Shree Balaad Handling Works : Material Handling Equipments,Pallet Truck
SAFE HANDLING OF FORKLIFT TRUCK TRAINING (BASIC PROGRAM)
Transcript of SAFE HANDLING OF FORKLIFT TRUCK TRAINING (BASIC PROGRAM)
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
SAFE HANDLING OF FORKLIFT TRUCK TRAINING
(BASIC PROGRAM)
FOR INTERNAL/EXTERNAL (PUBLIC)
TRAINING
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Fakhruddin @ Farud Bin Esa
I/C No.: 741214-01-6613
Home Town: Batu Pahat, Johor
Portfolio; S.H.E(W.W.T.P)/Building Maintenance/ Industrial
Engineering/Kaizen Practitioner/Manufacturing/Construction /Aviation
Working Experience: 23 years
Certified Green Book Holder and RPO
Completing PhD paper, UTHM Batu Pahat, Johor
Presented and Published Journal in International Conference
and was recently awarded as the best paper in ICMEIM 2017,
organized by WASET.
Trainer Profile
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
STEP 1
STEP 2
Ice Breaking, Fold & Write Your ID
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
TIME TOPIC
8.30 ~ 10.30 (2 hours) Theory;
Fundamentals of forklift
Model coding system
Data plate and serial number
Forklift stability triangle
Load capacity charts
10.30 – 10.45 am (15 min) Break
10.45 – 1.00 pm (2 hours
15 min)
Theory;
Driving control and instrument panel
Safe driving technique
Maintenance diagram
Pre-operation check and maintenance
Re-fueling and re-charging
Video : Forklift safety operation
1.00 – 2.00 pm (1 hour) Lunch
Session Plan & Table of Content
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
TIME TOPIC
2.00 – 3.00 pm (1 hour) Practical;
Walk around inspection
Visual inspection on the machines
3.00 – 3.15 pm (15 min) Break
3.15 – 5.00 pm (1 hour 45
min)
Practical;
Forklift operating technique
Driving the machine in confined area
Picking up the load
Loading and unloading
Ramps and gradients
Session Plan & Table of Content
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Objectives
Understand how forklifts work
Operate a forklift safely and skillfully
Identify operating hazards
Apply general principles of safe operation
Properly inspect and maintain a forklift
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
THEORY
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Fundamental of Forklift
SeatBelt
LiftControl
OverheadGuard
TiltControl
Forks
Carriage
Backrest
LiftChains
LiftCylinder
Mast
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Truck Body
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Overhead Guard
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Hydraulic Lift
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Tire Types
X > 10 Tonne; Pneumatic
X < 10 Tonne; Solid
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Types of Forklifts
Different types of forklifts are
available, mainly for different
environments/usage:
•Diesel powered
•Electric powered
•Gasoline powered
•LP-Gas powered
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
JPJ License for Forklift; F
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Forklift Operation
OSHA 1910.178 states “Only
trained and authorized operators
shall be permitted to operate a
powered industrial truck.”
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
•Forklifts weigh thousands of
pounds.
•Are extremely powerful.
•Use rear wheel steering.
•Can turn in a very tight circle.
•Are not very wide for use in
aisles.
Interesting Facts
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Model Coding System
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Model Coding System
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Data Plate & Serial Number• OSHA requires a
legible nameplate
• It includes information about the forklift and attachments
• It lists the maximum load capacity
• It describes the load center
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Forklift Stability TriangleVehicle Center of
Gravity (unloaded)
Stability Triangle
Center of Gravity of
Vehicle and Maximum
Load (Theoretical)
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Forklift Stability Triangle
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Load Capacity Chart
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Driving Control & Instrument Panel
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Safe Driving Technique
Rear Wheel Steering
Unlike a car or truck, lift trucks
use the rear wheels for
steering.
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Safe Driving Technique
Load Capacity
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Safe Driving Technique
Load Centering
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Safe Driving Technique
Load Centering
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Safe Driving Technique
Load Centering
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Speed
KEEP
YOUR
SPEED
DOWN!
05 KM/hour (max) – Outdoor Driving
15 KM/hour (max) – Indoor Driving
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Quick Turns
Safe Driving Technique
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The 8 Inch Rule
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
If Your View is Blocked
If a load
blocks your
view, travel in
reverse.
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Overhead Clearance
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Center Your Loads
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Loose Loads
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Wide and Long Loads
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Driving on Ramps
Unloaded
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Driving on Ramps
Loaded
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Driving Across Ramps
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Driving on Various Surfaces
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Loading Docks
Will the floor of the trailer
support your load?
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Loading Docks
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Loading Docks
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Parking
Always park your truck away from
traffic and on a level surface.
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Parking
Lower forks flat
on the floor.
Set directional
control in
neutral.
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Parking
Turn engine off
and remove
key.
Set parking
brake.
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
As you drive, watch out for people walking, and at intersections, slow down, look for
traffic, and sound your horn frequently.
Remember, ALWAYS come to a complete stop before changing direction.
Intersections
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Raised Forks
Never let anyone, including yourself, walk or stand under the forks
when they are raised
Keeping Work Area Clear
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Keep in mind that you are a lift truck operator, not a taxi service.
You should never allow anyone to ride on your lift truck.
No Riders
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Safety Devices
Seat Belt - Most lift trucks are equipped with a
seat belt.
Use it!
Wear Your Seatbelt
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Safety Devices
Horn - Sound your horn:
* Before backing up
* At intersections
* When traveling through doors
* Anywhere your vision is limited
or blocked
Using Your Horn Often
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Safety Devices
Backup
Backup Alarms
Safe Driving Technique
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Safety Devices
Warning Light - Some trucks are
Warning Light
Safe Driving Technique
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Warning Light - Some trucks are
Maintenance Diagram
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Warning Light - Some trucks are
Maintenance Diagram
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Warning Light - Some trucks are
Maintenance Diagram
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Warning Light - Some trucks are
Pre-Operation Check & Maintenance
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Daily Inspection
The safety equipment you must
inspect daily is:
•Seat Belt
•Warning Light
•Backup Alarm
•Horn
Pre-Operation Check & Maintenance
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Daily Inspection
The safety equipment you must
inspect daily is:
•Steering
•Brakes
•Carriage, chains, forks
•Hydraulic hoses
Pre-Operation Check & Maintenance
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Daily Inspection
The safety equipment you must
inspect daily is:
•Hydraulic lift/tilt controls
•Tires
•Hour Meter
•Leaks
Pre-Operation Check & Maintenance
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Daily Inspection
The safety equipment you must
inspect daily is:
•Fuel level
•Oil level and pressure
•Water level
•Fan Belt
Pre-Operation Check & Maintenance
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Refueling and Recharging
*
•Park in designated refueling or
recharging area.
•Do not block emergency equipment.
•Make sure area is well ventilated.
•Have extinguisher nearby.*
*
*
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Refueling and Recharging
*
*
*
*
•Turn off engine and lights.
•Do not smoke.
•Do not spill fuel.
•Use only approved cans.
•For LP, shut off valves.
•When charging, remember
gases.
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Forklift Safety Operation
*
*
*
*
•Video 1
•Video 2
•Video 3
•Video 4
•Video 5
•Video 6
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Sample of “Authorized Driver ID”
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Forklift Service Centre
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CASTING PLANT (CLASS II ACCIDENT) – 01/02/2016
Root Cause Corrective Action
When? 01st February 2017 at 05:45 p.m.
Where? Casting Machine #18’s Holding
Furnace
Who? Abu Ghulam
What? Holding furnace on fire
How? Caught on fire after molten
aluminum spilled over from the
holding furnace right to the oily
floor.
MC N/A
LWD N/A
First Aid Accident
- Briefed to all related
personnel on safe work
procedures prior
implementing the same task
in the future.
- Introduce “DO” and “DON’T”
visual control at site.
Unsafe Act & Unsafe Condition
1
Preventive Action
- Review on safe work
procedure at the work
station during charging
process.
- Lesson learnt session
with everyone at Casting
Div. Carried out
explanation on things
that need to be followed
(information alert) prior
carrying out the similar
process in the future.
CHRONOLOGY
Case Study
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
CASTING PLANT (CLASS II ACCIDENT) – 01/02/2016 Chronology
1 2 3
Abu Ghulam charging out molten aluminum at
Casting Machine #18 around 5.45 pm.
He keep charging out the balance of molten aluminum into the
Casting Machine #17’s holding furnace while at the same time
fire start ignited
He immediately stopped the charging
operation at Casting Machine #17 right
after he noticed on the fire existence.
He used the ABC fire extinguisher
(Powder type) attached to the post next
to Casting Machine #18 and managed
to extinguish it less than 3 minutes.
Oily floor was intentionally in contact
With molten aluminum
ROOT CAUSE 4
A minute later, he went to Casting Machine #17 to charge out
the balance without notice that the molten aluminum in the
holding furnace spilled over and was in contact with oil
residue on the floor.
Oil
Residue
Molten
Aluminum
Mirror
Visual Control
Oil
Residue
Spilled over
molten aluminum
Fire ignited at
DCM#18’s holding furnace
Smoke appears right after the fire extinguished
ABC Powder fire
extinguisher
Sprayed & aimed at the
fire soure
Case Study
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PRACTICAL
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Forklift is properly disengaged
Walk to both sides
Check front
Walk to rear
Inspection Walkaround
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Visual Inspection on the Machine
• Propane-powered• Check all oil and
fluid levels
• Check cables
• Check fan belt, fan, and radiator
• Check tank, and hose attachments
• Electric-powered• Check the battery
condition
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Forklift Operating Technique
• Authorized operators only
• Quickly report accidents
• Always wear seat belts
• No person under the forks
• Operate controls only from driver’s seat
• Never block exits or emergency equipment
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Driving the Machine in Confined Area
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Picking up the Load
• Working around loading docks
• Loads that block the forward vision
• Stacking and unstacking on racks
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Loading / Unloading
• Never overload forklift
• Check load weight • Locate load’s
center of gravity
• Inspect the load
• Restack or secure unstable loads
• Be sure forks are under load
• Tow from rear towing pin
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Ramps / Gradient
• No turns on a ramp
• Load facing upgrade
• Go slow
• Cross railroad tracks diagonally
• Never park within 8 feet of the center of railroad tracks
What’s Wrong Here?
Forklift parked on sloped surface
Forks not fully lowered
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
Ramps / Gradient
BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849
REMEMBER TO DRIVE SAFELY.....
END OF PRESENTATION