warning Devices 8
Training, Systems, Policies, Procedures 9
Personal Protective equipment 11
external Traffic Management Requirements 12
Sample Warehouse Traffic Management action Plan 13
RISK ASSESSMENT MATRIX 14
DEFINITIONS 15
MORE INFORMATION 17
2
INTRODUCTION
The consequences of being hit by loadshifting equipment and other vehicles can be serious,
resulting in injury or even death. There is a significant cost to the victim, the employer, the
victim’s family and the community.
This Traffic Management Plan Checklist provides guidance to managers and supervisors
of small to medium businesses on how to develop, implement and maintain safe systems
of work, intended to eliminate or control the risks of collision in a warehousing and/or
storage environment.
an important part of managing your business is to ensure the health and safety of your
employees and other people, such as customers, visitors or tradespeople who visit your
workplace.
To ensure you fulfil your obligation for a safe workplace, you need to be aware of what can
cause harm and then take action to ensure no one is at risk while they are in your workplace.
The following questions will help you evaluate how well you are currently managing safety in
your workplace:
Do you talk with your employees about safety issues? Yes No
Do you encourage your employees to report safety problems? Yes No
Do you regularly inspect your workplace to identify safety problems? Yes No
Do you fix identified problems? Yes No
Do you supervise and train employees so that all work is carried out safely? Yes No
If you answered ‘no’ to any of these questions, you may not be meeting all of your
obligations under the Occupational Health and Safety Act 2000 (the OhS act).
even if you answered ‘yes’ to all these questions, this Traffic Management Plan Checklist will
help you to systematically identify the traffic management safety risks in your workplace and
take the necessary steps to make your workplace safer.
When using the Traffic Management Plan Checklist, it is important to involve your
employees, as they are the people most affected by safety issues and can help to identify the
best safety solutions. Involving your workers is one of your obligations under The OHS Act, to
consult with your employees on workplace safety issues, including when developing safe work
procedures.
When you complete the Traffic Management Plan Checklist, it is important to determine how
often it needs to be reviewed. as a guide, it is a good idea to review the Traffic Management
Plan Checklist at least once a year. however, you may also need to review the Traffic
Management Plan Checklist if there are changes to your workplace that may impact on
safety, eg when new equipment is introduced into the workplace, in situations where plant/
processes are modified and during seasonal peak periods.
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By completing this Traffic Management Plan Checklist, identifying and controlling any
problem areas and reviewing it regularly, you will be well on your way to meeting your legal
obligations to provide a safe and secure workplace.
Instructions
Simply tick ‘Yes’ or ‘No’ to each question and add any comments you consider appropriate.
If the question does not apply to your workplace, tick ‘N/a’. If you tick ‘No’ to any question
you will need to take action to rectify the issue. an action plan template is provided in this
Traffic Management Plan Checklist and may be used to map the necessary steps required to
make your workplace safer.
for more information or assistance, go to www.workcover.nsw.gov.au or contact the WorkCover
assistance Service on 13 10 50.
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TRAFFIC MANAGEMENT PLAN CHECKLIST
Date checklist completed: _______ /_______ /_______
Date checklist to be reviewed
(if not reviewed earlier due to a change to the workplace): _______ /_______ /_______
Name(s) of person(s) who completed checklist: _________________ Title: _________________
Name(s) of person(s) who completed checklist: _________________ Title: _________________
1. LOADSHIFTING EQUIPMENT
Issue YES NO N/A POSSIBLE Control Measure Action to be taken
1.1 Is a forklift required for this job?
• substitute forklift with more ‘pedestrian friendly’ loadshifting equipment (eg pallet jacks, walker stackers)
• if the above is not practicable, design the workplace to eliminate the need for pedestrian access in the vicinity of a forklift.
1.2 Have you studied the loadshifting equipment and pedestrian movement in the workplace to identify the risk of collision with a pedestrian?
• study the loadshifting equipment and pedestrian movement in the workplace
• identify the potential for collisions with loadshifting equipment and pedestrians, columns, racking and other vehicles.
1.2a Have you implemented control measures to address the risks identified in the above study?
• mark ‘No Go’ for exclusion zones for both pedestrians and powered loadshifting equipment based on pedestrian and equipment movements, braking distance, stability and loads being handled
• change layout
• change equipment.
1.2b Have you implemented appropriate measures to monitor the effectiveness of the controls?
• ensure there is an appropriate level of supervision provided to see control implemented
• ensure there are appropriate arrangements in place so that incidents and near misses are reported
• ensure arrangements are in place to modify controls where necessary based on feedback from incident and near miss reports.
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1. LOADSHIFTING EQUIPMENT (CONTINUED)
Issue YES NO N/A POSSIBLE Control Measure Action to be taken
1.3 Have you determined parking areas for loadshifting equipment?
• ensure loadshifting equipment has its own clearly marked parking and/or recharging areas
• design work processes so that no loadshifting equipment is required to park on pedestrian walkways.
1.4 Are daily pre-operational checks being completed for these components?
• falling object protection
• brakes
• seat belts (where fitted)
• lights
• warning devices
• steering
• tyres
• controls
• horn
• mast and hydraulics
• chains
• hand brake
• load capacity plate
NOTES
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2. BARRICADES/BARRIERS/BOLLARDS
Issue YES NO N/A POSSIBLE Control Measure Action to be taken
2.1 Are physical separation structures installed to keep pedestrians out of loadshifting areas? (they may be essentially visual in nature or only strong enough to resist accidental actions by the pedestrian)
• enclose designated loadshifting equipment operating areas with physical barriers to prevent pedestrian access
• if employees work within loadshifting equipment operating areas eg desks, counters, goods dispatch areas or workstations:
– relocate them away from traffic areas
– erect physical barriers to protect such areas, eg steel railings.
2.2 Are pedestrian crossings clearly marked?
• clearly designate pedestrian crossings by installing inward opening pedestrian gates as a calming device to ensure people stop and look before crossing
• have right of way procedures in place and enforced, clearly indicating who must give way
• pedestrian crossings on the pavement.
2.3 Are adequate bollards and safety railings being used to reduce the risk of vehicle and pedestrian collision in the battery charging area and waste bin work zones?
• clearly delineate the battery charging area for electric loadshifting equipment by installing adequate bollards/safety railings
• separate access paths for vehicles and pedestrians, eg vehicles access from the end and pedestrians from the side barricading and markings to match
• ensure clear visibility around waste bin areas to avoid pedestrians stepping out into traffic from ‘blind spots’
• install barriers/bollards to protect other vulnerable equipment, pits or places where employees work.
2.4 Do entry and exit points to the building protect pedestrians from being struck by vehicles?
• install barriers or bollards at the entry and exit points of the building to prevent pedestrians walking into the path of oncoming vehicles
• where buildings or walkways open directly onto roadways or traffic zones, erect permanent barriers to ensure pedestrians do not step into the path of passing vehicles
• use bollards/barriers to prevent vehicles obstructing emergency exits.
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3. LAYOUT/LINE MARKING
Issue YES NO N/A POSSIBLE Control Measure Action to be taken
3.1 Is there an effective workplace layout to separate pedestrian and powered loadshifting equipment traffic?
• clearly line mark pedestrian walkways, roadways and loadshifting equipment operating areas based on speed limits, stopping distances and efficient workflow
• minimise the cross flow of traffic, intersections and blind spots
• line mark ‘customer pick-up’ parking areas
• make sure ‘customer pick-up’ parking areas are positioned close to pedestrian walkways and provide access without crossing driveways or loading dock vehicle paths
• clearly define areas where powered loadshifting equipment is used as ‘pedestrian exclusion zones’ and clearly exclude powered loadshifting equipment from pedestrian walkways/work areas
• use line markings and/or marker posts in docking areas to indicate distances from dock, ie 1 metre increments advising driver of proximity to dock, reducing the need for assistance reversing
• provide line marking for:
– traffic flow markings
– loadshifting equipment parking
– driver designated safe areas
– car parking
– keep clear zones
– lane numbering where multiple docks exist
– speed humps.
3.2 Is there effective line marking to separate pedestrian and powered loadshifting equipment traffic?
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4. SIGNAGE/WARNING DEVICES
Issue YES NO N/A POSSIBLE Control Measure Action to be taken
4.1 Is there adequate lighting and visibility to minimise the risk of collision?
• install ‘eye ball’ convex mirrors to provide clear visibility of approaching loadshifting equipment and/or pedestrians
• all loadshifting equipment to carry high visibility and/or reflective markings
• pedestrians within vehicle access areas to wear high visibility clothing or vests
• provide additional lighting.
4.2 Is there clear warning of loadshifting equipment hazards?
• loadshifting equipment have fitted and maintained reversing beepers and/or flashing lights
• clearly mark such things as cabling or ducting with high visibility materials
• have signs conforming to the australian Standard aS1319 – ‘Safety Signs for the Occupational Environment’
• prominently display clear warning signs in relevant, well lit areas to remind persons of the traffic management hazards and requirements.
Signage examples:
– ‘Pedestrians Prohibited – loadshifting equipment Operating area’
– ‘loadshifting equipment Prohibited’
– ‘Pedestrian Safety Zone’
– ‘Beware loadshifting equipment operating within the area’
– ‘Vehicles must give way to pedestrians’ or a ‘priority’ or ‘right of way’ procedure that applies to pedestrian crossings.
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5. TRAINING, SYSTEMS, POLICIES, PROCEDURES
Issue YES NO N/A POSSIBLE Control Measure Action to be taken
5.1 Are operators adequately trained and licensed where required?
• make sure operators are adequately trained and competent, even for machines that do not require a Certificate of Competency
• do NOT allow other people (eg visitors, delivery drivers, etc) to operate machinery without assessing their competency and sighting relevant Certificates of Competency
• make sure learner operators are properly supervised and complete logbooks
• induct operators into the operation of new plant
• have operation manuals for plant available for operators to read
• keep copies of loadshifting operators’ Certificates of Competency.
5.2 Have employees undergone a site safety induction prior to being permitted to use loadshifting equipment?
• conduct a work environment induction
• conduct a traffic management site induction.
5.3 Are safe work procedures in place for operators of loadshifting equipment?
Consult with staff and consider incorporating the following into your safe work procedures:
• pre-use inspection procedures to check for obvious defects
• means to ensure loads do not exceed the capacity of the equipment
• loadshifting equipment key control procedures to ensure only competent operators use the equipment
• loadshifting equipment to cease work if pedestrians enter a pedestrian exclusion zone
• loadshifting equipment operators to keep the tynes as close to the floor as practical when travelling and operating within the site
• loadshifting equipment operators to ensure that their load (mast) has appropriate rearward ‘tilt’ prior to moving pallet/stock and not travel with tynes extended
• loadshifting equipment operators should lower their loads before turning in the direction of travel
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5. TRAINING, SYSTEMS, POLICIES, PROCEDURES (CONTINUED)
Issue YES NO N/A POSSIBLE Control Measure Action to be taken
5.3 Are safe work procedures in place for operators of loadshifting equipment? (cont)
• sound loadshifting equipment’s horn (warning device) when crossing intersections, pedestrian walkways and access and egress points for pedestrians
• no loadshifting equipment is to be used to move or shunt another piece of equipment
• no tampering or modifying of loadshifting equipment by staff
• ‘Out of Service’/‘Danger’ tag system clearly understood and carried out by loadshifting operators
• ensure operators of loadshifting equipment travel in reverse if the load obstructs their view.
5.4 Have procedures and training on traffic management been given to employees and any visitors to the workplace?
• ensure pedestrians are aware of traffic management rules, including not walking behind loadshifting equipment when in operation and staying on designated walkways and pedestrian areas
• ensure all contractors and visitors working on site receive induction regarding traffic management and are signed in
• ensure non-inducted visitors are supervised at all times when walking through the site
• monitor and assess employee’s compliance with the traffic management procedures.
5.5 Have you clearly identified pedestrian walkways and traffic directions?
• develop a site plan clearly identifying pedestrian walkways and traffic directions
• review the site plan regularly (at least annually), have it dated and signed off by the OhS Committee/Representative and Site Manager.
5.6 Are external delivery drivers aware of your site’s traffic safety procedures?
• develop a truck docking procedure to ensure delivery trucks engage trailer braking, chocks and parking brakes at all times during unloading
• ensure risks of ‘drive-offs’ during loading and unloading are minimised (eg driver not permitted to stay inside vehicle while being loaded/unloaded or ignition key put on a hook inside the dock).
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6. PERSONAL PROTECTIVE EQUIPMENT
Issue YES NO N/A POSSIBLE Control Measure Action to be taken
6.1 Do pedestrians and drivers (internal and external) wear high visibility clothing in traffic areas?
• provide high visibility clothing that meets the australian Standard aS/NZS 4602 – ‘High Visibility Safety Garments’ and is appropriate for their specific use – day or night
• ensure pedestrians and delivery drivers wear high visibility clothing (day or night) in traffic areas
• provide high visibility clothing (eg vests) for visitors or other employees accessing traffic areas from other areas of the workplace, eg office staff entering warehouses.
6.2 Do you have a policy regarding appropriate footwear in the workplace?
• write a policy regarding appropriate footwear in the workplace and clearly define the term ‘appropriate footwear’ for each area of the workplace
• ensure persons accessing vehicle areas wear closed-in and/or safety footwear.
NOTES
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7. EXTERNAL TRAFFIC MANAGEMENT REQUIREMENTS
Issue YES NO N/A POSSIBLE Control Measure Action to be taken
7.1 Do you have external controlled speed limits in place for trucks, customer’s or visitor’s vehicles to the site?
• install traffic-calming devices to reduce the speed of vehicles, especially when approaching pedestrian or loadshifting equipment operating zones eg boom gates and self closing gates.
7.2 Have you provided safe access and egress to and from your site for pedestrians?
• provide line markings, signage and barriers for safe pedestrian walkways.
7.3 For common areas where pedestrians and vehicles are required to operate within the same area, have you provided adequate safety control measures?
• provide line markings on the ground to indicate appropriate parking lanes, driver safe zones and walkways for drivers of vehicles being loaded and unloaded
• clearly define safety zones protected by bollards/barriers so that drivers or unloading crew can supervise unloading at a safe distance from loadshifting equipment and falling loads.
NOTES
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SAMPLE WAREHOUSE TRAFFIC MANAGEMENT ACTION PLANAction Required
Priority Person Responsible
Est Completion Date
Completed by Signature/Date
Comments
1. Re-do line marking of all pedestrian walkways
high Med low
M. Brown January 2009 Check all pedestrian walkway areas within the warehouse
high Med low
high Med low
high Med low
high Med low
high Med low
high Med low
high Med low
high Med low
high Med low
high Med low
high Med low
high Med low
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RISK ASSESSMENT MATRIXHOW DANGEROUS IS THE HAZARD YOU HAVE IDENTIFIED? FOR EACH HAZARD THINK ABOUT THE FOLLOWING:
WORKCOVER HAZPAK MATRIX HOW LIKELY IS IT TO HAPPEN?
HOW BAD IS IT LIKELY TO BE? VERY LIKELY:Could happen at any time ++
LIKELY:Could happen some time +
UNLIKELY:Could happen, but very rarely –
VERY UNLIKELY:Could happen, but probably never will – –
Kill or cause permanent disability or ill health
1 1 2 3
Long term illness or serious injury
!!!
1 2 3 4
Medical attention and several days off work
!!
2 3 4 5
First aid needed
!3 4 5 6
The numbers show how important it is to do something.
1 top priority: immediate action required
6 low priority: take action when possible.
Example
Hazard: Plate glass door at foot of steps
Judge severity: Someone falling down the steps could smash through the glass and be
very seriously injured. So it is a !!! hazard. (look in the second row of numbers.)
Judge likelihood: This could easily happen at any time. So it is ++ very likely. (look in
the first column of numbers.)
Second row, first column is priority number 1. So it is extremely important to fix this
hazard soon.
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DEFINITIONS
WHOLESALE TRAFFIC MANAGEMENT
Traffic Control Bollards, Barriers, Railings and Barricades
a physical barrier installed to separate pedestrians or property from loadshifting equipment
and other vehicles.
Competent Person
a person who has acquired through training, qualification or experience, or a combination of
them, the knowledge and skills to carry out that task.
Personal Protective Equipment (PPE)
Safety devices or safeguards worn by workers to protect against environmental hazards. PPe
includes such items as helmets, safety goggles, hearing protectors, face shields, sun screens,
respirators, harnesses and lanyards, arm guards, smocks, gloves, high visibility clothing and
safety boots.
Plant
any machinery, equipment (including scaffold), appliance, implement or tool and any
component or fitting thereof or accessory thereto.
Risk Assessment
a process that estimates the effects or consequences of hazardous events on people,
property and the environment. The process would consider the likelihood of occurrence and
the severity of the consequences.
Safe Work Method Statement or Job Safety Analysis
a statement that:
• describes how work is to be carried out
• identifies the work activities assessed as having safety risks
• identifies the safety risks
• describes the control measures that will be applied to the work activities, and includes
a description of the equipment used in the work, the standards or codes to be complied
with, the qualifications of the personnel doing the work and the training required to do
the work.
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Scheduled Work
Scheduled Work is defined in the Occupational Health and Safety Regulation 2001, Part 9.1,
Clause 266 and includes some types of cranes and loadshifting equipment used in warehouses.
Pedestrian
a person travelling on foot.
Loadshifting Equipment – plant designed to lift and/or move loads
• Powered: eg motorised pallet mover/jack, forklift truck, walk-behind forklift, stock picker/
order picker, overhead crane, vehicle mounted crane
• Manual: eg manual pallet jack, trolley, wheeled pallet.
Dock
any area designated for the physical receipt and/or despatch of goods.
Delivery Vehicle
any vehicle delivering or picking up items from a workplace (eg bicycle, motorcycle, car, van,
ute, truck etc).
Safety Zone
Designated work area protected by a physical barrier separating pedestrians and loadshifting
equipment.
Certificate of Competency
Certification determining competency to operate specific machinery, which is scheduled
under Clause 266 of the Occupational Health and Safety Regulation 2001 (eg specified
types of forklift, crane, hoist etc). also commonly called a Ticket or a licence.
Site Plan
Building and perimeter layout detailing the flow of work processes and all necessary movements
of people, loadshifting equipment, vehicles, material and equipment of different types.
Traffic-calming Devices
Methods used to bring traffic movement to a momentary halt or reduce the speed of vehicles
eg boom gates, self closing gates, speed humps, chicanes.
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MORE INFORMATION
GUIDE TO OBTAINING MORE INFORMATION
WorkCover NSW Phone: 13 10 50
http://www.workcover.nsw.gov.au/
WorkCover NSW publications are available on the WorkCover website or by calling the Publications Hotline on 1300 799 003. Some useful publications are:
• Making your forklift work for you
• Forklift Truck: National Certificate of Competency
• Plant Guide 2001
OHS Legislation Occupational Health and Safety Act 2000
Occupational Health and Safety Regulation 2001
http://www.legislation.nsw.gov.au/
Australian Standards Standards Australia
Phone: 1800 035 822
http://www.standards.org.au/
australian Standards are available from SaI Global www.saiglobal.com/shop
email: [email protected] or phone 13 12 42
WorkSafe VIC Forklift Safety Reducing the Risk
http://www.worksafe.vic.gov.au/wps/wcm/resources/file/ebcad2435c446c8/forklift_safety.pdf
ACT WorkCover A Guide to Forklift Safety – July 2005
http://www.workcover.act.gov.au/pdfs/guides_cop/forklift_Safety_Booklet.pdf
Worksafe – WA Guidance Note – Safe Movement of Vehicles at Workplaces
http://www.docep.wa.gov.au/worksafe/PDf/bulletins/safe_movement_vehicl.pdf
Shop, Distributive and Allied Employees’ Association (NSW Branch) InfoSheet8 – Working with Forklifts
http://www.sdansw.org.au/www/forms/forklifts.pdf
Safety-Engineer.com Forklift Safety by Design
http://www.safety-engineer.com/forklift.shtml
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Health & Safety Executive – UK Improving the Safety of Workers in the Vicinity of Mobile Plant
http://www.hse.gov.uk/research/crr_htm/2001/crr01358.htm
Workplace Transport Safety
http://www.hse.gov.uk/pubns/indg199.pdf
Monash University Accident Research Centre (MUARC) Forklift Trucks and Severe Injuries: Priorities for Prevention
www.monash.edu.au/muarc/reports/muarc030.html
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NOTES
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Catalogue No. WC05856 WorkCover Publications hotline 1300 799 003
WorkCover NSW 92-100 Donnison Street Gosford NSW 2250locked Bag 2906 lisarow NSW 2252 WorkCover assistance Service 13 10 50Website www.workcover.nsw.gov.au
ISBN 978 1 74218 075 5 ©Copyright WorkCover NSW 0209
