Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 1

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1 STANDARD OPERATING PROCEDURE SOP No: 001 Forklift Forklift Review Completed by:- Approved By: -Marcus Castro Date: 10/6/2010 Sequence of Job Steps Potential Hazards/ Risks of Each Step Standard Operating Procedure Personal Protective Equipment Forklift operators must hold a valid NSW WorkCover ticket Code LF Inspect Work Area Ensure the work area is clear. Check forks for cracks or deformations and oil leaks. Any faults - affix danger tag to machine and immediately advise supervisor. Moving off Hitting Obstacles Tipping Due To Forks in Wrong Position Ensure there are no persons or obstacles in the path of travel. Ensure that forks are at lowest safe working height (approx. 20 cm above floor level). Sensible clothing Travel at a safe speed. Safety Boots Look behind before reversing. Gloves Assess Load to be Lifted Dropping load Tipping Overloading Ensure load is central and square for lifting. Ensure correct weight ratio as per data on plate fixed to machine. Ensure the floor can take the combined weight of the forklift and the load Break down load to smaller (lighter) lifts if there is a risk of overloading the floor Sensible clothing Safety Boots Gloves Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 1

2 Ensure that both the forklift and the load are on level solid ground Bring the load to the truck with the forks at the lowest safe working height Apply the hand brake before lifting the load to just a few centimetres above the truck tray VeraR Jun 10, '10, 3:06 PM Added: Paragraph Break VeraR Jun 10, '10, 3:07 PM Added: Paragraph Break When lifting loads on a truck or other raised area When lifting loads off a truck or other raised area Tipping Tipping Release hand brake and move the load over the truck tray, making sure the load has enough clearance on the sides. Apply hand brake, ensure that no other persons are near the load or the truck before lowering the load onto the truck tray Warning: the weight of the load may cause the truck tray to lower slightly. Travel in reverse when the height of the load impedes your vision. Release the hand brake and slowly reverse the forklift once the forks are clear of the weight of the load. Once clear of the truck tray, lower forks to travelling height, approx. 20 centimetres Ensure that both the forklift and the load are on level solid ground Bring the forklift to the truck with the forks at the lowest safe working height Apply the hand brake before bringing the forks to just a few centimetres above the truck tray Release hand brake and move the forks under the load, making sure the load has enough clearance on the sides. Apply hand brake, ensure that no other persons are near the load or the truck before lifting the load slightly Warning: lifting the weight of the load may cause the truck tray to raise slightly Lifting the load may cause it to shift. Check the load to make sure the weight is balanced. Travel in reverse when the height of the load impedes your vision. Release the hand brake and slowly reverse the forklift. Once clear of the truck tray, lower forks to travelling height, approx. 20 centimetres Sensible clothing Safety Boots Gloves Sensible clothing Safety Boots Gloves Ensure that forks are at lowest safe working height. Travelling while Loaded Dropping Load Tipping Travel on level floor areas only Lower carefully. Look behind before reversing. Travel in reverse when the height of the load impedes your vision Sensible clothing Safety Boots Gloves Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 2

3 STANDARD OPERATING PROCEDURE SOP No: 002 EWP EWP ( Scissor lift under 11 mtr) Review Completed by:- Approved By: -Shaun Cavanagh Date: 10 June 2010 Sequence of Job Steps Potential Hazards/ Risks of Each Step Standard Operating Procedure Personal Protective Equipment Ensure the floor can support the weight of the EWP Inspect Work Area Ensure the work area is clear of any rubbish Ensure the work area doesn t contain any hidden holes (look under the carpet tiles) You must have been instructed in the safe use of the EWP Read and understand the operating manual Operating the EWP Serious Injury Obey all Danger, Warning, Caution, Important Notices and Operation Instructions Check the EWP for visual damage or deformations Check EWP logbook for defects DO NOT USE EWP IF THERE ARE ANY KNOWN DEFECTS Serious Injury Never drive elevated unless unavoidable Driving (lowered) Ensure you have a clear view of your path of travel Crush In tight areas or low-lighting situations, use a spotter to ensure a safe travel Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 3

4 Elevating work platform Working from EWP Travelling with platform elevated Lowering the work platform Emergencies SPECIAL NOTE Serious Injury Tip over Fall from height Serious injury Tip over Fall from height Serious injury Crushing limbs Tip over Serious injury Crushing injury or death Ensure the EWP is on solid ground, use outriggers if fitted Ensure EWP is level Ensure the access gate is closed Ensure the path up is clear of obstructions for the full size of the platform Do not overload the EWP Do not use the EWP as a crane or lifting device Don t push or pull other objects from or with the EWP Ensure tools are secured with lanyards to prevent falling Ensure no other person(s) are under the work area use barricades if suitable Do not sit or stand on the handrails Do not use ladders, scaffolding or other objects to gain height Always lower the platform as low as possible Do not travel long distances with an elevated platform Have a floor spotter to walk with the EWP and clear the path of travel Do not travel on slopes when elevated Ensure the path down is clear of any obstructions Ensure that no person is near the lifting mechanism Secure the EWP to prevent unauthorised use Never climb out of the EWP if the mechanism fails Notify the ground person and ask the Emergency Valve to be used to lower the work platform Check Operation Manual for details There is no WorkCover recognised ticket for EWP under 11 metres but operators must have received plant specific safe operating instructions Scissor lifts normally do not require a harness and fall arrestor to be worn, boom arm EWP always require a harness and fall arrestor to be worn Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 4

5 STANDARD OPERATING PROCEDURE SOP No: 003 Boom EWP ( Boomlift over 11 mtr) Review Completed by:- Approved By: -Pat Clark Date: 10 June 2010 Sequence of Job Steps Potential Hazards/ Risks of Each Step Standard Operating Procedure Personal Protective Equipment Ensure the floor can support the weight of the EWP Inspect Work Area Ensure the work area is clear of any rubbish Ensure the work area doesn t contain any hidden holes (look under the carpet tiles) Operating the EWP Harness Serious Injury Fall from height You must hold a WorkCover WP Certificate of Competency to be able to operate a boomlift. Read and understand the operating manual Obey all Danger, Warning, Caution, Important Notices and Operation Instructions Check the EWP for visual damage or deformations Check EWP logbook for defects DO NOT USE EWP IF THERE ARE ANY KNOWN DEFECTS When operating a boomlift, you must wear a fullbody harness and be attached to the basket with a fall-prevention (restrictive) lanyard at all times. DO NOT USE A FALL-ARREST LANYARD! Adjust the lanyard in such a way that it prevents you from falling out of the basket Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 5

6 Driving (lowered) Serious Injury Crush Never drive elevated unless unavoidable Ensure you have a clear view of your path of travel In tight areas or low-lighting situations, use a spotter to ensure a safe travel Elevating work basket Working from EWP Serious Injury Tip over Fall from height Serious injury Fall from height Travelling with basket elevated Serious injury Lowering the basket Emergencies Tip over Crushing limbs Tip over Serious injury Crushing injury or death Ensure the EWP is on solid ground, use outriggers if fitted Ensure EWP is level Ensure the access gate is closed Ensure the path up is clear of obstructions for the full size of the basket Do not overload the EWP Do not use the EWP as a crane or lifting device Don t push or pull other objects from or with the EWP Ensure tools are secured with lanyards to prevent falling Ensure no other person(s) are under the work area use barricades if suitable Do not sit or stand on the handrails Do not use ladders, scaffolding or other objects to gain height Always lower the basket as low as possible Do not travel long distances with an elevated basket Have a floor spotter to walk with the EWP and clear the path of travel Do not travel on slopes when elevated Ensure the path down is clear of any obstructions Ensure that no person is near the lifting mechanism Secure the EWP to prevent unauthorised use Never climb out of the EWP if the mechanism fails Notify the ground person and ask the Emergency Valve to be used to lower the work platform Check Operation Manual for details Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 6

7 STANDARD OPERATING PROCEDURE SOP No: 004 Loading trucks Loading / unloading trucks and vans Review Completed by:- Approved By:-Greg Davies Date: 10 June 2010 The job Potential Hazards/ Risks Standard Procedures All persons stand clear when first opening the truck doors Personal Protective Equipment Opening doors of a loaded truck Objects falling out Person opening the doors to remain behind the door so to be shielded from falling objects If the truck needs to reverse up against a loading platform, make sure no objects can fall out. Manual handling - general Back injury Strained muscles Squashed limbs DO NOT RIDE IN THE BACK OF THE TRUCK DURING MOVEMENT, even if it is only 1 metre! Use correct manual handling techniques ie..: - Lift with your knees, not with your back - Do not lift more than 30kg alone - Yell out if you are loosing your grip and put the load down safely Sensible footwear (steelcap preferred) Gloves No loose clothing No Jewellery Lifting standard cases Back injury When lifting with two people, one to take the lead and give instructions When lifting with more than two people, a supervisor must manage the team lift and give instructions Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 7

8 Lifting awkward objects Back injury Strained muscles Squashed limbs Check with your supervisor. Often there is a right way and a wrong way to lift awkward and heavy objects Watch alll others in a team-lift and warn if you see someone struggle Warn others if you feel you are loosing your grip Stacked objects Personal Injury Always check what is above or behind the object you are about to lift, things may have been stacked on top and could fall off Things stacked behind could fall over and cause a trip hazard or put you offbalance Objects falling over Check stability of objects when you put them down, odd shapes can have an unexpected centre of gravity Personal injury or death When loading / unloading truss or other objects vertically, one person to be in Entrapped or squashed charge of keeping them balanced. The movement of the truck suspension limbs could cause them to fall over. For large quantities, secure regularly using ratchet straps or load-bars. Climbing on or over objects Personal injury Damage to objects Don t step on objects unless you are sure it is strong enough to hold you. Stepping on unknownn objects is not only dangerous, it can also cause expensivee damage Use of trolleys Back injury Strained muscles Squashed limbs A fully loaded trolley can be very heavy, be careful when you move it: - Don t jerk but slowly increase force until the trolley moves - If it is too heavy, get someone to assist - Trolleys have swivel wheels, keep your feet clear from all wheels - Heavy trolleys may be difficult to stop, allow enough space and don t put yourself between the trolley and any fixed objects - Don t make sudden turns that could cause things to fall off the trolley Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 8

9 STANDARD OPERATING PROCEDURE SOP No: 005 Stock Picking Ladders Stock Picking Ladder Review Completed by:-chris Harrison Approved By:- Date: 17 June 2010 The job Potential Hazards/ Risks Standard Procedures Personal Protective Equipment Conduct a visual safety check of ladder Hi Vis Vest Move ladder to the location where it is intendedd for use Collision with people, objects or moving plant Area to be clear of obstructions. Operators to be vigilant when moving ladders around peoplee or equipment and where possible, obtain assistance from other factory crew. Position and secure ladder at desired location Possible collapse of structure resulting in a fall of person and/or equipment Ladder needs to be set-up on a flat and even surface Ascending and descending ladder Possible fall Training in the correct use of Stock Picking ladders. Maintaining a firm grip on the hand railing and safe footing on steps Face always to ladder, never walk down face first Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 9

10 STANDARD OPERATING PROCEDURE SOP No: 006 Installing & Changing Xenon Lamp Installing and Changing Xenon Lamp in Griven Imperial Search Lights Review Completed by:-alex Magat Approved By:-Alex Magat Date: 16 July 2010 The job Potential Hazards/Risks Standard Procedures Personal Protective Equipment Position the light in a location that is away from people and on a level surface before starting the maintenance process. Always remember that the lamp must be left to cool down and the light disconnected from the power before any work commences. Unscrew the four lugs on top of the unit and store in a safe place Make sure you have all your protective wear on prior to starting next step Remove glass cover and also store in a safe location. Place safety cover over lamp. Please note: The safety cover used for this step is a modified cover and is only to be used for this task and not for transporting lamps. Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 10

11 Undo and remove positive cable from frame of light casing. Spanner or screwdriver could fall and explode lamp All staff undertaking this task are required to wear the appropriate PPE. Temporary safety cover must be in place. Remove the two screws holding Screwdriver/screws/bar the lamp restraints and remove could fall and explode the restraining bar lamp All staff undertaking this task are required to wear the appropriate PPE. Temporary safety cover must be in place. Hold the top of the lamp being changed (the positive electro) and gently twist clockwise and anti clockwise to freee the lamp from its housing Lamp could explode All staff undertaking this task are required to wear the appropriate PPE. Temporary safety cover must be in place. Remove lamp with safety cover still on and place in a safe location away from people. Replace the modified safety cover with the full lamp safety cover. Lamp could explode To replace a blown lamp, reverse the above mentioned process All staff undertaking this task are required to wear the appropriate PPE. Temporary safety cover must be in place. Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 11

12 If the lamp is burnt-out and needs to be disposed of, it can be returned to the manufacturer or destroyed by the user. Lamp could explode To do this, burnt-out lamps must be wrapped in strong coarse cloth and broken with a hammer; the Xenon gas that escapes is not poisonous. The remains of the lamp can be disposedd of as rubbish and electros and rods (tungsten) saved for recycling. All staff undertaking this task are required to wear the appropriate PPE. Temporary safety cover must be in place. This procedure must be done away from people. Chameleon Touring Systems Pty Limited SOP Updated 8 September 2011 Page 12

Ladders LADDER 2 WARNINGS:

Ladders LADDER 2 WARNINGS: STANDARD OPERATING PROCEDURE Number 1 LADDER 2 WARNINGS: 2.1 Safety Precautions: See Risk Assessment Ladders Poorly maintained or defective ladders Working at heights Using conductive ladders when using