INTRODUCTION

Introduction ...........................................................................................................4

Course Information .............................................................................................5

Block Syllabus ........................................................................................................5

Detailed Syllabus ..................................................................................................6

Course Timetable .................................................................................................8

How to use this Guide ........................................................................................9

COURSE SESSIONS

Session 1 - Course Introduction .................................................................. 12

Session 2 - Walk Around Tour and Observation .................................... 14

Session 3 - Why are We Here Today? ......................................................... 16

Session 4 - The Regulations ...........................................................................19

Session 5 - Manager and Supervisor Responsibilities .......................... 24

Session 6 - Operator Training ....................................................................... 31

Session 7 - Operational Safety .....................................................................38

Session 8 - Theory in Practice ......................................................................48 Session 9 - Next Steps.....................................................................................50

Session 10 - Course Close .............................................................................. 51

ASSESSMENT

Assessment Introduction .................................................................................53

Stage 1 - Associated Knowledge Examination .........................................54

Stage 1 - Associated Knowledge Question Bank.....................................55

Stage 1 - Associated Knowledge Candidate Sheet .................................67

Stage 2 - Hazard Perception Test ..................................................................68

Stage 2 - Hazard Perception Test Marking Criteria ..................................69

Stage 2 - Hazard Perception Test Marking Sheet ....................................71

APPENDICES

1 - Record of Training - Basic Operator Training ......................................74

2 - Authorisation to Operate Form ...............................................................76

3 - Course Delivery Feedback Form .............................................................77

4 - HSA & HSENI Guidance ...............................................................................78

5 - MHE Operator Training Paths ...................................................................79

CONTENTS

SAMPLE TRAINER’S GUIDEThe pages in this sample have been taken from LTG31 Managing and Supervising Material Handling Equipment Operations.(It is not a full guide, it is just selected pages from the guide and PowerPoint Presentation).

CONTENTS3

This course has been designed to allow appropriately qualified and registered instructors to set up and conduct RTITB Material Handling Equipment Manager and Supervisor training. This course can only be conducted by currently qualified and registered RTITB lift truck instructors.

The lessons provided in this guide have been written in-line with the requirements and guidance set down in the Health and Safety Executive’s (HSE) Approved Code of Practice (ACOP) L117: Rider-operated Lift Trucks– Operator Training and Safe Use, along with other recognised guidance from the HSE, such as HSG136: A Guide to Workplace Transport Safety.

Introduction

Material Handling Equipment (MHE), and in particular equipment found in warehouses and distribution centres, such as reach trucks, counterbalance trucks, pallet stackers and order pickers, etc., are an essential part of any business in the logistics chain, allowing businesses to manoeuvre goods easily between storage locations and vehicles. Unfortunately, there is an element of risk associated with any MHE, especially when it is operated in confined environments and/or around other people. Effective operator training goes some way to mitigating this risk, but without suitable workplace safety and supervision systems in place there is no way to ensure that a) operators will continue to perform to the safest and most efficient standards under the pressure of the live workplace, b) safety issues will be

Instructors are at liberty to amend details wherever the information provided is not applicable to their training situtation; however, there should not be the need for significant change to the programme and course content

as laid out. Instructors should also note that the content is not exhaustive, and they are free to expand sections according to local requirements.

For all references to HSE guidance and documentation, please see Appendix 4 for equivalent Health and Safety Authority (HSA) and Health and Safety Executive Northern Ireland (HSENI) guidance. Where equivalent

documentation is not available, the information provided in the HSE guidance can still be referenced as part of your training course.

reported and resolved, and c) that administrative and training objectives will be met. The MHE supervisor and manager therefore plays a vital role in the post-training, or operational, phase of the operator’s career.

The purpose of this course is to introduce candidates to the requirements of this critical role and the training and safe operating practices that should be at the heart of any MHE environment. The content found in this course is aimed at those wishing to move into a managerial or supervisory role within an MHE environment and those already in the role looking to improve their understanding of their duties.

Upon successful completion of this course and assessment, candidates will be issued with a certificate to prove their attendance. This should not, however, be the end of the learning process because the real test will be the application of what has been learnt in the working environment. It is also essential to remember the importance of renewing this qualification through Refresher training; this is required from a NORS registration point of view, but it is also critical for each individual’s continued development and effectiveness in their role.

INTRODUCTION4

Course Objective

By the end of this course, candidates will be able to discuss their management and supervisory responsibilities with regards to material handling equipment (MHE) operations, and they will be able to identify steps that can be taken to minimise risk related to MHE in the workplace.

Candidate Specification

Management and supervisory staff who have responsibility for MHE operators or who have MHE operators amongst their operational resources.

Training Ratio

12 course members to one instructor.

Course Duration

7 hours 10 minutes

Training Locations

• Classroom• If available, suitable and risk assessed, pedestrian segregated work areas

(could be delivered in commercial training centre as an “open” course).

ACTIVITY TIME

Course introduction 10 mins

Walking the floor (practical exercise) 30 mins

Why are we here today? 20 mins

The regulations 60 mins

Manager and supervisor responsibilities 40 mins

Operator training 60 mins

Operational safety 60 mins

Theory in practice (practical exercise) 30 mins

Next steps 30 mins

Course closure 10 mins

Assessment 1hr 20 mins

TOTAL DURATION7 hrs 10 mins (minimum)

Course Information Block Syllabus

The session durations outlined in this block syllabus are estimates and will vary depending on the knowledge, experience and capability of the candidates attending the course. Please feel free to extend durations for individual

sessions where appropriate but please ensure that overall, across the whole day, a minimum of 7 hours 10 minutes course duration is achieved.

COURSE INFORMATION5

HOW TO USE THIS GUIDE10

How to use this GuideWeblink/MultimediaThis icon points to additional resources, either online or included on the DVD supplied with this guide.

WarningThese boxes contain critical information or warnings.

Further InformationThe information in these boxes expands on the topic being discussed.

Further readingThis icon provides details of documents, leaflets or books in which further information can be found.

Group ContributionThis icon is used when the accompanying information, powerpoint or presentation requires further group discussion.

Session Objective

Session Location

Session Duration

Session Resources

Additional Information

Throughout this guide you will find some text in brightly coloured boxes. The information in these boxes might be simple additional information, a warning or further reading references. You’ll also find icons that denote different things like learning objectives or training locations. Following is a key explaining what each icon means.

Group ParticipationThis icon is used when the accompanying information contains instructions for group participation exercises.

DemonstrationThis icon is used when the accompanying information contains guidance for practical demonstrations.

WHY ARE WE HERE TODAY16

12:1 - 20 mins

Classroom

Workplace Transport Manager and Supervisor video found on in the “Why we Are Here Today” section of the course presentation.

By the end of this session, candidates will be able to discuss the importance of the material handling equipment (MHE) manager and supervisor in the workplace and their role.

The aim of this session is to discuss with the candidates the purpose of this training course and the role of the manager and supervisor in the workplace.

3 - Why Are we Here Today?

3 - Why Are we Here Today?Now that the candidates have had a chance to walk around the facility purely for the purpose of observing working practices and the environment, show them the Material Handling Equipment Manager and Supervisor video to set the scene for the rest of the course.

Explain that under the guidance provided in L117: Rider-operated Lift Trucks – Operator Training and Safe Use, employers must ensure that all MHE operators (even those that are trained and experienced) must be monitored in the workplace and, if necessary, retested and refresher trained to ensure operations continue safely. The people in the room have been selected to carry out this important work – as the video shows, it’s a big responsibility with lots to learn, but much of it is about common sense and putting an effective system of work in place. These are the things that will be taught and discussed during this course.

The HSW Act [Health and Safety at Work Act] requires you [the employer] to provide adequate supervision. It is essential that supervisors have enough training and knowledge to recognise safe and unsafe practices. This does not mean they need full operator training, but they do need to understand the risks involved, and how to avoid or prevent them. (L117: Rider-operated Lift Trucks – Operator Training and Safe Use, paragraph 84).

Explain to the group that although L117 refers to lift trucks, the guidance is intended for MHE in general and, as such, although the video that the candidates have just watched featured lift trucks, the principles discussed in the video and throughout this course are intended to apply to MHE in general.

The simple fact is that every week serious incidents and near misses involving MHE, in particular lift trucks, are reported to the HSE. The HSE will take action against companies for breaches of the Health and Safety at Work Act, which could result in prosecution of company officials, including those responsible for management and supervision of operators using this type of equipment. Whether the incident is caused by a lack of operator training, ineffective segregation of machinery and pedestrians, or dangerous operating practices, often poor supervision and management is in some way responsible for the eventual outcome. It is therefore vital that those given responsibility for managing and supervising MHE operators are aware of their responsibilities and the steps that should be taken to control risk.

WHY ARE WE HERE TODAY17

WHY ARE WE HERE TODAY18

3 - Why Are we Here Today?

Briefly discuss the video with the group:

Was there anything in the video that surprised them?Has the video changed their perception of the role?

You’ll find example HSE press releases that outline several incidents involving MHE in the multimedia pack supplied with this course guide. You might like to use these to highlight the range of incident types that can occur without a decent level of supervision.

Outline the things that the candidates will learn today in order to equip them for the role, for example:

• How operators are trained• Certification and training records• Authorising operators in the workplace• Safe operating standards• Equipment inspection• Challenging poor practice• Encouraging good practice

ASSESSMENT

ASSESSMENT52

Time allowed: 50 minutes

Stage 2 - Hazard Perception Test

Introduction

During this part of the assessment process, candidates will be required to watch 10 video clips (located in the assessment presentation supplied with this guide). For each clip they will be required to identify 2 errors or safety issues and note why each error represents a risk to safety in the workplace.

Notes on each clip are provided in the ‘Marking Criteria’ section, but it is expected that, depending on personal working circumstances or personal experience, some candidates may offer explanations that, while not exactly matching those offered in the Marking Criteria, are still acceptable. Instructors may exercise personal judgement as to whether or not they feel a candidate’s response is appropriate.

Conduct of the Test

Each candidate will be supplied with an answer sheet (supplied later in this section) and a pen with which to write their answers.

The total time allocated to this part of the assessment is 50 minutes.

The total video footage running time is approximately 12 minutes, candidates therefore should be given approximately 2 minutes to write a response to each video; this will allow enough time for some videos to be played twice.

Candidates will receive 1 point per fault in each clip for correctly identifying the fault and 1 point for each corresponding risk. So, for each clip there are

4 points available, making a total of 40 points. Candidates must score 32 to pass this part of the assessment.

The multimedia content supplied with this guide includes the assessment clips to be shown to the candidates and a duplicate set of answer clips for the instructor’s use. Click on the RTITB logo on each assessment slide to see the answer clip.

HAZARD PERCEPTION TEST68

Clip Fault / Issue Risks

A Keys provided without checking evidence of qualification or issuing Authorisation to Operate/No safety induction

The operator may not be trained and may have no experience operating the equipment used on the site (Specific Job Training), or in the site working conditions (Familiarisation) / Without a proper safety induction, the operator may stray into unsafe locations or carry out operations that are against the company’s safe working practices. Additionally, the operator will not know what steps to take in the event of an emergency on the site – e.g., fire, first aid.

B Turning while the load is raised/Operating hydraulics on the move

Turning with the load/forks raised could seriously destabilise the vehicle and result in a tip over/Operating the hydraulics on the move could destabilize the vehicle and the operator is also distracted from the task of safely driving the equipment.

C Trucks are travelling too close together, they should be at least 3 truck lengths apart/Incorrect dismount

If trucks are travelling too close to one another there is an increased risk of a collision, operators have less time to react in the event of an incident/Operators who do not follow correct dismounting procedure are at risk of injury. Three points of contact must be used reduce the risk of slips, trips or falls and the operator must observe all around the vehicle before dismounting, facing the cab.

D Keys left in/Forks not parked properly If the keys are left in the ignition there is a risk that an unqualified or unauthorised person may use the equipment, there is also the risk that the equipment is still “live”/the forks/load left in a travel position represents a trip hazard.

Explanation of Marking Criteria

The video clips supplied for use with this test each contain 2 clear faults. As well as identifying the errors or issues in each clip, candidates will also be required to supply a brief explanation of why the fault or issue represents a risk to safety; it is accepted that explanations may vary, depending on each candidate. The following table explains clearly what faults should be identified in each clip and also provides guidance on the general direction that the candidates’ written answers should take. The examiner will need to use their judgement to gauge whether or not each candidate’s response meets the criteria provided.

Stage 2 - Hazard Perception Test - Marking Criteria

HAZARD PERCEPTION TEST - MARKING CRITERIA69

Included with selected RTITB Trainers Guides is a USB containing the PowerPoint presentation, photos, videos and resources to accompany the theory sessions of our courses. Below are some sample slides (in pdf for-mat) for you to take a look at so that you can compare the quality of our course materials with any others you may be considering for your business.