Jay Industries, Inc. Powered Industrial Trucks (Forklifts) Written Program and Procedures 07/02/11
JAY INDUSTRIES, INC. Jay Plastics Division Broshco Fabricated Products Crestline Paint Division Kronis Coating Division Sarca Manufacturing Powered Industrial Trucks (Forklifts) Written Program and Procedures PURPOSE. To describe the procedures and responsibilities regarding the safe operation and use of forklifts and to assure the safety of all employees who work on or near forklift equipment. RESPONSIBILITY. All trained forklift operators are charged with the responsibility for full compliance with this procedure. A copy of the OSHA 1910.178 Regulation regarding the operation of forklifts may be obtained through the EHS Office. General. Policy, Guidelines and Procedures for the operation and use of Powered Industrial Trucks (forklifts). Operator Training and Qualifications. 1. The employer shall ensure that each potential operator of a forklift is capable of performing the duties that are required of the job. 2. In determining operator qualifications, the employer shall ensure that each potential operator has received the training required by paragraph (l) of this standard, that each potential operator has been evaluated by a designated person while performing the required duties, and that each potential operator performs those operations competently. 3. Only trained and authorized operators shall be permitted to operate forklifts. Training is available through the EHS Office for those, recommended by their supervisors, and whose job description specifies operating forklifts. 4. Initial forklift training for new and experienced operators is specified under section (l), OSHA regulation CFR 1910.178, for operator training. The training can consist of a combination of classroom instruction (lecture, discussion, video tapes, and/or conference) and practical training (demonstrations and practical exercises by the trainee). 5. Forklift operators will be evaluated on operational skills, policy and safety while operating forklift on the job every three years from the date of initial training. 1
6. The evaluation will be done by observers, trained and authorized by the EHS Director. Operators found not operating in an acceptable manner will be retrained and reevaluated within 30 days. If, after the second evaluation, the operator is judged to be still not operating the forklift, in accordance to the Jay Industries, Inc. Policy, the operator will be relieved of his/her operating privileges. Forklift Operation. 1. The types of forklifts used throughout Jay Industries are electric, LP gas and compressed natural gas (CNG). Warehouse conditions may pose a potential high exposure risk to carbon monoxide (CO). All precautions must be taken to minimize carbon monoxide levels. Carbon monoxide shall not exceed levels specified in OSHA Regulation 1910.1000. Forklifts shall not be left unattended with the engine running or left idling when not in use. 2. The storage and handling of LP Gas (Liquid Propane) shall be in accordance with NFPA No. 58-1969 regulation. The storage area shall be located outside and under no circumstances shall LP Gas cylinders full or empty be stored inside the facility. Electric forklifts shall be operated in accordance with manufacturer s specified guidelines. (Refer to the Electric Forklift Instructions).Open flames shall not be used for checking electrolyte level in batteries or gasoline levels in fuel tanks. An explosion may occur. 3. Operators shall not use or have in their possession while operating a forklifts any type of audio equipment (radios, tape players, CD players, cell phones, headphones etc.).company and division two way radios may be used only while the forklift is stopped. 4. Operators are required to wear safety toe shoes and safety glasses when operating forklifts. 5. Forklifts shall not be driven up to anyone standing in front of a bench, wall, material or other fixed object. 6. No person shall be allowed to stand on or pass under the elevated portion of any forklift, whether loaded or empty. Unauthorized personnel shall not be permitted to ride on forklifts. 7. Operators shall not place head, arms or legs between the uprights of the mast at any time or outside the running lines of the forklift while in operation. 8. (a). When a forklift is left unattended, load engaging means shall be fully lowered, controls shall be neutralized, power shall be shut off, and brakes set. Wheels shall be blocked if the forklift is parked on an incline. A forklift is unattended when the operator is 25 ft. or more away from the vehicle which remains in his/her view, or whenever the operator leaves the vehicle and it is not in his/her view. (b). When the operator of a forklift is dismounted and within 25 ft. of the vehicle, still in his/her view, the load engaging means shall be fully lowered, controls neutralized, and the brakes set to prevent movement. (c). There shall be sufficient headroom under overhead installations, lights, pipes sprinkler systems etc. 9. Exits, fire aisles, access to stairways, fire and emergency equipment shall be kept clear all times. 10. No welding shall be performed from, near, or on forklifts unless precautions have been taken to prevent fire from sparks reaching the forklift hydraulics, engine compartment or fuel supply. 11. Forklift operators shall not lift or raise anyone standing on the forks of a forklift. Forklift cages that meet OSHA requirement are provided at all locations and are to be used when raising employees. Instructions are posted on all cages and shall be observed at all times. 12. Operators are required to report to their supervisor any damage resulting from their operation or that they observe to forklifts, the facility, equipment or machinery, truck, trailers and also incidents, close calls, or accidents causing injury or damage to property. 2
13. Operators involved in incidents, close calls or accidents that cause injuries or property damage will be required to take a drug/alcohol test immediately after the event. 14. The operator shall not eat or drink while operating a forklift. Docks, Trucks and Trailers 1. A safe distance shall be maintained from the edge of docks, ramps or platforms or while on any elevated surface. 2. Brakes shall be set and wheel chocks shall be in place to prevent movement to trucks and trailers while loading or unloading. 3. Forklift operators loading or unloading trucks or trailers are responsible for the dock log. Truck drivers are to sign in and out and forklift drivers are required to check to assure wheel chocks are in place. 4. Dockboards and bridgeplates, shall be properly secured before they are driven over and shall be driven over carefully and slowly, and their rated capacity never exceeded. 5. All Trucks and Trailers shall be inspected before loading or unloading. Look for; Loose plywood on side walls or end, scuff plate is in place, holes or separation between the floor and side walls. Post and steel construction one or more posts are missing or damaged. Floors check for holes, weak spots and weather damage. Roof bows two or more roof bows are damaged or missing. 6. Trucks and trailers found to be unsafe shall be reported to your supervisor and rejected. 7. Be aware of the difference between the dock floor and the height of the truck or trailer opening. 8. ISO and domestic container trailers shall not be entered with forklifts with the lifting capacity greater than 5000 lbs. 9. Standard duty highway trailers shall not be entered with forklifts with the lifting capacity greater than 8000 lbs. 10. Only forklifts labeled (H D) for heavy duty use shall only enter trailers labeled (H D). Traveling. 1. Forklift operators are required to use seat belts on forklifts that are equipped with seat belts. Seat belts shall be free of knots and kept in working order. 2. A safe distance shall be maintained approximately three forklift lengths from the forklift ahead, and the forklift shall be kept under control at all times. 3. Other forklifts traveling in the same direction at intersections, blind spots, or other dangerous locations shall not be passed. 4. The driver shall be required to slow down and sound the horn at cross aisles and other locations where vision is obstructed and areas with high pedestrian traffic. If the load being carried obstructs forward view, the driver shall be required to travel with the load trailing. 5. The driver shall be required to look in the direction of, and keep a clear view of the path of travel. 6. Grades shall be ascended or descended at a SLOW speed. 7. On all grades the load and load engaging means shall be tilted back if applicable, and raised only as far as necessary to clear the road surface. 8. Under all traveling conditions the forklift shall be operated at a safe speed that will permit it and the load to be brought to a stop in a safe manner. Safe operating speed is the speed of a fast walk or about 3-5 MPH. Lift and tilt speeds are controlled by engine RPM s. 3
9. Stunt driving and horseplay shall not be permitted. 10. The driver shall be required to slow down for wet and slippery floors. 11. Running over loose objects on the roadway surface shall be avoided. 12. While negotiating turns, speed shall be reduced to a safe level. Sharp turns and pivots shall only be negotiated at a SLOW speed. Failure to do so may result in a forklift tip-over which may cause serious injury or death to the operator. 13. Forklift operators shall travel with the forks as close to the floor as possible without dragging on the floor and the forks shall NOT be raised or lowered while the forklift is in motion. Loading. 1. Only stable or safely arranged loads shall be handled. Caution shall be exercised when handling off-center loads which cannot be centered. 2. Only loads within the rated capacity of the forklift shall be handled. 3. The long or high (including multiple-tiered) loads which may effect capacity shall be adjusted. 4. The load engaging means (forks) shall be placed under the load as far as possible; the mast shall be carefully tilted backward to stabilize the load. 5. Extreme care shall be used when tilting the load forward or backward, particularly when high tiering. Tilting forward with load engaging means (forks) elevated shall be prohibited except to pick up a load. An elevated load shall not be tilted forward except when the load is in a deposit position over a rack or stack. When stacking or tiering, only enough backward tilt to stabilize the load shall be used. 6. When handling 55 gal. drums of paint, solvents, or chemicals, they shall be lifted with barrel slings only and placed on a pallet for transporting. Drums shall not be lifted on the forks or under the rim of the drum. 7. Forklifts shall not be used to shake down parts in baskets, crates or tubs to create more room. This maneuver creates excessive wear and tear on bearings, hoses, chains, seals, and cylinders and leads to expensive repairs. Maintenance of Forklifts. 1. If at any time a forklift is found to be in need of repair, defective, or in any way unsafe, the forklift shall be taken out of service until it has been restored to a safe operating condition. All repairs shall be made by authorized personnel. 2. No forklift shall be operated with a leak in the fuel system. Those repairs to the fuel and ignition systems on forklifts which involve fire hazards shall be conducted only in locations designated for such repairs. 3. Forklifts in need of repair to the electrical system shall have the battery disconnected for such repairs. 4. All parts of any such forklift requiring replacement shall be replaced only by parts equivalent as to those used in the original design. 5. The forklift operator is responsible for the safety inspection of the forklift prior to the start of their shift and periodically during the work shift. Forklifts shall be examined before being placed in service and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examinations shall be made at least daily, and where forklifts are used on an around-the-clock basis, they shall be examined before each shift. The Forklift Daily Checklist (Appendix shall be filled out when the checks are done and filed at the end of the week (as required by divisions). Defects, when found shall be 4
reported immediately to the maintenance department so corrections can be made. The checklist is an OSHA required document and shall not be falsified in any way. 6. When the temperature of any part of any forklift is found to be in excess of normal operation temperature, thus creating a hazardous condition, the vehicle shall be removed from service and not returned to service until the cause for such overheating has been eliminated. 7. Forklifts shall be kept in a clean condition, free of lint, excess oil, and grease. Noncombustible agents should be used for cleaning forklifts. Low flash point (below 100 F) solvents shall not be used. High flash point (at or above 100 F) solvents may be used. Precautions regarding toxicity, ventilation, and fire hazard shall be consistent with agents or solvents used. 8. The user shall see that all nameplates and marking are in place and are maintained in a legible condition. Refueling Jay Plastics and Broshco CNG Forklifts. Procedures. 1. Park the forklift alongside refueling station so it is in reach of the refueling line. This is a NO SMOKING AREA. 2. Eye and face protection is required during refueling. 3. Lower the forks to the ground set the hand brake and turn off the ignition. 4. Notice the red EMERGENCY STOP BUTTON on the control panel. If at any time during the refueling operation a problem occurs, press this button. It will shut down the unit. 5. Disconnect the refueling line from the main unit and connect it to the CNG tank. Open valve at the end of the line 180. This vents the line and starts to fill the tank from Bank #1. After hissing sound subsides, the pressure in both the fill unit and the tank on the forklift are equal. Turn the valve handle from Bank #1 to Bank #2 and wait for the pressures to equalize. Turn the handle to Bank #3 until the pressure is equal. The forklift tank is now full. Return the Bank valve handle back to #1 and close the valve at the end of the fill line (back 180 ). Disconnect the line from the forklift tank and return it to the connector on the main unit. 6. To the right of the refueling station you will see two gray control units side by side. Press both start buttons. This will refill all three banks in the main unit outside. 7. If you run out of CNG, DO NOT PUSH OR PULL FORKLIFT TO THE REFUELING STATION. Use the tank on the two wheel cart to fill the tank on the forklift enough to drive the forklift to the refueling station. If you use this tank, make sure it is refilled when you are finished. Changing LP (liquid propane) tanks. Procedures. Wearing gloves and full face shield, turn off fuel supply valve and remove fuel line from tank. Take empty tank to outside storage rack and retrieve full tank. Replace full tank and while wearing gloves and full face shield check to assure fuel supply valve is in the off position and reattach fuel line and turn on the fuel supply valve. All LP tanks not in use must be stored in the out side storage rack. NO EXCEPTIONS. 5
Electric Forklift Instructions Hyster forklifts at Sarca. Charging The Battery. 1. The charging or replacement of electric forklift batteries shall be done only in a designated area. 2. The forklift shall be positioned with forks lowered to the floor, the parking break set and the key switch in the off position before changing or recharging the battery.. 3. Eye and face protection is required when changing or recharging batteries. Battery acid exposure to the eyes or skin must be immediately flushed with water, not less than 15 minutes. For eye exposure, get medical attention immediately. 4. Disconnect the battery when doing cleaning and maintenance. 5. Never connect the battery charger to the plug of the forklift. You can damage the traction control circuit. 6. Batteries generate explosive fumes when they are being charged. Keep fire, sparks and burning material away form the battery charging area. Prevent sparks from the battery connectors. 7. Never let the battery discharge below the minimum value given by the battery manufacturer. A fully charged battery will have the specific gravity of 1.256 to 1.310 at 77 F. Never charge a battery at a rate that will raise the electrolyte temperature above 120 F. Do not let a battery stay discharged for a long period of time. 8. NORMAL CHARGE: This charge is normally given to a battery that is discharged from normal operation. Charging the battery at regular intervals will keep the battery correctly charged if the battery is not discharged below the limit. Always use a hydrometer to check the battery if the battery is charged at regular intervals. Frequent charging of a battery has a 2/3 or more charge can decrease the life of the battery. 9. EQUALIZING CHARGE: This charge is at a low rate and balances the charge in all of the cells. The equalizing charge is normally given approximately once a month. It in a charge at a slow rate for three to six hours in addition to the regular charging cycle. Do not give an equalizing charge more than once a week. The most accurate specific gravity measurements for a charged battery will be after an equalizing charge. If the specific gravity difference is more that 0.020 between cells of the battery after the equalizing charge, there can be a defective cell. Notify Maintenance. Changing the Battery 1. Batteries are heavy and can cause an injury. Use care to avoid injury. Do not put hands, arms, feet and or legs between the battery and a solid object. 2. The weight of the battery is normally shown on the battery case. The maximum battery weight is shown on the forklift nameplate. 3. Before connecting the battery, make sure the key switch is in the OFF position and the parking brake is set. 4. Disconnect the battery. Move the connector and cables so that they will not be damaged when the battery is moved. Tilt the steering column forward and make sure the detent engages to hold the steering column. Slide the seat to the rear adjustment position. Release the lock on the battery restraint and tilt the battery restraint and seat to the up position. Make sure the battery restraint and the seat are locked in the up position. 6
ELECTRIC FORKLIFT INSTRUCTIONS CATERPILLER FORKLIFTS AT KRONIS COATINGS 1. The charging and replacement of batteries shall be done in a designated area. 2. When the digital display on the forklift reads 2 or 1 only, it is time to charge the battery. 3. Position the forklift in the designated area for charging. Lower the forks to the floor, set the parking brake and turn the key to the OFF position. 4. Eye and face protection is required when changing or charging batteries. Battery acid exposure to the eyes or skin must be immediately flushed with water, for not less than 15 minutes. For eye exposure, get medical attention immediately. 5. Disconnect the battery and move the connector and cables so that they will not be damaged when the battery is removed form the forklift. 6. Batteries are heavy and can cause an injury. Use care to avoid injury. Do not put hands, arms, feet and or legs between the battery and a solid object. 7. If the battery is not warm to the touch, it is OK to charge. Plug the battery into the charger. 8. Document the readings on the forklift and the charger. Do not add DI water until after charging. 9. Check the battery level in the 2 nd battery before putting it into the forklift. 10. If the level is low, fill with DI water just ¼ inch above the black plates in the battery. 11. Hoist the 2 nd battery into the forklift and plug in the battery. Conclusion. Failure to comply with this policy may result in loss of operators license and/or disciplinary action up to and including termination of employment. Appendix I Dock Log/ Truck driver sign in sheets. Appendix II Daily safety check sheet for LP and CNG forklifts. Appendix III Daily safety check sheets for electric forklifts. 7
8 Appendix I
9 Appendix II
10 Appendix III
Z:\My Documents\allen\Safety\Plans\Powered Industrial Trucks Jay Industries, Inc. Powered Industrial trucks (Forklifts) Written Program and Procedures Revision Log Reviewed/Revised June 9, 2004 06/04/08 reviewed and revised added revision log. 06/12/08 Added appendix I, II, and III. 06/15/09 Reviewed and updated 05/07/10 Reviewed and updated 07/02/11 Reviewed and updated OSHA Regulation 1910.178 Ohio Administration Code 4121:1-5-13 American National Standard Institute (ANSI) for Powered Industrial Trucks. Part II, B56.1-1969 Manufacturers Specifications and Recommendations 11