Standard FAS08-080

Powered Industrial Vehicle and Pedestrian Safety

Authorized by Human Resources
Revision Date: 20080327 Supersedes Date: 20020328

1.

FORWARD 1.1 1.1.1 Approval: This standard is owned by Corporate Occupational Health and Safety (OHS), Human Resources. Questions related to the correct application or interpretation of this global standard should be directed to the Corporate Occupational Health and Safety Office. Questions associated with local issues of application or interpretation should be directed to the responsible regional health and safety activity. Purpose: The purpose of the standard is to provide a comprehensive strategy to minimize the risk of incidents involving powered industrial vehicles and employees (pedestrians). Applicability / Scope: This standard applies to all Ford automotive activities and wholly owned subsidiaries involved in the manufacturing and distribution of vehicles and associated components. If more stringent, Company guidelines in this section may be superseded by governmental regulations. Regional guidelines may also apply at various facilities around the world. Consult with the Regional Safety Professional for these guidelines. Change Control/Review Process: Requests for changes to this standard shall be made to the Director, Occupational Health and Safety.

1.1.2

1.1.3

1.2 1.2.1

1.3 1.3.1

1.3.2

1.4 1.4.1

This document and any of its contents shall be considered transient when printed. GIS Information Management GIS1 Item Number 13.16 GIS2 Classification: Proprietary

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1.4.2

This standard will be reviewed every five years from the effective date or when significant changes occur to Company policy or external regulations or standards that are the basis for this standard. The master copy (controlled copy) of the standard will reside on the Ford Motor Company Occupational Health and Safety website. During the review process, draft revisions or additions to this standard will be highlighted in yellow Existing text proposed for deletion will be crossed out and shown in red (e.g. deleted text). Deviation Process: Requests for deviation shall be submitted in writing to the applicable Corporate Subject Matter Expert (SME). Supporting documentation for alternative specifications that demonstrate equal or superior protection shall be included with each request. The SME shall deliver the request to the Director of Occupational Health and Safety. The ruling on the deviation shall be communicated to the requesting organization within 30 working days.

1.4.3

1.4.4

1.5 1.5.1

1.5.2

2.

DEFINITIONS 2.1 2.2 Operator: Refers to the person driving or operating powered industrial vehicles Pedestrian: Any person who potentially can walk into an area of a Company facility where industrial vehicles operate. Powered Industrial Vehicle: Motorized vehicles on wheels, including all powered material handling vehicles, maintenance vehicles, burden carriers, personnel carriers, personnel lifts, construction vehicles (i.e., front end loaders, backhoes) and lawn tractors. Qualified Person: One that has exhibited knowledge of safely operating powered industrial equipment to the satisfaction of the facility safety professional, or the facility safety professional's designee, and therefore possesses a valid operator's safety permit for the specific equipment. Qualified Trainer: One that has exhibited both skill and knowledge of safely operating powered industrial equipment to the satisfaction of the facility safety professional and therefore can train others to use powered industrial equipment. Qualified Trainers are appointed by the facility safety professional.

2.3

2.4

2.5

3.

INSTRUCTIONS/REQUIREMENTS 3.1 3.1.1 Minimizing the overall vehicle fleet within the facility. Facilities, with assistance from the appropriate regional/local staff functions (i.e., MP&L, Plant Engineering, Manufacturing Engineering, Purchasing) are responsible for a) determining the optimal numbers of vehicles necessary to move materials throughout the plant efficiently, b) determining the types of mobile equipment needed to perform maintenance tasks, and c) determine the
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need for personal transport vehicles such as personnel carriers, burden carriers and bicycles. The facility has a responsibility to minimize the use of personal transport vehicles to those employees with a need to travel throughout the facility on a frequent basis. 3.2 3.2.1 Optimize material flow and storage. The organization responsible for facility material flow strategies shall ensure proper application of Synchronous Material Flow guidelines such as Call Market Areas, Plan for Every Part, and Materials Delivery Strategy which will provide an orderly and predictable traffic flow throughout the facility. Synchronous Material Flow can be found on the website for the Ford Production System. Isolate pedestrians from vehicle traffic. A re-assessment of the facility shall be conducted whenever changes in layout or process affect the facility modifications stated in 3.2. At a minimum, a reassessment of the Pedestrian and Vehicle Safety Marking Program Guidelines shall occur annually. Operator training and enforcement of safe operating rules. Only trained and authorized persons shall be permitted to operate a powered industrial vehicle. Operators shall be qualified as to visual, auditory, physical and mental ability to operate the equipment safely. Operator training shall be conducted by a Qualified Trainer. Operators of any powered industrial vehicle shall receive training on the safe operation of the specific vehicle(s) which they will be assigned to operate. Prior to operating any powered industrial vehicle, a potential operator shall have successfully completed training on the following topics: How to operate the vehicle. Pre-use inspection. Safe operating parameters including: o Aisle markings and signage (refer to section 3.3.1). o Operator/Pedestrian - Two (2) Feet (60cm) Vehicle/Pedestrian Rule. o Vehicle capacity and stability. o Operating limitations. o Surface conditions. o Composition of loads. o Narrow aisles, restricted places and hazardous locations where the vehicle may be operated. o Pedestrian traffic in areas where the vehicle will be operated. o Using warning devices such as horns. o Refueling and recharging of batteries. o Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.
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3.3 3.3.1

3.4 3.4.1

3.4.2 3.4.3

o On the job training and evaluation to ensure qualifications are met. 3.4.4 Refresher training in relevant topics shall be provided to the operator when: The operator has been observed to operate the vehicle in an unsafe manner. The operator has been involved in an incident, and was found to be a contributing factor. A condition in the workplace changes that could affect the safe operation of the vehicle.

A new type of powered industrial truck has been introduced. A minimum of three years has elapsed since the previous training. In addition to operator refresher training, an evaluation of each operator's performance shall be completed at least every 3 years. Attachment #1 Powered Industrial Vehicle Operator Skills Evaluation may be used for this purpose. 3.4.5 Operators of powered industrial vehicles shall be furnished with a license as proof they have received the required training. Pedestrian (employee) Requirements Employees who may have potential to interact with powered industrial vehicles shall receive: Training on the aisle markings and signage as related to pedestrian safety. Orientation in the Pedestrian/Vehicle Two Foot (60 cm) Rule. 3.6 3.6.1 Additional Requirements At least annually, employees shall receive a safety talk on pedestrian safety requirements. At least annually, operators shall receive a safety talk on pedestrian safety as it relates to operating their assigned powered industrial vehicle(s). Visitors and contractors to the facility shall be oriented on adhering to the pedestrian safety rules.

3.5 3.5.1

3.6.2

3.6.3

4.

COMPLIANCE PROGRAMS 4.1. Ford Organizational Health and Safety Activities are responsible for developing compliance programs that: 1) meet the requirements of the global standard, and 2) meet applicable regulations and/or standards unique to their organization or jurisdiction. Subject compliance programs shall be developed in one of the following groupings as appropriate: Ford Organizations:

4.1.1

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 Regional (e.g., Ford Asia Pacific, South America, North America) Brand (e.g., Jaguar, Volvo) Division (e.g., Vehicle Operations, Powertrain Operations, Product Development) Other (e.g., majority joint ventures) Government Jurisdiction: Regional (e.g., European Union, North America) National (e.g., U.S.) Local (e.g., state, province, city) 4.1.2. Ford Organizational Health and Safety Activities shall update compliance programs as necessary following revisions to global standards or applicable regulations and/or standards unique to their organization or jurisdiction. 4.1.2.1. Ford Organizational Health and Safety Activities shall develop time-bound implementation plans for the development of compliance programs to conform to all new and revised published global standards. 4.1.3. The OH&S staff shall maintain a Corporate OH&S Global Standard Compliance Matrix (FAP08-001, Attachment C) to document compliance with the global standards. The matrix shall be published annually and will identify all new and updated standards from the previous year. 4.1.4. Annually, Ford Organizational Health and Safety Activities shall be required to document compliance to Company standards by updating the Corporate OH&S Global Standard Compliance Matrix. Completion of the matrix shall signify the Ford Organizational Health and Safety Activity has reviewed and certified the accuracy of the matrix.

5.

ATTACHMENTS 5.1 Attachment #1: Powered Industrial Vehicle Operator Skill Evaluation

6.

REFERENCES 6.1 6.1.1 6.1.2 6.1.3 6.2 6.2.1 6.2.2 Ford Motor Company References: Pedestrian and Vehicle Safety marking Program Guidelines Two (2) Feet (60cm) Vehicle/Pedestrian Rule FAP08-001, Attachment C External Standards United States: OSHA Standard 1910.178, "Powered Industrial Trucks" Europe:
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6.2.2.1 Council Directive 92 / 58 / EEC as per 24.06.1992 6.2.2.2 Great Britain: Statutory Instrument 1997 No. 2400, "The Zebra, Pelican and Puffin Pedestrian Crossings Regulations and General Directions 1997." 6.2.2.3 Great Britain: Health and Safety Executive / Local Authorities

Enforcement and Liaison Committee (HELA) - Approved Code of Practice L117

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