< FACULTY OF SCIENCE AND TECHNOLOGY>

< SEPTEMBER/2018>

< XBOS3103 >

< OCCUPATIONAL SAFETY I >

MATRICULATION NO : <>
IDENTITY CARD NO. : <>
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INSTRUCTIONS
 Do not copy the assignment question and instructions to your answer.
 Prepare your assignment answer following the layout of the ASSESSMENT
CRITERIA shown in the RUBRICS provided for the course. Where RUBRICS
are not provided, follow the instructions/guidelines specified by the Faculty for
the assignment concerned.
 Your assignment should be between 3000 to 5000 words (depending on the
number of words outlined in the assignment instruction) EXCLUDING
references.
 Type your answer using 12 point Times New Roman font and 1.5 line spacing.
 Show the number of words at the end of your assignment.
 Tables and figures where provided should be appropriately titled.
 List your references separately in the APPENDIX page.

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1.0 Introduction

Forklifts or industrial lift trucks are used to lift, stack and transfer loads in warehouses,
factories, shipping yards, freight terminals and in some different workplaces. Forklifts are
an essential part of modern manufacturing plants around the world, forklifts are powered
industrial trucks used to lift and move materials, forklifts are powered by internal
combustion engines fueled by LPG (liquid petroleum gas), Diesel or Petrol, and electrical
powered forklifts are also used using DC motors with lead-acid batteries.
As the name suggests forklifts are used to lift objects by using its fork combined with a
hydraulic ram and its mast combined with a lifting chain and fork. Forklift which is a sit-
down model powered by a diesel or battery engine. Counterbalanced forklifts have the
majority of its mass situated behind the driver's compartment, the engine and
counterweight are put over the rear axle to provide a counterbalance. With its inherent
instability forklifts have a high center of gravity especially when it's loaded.

1.1 Factor related to the forklift or industrial lift truck accident

There is come hazard related accident involving this machine, several causal factors have
been identified that is.

a) Human factor
Among the factors that lead to human error are an excessive burden, inappropriate
responses, and inappropriate activities. In addition, the human factor causing the
accident is also like:
 Emotional and mental stresses include personal problems.
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  Nothing or lack of experience or knowledge.
 No or fewer skills and training.
 Lack of physical ability.
b) Environmental factors
Environmental factors can also cause accidents in between:
 Slippery floor.
 Dark or less illumination workplace.
 The atmosphere at the workplace is noisy.
 Narrow path.
 Uneven floors.
 Dirty workplace.
c) Vehicle factors
Vehicle factors that cause accidents are as follows:
 Overload.
 Design mistakes (example, error determination of load capacity that
can be lifted).
 Inadequate machinery equipment (for example, no lights or warning
buzzers).
 Mechanical failure (example brake system)
 Incompatibility of use (for example, transporting loads using
unsuitable machinery).

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Figure 1.2: A truck accident happened when the truck driver was blocked by his load and
the Warehouse staff at the edge of the box was unaware of the presence of the pickup truck
(decorative image)

2.0 Principles and Occupational Safety Guidelines for Safe forklift practices
The existence of such a vehicle or machinery may enable and facilitate and expedite the
process of transmission or transfer of cargo. However, there are frequent accidents during
the process, including inverted, human-busted, overtaken vehicles and rammed into
buildings. The factors that cause the accident are human factors, environmental factors, and
machinery factors. Various ways to prevent the occurrence of accidents during
transportation. Among the most frequent fatal accidents involving these machines are:
 Inverted machinery
 Machinery violate workers or other objects
 Crushed machinery or machinery components during maintenance
 Falling from machinery
 Crashed or damaged material transported

Accidents involving machinery conveyance can be prevented through the following safety
principles:

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a) Control over drivers
 Select a competent driver who has lessened in driving the apportioned truck.
 Provide transportation safety training to drivers (including outsiders).
 Allows only authorized drivers eligible to drive the truck.
 Encourage feedback or report any damage or incident occurring on
vehicles.
 Conducting annual medical checks on drivers to avoid the desired event
caused by human factors.

b) Start and stop procedures control

 Driver must carry an operational check of the forklift components such as
the hydraulic system for leaks, brakes and throttle position.
 When starting be sure to sound your horn, and also when turning.
 When stopping make sure that the forklift is stopped within a safe area
 Brake steadily and neutralize the controls and set the parking brake while
turning off the ignition.

c) Direction changes procedures

 Carry out a trail braking to prevent the load from dropping off the fork when
turning.
 Never brake suddenly and turn.
 While reversing make sure all rear-view mirrors are properly set up
 Make sure there is room for pedestrians to walk by
 Never assume pedestrians will notice a forklift backing up.

d) Visibility control procedures

 Keep the load below the field of view, never drive with the view blocked.
 Make sure the forklift has adequate lighting,
 Make sure there are barriers put up to prevent forklifts from hitting racking
systems.

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e) Control of machinery or vehicles
 Conduct preventive maintenance programs for vehicles.
 Conduct inspections of vehicles.
 Installing devices that control vehicle speed limits.
 Install safety equipment or alarms for moving backward.
 Choosing appropriate conveyance machines and capable of carrying out their duties
 Ensure the use of machinery is limited to a specific driver at any time.

f) Environmental control
 Make a yellow line on the floor for the path of the machinery.
 Ensure the floor structure is suitable and can accommodate the burden of
machinery and cargo.
 Provide a place for loading or parking.
 Put a mirror on a sharp angle.
 Install warning lights in the area of the track.
 Separate routes between pedestrians and machinery.
 Provide adequate lighting for dark areas.

g) Administrative control
 install speed limit signage, 'No Entry' and so on.
 Supervise the critical transportation work.
 Monitor the implementation of the procedures and work systems that have
been introduced.
 Provide and enforce the regulations of traffic control in the work premises.

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 Figure 2.1 Show how to safeguard the forklift

Figure 2.2: Figure shows the correct way of

loading and loading forces using a forklift.

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 3.0 Daily Forklift Safety Checklist

Daily Forklift Safety Checklist

Employee Name:Forklift Number:Date Inspection:

Tick if the item is acceptable, cross if it is not (✔, ✖)

Visual Check Control Measure
1 General - Good condition with no injury, excessive dirt or rust. Check the previous record
Any defects antecedently noted repaired. any damage
Maintain good housekeepi
2 Overhead Guard / Roll Over Protection Frame: Secure, Regular inspection require
unbroken with no loose things. and ensure in good conditi
3 Forks: Correctly positioned, not broken, cracked, bent or worn. Regular inspection require
Anchor pins secure and not worn, loose or bent. change the forks if damage
always place down the fork
the forklift stop or not in
operation
4 Mast: No damage, distortion or cracks. No undue wear, scoring, Regular inspection require
dirt or foreign bodies in channels. end stops securely. Rollers, no Change the mast if damage
uneven wear or incorrect tracking. Slides intact and secure.
5 Backrest Extension / Load Guard: In good shape, secure with no Ensure that bent backrests
distortion or cracks. in good condition and not
hitting any other part of th
truck during mast operatio

6 Lift Chains: Not broken worn or stretched, no broken links or rust. Regular chain maintenance
All pins in place. important
Apply suitable lubrication

7 Tires: No damage, excessive dirt or wear, rust, cracks, splits or Regular inspection air pressure

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 separation of tires and rims. pneumatic tires correct air pressure. at forklift tire is at the correct
level. Avoidance of ‘bleeding’
as a means to lower air
pressure
8 Wheels: Undamaged and free from obstruction and scrap. All nuts moving joints or parts are
secure and in place. greased with suitable grease
9 Energy Source: Always connect/disconnect
• Gas or Diesel: Engine oil, fuel and radiator water level correct. with the power off. If a fire
Gas bottle secured, no rust, corrosion or broken pipes, hoses or occurs when power is
seals. reapplied then isolate
• Electric: Electrolyte level, battery plug, and connections correct. immediately. Ensure bay is
power cable intact, connected and secure. No exposed wires, clear of flammables.
battery brackets secure and battery adequately charged. . Wear proper PPE when
handling
10 Hydraulics: No harm or fluid leaks, no splits into hoses, no leaks Regular inspection of
around fittings. hydraulic oil and refill the oil
when needed
. use proper PPE when
handling
. Check and record hydraulic
pressure
11 Access: Steps and grab handle in good shape and clean. Visual inspection
Change the step and the grab
handles if damage
12 Lights, Windscreen and Mirrors (if fitted): Clean and Regular inspection needed to
undamaged. ensure lights are working and
in a good condition
Operational Check
13 Seat: Good condition, secure and adjusted properly. Ensure forklift seating is in
good condition and can be
adjusted for different body
types
14 Safety Belt: Accessible, in good condition and working correctly. Ensure safety belt is good
condition, properly fitted and
no damage
15 Ignition & Electrical System: Working properly. All gauges and Ensure the forklift is serviced
instruments visible and working. or repaired by a qualified
person and only manufacturer-
recommended parts and
accessories are used.
16 Reversing Alarm and Horn: Working properly and audible. Regular inspection required

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17 Hydraulic Controls: Working smoothly and properly. Regular inspection needed
18 Brakes (Foot & Parking): Working properly. An authorized and qualified
person is required for repairing
19 Clutch & Gearshift: Working smoothly and properly. work only manufacturer-
20 Steering: Working properly with no excessive play. recommended parts and
accessories are used.

 The checklist is to be completed every day prior to using the equipment. The operator is to initial when
inspected, Supervisor is to review the checklist and sign off at the end of each shift

 If any items above are not working, the forklift is to be tagged out and reported to the supervisor for repair.
Description issues…………………………………………………………………………………………………
…………………………………………………………………………………………………………………
Date & Time Tagged Out………………
Tagged By…………………...................
Employee Sign Off………………………….
Supervisor Sign Off………………………….

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4.0 Steps to enforce the use of the developed checklist to minimize safety risks related
to forklift in the workplace.
There are some steps and ways that we can take to enforce an employee to follow the
developed checklist to minimize safety risk related to the forklift.

1. Conduct awareness safety training for all the employees that involve in forklift
operation

a) Initial training
The Safety and Health Officer needs to conduct awareness safety training to all
employee presently involved in operating a process, and each employee before
being involved in operating newly assigned employees shall be trained in an
overview of the process and in the operating procedures. The training shall
include emphasis on the specific safety and health hazards, emergency
operations related hazards or what accident will occur when handling the
vehicle and how to avoid the accident related with the vehicle operation by
doing this the forklift drivers will aware the potential hazard that will happen
and how to handle the problem when their operating the vehicle.

b) Bring an external qualified forklift mechanic

The Safety and Health Officer also needs to bring the qualified forklift
mechanic from outside and explain how to use the checklist that has been
developed to minimize the accident related to the forklift. The qualified person
needs to teach the forklift drivers the basic things that need to monitor and how
to check the forklift in the proper way. By doing this the forklift drivers will
have the more knowledge about how to use the checklist and what the important
things that they need to do and don‘t when they want to use the forklift for
operation.

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 c) Refresher training
The Safety and Health Officer also needs to have refresher training. The training
shall be provided a minimum of every 3 years, and more often if necessary, to
every worker concerned in operating a process to assure that the worker
understands and adheres to the present operating procedures of the process. The
refresher training need to conduct under the following condition
 Introduction of new or different equipment un the workplace
o Assignment the forklift driver to a new or different type or class
of forklift
 When the modification to the equipment that uses by the forklift driver
 When there are changes to the operating condition and environment of
the workplace
o Newly or additional forklift, equipment, or a flammable
component
 The supervisor has identified skill or knowledge deficiencies
o Some driver involves in an accident, near miss. Or observe
unsafe action at the workplace
The employer, in consultation with the workers concerned in operational the
method, shall determine the acceptable frequency of refresher training.

2. Reward Giving and incentive system practices

To make employee follow the develop checklist the employer sometimes need to
follow some procedures that involving in giving rewards and incentive to
employees.
The rewards or incentive need to give to the employees who are regularly
performing their work or given task adequately, employees who have a good
attitude and behavior in the workplace and also who are able to follow all the safety
protocol that has been set by the company. By practices this method the employees
will be more productive and will have a set of mind to perform well in their work.

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3. Develop a safety committee at the workplace
The Safety and Health Officer needs to create a safety committee at the workplace
and assign few members to monitor the forklift driver and all the activities that
happen in the workplace.
The safety committee members need to identify the hazards in the workplace and
make a recommendation to correct them. They also need to educate fellow workers
about the risk and the committee members also should record and report to their
superior officer all the unsafe act or unsafe condition that they have found in the
workplace so that the Safety and Health Officer can improve the problem in the
upcoming safety meeting that will be conducted in the company. By practices this
method the forklift drives will be always beware that they have been monitor and
need to follow the rules that have implemented by the Safety department.

4. Spell out discipline procedures for minor and major misconduct

This going to be a final step that needs to do by the management if they have found
the workers never follow the rules that have been set by the management. For the
minor misconduct for (example never follow the pedestrian walkway, using phone
or horseplay while working, etc) can be handled with a writing a warning letter to
the employees that spell out more severe consequences for repeated offenses. But
for the major misconduct by the workers they should handle with a writing a
terminate or dismissal letter to the workes and eliminate potential claim of
employee persecution or favoritism. By doing this the employees will more aware
that they will be serious consequences will give to them if they never follow the
rules.

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5.0 Conclusion
Forklifts are tools or machinery for labor force savings. It saves time and reduces the
likelihood of injuries associated with manual handling activities. However, forklifts can be
very dangerous if they are operated by untrained or reckless operators. All forklift drivers
should receive safety training before being allowed to carry forklifts.
Forklift accidents tend to be very serious which involves both personal injury and property
damage. In the event of an accident on the premises, this condition also results in an
increase in financial costs in terms of expenses involving both parties whether the employer
or the victim. Compensation to victims and medical expenses cost a lot. In addition, the
employer also has to pay the costs of repairing the vehicle and replacement if necessary
while paying the penalty if convicted. The accidents are not only burdensome both
employers and employees, but also involve external agencies such as Police, DOSH and
certain agencies. Employers are required to report the occurrence of accidents to these
related parties to conduct an investigation for each established procedure.
Accidents can be avoided if drivers follow work procedures or safe operation. Continuous
improvement in knowledge, skills, and enforcement is crucial in ensuring safe conditions,
conditions and behaviors are created.
Everyone is at risk of being exposed and potentially involved in an accident. This really
needs to be applied to everyone's mind at every workplace so that negligence can be
prevented and security cannot be compromised. If all staff are in compliance with all safety
regulations and everyone is nurtured to practice the prudent working culture and to be
cautious as part of the safety culture the accidents can be avoided and protected. The safety
responsibility is for everyone’s.
(2665 words)

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REFERENCES

 Retrieved from
https://www.hsa.ie/eng/Topics/Work_Related_Vehicle_Safety/Forklift_Trucks/
How to Maintain Forklift Tyres. Retrieved from http://resources.axistyres.com.au/resource-
centre/how-to-maintain-forklift-tyres/
Enforce Office Rules Wisely to Ensure a Productive and Harmonious Operation. Retrieved
from https://www.middlemarketcenter.org/expert-perspectives/enforce-office-rules-wisely-
to-ensure-a-productive-and-harmonious-operation/
Gilman P. Health assessment document for diesel engine exhaust, EPA/600/8–
90/057F. Washington, DC: US Environmental Protection Agency; 2002
Workplace Health and Safety Queensland - WorkSafe Connect. Retrieved from
https://www.worksafeconnect.com/HR Forklift - forklift-safety-reducing-risks.pdf
Rubino, M. (n.d.). Peraturan Keselamatan Forklift. Retrieved from
http://ms.safetytoolboxtopics.com/Forklifts/forklift-safety-rules.html
A Guidebook of Industrial Traffic Management & Forklift Safety. (n.d.). Retrieved from
https://www.monash.edu/__data/assets/pdf_file/0017/218123/guidebook-forklifts-03.pdf

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