OJT Forklift Operation - Eclipse Training Solutions...

Forklift Operation On-Job Training Process Others set their standards by what you do every day!

Reviewed/Revised 11/17/2015 Cottage Grove

OJT Process

Who is required to complete this packet: New to this position Cross Training

Staying Qualified on a Job: Team Member must

o enter time for job performed o when working (enter task profile ID) and inform their

Team Leader Role and Responsibility

Team Leader: Following through with each employee

Trainer: Ensure OJT checklist requirements are met

OJT Facilitator: Recordkeeping and facilitating information

Safety Steward: Cover all aspects of training on Safety Steward Guidelines

Learn and use Safe Start methods to ensure your safety



Team Leader & Trainer Expectations Team leader:

Be a partner with the trainer. Discuss the job and training aspects with trainer BEFORE the trainee arrives:

o Make sure that trainer understands the OJT and the Intrac module. o Review their expectations with them.

Talk about some of the more difficult parts of the job: o What are some common and uncommon upset conditions?

Talk about some of the misconceptions that people have about the job: o For instance, the difference between learning a job and becoming an expert at your

job. o Let the trainer know how important the training is…for safety, for production, for

Cottage Grove. “If it’s worth doing it’s worth doing right.” Let trainer know that the team leader will be talking with them throughout the training:

o To see what the trainer thinks is going well. o Where the trainee might need help. o DO NOT hurry the process. o What ideas do you have that would help the next trainer?

Let the trainer know how important their contribution is to the team and that they are part of the success of Cottage Grove.

While training, review the checklist and the trainer’s notes: o What is missing from the packet? o What is not current? o There should be ample notes in the completed checklist to show a true evaluation of

the training process. Trainer:

Current full time Operator for the area where training is taking place. Read through the process before training begins. Talk with the team leader and safety steward about concerns that may come up during

training. If trainer is not sure the trainee is ready, talk with the team leader about this. Give the trainee the necessary time to learn the job – no rush. Realize not everyone is the “greatest” right off the bat. You can be a good operator in a

couple of weeks, but it takes time to be a great operator. No exceptions. Be patient. All areas of the OJT must be reviewed and completed with the trainee. Read all the pages…make notes as you go through the process. Stress the importance of knowing your up and down stream customers – how you can work

with them for the benefit of all.



Rolling Stock Area – Job Expectations and Scope Expectations:

Perform your job in a safe, conscientious manner abiding by all company policies and procedures.

Attendance – be on the job when whistle blows with proper PPE. Take breaks within the handyperson’s schedule. Keep your cab and work area clean. Make sure all tools are sharp and stored properly. Notify handyperson when need for

replacement. Train other operators as required and keep up with all training – Intrac, JSAs. Communicate any operational events that may affect safety or production to appropriate

persons including other shifts. Teamwork – work and communicate well with others. Treat others with dignity and respect

and pay attention to up-stream and down-stream customers. Qualified operators must maintain the required production levels.

Forklift Operator:

Responsible for safely off bearing rough loads from the sawmill and transporting units to the “Correct Storage Area.”

Help to maintain an efficient, organized and safe GIP. Communicate / write work orders and document needed repairs of forklift (tag out unsafe

forklifts) or work area. Constantly look out for pedestrians and other vehicles. Responsible for keeping the sawmill outfeed clear so the stacker can continue to operate. Perform pre-shift vehicle inspection with documentation. Monitor forklift operational readiness (fluids, tires, etc) throughout shift. Any oil/fluid leaks, move forklift out of the way, shut down and notify Team Leader or

mechanic. This is not a definitive list of all required duties.

Trainee Date Team Leader Date

For Employee’s File



Forklift Licensing Process Simple as 1-2-3

#1 – Prerequisite to training Forklift Class w/ Forklift Trainer –

Safety Qualified Card (expires in 6 months) equivalent to a “permit” #2 OJT Training

Train and Drive with a qualified forklift driver o Complete OJT and hours required for position

#3 Forklift Trainer again observes your driving and issues a forklift license (3 yr) Once you have a current forklift license the process to qualify for a 2nd area begins at #2

Q & A Q: My Safety Qualified card expired and I want to train for a driving job….what now? A: Start from Step 1 Q: How do I know if my forklift license is expired? A: The expiration date is noted on your license. The team leader can also look this up for you in the Intrac database. Q: I lost my license – what now? A: You can get a duplicate from the Training Facilitator or a forklift trainer. It is your responsibility to keep track of your license and expiration date. Q: I have a valid license for one area but want to drive in another area. What do I do? A: Print an OJT Forklift checklist and work with a trainer. Once you are through the OJT, contact a forklift trainer to observe you and make out a license. Q: My forklift license is going to expire soon….what do I do to renew my license? A: Complete the Forklift Intrac module and let your team leader know that you need a Forklift Trainer to observe and issue an updated license. Q: My CG Seniority is expired but my license is current…can I sign up for overtime? A: No, your CG Seniority is expired. You must complete the OJT training to become a qualified operator again.



3 Tier Training Plan –

Trainer

Trainee

Team Leader

• Tier One –

Trainee reviews OJT and completes special training for job and Intrac training

Trainee observes trainer doing job

• Tier Two –

Trainee safely performs job tasks for short periods of time

Trainer can leave trainee for short periods o Trainer must have radio or be close by

• Tier Three –

Trainee safely performs job tasks for at production levels.



Qualification Checklist

Trainee:

JOB/Location/Shift:

Date Training Starts: Date Qualified

Trainer Signature: (Current full time Operator)

2nd Trainer Signature: (Current full time Operator)

Safety Steward Signature: Forklift License obtained: Step #3 Finish Outfeed: David Hill/ Ben Hunt/Amy Slay Purpose of Training:

�Bid Job – �Cross Training Date completed: Date completed: �Pinkpak / �Intrac Completed 2X

�ESC �Safety Intrac current

Teamleader: Date Operations Manager Review

OJT Facilitator:

Safety Intrac, & Safe Start Modules up to date

Checklist entered into Intrac Job Intrac Completed 2X

CG Seniority Database Training Time Card

Area License Obtained Forklift License Expiration



On-Job Training Intrac Training / Specialized Training – First Week � All Safety Intrac Modules must be up to date Machine Center Intrac Module must be completed

before moving to next step. Specialized training must be completed now:

�forklift license for each area you want to drive

� Review RADAR / Hazard ID /Safe Start – What does it stand for? How do I use it? Begin machine center job training.

� Begin On-Job Checklist – Mark corrections for needed updates/changes. Job Training (Second & Third Weeks of Job Training)

� Additional training 1 week minimum with 2nd full time operator (prefer on another shift – training with handy giving breaks does not count)

� Work with Up & Down Stream Customers – minimum 4 hour each ________________________ ________________________

________________________ ________________________

� Complete Intrac job training module for the second time.

� Please note any corrections that need to be made to the Intrac Module and give notes to

OJT Facilitator with your checklist packet.



Learn more about the Job Area

Trades People OJT with Operator – Rolling Stock

Rolling Stock Mechanic

• Show me how to do a Pre-Shift Inspection.

Catch potential hazards here

• Tires

• Mast / Carriage

Height marks

Chains

• Warming up a forklift

• Driving hard and fast – is there a better way?

• Lights and computer systems in the forklift – shut down/start up

• Inching pedal – how does this work?

• Repair forms / locking out a forklift.

• Stop by anytime with questions!

Rolling Stock Mechanic: Rolling Stock Mechanic:



Final Check Off Trainer, Team Leader, Safety Steward and OJT Facilitator confirm all requirements are met: Evaluate:

� Checklist have been completed

� Trainee describes the flow of the area

� Trainee demonstrates safety requirements

� Trainee demonstrates willingness to accept directions

� Comments/Concerns from engineering, trainers, Safety Stewards, Team Leader



Questions / Observations / Suggestions: ________________________________________________________________________________

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Feedback: ________________________________________________________________________________

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Forklift Operation On-Job Training Checklist Others set their standards by what you do every day!


On-Job Training Checklists

The following procedures will be demonstrated by your Trainer. When you have had time to practice, your Trainer will ask you to perform each item and will check you off. If you don't understand any item, ask the Trainer to repeat the demonstration or explanation.

PPE

DEMO

CHECK

• Identify personal protective equipment required:

Hard hat

Safety boots

Hearing protection (unless cab doors and windows are closed)

Safety glasses (unless cab doors and windows are close)

Disposable Respirator (optional)

Goggles when using an air hose

Gloves – appropriate for the task

Company radio

CB Radio

Company approved high visibility clothing:

- If you get in and out of your forklift to do your job, you must wear company approved high visibility clothing.

• Safe Start –

These four states….:

Rushing

Frustration

Fatigue

Complacency

Can cause or contribute to these critical errors….

Eyes not on Task

Mind not on Task

Line-of-Fire

Balance/Traction/Grip

…which increase the risk of injury.



Emergency & Environmental Self Trigger on State to prevent critical errors

First Aid/Emergency Response/Environmental

DEMO

CHECK

• Identify location of the following:

First Aid kits

Bloodborne Pathogen kits

Eye wash stations

All Fire extinguishers, All Fire Alarms, Plant Evacuation Alarm

• Locate assembly areas:

Primary assembly area —

Secondary assembly area —

• Identify appropriate emergency response for your area:

First Aid:

- Call a First Responder – know First Responders for your area and shift.

Imminent danger to you or others:

- Hit the EMERGENCY STOP button on operator console.

Help Needed Whistle:

- Safely shut down machine center and listen for instruction from the Teamleader.

Fire Alarm — Evacuation:

- Safely shut down machine center and evacuate to assembly area.

Plant Evacuation Alarm — Evacuation:

Call 9-911 as appropriate in any emergency.

• Identify spill response:

Ensure personal safety and the safety of those around you.

Contain and stop the

if possible.

Call for help (your Team Leader and/or 2U).

Notify your Team Leader if you have not already done so.



• FYI

Did you know that 70 gallons of oil are pumped per minute through the forklift? DO NOT drive to the Rolling Stock Shop when you discover a leak – call the Rolling Stock Shop and they will come to you.



First Aid/Emergency Response/Environmental (cont.) DEMO CHECK

In an emergency, there are specific procedures for Finish forklift Infeed and Mill B Outfeed drivers, 2U, the Log Yard Operator and the Weight Scales.

Mill B Outfeed or Finish Infeed forklift drivers will both go to the front gate. o After being informed where the emergency is located the forklift from that

area will lead emergency vehicles onto the plant site.

The second forklift will: o Bring traffic off Hwy 99 and stage them away from the entrance – to

allow emergency vehicles unobstructed entry and exit. o Once the “all clear” is given you will direct traffic to its intended

location. o If necessary, call 541-957-2503 and request that the tracks be cleared

due to an emergency.

2U will complete the above duties during the Window between shifts. Whoever is on or near 2U rolling stock, they will make their way to the gate to perform the traffic duties.

The Log Yard Operator will proceed to the back gate to stop all incoming traffic until the “all clear” is given and if necessary, to escort emergency vehicles onto the plant site.

The Weigh Scales will stop all traffic in their area from entering beyond this point until the “all clear” is given.

• Locate SDS for materials you may be exposed to:

Access through 3E system electronically.

Hard copy available from Environmental Manager.

• Locate the satellite station for aerosol cans.



Forklift Care

DEMO

CHECK

• Clean work area

Keep cab clean o Take out the trash at end of each shift o Keep paperwork neat and orderly o Clean heater/cooler vents

Wash forklift by driving through truck wash after fueling



Procedures - Self Trigger on State to prevent critical errors

RADAR/Hazard ID/Safe Start

DEMO

CHECK

• Use RADAR 10-Step Assessment process for any stop in the flow or process (upset

condition):

What State am I in?

Complete RADAR form and leave on the RADAR clipboard (the Teamleader will pick these up throughout the week).

Identify potential hazards — if you check the Hazard ID box.

Turn in completed forms to your Team Leader.

Communication

DEMO

CHECK

• Identify appropriate channels to use on the company radio and CB radio — print

from Intrac module.

• Explain the importance of communication:

During an emergency.

To facilitate production changes.

To know what is happening on your shift.

• When notified by others that they will be in your area you must acknowledge

their communication. (example: 2U / maintenance forklift, persons entering the yard either on foot or in a vehicle)

Safe Ergonomic Practices

DEMO

CHECK

• Dr Greg appointments can be used for on or off the job advice. Let your Team

Leader know you would like an appointment.



Identify Hazards and Safe Work Procedures DEMO

CHECK

What state are you in? Rate Your State!

• Watch for low overhead clearance areas.

• Watch for and report pot holes to your Team Leader.

• Report all near misses to your Team Leader or PFC/Optimizer.

Safe Work Practices - PPE

DEMO

CHECK

• Demonstrate safe use of an air hose:

Wear goggles (dust mask optional).

Ensure air nozzle has relief holes in it.

Maintain a firm grip on hose.

Watch your footing.

Keep hose clear of moving equipment.

Never use an air hose to clean off yourself or your clothing.

Never blow pressurized air towards others.



Yard Maintenance — Pot Hole Procedure Use RADAR and the 10 Assessment Steps

DEMO

CHECK

• When a pothole is identified:

Communicate with all drivers on shift the location of hazard.

Communicate with next shift of drivers.

Complete a Hazard ID and a RADAR form. Notify your team leader

• Mark the pothole with spray paint and set out cones with yellow caution tape

surrounding the pothole:

The Team Leader will notify the Log Yard Team Leader and the Utility Crew (2-U) the location of the pothole.

The Outside Clean-up crew will apply cold patch to fill the pothole.

The Team Leader will monitor the hole and remove cones and yellow caution tape when cold patch has set.

The Paving Team will be responsible for managing the yards for potholes and ensuring that all necessary repairs are made immediately.

Procedure for Forklift Flat Tire Use RADAR and the 10 Assessment Steps

• Move your forklift the shortest distance possible to be out of the way of

production.

• Call the Rolling Stock Shop – if after hours tell your team leader. (email the

shop or call in a mechanic if the forklift is needed.)

• GIP yard is especially hard on tires

Avoid hitting metal bunks – the sharp edges damage the tires

GIP Sprinklers

• GIP sprinklers are automatic. If you have concerns please talk with the Head

Grader.



Rolling Stock LOTOT Procedures Self Trigger on State to prevent critical errors

DEMO

CHECK

• Respond to a mechanical failure that involves leaking fluid, such as hydraulic oil,

engine oil, coolant, etc.:

Only move the vehicle if it creates a hazardous condition or is directly impeding traffic flow.

If moving the vehicle is required, only move it as far as is necessary to eliminate the hazard.

Be sure to initiate spill cleanup as soon as possible and notify appropriate personnel.

• Respond to a mechanical failure or problem to a rolling stock machine during shop

working hours:

Take the equipment to the Rolling Stock shop to be repaired.

Inform the Rolling Stock Mechanic of the problem.

When leaving the equipment parked outside the shop, install the equipment “Out of Service Tag”:

- Any untagged machine shall be considered in service.

• Machine problem during NON shop hours including mechanical failure or other

problems:

Park the machine at the Rolling Stock Shop and install an “Out of Service” tag in the window over the steering wheel:

- Only rolling stock mechanic can remove the tag.

Fill out a Rolling Stock Repair Request Form:

- Found in the Rolling Stock Repair Request Shack

Place the white copy in the service slot at the truck shop:

- The yellow form will stay in the book as a record.



Rolling Stock LOTO Procedures (cont.)

DEMO

CHECK

Watch for warning lights and codes on the dash board and flashing lights on the steering column. If they are lit, or codes are shown in the display, contact the RSS.

• Respond to rolling stock machine breakdowns on the operations floor or in the yard

during or after the truck shop hours:

Contact the rolling stock truck mechanic to help move the machine, if possible.

Leave it for a Rolling Stock Shop mechanic if possible.

If in an unsafe situation or hindering production, have another machine assist in moving the machine out of the traffic area:

- Caution: Most rolling stock equipment requires hydraulic or air pressure to release the brakes.

When the shop is closed contact Team Leader and he will contact a mechanic if necessary.

Place “Out of Service” tag in the window over the steering wheel:

- Only a Rolling Stock Shop mechanic can remove the tag.

Fill out a Rolling Stock Repair Request Form.

• Pick up rolling stock machine from the truck shop after being repaired:

Move the machine to a level area and complete a pre-shift inspection before operating equipment:

- Do not just climb into the rolling stock machine and drive it away.



Forklift Components – Identify Self Trigger on State to prevent critical errors

DEMO

CHECK

• Identify basic components and their functions:

Mast

Carriage

Counterweight

Forks

Overhead guard

Fuel tank

Hydraulic cylinders

Capacity plate

Operating light

Back-up alarm

Identify Functions of Each Forklift Control

• Ignition.

• Transmission/gears.

• Brakes:

Service brakes

Inching brake

Parking brake

Identify Forklift Components

• Accelerator.

• Lift, tilt and side shift controls.

• Gauges and warning lights.



Tour Facilities – Identify Locations

DEMO

CHECK

• Locate:

Parking areas

Refueling area:

- Check key number before logging into fuel system.

- If you enter wrong number three times, you will be locked out.

Pedestrians walkways

Truck traffic in the yard

Train tracks:

- Train car movement and safety precautions.

Rolling stock shop:

- Taking a forklift out of service.

- Who to call if you have a problem.

Yards:

- GIP yard

- Shipping

- Shed

VMT - Finish Outfeed and Finish Handy (Scanner and Vehicle Mounted Terminal — VMT)

• Never look into the aperture of the scanner:

Potential for eye injury.

• Do not point scanner at others.

• Touch blackout button on screen before moving forklift:

Activates screen saver to reduce distraction.

• Secure scanner in holster.



VMT – continued

DEMO

CHECK

• Handle VMT carefully:

Set VMT on floor of forklift when exiting or entering the machine, then remove once you are safely on the ground or in the cab.

• Adjust VMT for best vision in cab:

Ensure wires do not create a hazard.

Use clamp on ball joint to adjust.

Check that wires are not loose.

• Shut off VMT:

Log off SAP

Close all applications

Go to Start menu and choose SHUT DOWN

After shutting down computer you can turn off the forklift.

.



Pre-Shift Inspection Eyes and Mind on Task to fight Complacency

Perform Start-up Checks

DEMO

CHECK

• Obtain a Pre-shift Inspection form and complete it as checks are done.

• Approach parked forklift:

Check that forks are lowered to the ground and tilted slightly forward.

Check that parking brake is applied.

• Open hood and check visually for signs of wear or damage:

Ensure visible belts are in good condition.

Check for loose or disconnected wires.

Ensure radiator is clear of debris.

Look for signs of oil, water, or fuel leaks.

• Check fluid levels — if low, note on inspection form and inform Rolling Stock as

soon as possible:

Coolant

Engine oil

Hydraulic oil

Transmission oil – check with engine idling

• Check battery cables:

Ensure connections are tight.

Ensure metal is not corroded.

Ensure battery is securely attached to frame.

• Check counterweight bolts:

Check bolts visually to ensure they are in position and tight.



Perform Start-up Checks - continued

DEMO

CHECK

• Check capacity plate; ensure it is securely attached:

Ensure machine is rated for the tasks to be performed.

• Check wheels:

Ensure lugs are tight.

Check tread for wear.

• Check hydraulic hoses and cylinders:

Check hoses for leaks.

• Check mast, lift chains and chain pins:

Look for loose bolts or pins.

Look for cracks and damage

Look for loose bolts or pins.

• Check forks for wear or damage.

• Ensure fire extinguisher is in place:

Check tag to ensure it has been inspected.

• Start engine:

Ensure transmission is in neutral.

Ensure park brake is on.

Turn on all lights and check if they are working – if not take machine to RSS

• Bring engine hydraulics and transmission to optimal working temperature by easing

up into full capacity operation for 10 – 15 minutes.



Perform Start-up Checks - continued

DEMO

CHECK

• Check operation of components:

Check steering; watch wheels as you turn.

Check service brakes.

Check lights and ensure they operate correctly.

Test horn.

Check back-up alarm and light. If unsure ask someone to give you visual confirmation. Never stand behind a forklift with the engine running and transmission in reverse even with parking brake applied.

• Check parking brakes:

Put machine into gear and attempt to move.

• Check lift and ensure carriage raises/lowers smoothly.

• Check tilt and side shift operation:

Observe cylinders; check for wear or leaks.

• Release parking brake and place machine in gear:

Check transmission operation.

Check brakes to ensure they work properly:

- If you suspect any problems with the brakes, report the problem to the mechanics.

• After machine is warm, check transmission fluid level:

Lower forks and place engine in neutral.

Top up fluid as needed.

• Record all checks on form provided:

Sign, date, and hand in form on last day of your week. Turn in at file box outside Receiving Office (next to door)

• Report any problems to mechanics as soon as possible.



Safe Driving Line of Fire

Shut Down and Park Forklift – Drive to parking area with lower RPMs to allow for the Turbo Charger to cool down.

DEMO

CHECK

• Position machine in correct parking area.

• Lower forks and tilt slightly forward.

• Put the shifting lever in neutral and set parking brake.

• Turn off ignition.

• Turn off batteries.

Climb On and Off Machine Safely – 3 Point Contact

DEMO

CHECK

• Always use three-point contact when entering or exiting the cab:

Do not jump out of the cab to ground level.

Do not run and jump onto forklift or side steps.

Don’t rush — steps may be slippery.

Hands should be free.

• Do not carry items into or out of the forklift as you are entering or exiting. Place them onto the floor of the forklift, climb into the forklift and get seated, lift item up and into place.

• Look at your foot placement as you are exiting to ensure your feet are placed securely onto each step.

• Wear seat belt at all times while in forklift (Plant Safety Rule).



Demonstrate Safe Operation (cont.)

DEMO

CHECK

• Check gauges and warning lights while operating.

• Report any problems to Rolling Stock:

Never operate a machine if it is not safe to do so.

• Demonstrate control while operating in reverse.

• Demonstrate how to lock out the forklift using proper tags.

• Identify safety hazards in the yard, and demonstrate precautions required:

Notify other vehicle operators before entering their work area.

Observe safe speed limits — slow down in icy or wet conditions.

Watch carefully near buildings or pedestrian walkways.

Slow down and look carefully before going around corners or areas of obstructed view.

Never carry riders.

Watch for others in the area; e.g., Interstate Sweepers, Engineering, Outside crew.

• Always check behind – double shoulder check and look around before backing

up.

• Travel with forks raised high enough to avoid obstructions, railroad tracks, dips

in pavement or speed bumps. Use markings on mast to align carriage and mast for proper height.

• When stopping (e.g., pedestrian approaches vehicle), lower forks to the ground,

take machine out of gear, and apply parking brake.

• Watch for boards or debris in travel path:

Pick up objects — keep the work area clean.



Demonstrate Safe Operation (cont.)

DEMO

CHECK

• Use mirrors in warehouse to monitor vehicle and pedestrian traffic:

Use caution near walkways

• Always shut down safely and set brakes before getting off machine.

Carry Load Safely

• Carry load at correct height and slightly tilted back:

When possible to see over load, carry it as low as possible.

Travel in reverse if view is obstructed.

Travel forward with load raised (to see beneath) only when it is safe to do so.

Never carry a load higher than the back stops.

• Demonstrate safe speed and smooth stopping and turning while carrying the

load.

Demonstrate Correct Way to Pick Up Loads

• Ensure load is within weight limits for machine.

• Approach load slowly, adjusting fork height so that it does not damage the load

or the surface:

Ensure load is centered, with forks clear of dunnage.

Ensure forks are clean — wipe off any mud or debris.

Use caution when manually adjusting forks.

• Ensure load is tight against carriage, then tilt back to take the weight:

Lift enough to clear dunnage, and then back away — always check behind.



Demonstrate Control of Unloaded Forklift

DEMO

CHECK

• Check that parking brake is released.

• Select correct gears.

• Start and stop smoothly.

• Make smooth turns and control direction of movement accurately.

• Stop before reversing.

• Check rear clearance before backing up.

• Allow for rear-end swing clearance while turning.

• Demonstrate correct use of inching brake.

Set Load Down Safely

• Set loads down safely on dunnage, without dropping or damaging load:

Ensure loads do not contact mud or other debris.

• Adjust tilt of forks and lower mast to release forks.

• Back away without scraping the surface or dislodging dunnage.

Demonstrate Use of Man Basket — Rescue

• Locate the man basket stored in the GIP yard next to finish/main office parking.

• Demonstrate how to safely hook the man basket onto the forklift.

• Demonstrate how to safely maneuver the forklift with the man basket attached.



Identify Storage Areas

DEMO

CHECK

• Locate storage bays for all products and sizes in the GIP yard.

• Locate storage bays for all products and sizes in the Finished Storage area.

• Locate storage bays for sizes in the Planer Staging area.

• Locate storage bays for all products and sizes in the warehouse.

• Identify sticker and dunnage placement requirements for loads in the GIP yard

(print from Intrac module):

Place more stickers on 2x4 loads as needed for stability.

Double up stickers on top of loads.

• Identify stacking requirements in storage areas:

GIP yard — no more than 3 loads high.

Near pedestrian walkways — no more than 2 loads high.

Finished loads near rail line overflow, log yard, or fence — no more than 4 loads high.

In finished storage — no more than 6 loads high.

In sloped areas — no more than 3 loads high.

Ensure loads are placed on stable ground.

Ensure loads are placed behind yellow painted lines.

• No stacking units over storm drains.

• Rows must not be extended to the point they interrupt traffic patterns.



Identify Quality Control Requirements

DEMO

CHECK

• Maintain a minimum of 10" between stacks in GIP to minimize fork damage.

• Ensure longer lengths are not stacked on top of shorter lengths in any area.

• Maintain a gap of a minimum of 3' between rows for access.

• Place partial units on single units only for planer infeed.



Specific Area Hazards and Safe Procedures

DEMO

CHECK

Right-of-way is a shared responsibility between vehicle drivers and pedestrians. Care and attention must be taken at all times to ensure safe movement of both people and vehicles on site; watch for pedestrians near exits and around buildings.

• Pedestrians at a cross walk:

Stop before reaching cross walk.

Make eye contact with pedestrian.

Wave the pedestrian across.

Do not resume until pedestrian is completely across cross walk.

Rolling Stock 10’ Rule

• Pedestrians wanting to approach your forklift to talk with you:

Stop your forklift.

Lower your forks to the ground.

Put forklift into neutral and engage the parking brake.

Establish eye contact with pedestrian.

Wave them to approach.

• Shipping — forklifts staging railcars:

Maintain eye contact with ground crew.

Do not back up towards the railcar.

Leave at least 5' between first loads staged and the carline bench to allow sufficient clearance. Use painted lines to guide you.

Place home center single (for tools/tar) in front of white cabinet doors.

When waiting for carline to finish prepping car, keep loads on the forks close to the ground. Use hand/radio signals to indicate carline personnel are clear and forklifts can commence loading.



Specific Area Hazards and Safe Procedures (cont.)

DEMO

CHECK

• Shipping — banding racks:

Attempt to leave walkways open between racks for carline to move from one side of rack to the other. Due to the variety of lengths, this is not always possible.

Forklifts: Make sure personnel are at least 20' away (on forklift side) or 5' from rack (on lunchroom side), before placing or picking up loads. Be aware of the lines on the floor and use them to guide you.

Carline: Make sure forklift is completely clear of the load/rack before approaching rack. Be aware of the lines on the floor and use them to guide you.

• Identify procedure to follow when a unit spills:

Assess situation — use RADAR 10 assessment steps.

Develop a safe plan.

Inform other drivers of hazard in area.

Wear proper PPE if you need to exit forklift.

Get assistance to restack unit if necessary:

- Follow safe lifting procedures.

- Watch for pinch points.

• Identify procedure to follow if a unit skews at planer outfeed:

Assess situation — use RADAR 10 assessment steps.

Develop a safe plan.

Inform Strapper Operator and other drivers of hazard.

Wear proper PPE if you need to exit forklift.

Take unit to repair area or to strapper infeed.



Fueling Line of Fire

Fuel Forklift (Diesel)

DEMO

CHECK

• Pull up close to the fuel station.

• Shut down the engine and ensure there is no other source of ignition.

• Remove nozzle and turn pump on.

• Insert nozzle and begin fuelling:

Wear gloves.

Do not top off tank.

Watch the nozzle throughout the process.

Shut off pump if a problem occurs.

• Shut off pump and replace nozzle. Make sure the fuel tank cap is on properly.

• Press EMERGENCY SHUT OFF if pump does not shut off:

Use radio to communicate problems.

Use spill clean-up materials to clean up spills immediately:

- Dispose of rags or cleanup materials in contaminated material container.

Report spills.



Move Bunks

DEMO

CHECK

• Use the forklift to maneuver bunks into place — do not manually move metal

bunks.

• Realign bunks into straight rows:

Lift carriage and straddle out of place bunks, lower forks onto sides of bunks and use side shift to move bunks into desired location, or

Side shift forks as far as they will go either left or right, depending on location of bunks, drive to opposite side and lower forks to bunk height, and use side shift to slide bunk into desired position.

• Move overlapping bunks to end to end bunks:

Drive forward until the heel of fork clears the end of the bunk.

Lower the carriage, placing back side of fork at out of position end of bunk.

Slowly back up, pulling bunk with you – this maneuver will only drag bunk straight backwards — be careful not to run over bunk.

Identify Area Specific Concerns Rolling Stock Shop

DEMO

CHECK

• When bring a vehicle to the Rolling Stock Shop, do not drive it in the shop if

you see open doors and empty stall:

You are not expected, therefore there may be tools or people in your path.

Mechanics may have all the tools and materials for some other machine lined up and ready to be worked on.

A mechanic could be walking across the bay and you could easily hit them with your machine.

• Call the shop on the phone or radio before arriving for instructions on where to

park.

• If you have not contacted the shop, park your machine on the side of the shop

and go talk to one of the mechanics.



Area Specific Concerns – Area 1 Line of Fire

Area 1 — Engineering and Outside Clean-up

DEMO

CHECK

• Call and receive acknowledgement before entering production forklift traffic

areas.

• When leaving shop to travel through Finish specific safety procedures must be

followed.

• You must have a spotter before exiting out from sorter.

• You must have a spotter before turning to bander line 1 .

• To return to the shop you must have spotters at the same corners.

• .Look for and obey HONK signs.



Area Specific Concerns – Area 2

Mill B Outfeed & Finish Infeed Line of Fire

DEMO

CHECK

• Re-entry ramp

If cones are placed in front of re-entry ramp be aware that work is being performed in the area.

Call on radio channel 4 for information

• Identify process for re-run loads:

Pick up from Finish or storage, and feed into mill.

• If a load is not level for bunks (forklift drivers will be responsible for leveling

loads before they place bunks for stacking):

Turn short boards in place.

Level long boards one end at a time.

• Make a plan – place loads with uneven top layers to the side to be the top load

in the yard.

• Communicate with Infeed forklift driver to see what the planer is running:

Double loads to help out.

• Identify when and where to put loads into overflow areas:

Mark them for easy identification.

• Identify how to pick up bunk loads made by the planer operators.



Mill B Outfeed & Finish Infeed - cont

DEMO

CHECK

• Identify where bunk loads are stored in GIP yard

• Move bunk carts around to appropriate areas.

• Help Mill B Outfeed by moving bunk carts around to appropriate areas.

• Work with Planer Operator to move strapped loads from drop out cart to Mill B

re-entry storage area

• Use the marked walkways for foot traffic around the edge of the storage area

(from golden arches walkway to planer infeed).

• Place bunks for reman loads:

Be aware of bunks and their placement – get out of the forklift if needed to reposition them.

Place all bands from reman loads into the recycle can.

Empty can as needed or call 2U when can is full.

• Demonstrate how to safely cut strapped loads.



Managing Mycostat K20

• Communicate with the Optimizer when loads are moldy

Optimizer will turn on the Mycostat K20

• Communicate with Optimizer once the mold issue is resolved (no more mold)

Optimizer will turn off the Mycostat K20

Area 2 — Finish Infeed

DEMO

CHECK

• Identify all photo eyes on infeed transfers

• Forks can reach photo eyes

When tilted forward

Area 2 — Forklift Wheel Stop

DEMO

CHECK

• Come in square until front wheels impact wheel stop

Set load onto infeed transfers

Keep mast straight up and down as you place your load – o this enables the camera to properly read your load o prevents damage to equipment



Remote for Mill B Outfeed Chain: Outfeed Code – 111



Area Specific Concerns – Area 3 & 4

Finish Outfeed – Handy - Shipping Learning to SAFELY negotiate in, as well as the proper location and rotation of stock in the Finished Goods Yard

Area 3

DEMO

CHECK

• You must meet with the Shipping Team Leader (Randy Thoms) and the

Shipping Clerk (Ray Shoptaw) to discuss the safety and key points of negotiating the yard as well as several stock issues:

Randy or Ray are required to sign-off on the checklist qualification page.

Area 3 — Finish Outfeed - Forklift Entering Strapper Pedestrian Area

DEMO

CHECK

• Enter Strapper Pedestrian area only to:

Deliver strap and bunks for storage.

Upon request

• Refer to CG SPC-024 Procedure for Forklifts Entering Strapper Pedestrian Area.

1. The forklift driver or strapper operator will pull retractable barricade tape across the (1) walkway coming from the golden arches to strapper, (2) walkway across from sorter to strapper, (3) between the valve house and the strap feeder.

2. Before entering the forklift driver will alert the strapper operator that the forklift will be entering the pedestrian area y radio and Honking horn before entering

3. When all forklift work is completed the driver will notify the strapper operator who will retract all barricade tape locations. Tape should not be left pulled out once forklift work is completed or between shifts.



Area 3

DEMO

CHECK

• Do not park in the pedestrian area:

Pedestrians can enter the Pedestrian area when the forklift is not in the area – with or without barricade tape pulled out or retracted.

Area 3 — Finish Outfeed and Railroad Safety

DEMO

CHECK

• Watch for train cars entering the shipping building:

Red flashing light (overhead light) is activated:

- Light goes out when track is clear.

Use RADAR — be aware of your surroundings.

Area 3 & 4

DEMO

CHECK

• Stock rotation — SAP :

Using the VMT you will enter the product and then enter the location where that product is stored. This allows for accurate stock tracking.

• Watch for train pulling cars into or out of shipping shed and into shipping yard:

Use RADAR — be aware of your surroundings. Red rotating light – located near carline and near finish outfeed

• Loading railcars:

Watch for pedestrians.

Keep load balanced so it doesn’t drop from forks or car. Pedestrian crosswalk light – what, where and how is it used?

• Watch for truck traffic (contractors).

• Ensure loads are placed behind the yellow painted lines.



Identify Area Specific Concerns Area 3 & 4 — Shipping Radio Communication

DEMO

CHECK

• Follow proper radio procedures.

• Announce on channel 7 that you are moving rail cars in and out of shed.

• Announce on channel 1 (Finish Outfeed) when you are moving cars in and out of the finished goods yard (Latham Road side of shed):

Wait for acknowledgement from Outfeed drivers.

• Communicate on channel 6 with spotters for coupling and moving cars.

• If any radio misunderstandings occur, ask spotter to repeat — do nothing until spotter is clearly understood and gives orders.

Area 3 & 4 — Finish Outfeed Carline

• Shipping Forklift will announce on channel 1 (Finish Outfeed) when they are moving cars in and out of the finished goods yard (Latham Road side of shed):

Outfeed drivers must acknowledge the radio call.

Proceed with caution looking out for carline spotter at the tracks when cars are moving.

Area 3 & 4 — Travel Routes

• Use big doors (on I-5 side of building) during shipping hours:

Shipping forklifts — use door closest to carline.

Day Shift Finish Outfeed Operator — use door closest to finish department. Off shifts have a their own route system.

• Cross weight scales safely:

Do not turn machine while driving across scales — scale components could be damaged.

Do NOT drive through rail cars until after 3:30 p.m. – after shipping has gone home for the day.



Area 3 & 4 — Travel Routes - continued

DEMO

CHECK

• Shipping Rail Scales – Red sections of the rail road tracks indicate the location

of the rail scales.

DO NOT attempt to cross tracks at the RED section

Area 3 & 4 — HAZARD - Pedestrians and Forklifts at Carline

DEMO

CHECK

Be Aware of this procedure: • Pedestrians will do the following before crossing areas (to office, from office to

lunch room):

Make radio (contact and eye contact when possible) and with forklift drivers

Activate the pedestrian crossing light

Proceed with caution

• After shipping hours when traveling between rail cars:

Pay close attention to pedestrian crossing light – there is occasional foot traffic after hours. (clean-up people)



Area 4 — Demonstrate Safe Procedures for Loading Trucks/Railcars

• Ensure truck driver is in the cab while you are loading:

Curtained trucks: when cleared by forklift driver to move curtains, truck driver will stay on same side as forklift, then return to cab of truck.

Recommend driver moves all curtains either to front or rear of trailer to begin, then when directed by forklift, move all curtains to opposite end. This is opposed to putting all curtains in center of van and trying to load around them.

Driver should remain in view of forklift at all times.

• Do not unload truck until all straps have been removed and driver has returned

to the cab or next to cab in order to roll straps.

• If necessary, driver may throw and tighten “gut wraps” in loading area, while

the forklift stays clear of the truck. Ensure driver has returned to cab before proceeding with loading:

Loads will be tied down in the designated tie down area.

• Ensure truck drivers comply with plant safety policies and loading/unloading

procedures:

Stop loading/unloading process, if driver is out of compliance.

• Watch for other forklifts and pedestrians when loading railcars.



Process Learning to SAFELY negotiate in, as well as the proper location and rotation of stock in the Finished Goods Yard

Forklift Qualification Process

DEMO

CHECK

• Step One: Safety Certification (Forklift Trainer):

Classroom Training – 6 month expiration.

• Step Two: Forklift OJT is completed:

Time card:

- 40 hours for Maintenance.

- 80 hours for Sawmill and Finish.

- 120 hours for Shipping.

• Step Three: Forklift Trainer and Team Leader evaluate driver for area license.

• Step Four: Forklift Trainer issues license and gives to OJT Facilitator along

with training records.

• Step Five: OJT Facilitator confirms all training is completed and license is

given to driver.

• Recertification: For specific areas every 3 years:

Review OSHA rules - Print from Intrac Module.

You must carry or have available your Rolling Stock Certification Card while working.



Name Training for Area This time sheet must be completed and turned in with the OJT. This is an OSHA record.

Date Hrs Worked Print name of Trainer

Each day’s date Each day – number of hours worked

Trainer Signature here

All Forklift Licensing Requirements have been met – Minimum Training Time Requirements:

Sawmill & Finish – 80 hours Shipping – 120 hours

iLevel

Forklift Operation Record of Revisions


SAFETY STEWARD Guidelines

� Who are your up and down customers? How can you affect them?

� Tell me what specific PPE you are required to wear for this job?

When forklift door or window is open?

Walking in traffic area?

� RADAR/HAZARD ID — when do you fill out one of these forms: • Give me an example of each.

� What are the 10 assessment steps of RADAR? Why are they important?

� Where is your closest access to a fire extinguisher?

� What are your specific responsibilities during an emergency: • If the emergency is not your area, what are your responsibilities?

� If the emergency requires the rescue basket: • Where is the basket located? • Have you attached the basket to your forklift? When? if not, why not?

� Who are your shift Safety Stewards on this shift? ... First Responders?

� Who are your Shop Stewards? Head Steward? Do you understand how they can help you?

� Tell me about what you would do if your forklift had an oil leak.

� What are your safety questions?

� What safety improvement recommendation do you have?

� Do you know when to report a near miss?

� Where should your cell phone be when you are driving a forklift?

OJT Forklift Operation - Eclipse Training Solutions...

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