Forklift Safety Plan Table of Contents SECTION 11.0 PAGE NO.

Policy........................................................................................................................11.1 11.1 11.2 Purpose ........................................................................................................11.1 Types of Lift Trucks .....................................................................................11.1 11.2.1 Counterbalanced Forklifts ...............................................................11.1 11.2.2 Powered Pallet Trucks .....................................................................11.1 11.3 The Principles Forklift Safely ......................................................................11.1 11.3.1 Fulcrum Point and Load Center ......................................................11.2 11.3.2 Load Capacity and Load Rating ......................................................11.2 11.3.3 Stability and Center of Gravity ........................................................11.2 11.3.4 The Stability Pyramid/ Triangle .......................................................11.3 11.4 Operator Safety Rules and Procedures ......................................................11.3 11.4.1 Traveling ...........................................................................................11.3 11.4.2 Loading and Unloading the Forklift ................................................11.4 11.4.3 Driving Into A Trailer ........................................................................11.5 11.4.4 Lifting and Lowering People ............................................................11.5 11.4.5 Recharging Batteries .......................................................................11.5 11.5 11.6 Training ........................................................................................................11.6 Maintenance and Service ............................................................................11.7

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Policy

It is "The Company" policy that all employees who operate a powered industrial lift truck receive adequate training, and demonstrate competency in the safe use of the lift trucks assigned to each "The Company" work area. 11.1 Purpose

This Plan establishes policies, safe work practices, and procedures for a safe and compliant lift truck (forklift) program. This Plan is based on OSHA requirements for Industrial Lift Trucks (Title 8 CCR, Article 25). This Plan provides the standards by which forklift safety is managed in all "The Company" facilities and is intended to provide guidance and serve as an informational resource for forklift users. 11.2 Types of Lift Trucks

"The Company" uses electric-powered forklifts and powered pallet trucks in the Shipping and Receiving Departments. Both types of lift trucks are battery-operated, and are maintained by Shipping and Receiving staff. The following sections describe the types of lift trucks used at "The Company". 11.2.1 Counterbalanced Forklifts

"The Company" uses electric-powered rider trucks in both warehouses, which are counterbalanced with weights and the battery pack that powers the machine. These units require the operator to be seated in a cage with an overhead guard, and are intended for one operator. These forklifts are rated at __ pounds, which is based on the weight of the counterbalance. They are equipped with solid tires, intended for indoor use. The forklift trucks "The Company" uses have ___ stages on the mast. Unlike a car, the rear wheels steer the forklift in a tight turning radius, while the front wheels are designed to drive it. The counterbalance is usually several thousand pounds in weight and is designed to offer stability when handling loads in both vertical and horizontal directions. 11.2.2 Powered Pallet Trucks

Among the type of powered pallet lift trucks "The Company" uses high-lift units, which are equipped with a high lift mast, useful for reaching high shelves on racking systems. The high-lift trucks is designed with two outrigger wheels in front that allow the forks to straddle a pallet, and serve to add stability, because these units do not have a counterbalance. They have a lower rated capacity, and are intended for lighter loads in small or constrained warehouses. Other types of high lift trucks have a counterbalance, and are without outrigger wheels. 11.3 The Principles Forklift Safely

There following four principles of lift truck safety work together to form the basis of safe operations. These are basic principles of physics related to stability and centers of gravity, as the following section discuss.

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Fulcrum Point and Load Center

The forklift is like a lever, with the center of balance, or fulcrum point, located directly under the front wheels of a counterbalanced forklift. The fulcrum point does not change, regardless of the size of the load. If the load is heavier than the counterbalance, the forklift will tip forward. However, a light load will not tip the forklift backwards, because the weight is distributed across the length of the forklift making it stable at rest. Load center is a term that means the center of gravity of the load. The load center is typically measured from the heel of the forks to the center of the load, and the closer the load center is to the backrest the more stable the load. As the load center moves away from the heels of the fork, or backrest, the capacity of the forklift decreases. For every inch away from the heel of the forks, the rated capacity will decrease by 100 pounds, which also moves the center of gravity further away from the counterbalance, thus reducing stability. 11.3.2 Load Capacity and Load Rating

All lift trucks have a capacity plate that indicates the manufacturer recommendation for the weight of a load the lift truck can safely handle. The rated capacity is based on a load center that is evenly distributed and at least 24 inches from the heel of the forks. Load capacity can change depending on the following. Distance of the load center from the forks The height of the load The location of the load center

The operator must assess the weight, and center of gravity (a.k.a. load center), of a load before trying to lift it. This ensures that the forklift is able to perform the job. The operator then must also assess how best to move the load and establish a safe center of gravity for both the load and the forklift. Awkward or odd sized loads may require extra thought as to the location of the load center, and how best to move it, because off-centered loads cause the load and the lift truck to be unstable. 11.3.3 Stability and Center of Gravity

The forklift has a center of gravity, just as the load has one. The primary difference is that the forklifts center of gravity changes with a load, and as the load is raised or shifted sideways. When the forklift is at rest, the center of gravity is underneath the drivers seat. When the load is lifted, then a combined center of gravity is created, which is based on the following factors. Size of load Weight or load Shape of load Position of the load

The combined center of gravity also changes depending on the tilt of the forks because it changes the load center. The most stable position of the forks is when the load rests against the backrest, and the forks are tilted slightly back. When the mast it tilted forward

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the combined center of gravity moves toward the front of the forklift, making it frontheavy. Forks must only be tilted forward only when picking up or dropping a load. 11.3.4 The Stability Pyramid/ Triangle

Drawing a line between the front wheels and the center of the rear axle forms an imaginary triangle, called the Stability Triangle. At rest, the center of this stability triangle is underneath the drivers seat, which is discussed above as the forklifts combined center of gravity with no load, or while at rest. As a load is lifted, the triangle turns into an imaginary pyramid, and the combined center of gravity rises through the center of the pyramid. As the load rises the stability pyramid, or stable range, becomes narrower and taller. If the loads center of gravity moves outside the stability pyramid, the forklift will fall over. Other forces, such as driving too fast, making sharp turns, braking hard, or moving a load with elevated forks will contribute to a loaded forklift falling over. 11.4 Operator Safety Rules and Procedures

The following rules are considered standard industry practice and are intended to reduce the risk

of overturning accidents, collisions, loss of the load, or injury to others. Wear the seat belt at all times when operating a forklift Make sure the load is stable and safely arranged on the forks Do not tilt the forks forward except when picking up or depositing a load Tilt the load backward only enough to stabilize the load Keep the load low just above the pavement with forks tilted back when traveling Enter truck trailers squarely, and not at an angle Keep the load uphill when going up or down an incline or ramp Drive at a speed that will allow you to stop safely within the stability triangle Slow down on wet or slippery surfaces Slow down to make turns Avoid driving over loose objects or on surfaces with ruts and holes Drive in Reverse if the load blocks the view Drive with forks only a few inches above the ground to maximize stability Lift the forks only when ready to place or lift a load Avoid driving along the edge of a loading dock, and always face the open door 11.4.1 Traveling

The basic premise for traveling is that you maintain control of your forklift at all times. Other rules include the following. Operate a forklift only while in the seat or operators station. Never start it or operate the controls while standing beside the forklift Never allow passengers Do not put any part of your body between the uprights of the mast or when traveling, outside of the forklift frame Always look in the direction of travel and keep a clear view of the travel path Travel in reverse if the load blocks your view Always observe posted speed limits at your workplace. A forklift should not be driven faster than a quick walking pace

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Keep a distance of at least three forklift lengths between you and any forklift traveling in front of you Do not pass a forklift traveling in the same direction Never drive a forklift up to anyone in front of a fixed object, such as a workbench Never allow anyone to walk or stand under the elevated forks even if the forks are not carrying a load Check that there is adequate clearance under beams, lights, sprinklers, and pipes for the forklift and load to pass Do not engage in stunt driving or horseplay Never leave a forklift unattended

An unattended forklift means that the operator cannot see the machine, or is greater than 25 feet away. Unattended forklifts must be turned off, have the forks on the ground and the brakes set or chocked, if on an incline. 11.4.2 Loading and Unloading the Forklift

Check the load before you pick it up. Secure it as necessary, and follow the rules outlined in this Plan. When you pick up the load: o Move squarely into position in front of the load o Position the forks at a width that keeps the load balanced o Drive the forks fully under the load o Tilt the mast backward slightly to stabilize the load, and then lift Check the destination before you place the load o Is the destination flat and stable or, will the load rock, tilt or lean? o Never place heavy loads on top of light loads. o Observe maximum stacking quantities and orientation if printed on cartons. o Know the load bearing capacity of your rack or storage loft destination o Check to see if rack legs or support members bent or disconnected, for the load bearing capacity of a damaged rack is unknown! Wait until the damaged component has been replaced before loading When you place the load at its destination: o Move squarely into position in front of the rack or stack where the load will be placed o When ready to place the load, tilt the mast to level o Only tilt forward when the load is over the spot where it will be placed o Lower the forks and back away o Visually verify that the load is stable

Operators are expected to use the proper attachment for handling specific types of loads. The forklift and forks are not to be modified to perform a job for which they are not intended. For special operations, use an attachment designed by the manufacturer for that purpose. Attachment types include:

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Push/ Pull Clamp Bale Clamp Barrel Clamp Rotating Carriage Turntable Fork Clamp Driving Into A Trailer

Operators may have to drive into trailers at the loading dock in Building 1. In these cases a dock plate must be used as the bridge for the forklift to safely enter a trailer. Before entering a trailer, employees are instructed to ensure it is safe to do so, Check for the following conditions. Trucks must be secured to the dock with a vehicle restraint or by chocking the rear tires Check the dock plates or boards for flaws or damage Check the bed of the trailer to ensure that it can handle the weight of the forklift and the load If a trailer is left at a loading dock without the tractor attached, then use trailer jacks, converters, or blocks to prevent it from up-ending when a forklift drives to the front of the trailer to load or unload Lifting and Lowering People

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Never allow anyone to be lifted while standing on the forks or on a pallet lifted by the forks. When using a forklift to raise an employee to an elevated position, use a platform or structure specifically built for this purpose that meets the following conditions. A person lift is available in Building 3 that meets the requirements of the OSHA standard. 11.4.5 The platform must have standard guardrails, which include a top rail 36 to 42 above the platform, a middle rail or closed cage, and toe board. It must also prevent contact with chains and shear points on the mast The platform must be securely attached to the forks such as by a clamp or chain. Lock or secure the tilt control to prevent the person lift from tilting A forklift operator must be at the normal operating position when lifting and lowering the platform. The operator must remain on the forklift at all times while a worker is elevated Do not move the forklift between two points when a worker is on the platform Recharging Batteries

The battery charging stations in Buildings 1 and 3 are also the off-hours parking locations. When charging or maintaining the batteries consider the following safety measures. Eye and face protection must be used when charging batteries. All leads and cables must be checked and in good condition. When charging batteries and when moving batteries, vent caps must be kept firmly in place to avoid electrolyte splashing. Chargers must be turned off when leads are being connected or disconnected. The battery compartment cover must be left open to dissipate heat and explosive

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gases. Have materials on hand to neutralize or absorb spilled electrolyte Ventilation must be adequate to disperse fumes from gassing batteries Take precautions to prevent open flames, sparks, or electric arcs in battery charging areas. The charging apparatus must be protected from damage A safety shower and eyewash fountain must be provided at or near (within 10 seconds) of the charging area and be able to dispense clean water for at least 15 minutes Make sure there is a fire extinguisher nearby. Training

OSHA requires that employees attend initial Forklift Safety training for new operators, and refresher training every two years. "The Company" requires that all employees who operate a lift truck of any type are trained, and show competency in the safe handling of a forklift, before being allowed to use one. There are three basic components to Forklift Safety training, which include the following. Formal instruction such as a lecture, discussion, interactive computer learning, videotape and or written material Practical training which includes hands-on demonstrations by the trainer and exercises by the trainee on the model of forklift the worker will use An evaluation of the effectiveness of the training by observing the operators performance while doing actual work using the forklift.

In addition, refresher training must be given if the operator has been involved in an accident, near miss or unsafe operations. OSHA requires that the following topics be discussed in training. Operating instructions Vehicle controls and instrumentation Engine or motor operation. Steering and maneuvering Fork and attachment adaptation, operation and use limitations. Vehicle capacity Vehicle stability Vehicle inspection and maintenance Refueling and/or charging and recharging of batteries. Operating limitations Warnings or precautions in the operator's manual

If an operator is assigned to a new type of forklift, or if workplace conditions change that could affect safety, then refresher training is required. Training covers the principles of forklift safety and the practices and procedures specific to the work area, and to the forklifts used.

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Maintenance and Service

Forklifts must be in good operating condition to be safe, and OSHA requires that lift trucks must be inspected daily to ensure their safe operation. Shipping and Receiving conducts daily inspections and keeps copies of the inspection checklists. When deficiencies or maintenance requirements are noted these are brought forth to the Warehouse Manager, and the unit is repaired. Forklifts have preventive maintenance performed on each lift truck at least once a year, or more often as needed.

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