Proceedings of HF 2002, Nov. 25-27, 2002, Melbourne, Australia

Raising the Forklift

Anthony Novosad

Brambles Shipping - OHS&E Coordinator.

E-mail -  anthony_novosad@shipping.brambles.com.au

Keywords:  Forklift, design, risk assessment and purchasing

Abstract

Over the last two years there has been significant work conducted on finding ways to improve the safety performance of forklift users. “Since 1988 in Victoria, there have been 45 recorded deaths involving forklifts. Those deaths involve pedestrians, operators and in one case a child. They range from deaths on the wharfs to small factories and timber yards. The problems vary from system failure to design issues with the equipment”. Work cover figures reveal that – “The costs of 5539 claims across all ’forklift’ profile areas totals to $101,168,367. The production and the costs to the health sector are not counted in the work cover figures”. Nationally, of the 225 fatal incidents that occurred, a Coroner, OHS Authority or other agency made recommendations arising from 112 (49.8%). Of these, 53 recommendations were specifically related to the design of equipment. Over the last two years, there has been significant work conducted at Brambles Shipping to ensure that new equipment purchased not only complied with local, international and national OHS&E legislative requirements, but also for the first time actually addressed the operating risks of our daily stevedoring industry.

1.      Introduction

Prior to adoption of the risk assessment approach, our standard was based on comparison of similar forklift equipment operating in our industry. We had maintained a policy of ensuring our equipment was in the forefront of equipment in general use in the waterfront industry. Brambles shipping had implemented Safety Map (initial level) certification and it was as a result of the initial certification audit that prompted the organization into embarking on a different approach to purchasing. With the tools developed and a strong focus on OHS&E, the task of risk assessment was applied throughout the entire new plant project and involved both local and international stakeholders.

During the process of risk assessment and consultation, it became apparent that close examination of each of the operating areas of our forklift fleet resulted in a very poor outcome. We had been very reliant on the “Industry Standards”, which had introduced a false sense of security that OHSE had been addressed to meet “our” needs and OHSE standards already, when in reality designers and manufacturers knew little of our specific day to day operation process hazards and operator/machine interactions.

This paper deals with the risk assessment process and project plan that was adopted, and describes how the business achieved what we feel is a benchmark approach to integrating ergonomics, OHS&E and achieving improved product design.

2.      Methods

The introduction of our new generation forklifts was a process of review and consultation, whilst at the same time meeting the criteria required to comply with Safety Map, which included –

·         Formulation and use of the “Design Review Checklist Form”.

·         Formulation of Plant Hazard Identification Checklist. (Ref: AS 4024.1-1996, Safeguarding of Machinery), risk assessments conducted at design after manufacture, and in operations.

·         Compliance with Safety Map criteria –

o        Element 1.4.2, Employee consultation where changes in the work environment have health and safety implications.

o        Element 2.1.1, Health, safety and environmental risks are to be reduced using a process of hazard identification, risk assessment and development of risk control measures.

o        Element 2.1.2, Risk control measures are determined in accordance with the hierarchy of controls.

o        Element 5.1.1, Technical data and other information relevant to health, safety and environment are examined prior to any decision to purchase goods.

o        Element 5.1.2, Purchase specifications for any goods, must comply with health and safety legislation and relevant standards.

o        Element 5.1.5, Health, safety and environmental requirements are evaluated and incorporated into all purchasing specifications, including formal contract specifications.

o        Element 6.1.1, Hazards associated with work processes have been identified, risk assessed and control measures implemented.

o        Element 9.1.1, There are systems to ensure that materials are transported, handled and stored in a safe manner.

o        Element 12.3.1, Training is provided to all employees to enable them to perform their tasks without risk to health, safety and environment.

2.1.     Aims

Our main aim was to provide new equipment that would be innovative and value adding to the business, whilst at the same time addressing critical OHS&E issues to minimize exposure to the workforce.

Our original forklift equipment was tried and proven and generally ahead of industry standards. However, issues of ergonomics, driver comfort, load management and access were not focused on and ranged from minimal to non-existent with all emphasis on robust design that met the basic standard of the day.

2.2.     Objectives

The way in which the project took place could be split into four stages –

Stage One.

A review of what equipment was available “world wide”, with each of the equipment provider’s strengths noted.

Stage Two.

To select what we considered to be the best equipment providers willing to further develop the proposed equipment to incorporate our own improvement.

Stage Three.

Introduce a standard trial new generation forklift and undertake a program of risk assessment, training and consultation with our workforce. With approximately 10 months of actual operating experience we were able to examine each main operating process in detail, and with constant feedback gained from our drivers integrated with detailed risk assessment, identify more improvements to forward to the designers/manufacturer..

Stage Four.

With strong feedback and support from drivers during the trial and risk assessments, we were able to put our own specification to suit our working environment and to fully address our operating risks both past and present.

During all stages, reference was made to the various local and international OHS&E standards, codes, regulations and guidelines, and not to the limitations of past equipment and overseas manufacturers and design engineers.

3.      Results

Our decision to run with the final supplier was based on the fact the suppliers standard forklift with the latest generation of cab had addressed a multitude of OHS&E, ergonomic issues that we were able to build on. The manufacturer was able to give us tried and proven technology, which we were able to further improve through our systematic risk assessment approach.

The attention to detail in OHS&E, e.g. access safe working provision required considerable re-working to meet our requirements. Care was taken to make sure our specification was strongly worded and detailed, so that we were able to introduce our requirements into their design, with attention to detail and reference to the appropriate standards, codes, regulations and guidelines.

Despite the adage of the customer being right, it was with some difficulty and initial reluctance from suppliers to come round to our point of view and to actually change the way they do business. We basically told one of the major worldwide forklift suppliers that their design was not right for us, compromises were reached, but high standards were maintained.

The cost of the design changes as a new build was relatively low against the reworking of existing forklifts. Implementation was also relatively easy, as the trials and driver consultation process had clearly established ownership of the new equipment.

The risks identified through plant risk assessment, manual handling assessment and hazard identification provided the framework for driver consultation and the compilation of specification. The forklift supplier was chosen on four main criteria:

·         They had a tried and proven load management system.

·         The proposed cab was the latest in ergonomic layout, comfort and vision.

·         Generally the forklift components were tried and tested for a number of years.

·         The supplier was flexible enough to accept our proposed changes, numbering approximately 140 modifications to the standard design.

The basis of the ongoing review was built on:

·         Risk assessment of plant and process

·         What changes were practical

·         What benefit did it offer

Finally the forklift supplier was issued the following and asked to confirm:

·         Basic aim of Brambles visit to confirm forklift details.

·         Confirmation of our current legislation and Australian Standards with a copy of all relevant documents issued.

·         Completion of a design review checklist.

Confirmation of standards met for –

·         Stability

·         Brakes

·         Axle design

·         Exhaust emissions

·         Noise emissions

·         Cab design

·         Capacity

·         Manufacture standard

Additionally, critical focus had been placed on training, with each of the drivers being introduced to the equipment at classroom level and in the field at cab instruction level.

3.1.     Significant outcomes from the risk assessment approach

Introduction of the new generation forklift has provided a quantum leap with improvements in the following areas –

·         Increased and integrated technology

·         Improved ergonomics e.g. joystick operation, seating, instrumentation visibility,

·         Major improvements for operator comfort

·         Introduction of automatic load management

·         Increased driver information

·         Improved communication and consultation

·         Risk assessment process of identification, evaluation, control and continuous improvement

·          Improved access and vision

·         Improved emergency exit from cabin

·         Reduction in risk

·         Improved working climate

·         Improved equipment stability

·         Purchasing

·         Equipment security

·         Maintenance

·         Improved training capability with trainer seat in cab.

·         More relevant operator manual, which incorporated site rules and procedures.

These improvements were brought about by single element risk assessments. Only by using the systematic risk assessment method were we able to breakdown a complex piece of equipment into a review system that identified the risks that needed to be addressed.

This process was then continually utilized again and again during the review, equipment trial period, and formulation of the specification, the build and finally introduction into the business. We have continued improving the equipment now being used on site through feedback from drivers and risk assessment.

The result is arguably one of the most advanced design forklift worldwide incorporating special design features that, for the first time, truly addressed the operating risks of our daily stevedoring operation.

4.      Conclusion

The introduction of this new generation equipment into both terminals, Melbourne and Burnie (Tasmania), has been successful. Our objectives have been met, and the workforce has ownership of the plant in a way never seen before. The project has not ended here though, as there are on going assessments occurring to further improve the new generation equipment, some recent areas highlighted have been positioning of the accelerator and mast/tilt indicators for the tyne forklifts (Figure 1.).

Through the risk assessment process the business has adopted a more pro-active approach when purchasing which integrates, safety, health, environment and ergonomics at the design stage.

5.      Acknowledgments

The author would like to thank the stakeholders whose input was critical to the success of the project. Credit goes to the Equipment Services Department personnel, Brambles Industrial Services personnel and Brambles Shipping personnel for the integrated approach and involvement that made the outcome successful.

6.      References

·         Fantuzzi Reggiane, 2000, Operational Manuals and Sales Materials.

·         Victorian Road Transport Industry Safety Group, Industry Alert, 2001,Forklift Safety – Raise your safety performance not your WorkCover premium. Forwarded findings from a forklift fatality inquest conducted by the Victorian State Coroner, Mr.Graeme Johnstone.

·         Work-related fatalities associated with design Issues involving machinery and fixed plant in Australia, 1989 to 1992, NOHSC, September 2000.

Figure 1.

Fantuzzi forklift – Tyne Model

Figure 2.

Fantuzzi Forklift – Top Load