SAFE SYSTEMS OF WORK FOR FORKLIFTS, CONVEYPRS AND PLANT RAILWAYS

The main causes of forklift accidents fall into three risk categories: user error, work
environment, and mechanical design. Inadequately trained personnel are responsible for a
significant portion of forklift accidents. According to the statistics as many as 70 percent of
forklift accidents could have been avoided through proper training. The primary causes of
major forklift accidents are given below:

Here are the main tips for establishing forklift safety:

1. GET FORKLIFT CERTIFICATION: Since many accidents are due to poor training, it is
recommended that only those who have been trained and licensed in accordance with the
Central Motor Vehicles Act be responsible for operating a forklift. Employers should evaluate
their employees’ performance at least once every three years and supplement training with
lectures, videos, software training, and demonstrations.
2. WEAR PROPER CLOTHING: Forklift operators should be dressed with the appropriate safety
equipment, including safety shoes, hard-hats, and a high-visibility jacket. Make sure to tuck
away loose clothing to prevent it from getting caught on the forklift.
3. KNOW THE FORKLIFT CLASS: OSHA recognizes many different forklift types and
classifications. Since each type has its own structure, weight limit, travelling speed, turning
radius, and usage, it’s important to know your equipment in order to follow the best safety
practices.
The most popular forklift types on the market today are:

 Warehouse Forklift
 Side Loader
 Counterbalance Forklift
 Telehandler
 Industrial Forklift
 Rough Terrain Forklift
 Pallet Jack
 Walkie Stacker
 Order Picker
 Reach Fork Truck

4. INSPECT THE FORKLIFT DAILY: Forklifts should be thoroughly inspected before every use.
Daily checks with the shift supervisor are recommended to identify and log any problems or
defects. Any equipment that requires repair should never be operated. Some of the
recommended checks include:

 Test operating controls such as brakes, lights, horn, and steering wheel
 Check mast and overhead guard for damage
 Examine tire and fluid levels (hydraulic, brake, engine, fuel, and coolant)
 Check for water, oil, or radiator leaks
 Ensure the forks are in good condition (e.g. straight, no cracks, no distortion)
 Look for potential hazards
5. MAINTAIN 3600 VISIBILITY: Keep forks low to the ground to provide clear forward visibility.
If the load restricts your visibility, operate the equipment in reverse. Always ensure you have
a good view of the rack when you are positioning the load. Additional best safety practices
are:

 Always make eye contact with pedestrians and other workers

 Always look in the direction of travel
 Use rear-view mirrors to boost visibility
 Use headlights if working at night, outdoors, or in areas where additional lighting is needed
6. IMPLEMENT A FLOOR MARKING SYSTEM: A floor marking system can help increase worker
safety. Use yellow to mark the physical hazards, such as areas prone to stumbling and falling,
and red to delineate fire hazards, fire equipment and emergency switches. Place way finders
and signs throughout the warehouse site to keep walking personnel away from forklift
paths, lead forklift along safe routes and improve the flow of overall traffic.

7. MAINTAIN EQUIPMENT CAPACITY: Be aware of the capacity of your forklift and any
attachments used. Avoid hauling weight that exceeds the counterweight of the forklift.
Overloading a forklift can cause the rear wheels to rise off the ground and the whole
machine to fall over, causing injury to personnel and damage to the equipment and
materials.
8. NEVER CARRY EXTRA PEOPLE: Do not allow other workers to ride on the equipment with
you unless a second seat is fitted into the forklift. Do not use the forklift to lift people, as
forklifts are designed to carry loads. If you need to lift a person, use only a secure work
platform and cage.
9. PAY ATTENTION TO THE FORKLIFT STABILITY: Before using a forklift, make sure your hands
and shoes are completely dry in order to avoid developing an accident and sliding controls
 off. Occupy the forklift driver seat in a comfortable position with all the controls within
reach. In addition to seating yourself securely, take the following steps before operating the
forklift to increase your safety:
 Each forklift has a centre of gravity – the point where the weight has equal
concentration – which it shares with the load it carries.
 Forklifts are built on a three-point suspension system, called the “stability triangle”
that operators must stay within to prevent it from tipping over.
 The heavier the load, the further out the centre of gravity is from the load centre,
decreasing your forklift’s lifting capacity.
10. ENSURE THE LOADS ARE STABLE AND SECURE: When placing loads on the loading dock, be
sure to check them for balance. Travel with the load tilted backwards and keep forks as low
as possible to increase the stability of the equipment, especially when navigating on ramps.
Use ropes or bindings to secure stacks and heavy loads if necessary and make sure any
pallets or skids used are the appropriate weight for the load.
11. MOVE AT AN APPROPRIATE SPEED: Drive your forklift within the designated speed limits.
It’s important to not stop, turn, change directions suddenly, or move fast when making
sharp turns, as these actions can cause the forklift to tip over. If your forklift starts to dip, do
not try to jump clear of the machine. Experts recommend staying in the vehicle, gripping the
wheel, and bracing your feet.
12. MAINTAIN A SAFE OPERATING DISTANCE: Always be mindful of the surrounding equipment
on the worksite. Do not operate a forklift in close proximity to other machinery unless
absolutely necessary, and keep a safe distance to allow you room to stop safely and avoid
other machines that are moving in an unpredictable manner.
13. AVOID THE HAZARDOUS AREA OF THE LOAD: Always be mindful of the surrounding
equipment on the worksite. Do not operate a forklift in close proximity to other machinery
unless absolutely necessary, and keep a safe distance to allow you room to stop safely and
avoid other machines that are moving in an unpredictable manner .
14. REFUEL AND RECHARGE THE FORKLIFTS : It’s important to keep equipment fully charged and
fueled. Be sure to recharge and refuel in specially designated locations, which are usually
well-ventilated and flame-free areas. Be diligent in switching off the equipment every time
it’s being refuelled.
15. PARK THE FORKLIFTS IN DESIGATED AREAS: At the end of the shift, be sure to always park
the equipment in the designated and authorized areas. The warehousing company should
make sure the parking areas do not block pathways or obstruct any exits or entrances. Fully
lower the forks until they fit the floor, apply the parking brake, turn off the engine, and
remove the key from the ignition.

SAFE SYSTEM OF WORK FOR CONVEYORS

Conveyors are very helpful in moving material and supplies within a warehouse. However, they
are a common cause of injury in the warehouse. The list of best safety practices that will help
keep you and your co-workers safe are listed below: 

1. DON’T SIT, STAND OR WALK ON THE CONVEYORS: Conveyors are never

meant to be occupied by a person.
 Conveyors have many features, including pinch points that can catch clothing or
people and cause serious injuries.
 A limb stuck in a pinch point can be severely damaged or even torn off.
  Industrial conveyors are not designed for people so you should never ride on
conveyors.

2. MAKE SURE CONVEYOR CONTROLS ARE OPERATING CORRECTLY: Controls that don’t work
properly can cause serious problems. Hence the conveyor controls shall be inspected to make sure
no employee has misused, modified, or disconnected them. The emergency stops shall be located in
highly visible and accessible locations. The Safety Trip Wire cables on the conveyor shall extend
across the entire length of the face of the conveyor and be located not more than 1.8 meters above
the floor or working level.

 3. CHECK THAT ALL CONVEYOR GUARDS ARE IN PLACE: The conveyor shall not be operated
if the appropriate guards are not in place. Conveyors contain gears, chains, belts, and other moving
parts that can be hazardous if exposed. Hence employees should not be able to bypass, remove, or
alter conveyor guards. Guard openings should be small enough to keep workers from entering
danger zones.
 4. BE WATCHFUL OF PINCH POINS: The Conveyors are exposing dangers by the very nature
through their pinch points that are plenty in number. The "Pinch point" means any point other than
the point of operation at which it is possible for a part of the body to be caught between the moving
parts of a conveyor. A partial finger amputation to the total leg amputation is the severity level of
the conveyor pinch point entrapment. Guards can help prevent workers from reaching into, through,
over, under or around the pinch point. Once any necessary guards are in place, employers must train
employees on what the guards are intended to do and the reason the machines need them.
 5. KEEP HAIR, CLOTHING, JEWELLARY AND OTHER LOOSE ITEMS AWAY: Conveyors can
catch loose clothes or long hair, resulting in severe injuries. Hence long hair should be tied back or
tucked under a cap. Bracelets, rings, watches or other jewellery should not be worn on any
circumstances.
 6. ALERT MANAGEMENT OF ANY POTENTIAL CONCERNS: The best way to correct an unsafe
situation (e.g. loose guards, a person riding the conveyor) is to alert the person responsible for the
area. Suitable training about safety issues and when to report them should be made available to all
employees.
 7. FOLLOW LOCHOUT/TAGOUT PROCEDURE: Failure to implement the Lockout/Tag out
(LOTO) procedure might be exposing the workers to the life-threatening injuries. Secure conveyor
systems before maintenance or repair by following proper lock-out/tag-out procedures. Lock-
out/tag-out procedures prevent equipment from being powered up while maintenance or repairs
are being done. Conveyor operators must be properly trained to perform lock-out/tag-out
procedures.

8. ALLOW ONLY AUTHORIZED PERSONNEL TO OPERATE THE CONVEYPR : This ensures technician
safety and optimal conveyor performance. Material handling equipment can be dangerous to those
who do not understand how to safely work on it. When something needs to be fixed, contact your
trained maintenance person. Only those employees who are trained to operate and perform
maintenance on conveyors should do so.

SAFE SYSTEM OF WORK FOR PLANT RAILWAY

The speed limit for the locomotive or train should not be permitted to move at a speed of greater
than 7 kilometers per hour. The gates through which a railway track passes should not be used for
the general passage of workers into or out of a warehouse. Where buildings or gates which open to
a railway truck, a barrier about one meter high should be fixed parallel to and about 60 centimeters
away from the building or wall outside the opening and extending several meters beyond it at either
end, so that any person passing out may become aware of the approaching train since his pace is
checked at the barrier. If the traffic of the nearest track is in one direction, the barrier should be in
the form of “L” with the end of the short leg abutting on to the wall and the other end the other end
opening towards the approaching train.

If the distance between the nearby building and the track is not able to accommodate such a barrier,
the barrier or turn-gate should be placed at the inside of the opening.

Every wagon should be provided either with self-acting brakes capable of being applied continuously
or with efficient hand brakes that should be maintained in good working order. The hand brakes
should be capable of being applied by a person on the ground and fitted with a device for retaining
them in the applied position.

No person should be permitted to be upon, whether inside or outside any locomotive wagon except
where secure foot-hold and hand-hold are fitted in the interest of safety. No locomotive or wagon
should be permitted to be kept standing in the warehouse plant railway area unless its brakes are
firmly applied. Where the wagon is standing on a gradient, it should not be permitted to be kept
standing without sufficient number of scotches placed firmly in position.

Loose shunting of wagons should be permitted only when it cannot be avoided; it should never
perform on a wagon not accompanied by a man capable of applying and pinning down the brakes. A
wagon not provided with brakes in good working order and capable of being easily pinned down
should not be loose shunted at all. Suppose it is attached with another wagon having efficient hand
brake and the rigid capability of being pinned down the brakes. Fly shunting of wagons should not be
permitted on any circumstances in a warehouse plant railway area. All shunting operations should
be carried out only with the directions of a properly trained jamadar. The hand signals used by the
shunting jamadar by a day and night should be in accordance with the shunting rules of the Indian
Railways Act 1890.
