Forklift Safety Presentation

Powered Industrial Truck Policy and Procedure : 

Powered Industrial Truck Policy and Procedure Policy / Procedure Owner: Jesse Estrada October 29, 2008

References : 

References TOLCO EHS Procedure – PIT Policy and Procedure Federal OSHA Standard CFR 1910.178 Cal-OSHA Regulation Article 25 – §3650

Powered Industrial Truck Program – Agenda : 

Powered Industrial Truck Program – Agenda 1. Powered Industrial Truck - Definitions 2. Powered Industrial Truck Policy 3. Powered Industrial Truck Procedure 4. Powered Industrial Truck Operator Training 5. Powered Industrial Truck Points Matrix

Powered Industrial Truck Program – DefinitionsWhat is a Powered Industrial Truck? : 

Powered Industrial Truck Program – DefinitionsWhat is a Powered Industrial Truck? Powered Industrial Truck (PIT) – Is any vehicle operated at the NIBCO Corona Plant other than those vehicles intended for over the road use.

Powered Industrial Truck Program – Definitions Define an Incident : 

Powered Industrial Truck Program – Definitions Define an Incident Incident - Powered Industrial Truck operation that results in an accident or near miss, that does or could result in a loss, including but not limited to injury, property damage, loss of production, or environmental harm, or the operator is observed exhibiting inappropriate behavior that could lead to an accident within the course of his or her material handling duties.

Powered Industrial Truck Program – Definitions Types of Incidents : 

Powered Industrial Truck Program – Definitions Types of Incidents Minor Incident - Incidents that would have little or no potential for loss. Incidents that would be considered a slight miscalculation or lapse in thought that would occur from time to time for a majority of drivers. Examples of minor incidents may include but not be limited to the following: bumping a rack, column, side of a trailer, etc., during which there is visible damage, such as a small dent, or other physical deformity for which minor repair is necessary, or the repair will not cost more than $250.00 in labor and materials. Serious Incident - Incidents in which there is property damage that requires repair for either functional or aesthetic reasons. Incidents in which a pedestrian is involved in either a near miss or an injury. Collisions between vehicles where the potential for injury does not require outside medical attention, and the vehicles can be repaired in our shop. Serious incidents will include but not be limited to damaged columns, bent rack legs, a damaged palletainer, damaged product, etc. The repair cost for serious property damage will typically be greater than $250.00 and no more than $2,500.00.

Powered Industrial Truck Program – Definitions Types of Incidents (cont.) : 

Powered Industrial Truck Program – Definitions Types of Incidents (cont.) Major Incident - Injury potential is such that a person could require outside medical attention, or much damage is done. Repair or replacement costs will typically be over $2,500.00.

Powered Industrial Truck Program – Definitions Defining Control : 

Powered Industrial Truck Program – Definitions Defining Control Partial Control - The operator was only partially responsible for a particular incident. There were clear external factors that contributed to the incident. Examples would include but not be limited to the following: sliding a short distance (two or three feet) on an unseen oily surface and causing property damage, removing improperly stacked material resulting in damage to product, making contact with another vehicle or pedestrian that didn’t stop or yield when they should have, or hitting a column or rack while avoiding a vehicle or pedestrian. Full Control - Incidents in which there were no external contributors. The driver was completely responsible for the outcome of the incident. Incidents in which the operator was in full control would include but are not be limited to: driving into a column, failing to stop in time because of excessive speed, driving under an overhead door when the door is in the process of opening or closing. Failing to recognize a hazardous condition that would be recognized by a qualified operator.

Powered Industrial Truck Program – Definitions Violations requiring Disciplinary Action : 

Powered Industrial Truck Program – Definitions Violations requiring Disciplinary Action Reckless Operation of Vehicle - A disregard for the consequences of ones actions, such as but not limited to: driving carelessly, horseplay, driving at a speed that is clearly excessive given the situation, turning a corner fast enough to bring one wheel off the ground, driving blind, purposefully spinning or sliding. (ref: General Duty Clause) Unreported Incident - A driver has an incident/accident that has a scope of serious or major, or a minor incident/accident in which repair and a drug test is necessary, and fails to report this to his or her Supervisor or Lead Person immediately,

Powered Industrial Truck Program – ResponsibilitiesCompliance Manager - EHS : 

Powered Industrial Truck Program – ResponsibilitiesCompliance Manager - EHS Responsibility for the day-to-day operations of the PIT program maintaining compliance to regulations, updating the procedure, monitoring program compliance, ensuring training requirements are met, Oversee the development of policies, procedures, work instructions, training curriculum, and oversee the training process

Powered Industrial Truck Program – Responsibilities Supervisors and Managers : 

Powered Industrial Truck Program – Responsibilities Supervisors and Managers will monitor and coach drivers of Powered Industrial Trucks Ensure the timely completion of vehicle inspection reports Notify Plant Services of any Powered Industrial Trucks requiring maintenance

Powered Industrial Truck Program – Responsibilities Human Resources Manager : 

Powered Industrial Truck Program – Responsibilities Human Resources Manager will make determinations regarding policy and disqualification from driving a powered industrial truck will assure post-vehicle accident drug screening activities will assure consistency in the application of discipline per TOLCO’s PIT Points Matrix system

Powered Industrial Truck ProgramTraining Program Overview : 

Powered Industrial Truck ProgramTraining Program Overview All PIT operators within the TOLCO facility including contractors must be qualified, all NIBCO associates must be licensed. Designated internal Powered Industrial Truck trainers will train drivers. (A. Munoz, R. Garcia, E. Mireles) All PIT operators must successfully pass a equipment specific PIT written and driving test prior to receiving their license. License is valid for 3 years. Operators incurring too many incidents or otherwise operating a PIT in a significantly unsafe manner may be disqualified from having a PIT license and driving. They may petition to become re-qualified after one year (See details in Procedure below). Disqualified individuals may be assigned to an open position if qualified.

Powered Industrial Truck ProgramOperator Guidelines : 

Powered Industrial Truck ProgramOperator Guidelines Operators must wear their PIT operators license at all times while operating a PIT. PIT’s must be inspected prior to use per OSHA guidelines, at least once per each shift of use. Vehicles not passing inspection or with concerns about their safety will be tagged out of service. All Powered Industrial Trucks must meet the design and marking requirements of 29 CFR 1910.178. PIT’s cannot be altered in any way, shape, or form unless written consent is obtained from the vehicle manufacturer.

Powered Industrial Truck ProgramPoints Matrix System - Overview : 

Powered Industrial Truck ProgramPoints Matrix System - Overview Operators shall be disqualified from operating a Powered Industrial Truck if they accumulate five (5) or more points in any rolling 12-month period. The Investigation Team will determine points after the incident has been investigated and analyzed. The NIBCO – Corona Human Resources Manager will analyze the official incident report filed by the Investigation Team. Definitions for Operator Control and Loss Severity categories are in section 4.0 of the EHS 28 – PIT Policy/Procedure.

Powered Industrial Truck ProgramPoints Matrix System – Investigation and Points Process : 

Powered Industrial Truck ProgramPoints Matrix System – Investigation and Points Process The Investigation Team’s job is to recommend what categories they believe the incident falls in, and the reasons why. The PIT Incident Review Team reviews their recommendations at their next daily meeting, and determines the points to be assessed by referencing the table below. ** Note that the Minor category incorporates a range to allow for exceptionally minor incidents that produce little or no damage, or cost to repair and that do not jeopardize safety (refer to definition in paragraph 4.3.1).

Powered Industrial Truck ProgramPoints Matrix System – Points System : 

Powered Industrial Truck ProgramPoints Matrix System – Points System Unreported incidents will be considered to have a severity potential of major and a control level of full. Recklessness - Up to two (2) additional points will be added to each value for reckless driving. Loss Severity Cost Reference – These are the cost guidelines for helping to determine the Loss Severity category. Final determination cannot be made until all facts of the incident are known and analyzed. See policy definitions for more details. $0 - $250 = Minor $251 - $2500 = Serious Over $2500 = Major

Powered Industrial Truck ProgramPoints Matrix System – Loss Severity Matrix : 

Powered Industrial Truck ProgramPoints Matrix System – Loss Severity Matrix

Powered Industrial Truck ProgramPoints Matrix System – Formal Conference Process : 

Powered Industrial Truck ProgramPoints Matrix System – Formal Conference Process After points are determined, the coordinator/manager of the associate involved in the incident will have a conference with the associate to explain the facts and outcome. This shall be documented on the standard conference/discipline form. The conference and documentation will consist of a brief review of the facts, the points determined and why, whether or not there is discipline involved, and what the outcome would be based on these or future incidents or points.

Powered Industrial Truck ProgramPoints Matrix System – Recordkeeping Process : 

Powered Industrial Truck ProgramPoints Matrix System – Recordkeeping Process The Compliance Manager - EHS will ensure the investigation gets properly closed out with the appropriate documentation attached. Any resulting PIT Matrix points are to be loaded into the appropriate PIT Matrix database for associate performance and recordkeeping purposes.

Powered Industrial Truck Program : 

Powered Industrial Truck Program Any Questions?