Top 10 Forklift Operator Safety Errors

Source from: http://materials-handling-eqp.com/safety-points/top-ten.htm

A recent study from the Center for Disease Control and Prevention (CDC) has shown the need to target safety training for younger workers. Inexperience and poor judgment skills place younger workers at risk for injury in the warehouse and the shop floor. If your training budget is limited, target the younger worker and then pair them up with more experienced workers.

10) " I don't need training, I'm experienced."

9) Failure to understand the capacity of the forklift and/or the weight of the load.

8) Failure to use proper personal lifting equipment and the failure to "tie off " the elevated worker.

7) Allowing "riders" on the lift truck.

6) Failure to keep a neat and obstruction free worksite "Housekeeping".

5) Wrong truck for the job/load.

4) Failure to lower the load when traveling or turning.

3) Failure to focus on the task at hand.

2) Failure to secure trailers when loading and unloading.

1) Failure to use the seat supplied with the forklift.

Scissor Lift Selection Guidelines

Source from: http://www.cisco-eagle.com/storage/lifts/Lifttables/scissor-lift-specification.htm

How can you specify the right lift table?

Start with thinking about your application. You'll need to have a know these factors:
The nature of your load

What are you lifting? Is it stable on a level surface? Will its size fit on a standard platform? You should understand:
...what the load consists of,
...the weights of the load components,
...the load's center of gravity (if it is not centered on the load, and the physical dimensions of the load). Off centered loads can reduce lift life dramatically if not properly handled. They put more demands on a structure than the simple lifting effort.

In all cases, assume the worst loading to be encountered with the lift in motion will be no more than half of the load on half of the platform. The critical information in these cases is where the center of gravity of the load will be in relation to the center of the platform (center of the supporting leg structure as described by the minimum platform size) when the unit is put in motion. Ideally, the center of gravity of a load should be placed in the center of the platform.

How do you intend to load your scissor lift?
How loads are transitioned onto and off of the lifts can be the critical factor in choosing an appropriate lift design. These movements determine the “edge loading” and/or “impact” that the structure must sustain and they may contribute to off centered load conditions during the lifting cycle.

The most common ways loads are transitioned on and off lifts are as follows:

ROLLED ON/ ROLLED OFF – with a wheeled vehicle or cart. Much is dependent on the type of rolling. If you are rolling a double axle cart or pallet jack with an even load onto the lift, the load is split 50/50 as the first axle rolls onto the table top. A single axle load, such as a large roll or a hand truck, places 100% of the load in one spot. A forklift radically splits the load, as much as 80 to 90% depending on the counterweight.

SLID ON/ SLID OFF – as in sheet feeding operations or conveyor operations.

The loading that requires the most judgment is the sliding load. When a load is sliding onto a conveyor, there is less of an impactfactor on the lift than a rolling axle would apply and the end conveyor roller (and platform edge) would never see the entire weight of the load because of deflection within the lift mechanism. In the case of supple incremental loads such as sliding sheets of paper onto a unit, the edge loading and impact are trivial and not a factor in selecting a lift. In the case of an ingot of lead being slid onto a platform, impact and edge loading requirements may be the deciding factor in lift selection. Therefore when considering the entire range of applications, judgments must be made about all of the following factors:

• Friction and impact
• Horizontal impact against stops
• Incremental layers (Each load increment must be considered as a percentage of both the total lifting capacity and the edge loadrating.)
• Footprint of the load increments relative to the overall platform size
• Footprint of the load increments relative to the minimum platform size
• Location of center of gravity of the load increments relative to the minimum platform size

PLACED ON/ PICKED OFF – as in stacking operations or crane loading. Some loading produces no edge loading requirements. Manually stacking layers of boxes would be a good example. This type of operation imposes negligible impact and no edge loading.Vertical loading with a crane or other overhead device is a good example of no edge loading, but the possibility of very highimpact to the lift. With a maximum capacity load, a lowering speed of 17 ft. per minute (fpm) will produce acceptable impact loadson opened lifts. Speeds in excess of 17 fpm may create damage to cylinder packings, hoses or structural members. Most industrialcranes are limited to speeds of 17 fpm or less, but applications with vacuum assist lifts, vertical conveyors or free fall applications,may produce destructive impacts. Obviously, the slower the rate of vertical impact the better.

Load Capacity and Side/End Loading Capacities

Load capacity is the amount of weight of an evenly balanced and centered load the lift can handle. Most loads should be lifted in this manner. Side/End capacity is the weight of the load over the edge when lift is in a fully raised position (it's often less than balanced load capacity).
What matters most with edge loading is what loads will pass over the edge of the lift in anything other than the fully loweredposition. In the fully lowered position the base frame, cylinders and leg assembly are fully supported and only the overhang of larger than minimum tops are subject to any bending forces.

A maximum capacity load may pass over the edge of a minimum size platform of a fully lowered lift without concerns about the edge loading of the lift in some situations. If the platform is larger than minimum, then proper supports must be placed under the platform to prevent any potential deflecting or bending. Typically these are rare applications, but if you are planning a lift project that includes them, contact us for assistance.


Vertical Travel

Determine the maximum raised height requirements to selectvertical travel model. Depending on your application, you'll be able to find a range in most standard lift models.

Platform Size
Standard platform sizes conform to standard base sizes. Platform sizes may be widened and/or lengthened up to an additional 24”. Side/End capacity is reduced by 2% per inch on oversized platforms. This is because the oversize platform overhang acts as a lever, increasing the forces incurred by the supporting leg assemblies for any given weight. Edge loading capacities are reduced or "derated" by the rule of thumb of 2% per inch for every inch that a platform is wider than minimum widthand for every inch that it is longer than minimum length.

EXAMPLE: an Advance Lifts P-2536 has a minimum platform size of 24" X 48". If it were equipped with a 48" x 54" platform, the unit would have the side edge load capacity reduced by (48" – 24") X 2% = 48%. The end of platform capacity rating would be reduced by (54"- 48") X 2% = 12%. There are many variables that go into the actual edge load capacities, but the 2% rule of thumb is a good general rule to use. Contact us for assistance if you are at all unsure.

Side Loading: Most scissor lift designs have much greater strength over the ends of the lifts than they have over the sides of the lifts. For this reason, loads should travel over the ends of lifts, parallel to the lift legs, rather than over the sides when the lifts are anything but fully closed.

Power Supply

When considering the duty requirements of the lift, it is necessary to think in terms of two systems, the lift mechanism and the power unit. It is necessary to know whether the lift application requires full stroke movement “up” or “down”, or will there be a series of incremental “jogs” in one of the directions. Specifically, we need the time intervals between operations and the direction and size of movement in each operational increment. Finally, the total number of cycles per hour, day and year should be calculated.

Applications with many short jogs in quick intervals may require the need of a special power unit. If the jogs are in a downwarddirection, the standard lowering solenoids are of a continuous duty type and nothing needs to be done. However, if the increments are in the “up” direction, the standard motor would not take the frequent motor starts without overheating. Therefore, the options to consider are going to an air operated unit, air over water unit, or a continuous running power unit. (See the power unit options for the specific table model that you are considering.)

Many lifts are hand or foot powered; you pump them to height. In Single phase 1 HP motor or three phase 1 1/2 HP motor isstandard as shown. Upon request motors can be interchanged.External/Remote power units are also available. See individual models for information. The motor you need will typically be matched with the capacity and force needs of the lift.


Controls
Hand held, push button up/down control are typical for most lifts. Optional foot operated controls, wall-mounted controls, and limit switches are alternate types of controls.

Frequency and Speed of Operation
Standard motor is intermittent duty rated. If usage is more than one full lift every four minutes or jogging action every 10 seconds, motor will overheat. Optional external power units available, as well as for increased lifting speed.

Lowered Height
For a lower than standard height, pit mounted units (ground level) are available. There are alternatives that can give you lifts with lowered heights as small as 2.9 inches (standard) and lower (custom). Pit mounted units must have beveled platform edges or electromechanical toe guards to conform to OSHA recommendations. Toe guards extend length and width of standard platform by 8”.


Mechanical factors

• Oversized Platforms: platforms can be widened and lengthened up to an additional 24”.
• Platforms with Beveled Edges: increases standard platform size 4” on each side.
• Pit Mounted Units: require electromechanical toe guards or a beveled edge platform.
• Lifting eyes are also required forinstallation.
• Portable (for moving empty lifts): 2 steel wheels – side or end mounted with wheeled dolly. For oversized platforms, please consult us.
• Turntables: custom sizes are available for rotating lifts.
• Conveyor Tops, Ball Transfer Platforms and special fixtures are also available to increase your lift's versatility.
• Optional Top Material: stainless steel skin and diamond plate.
• Transportable package available with two fixed and two swivel casters for moving loaded units.

Other Options to increase lift versatility

• Accordion (bellows) skirts: a safety option that safeguards the lifting arms, preventing human access during operation.
• Non-flammable and low temp. hydraulic fluid: in some settings, a good option to reduce chances of fire.
• Wash down units: good for food and other clean area applications.
• Adjustable flow control valve
• Fork pockets: makes it easy to move your lift with a fork truck.
  
  
  

6 Steps to conveyor system success

Source from: http://www.cisco-eagle.com/systems/conveyors/six_steps.htm

The Cisco-Eagle Process

High performance conveyor systems are a product of careful planning and execution. You need a managed project solution that removes doubt and masters details...

1: We start the process by learning your business
One size doesn't fit all, especially when it comes to conveyor systems. That's why the first thing we do is ask questions. Not just lots of them, but the right questions. We want to understand the nature of your needs so we can create the best possible solution. We'll learn your processes, identify the challenges, and help you turn them into competitive advantages.

2: We partner with you to develop a vision:
Meeting objectives through partnership is what we call it, and it's one of our core principles. The way we add value is a melding of what we've learned about you, and what we know about conveyors and integrated systems into a system that gives you a competitive advantage. Before there is a CAD drawing made or a file touched, we've got a clear picture of your vision for the project--what you want to accomplish, how you'd like to improve. We offer exclusive Consulting Services for in-depth analysis of your operations, as well.

3: Defining your solution options:
It's time for nuts and bolts. Determining what equipment you need and how it fits into your process is what we do. We've got the answers. We supply CAD drawings, specifications, parts lists, justifications, and more. It's all the what's, who's and how's involved in creating your world-class conveyor solution. It's a time where the plan is refined and all the details are in play.

4: Develop a schedule:
Especially when time is a critical factor--and it often is--the development of an accurate, timely schedule is crucial. Cisco-Eagle believes in defining that schedule accurately and quickly, then adhering to it tightly.

5: Implementation: Vision to Reality
It's time for the vision to become reality. Time for drawings and ideas to become rollers, belts, steel and bolts. World-class implementation involves much more than a precise, on-time installation. It involves debugging a system, training your people on its best operations, and making certain all the details are taken care of. We go to lengths to match your vision and improve your operations.

6: Post-Implementation:
We make your life easier after the system is installed. The way we do business is partner-oriented, meaning we aren't going anywhere once the hardware is installed, debugged and working. We offer maintenance services and training to our customers to make sure the ride is smooth.

Pallet Handling Conveyor Guide, Part 2: how to deal with pallets conveyed parallel to the rollers

Source from: http://www.cisco-eagle.com/systems/conveyors/conveyor-articles/pallet-conveyor-guide_2.htm

When conveying pallets on roller conveyors, you must take care to insure smooth movement on the rollers.

As discussed in Part I of this series, pallet runners should be conveyed perpendicular to the rollers. Pallet Orientation diagram (Pop-Up Information).

This is due reduced contact surface – it’s never desirable to place pallet runners parallel to the rollers. Admittedly, runners parallel is sometimes the only option available to you. If this is the case, some guidelines must be followed to insure the pallet will convey as smoothly as possible.

What if my runners are parallel, and I can't avoid it?

If runners-parallel is your only option, then the rollers should be set on very close centers to minimize potential conveying issues such as bouncing or rocking of pallet. When you convey a pallet with parallel runners, there should be a minimum of two rollers under each runner.

When conveying pallets with the runners parallel, a model 25-CREZD conveyor can be utilized quite successfully, as long as you observe the “two rollers per runner” rule. This conveyor can be specified with rollers on close centers. Both 3” and 5” roller centers are available.

If there are any questions or concerns as to whether a pallet will convey, it should be tested. Even though the test results may look good, actual conditions after final set-up in the plant may produce other issues.

Items such as broken boards, protruding nails, or old and worn out pallets, etc., could cause difficulties with the system.

If you have questions about this article, please contact us. If you want to inquire about a specific conveyor application, utilize our 24-hour response form or call customer service toll-free.

Pallet Conveyor: A load handling guide

..Source from: http://www.cisco-eagle.com/systems/conveyors/conveyor-articles/pallet-conveyor-guide.htm

When a pallet load application must be calculated, what questions should you ask?

(1) What's the pallet like?

This is a vital first point of information. What's the condition of the conveying surface (typically the bottom of the pallet)? Although you may think you're conveying a standard pallet, chances are you aren't. Don't believe it!

Many pallets appear to be similar, but they aren't. Careful attention must be paid to the pallet bottom deck. Will the pallet "runners" be parallel or perpendicular to the conveyor rollers?
Perpendicular is always best for conveying, and parallel should be avoided if possible. If your pallets are bi-directional (runners in both directions), it can be placed on the conveyor in either direction. Illustrations: Pallet Orientation (Pop-Up Information.)

Actually, most pallets are one of several variations of one-way-only stringers. Some standardization does occur in the pallet industry, and further standardization continues. But many pallet types are available and you must be aware of the type or types of pallets used on your conveyor. See some pallet examples (Pop-up information).

When purchasing pallets, cost is often a major concern. In this respect, we can't always expect to convey perfect pallets. But as your operation continues into the future, you should keep in mind that pallets purchased should be bought in mind with your conveyor system.

(2) What is the load weight?

Load weight is a fairly easy measure. It begins by selecting a conveyor with enough structural and drive capacity to handle your heaviest load. Typically, Cisco-Eagle or other conveyor vendors can help you configure the right conveyor for your load weight rather quickly.
If you have questions about this article, please contact us. If you want to inquire about a specific conveyor application, utilize our 24-hour response form or call customer service toll-free.

Material Handling Equipment can Reduce Forklift-Accident Related Injuries, Damage, and Costs

Source from: http://www.cisco-eagle.com/storage/Barriers/forklift_damage_prevention.htm


Eliminate lift truck damage with smart design, processes, and equipment

In a warehouse, collisions are costly--they can even be deadly.
How deadly? Lift truck accidents account for only about 1% of industrial accidents, but they produce a shocking 10% of the physical injuries. Lift trucks cause nearly 10,000 injuries a year. Typically, lift truck industries cost American companies over $135 million a year

1998 OSHA training standards attempt to rectify the disproportionate number of injuries and damage lift trucks cause with training. Cisco-Eagle agrees that better operator training will help, but there are other ways to reduce the potential for injuries, death, and damage.
Forklifts and foot traffic shouldn't mingle if they don't have to, and with the right warehouse design, equipment and processes, lighting, and environmental factors, you can significantly reduce the chances for a lift truck and a person to cross paths, or for a lift truck to run into a building column, a rack upright, equipment, or stored inventory.


Visibility & Noise: simple, but often overlooked

Warehouses that are too dark can cause injuries. This simple improvement can reduce the chances that an operator won't see people or objects in his traffic aisles. It seems simple, but the fact remains that a well-lit, clean warehouse environment within the acceptable level for general operations will reduce accidents. Consider enhancements items like Safety & Visibility Mirrors to improve floor visibility. They're inexpensive and can be mounted on ceilings, rack uprights, and other equipment to increase the chance that operators will see what's in their path--or around the other side of that row of Pallet Racks.

When forklifts enter and leave controlled areas, consider using Vinyl Strip Doors at door-points to control the environment while allowing easy access and good visibility. The forklift driver can see activities on the other side of the door, and people working on the other side can see the forklift coming.

A noisy facility increases danger, since workers have less of a chance of hearing the warning noise or a forklift's engine. Certainly, there are many operations that must take place in louder environments, but machinery can be muffled to be quieter, and processes to be certain people know a forklift is in operation can be created. Certain Conveyors and systems, such as EZ-Logic Accumulation Systems, operate much quieter than typical systems, for instance.


Create Traffic Islands and Traffic Aisles that separate people and industrial traffic

One of the easiest ways to prevent forklift collisions is by creating areas where forklifts are supposed to be--and where people aren't.

You can "hard" segment these aisles with hardware such as Steel Guard Rails. Tape markings also work, but they aren't obtrusive, keeping the lift truck on its side and the pedestrians on their side. It is hard to ignore bright-yellow, painted steel barriers. It's easy to ignore tape on the floor; one person, be he a forklift driver or a pedestrian, can easily miss those lines, or ignore them through inattention. While it isn't always possible to erect solid barriers, but when you can, it's much more effective.

Traffic Islands work even better. It's simply a matter of defining where forklifts aren't supposed to be and erecting barriers to stop them from being there. Barriers surrounding workstations, assembly points, in-plant offices, and other "people" areas are also recommended. Simply erecting inexpensive guardrails around a packing station, computer terminal, assembly station, or pick-point can instantly remove the potential for an errant lift truck colliding with personnel.


Reducing the Damage to Facilities, Equipment and Inventory

When a collision does occur, you can reduce the cost of that accident by utilizing material handling equipment to protect conveyors, rack uprights, workstations, and building columns.
Building columns are a problem since damaging them can be particularly expensive and dangerous. Utilizing Column Protectors enhances the visibility of the column and protects it in case of an accident. Column protectors disperse impact forces, protecting the lift truck as well as the building column.

Bollards can protect dock doors and other equipment by erecting a solid steel vertical barrier that protects a limited amount of space.


You should also protect your pallet racks. Damage to them can cause dangerous rack failure. Once again, simple Steel Guard Rails work great to run across the end of a row of racks and create a forklift barrier. For the upright columns themselves, using simple steel column protectors, or impact-absorbing rack column cushion guards can alleviate significant risks.

Training, design, equipment, and processes can all add up to helping you reduce the potential for serious injuries, protect your people, protect your buildings, lift drivers, equipment, and inventory. Want more information?
We'd be happy to discuss any of these methods with you, or to consult on your situation. Call Customer Service at 888-877-3861, or e-mail 24hours@cisco-eagle.com

What are the Typical Conveyor Hazard Points?

Source from: http://www.cisco-eagle.com/systems/conveyors/Conveyor-Safety/default.htm

According to FFVA Mutual Insurance Company, the top hazard points for conveyors are:
-Power transmissions
-Nip points
-Shear points
-Pinch points
-Spill points
-Areas under counterweights
-Transfer counterweights
-Transfer mechanisms
-Passage areas under conveyor
-Under special circumstances

How do you address these specific areas of concern?
Guards - Guards constitute one of the more common types of safety devices used for the protection of conveyors. Guards are coverings or barricades provided for safety purposes, such as gears, chains, or nip point guards.

Operation and Maintenance of Guards - It is the owner’s responsibility to see that his conveyor/conveyor system is never operated unless the guarding provided is in place. Also, that all guards be maintained in a safe condition and warning signs be kept in legible condition.

Power Transmission - The need for power transmission equipment is common to all types of powered conveyors involving items such as drives, gears, shafts, couplings, etc. Conveyor equipment must be carefully examined by the owners to assure that guarding is provided for all exposed power transmission equipment to protect their operators and others in the work area from accidental contact. Typical items to be observed include:

• Drive Guards for chain, v-belt, and gearing must be both practical and durable. Guards can be constructed of expanded metal, perforated or solid sheet metal, sire mesh, plastic, or other materials securely fastened to the conveyor framework.
• Coupling Guards must be provided around all direct connections between motors and gearboxes when couplings are used to connect shafts.
• Line Shaft Guards – Line shaft drives are still utilized on some types of conveyors to distribute power to the conveying mechanisms. Care should be taken in their location to prevent fingers, aprons, strings, or hair entering the line shaft guard.
• End Shaft Guards – The protruding ends of rotating shafts or keyed shafts are particularly dangerous. Plastic end caps can be used to enclose ends to prevent items from becoming caught in shafts.

Nip Points - “Nip Point” by definition is that point at which an element of the conveyor machinery moving in a line or rotating meets another element which is either rotating or moving in a line in such a manner that it is possible to nip, pinch, squeeze, or entrap objects coming in contact with one of the two elements.

Guarding Under Special Circumstances - All exposed, moving parts of a conveyor which present a hazard to employees at their workstation should be mechanically or electrically guarded or guarded by position or location. Ease of access or approach to conveying equipment is essential to assure proper and continuous usage. To assure an accessible and safe conveyor operation requires understanding between the design/manufacturer and safety training by the owner.

• Providing a safe working place involving conveyors also requires consideration of electrical controls. Companies that use powered conveyors should make reference to these sections of the Safety Standards regarding conveyor guarding using electrical controls and stop switches for safety.

According to FFVA Mutual, the majority of conveyor accidents are a direct result of an original design or implementation error. Conveyor safety is generally considered as a part of general safety. The practices described in this article may not give sufficient attention to the nuances required to provide a safe conveyor system. The responsibility for the planning, design and implementation of a conveyor system is often fragmented, lacking central responsibility. Attention to these details at the very beginning of the conveyor purchasing process can result in enhanced safety in your facility.

The importance of testing your product prior to conveyor specification

Source from: http://www.cisco-eagle.com/systems/conveyors/conveyor-articles/product-testing.htm

Testing can help specify the correct conveyor, and improve your conveyor project

The test loop features a variety of conveyors, diverters, transfers, and accessories needed for a proposed system. Product can be shipped in to Hytrol, tested, videoed, and the product returned to the customer.

One of the services Cisco-Eagle’s customers have at their disposal is Hytrol's sample product test program. Selected conveyor model sections are set up to run product samples in order to confirm conveying requirements. If you’re considering a system, testing is available.

How to test your conveyor application
To take advantage of this service, contact Cisco-Eagle and request a product test on Hytrol conveying equipment. We’ll take it from there. Hytrol will then set up a test run using either sample product from you, or simulated product based on size and weight. The information obtained from product tests can be invaluable in determining proper conveyor model selection, speeds, angles, and turning data. Your test product will be returned after it’s been run through the process.

The process includes documentation
Test results and recommendations will be documented and passed along in any format you request, including a custom video of the test. We can often take you to the testing facility to see the test run, if you want.

Virtually any product can be tested, regardless of size, shape, or weight.

Hytrol recently added the R&D test loop, an 80 ft. long x 33” BR (Between Rail) oval equipped with the latest roller conveyor models. The loop’s straight sections utilize ABEZ and ACC accumulating conveyor, with LRC and NSPEZC curve conveyors in the curves. A CT-200 chain transfer and a v-belt transfer can also be brought into the loop. This Test Loop can accommodate a wide variety of product tests as well as help us to check out new conveyor component parts.

A test run will ensure we have the right conveyor for the product, and help us avoid misapplication issues in the field. The product test service and video is absolutely free. For testing eligibility, contact Cisco-Eagle.

Vertical Reciprocating Conveyors - Vertical Lift - Mezzanine Lift System

Source from: http://www.cisco-eagle.com/systems/conveyors/Vertical%20Reciprocating%20Conveyors/Index.htm

A Vertical Reciprocating Conveyor (VRC) moves materials--in factories, warehouses, industrial plants, institutions--anywhere that products or supplies need to move from one level to another.

VRCs are not elevators. In fact, they have their own national code and are specifically exempt from the national elevator code. VRCs provide fast, efficient, convenient and safe access to or from mezzanines, balconies, basements, and between levels in multiple story buildings. They can be installed for through-floor, interior or exterior applications. The principle components of a VRC include guide columns, carriage and a mechanical or hydraulic actuating mechanism.

We offer the most complete line of VRCs from mechanical to hydraulic to fully automatic, customized systems for automated manufacturing and warehousing operations. VRCs are available in capacities from 10 lbs. to 100,000 lbs. with carriages from 30 x 30 in. to 30 x 30 ft., vertical heights from 4 ft. to over 200 ft. and travel speeds to 400 fpm. They meet or exceed ANSI and OSHA regulations.

Vertical Reciprocating Conveyor Benefits:
- Safely transport materials from one level to another.
- Install in new or existing building.
- Customized to your application needs.
- Less costly to install, operate and maintain than elevators.
- Safer than using a forklift to move materials between levels.
- Move loads of all shapes, sizes and weights from 10 lbs. to 100,000 lbs.
- Designed for mezzanines, through-floor and other multi-level applications.
- Install in unused elevator shafts.
- Proven in over 8,000 applications.
- Safe, efficient, convenient means of moving materials vertically.
- Meet or exceed ANSI B20.1 and OSHA regulations.
- Hydraulic, mechanical, fully automated systems.
- Equipped with advanced safety features to protect men and materials.
- Turnkey installation.
- Guaranteed code approval in every state.