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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Key Risk Areas – Loading and Unloading
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?&
Key Risk Areas – Loading and Unloading
People get complacent and WAY TOO Close to Forklifts
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Key Risk Areas – Loading and Unloading
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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Key Risk Areas – Loading and Unloading
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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Key Risk Areas – Loading and Unloading
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#
Key Risk Areas – Loading and Unloading
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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Key Risk Areas – Loading and Unloading
Loading&Docks&&" Falling%%forkli9s%are&a&killer&
" Can&be&forkli]&driver&error&
" Can&be&due&to&truck&moving&
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Key Risk Areas – Loading and Unloading
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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Risk Controls – Loading / unloading
" 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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Risk Controls – Loading / unloading
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#
Risk Controls – Loading / unloading
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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Risk Controls – Loading / unloading
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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Risk Controls – Loading / unloading
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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Risk Controls – Loading / unloading
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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
Risk Controls – Loading / unloading
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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Risk Controls – Loading / unloading
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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