Trg.

Pack on Safety in Material Handling

Be Clear Stay Clear
 Contents
1. Material handling
2. Sharing of incidences related to material handling
3. Briefing about ‘ Be clear, Stay clear’ methodology
4. Methodology for mitigating material handling related hazard
5. Hazards of material handling
6. Type of material handlings
7. Manual material handling – Hazards & precautions
8. Fork lift and mobile crane safety
9. Crane signaling
10. Safety in rigging (Slings , D shackle , hooks ,
Chain blocks etc)
9. Guideline on storage of materials
10. Common non compliances and Expectations

FY 17 Q2 Safety Campaign on Material Handling- 2

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 Material Handling

• Material handling is the function of safely moving the

right material to the right place in the right time, in
the right amount, in sequence, and in the right
condition to minimize production cost

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 BE CLEAR , STAY CLEAR
Identify examples where persons may be positioning
themselves in the “danger zone”
• What are the activities in your area that require
safe positioning or safe distances, for whom?
• Where are these safe positions and why, which
positions are unsafe and why?
• Do safe positions change during an operation,
from where to where?
• Do we currently understand safe positions /
walkways, where are we doing well, where have
we got things wrong?
• Can we improve? How, where, when?
 BE CLEAR , STAY CLEAR
Identify examples of misunderstandings and
miscommunications about intentions
• How do we communicate in activities that require safe positioning or safe
distances?
• Do we use particular signals or codes?
• Are we consistent in using these signals or codes?
• Do they refer to your formal training?
• Do communications include confirmation by particular signals or codes?
• Is there explicit confirmation or do we assume? Just simple eye contact or
even less (“we just understand each other)? How robust is our
communication?
• What could happen if communication is failing, if signals or codes are not
understood or misunderstood? What could be the consequences?
• Is someone in command, who? If not, why not; should someone be in
command?
 Factors affecting selection of Material Handling
Equipment
• Adaptability
• Flexibility
• Load capacity
• Speed
• Space requirement
• Supervision required
• Ease of maintenace
• Environment
• Cost
FY 17 Q2 Safety Campaign on Material Handling- 6
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 Importance of Material Handling
• Material handling accounts for 24% of all employees, 55% of the
space, and 87%of the production time.
•Cost of handling alone accounts for about 20-25% of total
manufacturing costs.
• Each part is handled 50-60 times while it passes through the
chain of manufacture.
• An average 59 tons of material are handled for every ton of
finished product.
•Material handling account for 21% of the permanent disabilities
and over 25% of the temporary disabilities.
•Modern handling methods have paid off in the reduction of
damage in parts and materials & improve safety

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 TSL India LTI Category Wise Year on Year
FY 14 Cumulative LTI's –TSL India FY 16 Cumulative LTI's –TSL India
FY 15 Cumulative LTI's –TSL India
Causes of LTI’s
Causes of LTI’s YTD Causes of LTI’s YTD
Slip/Trip/Fall 49
Slip/Trip/Fall 27 Slip/Trip/Fall, 17
Material Handling 25
Run Over / skidding 11 Hit/ Press by object 15 Hit/ Press/Cut by object 14
Hit or Press by Object 12 Material Handling 14 Material Handling 1
Dashing / Collision /Road 28
Material Falling 14 Material Falling 6
Structural Integrity 3
7 Skidding 1
Skidding
Derailment 1 Dashing/Collision 9
Electric Flash 9 Attack by Miscreants 3
8 Man-Machine Interface 7
Working at Height 4 Dashing/Collision
Electrical Flash/shock 2
Falling Object 1 Man-Machine Interface 3
Equipment / machinery damaged 3
Heat /Burn 3
Fire/Explosion/Excavation 11
Mechanical Failure of the 2 Hydraulic/Pneumatic,
Crane boom Explosion 5
Lifting tools tackles 1
Hydraulic/Pneumatic, 1
Collapse of material 1 Fall from height 2
Hydraulic/Pneumatic 2 Pressure Vesel rupture 1
Total 67
Gas Leakage/Energy Isolation 2 Run Over 2
Medical Ailment 1 Total 97
Total 164

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 Material Handling Hazards
• Workers being struck by or crushed
by falling loads due to improper
rigging and sling failures
• Workers being electrocuted due to
power line contact
• Workers being struck by falling
materials which are improperly
stored
• Being caught in pinch points
• Workers slipping, tripping, and
falling

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 Reasons for incidents
• Failure of material handling equipments
• Unsafe position of the persons
• Improper method of handling
• Swing of the materials
• Unstable / insecure material
• Improper communication

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 Objectives

• After this module you should be able to

– identify the most common material handling
hazards
– take the steps necessary to avoid those hazards

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Types of material handling

• Handling Materials manually

• Using moving machinery like
Þ Fork Lift Trucks
Þ Conveyors
Þ Cranes and Derricks
Þ Tower Cranes
Þ Overhead and Gantry Cranes
Þ Mobile Cranes
Þ Passenger Lifts and Material Hoists

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 Handling Materials manually consists of the
following activities
 Push
Pull
Lift
Lower
Hold and
Carry

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Safe lifting postures

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 The Forces Involved

When you add in the 105 pounds

of the average human upper torso,
you see that lifting a ten pound
object actually puts 1,150 pounds
of pressure on the lower back.

Given these figures, it is easy to

see how repetitive lifting and
bending can quickly cause back
problems. Even leaning forward
while sitting at a desk or table can
eventually lead to back related
problems.

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 Risky Moves
Certain actions are more likely to cause back
injuries than others. Anytime you find yourself
doing one of these things, you should think:
DANGER! My back is at risk!

Heavy lifting...especially repetitive

lifting over a long period of time

Twisting at the waist while lifting or

holding a heavy load. (This frequently
happens when using a shovel.)

Reaching and lifting...over your head,

across a table, or out the back of a truck.

FY 17 Q2 Safety Campaign on Material Handling- 16

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 More Risky Moves

Lifting or carrying objects with

awkward or odd shapes

Working in awkward, uncomfortable

positions...gardening, kneeling, tasks that
require you to bend over for long periods of time...

.
FY 17 Q2 Safety Campaign on Material Handling- 17
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 Contributing Factors to Handling/Lifting
Injuries

Overdoing it…
• Don’t be afraid to say, “This is too heavy for
me to lift alone.”

•It’s important to recognize your physical

limitations and abilities. Many people have
injured their backs because they were afraid to
ask for help.
FY 17 Q2 Safety Campaign on Material Handling- 18
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 Preventing Back Injuries
The best way to prevent back injuries is to develop
habits that reduce the strain placed on the back. There
are some basic things you can do to help.

Avoid Lifting and Bending Whenever You Can!

Place objects up off the floor. If you can set
Something down on a table or other elevated
surface instead of on the floor, do it so you won't
have to reach down to pick it up again.

Raise / lower shelves. The best zone for lifting is

between your shoulders and your waist. Put heavier
objects on shelves at waist level, lighter objects on
lower or higher shelves.

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FY 17 Q2 Safety Campaign on Material Handling- 20
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Material handling via machine
Various type of machine used for material handling

Forklift Crane Tower Crane Conveyer

Overhead and Mobile Crane Passenger

Gantry Cranes Lifts and
Material
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Hoists 21
Hazard during Material Handling via machine
1. Capsizing/Toppling of Crane

2. Collapse/Failure of Boom

3. Failure of sling, rope, chain etc

4. Struck by the moving machine

5. Object falling from height

6. Swinging & hitting of load to adjacent

structure

7. Finger entanglement with rope,

chain, sling etc while lifting

8. Electrocutions

9. Storm/ heavy wind

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Reasons for incident during material handling

1.Failure of material handling equipment

2.Unsafe position of the persons
3.Improper method of handling
4.Swing of the materials
5.Unstable/ insecure of materials
6.Improper communication

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 Requirement of material handling

There are mainly three requirement for safe material

handling activity

1. Load security
2. Equipment competency
3. Crew competency

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 Failure modes

• Uncontrolled fall
• Contact with falling object
• Contact with machine or hand held tools
• Contact with vehicle
• Contact with an object
• Contact with hazardous substance

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 Operating a Forklift Safely
•Keep arms and legs inside the truck.
• Handle only stable loads.
• Keep speed low - you may have to stop.
• Be careful when making sharp turns with
a raised load.
• If a load blocks your view, travel in
reverse.
• No riders, unless there’s an approved seat.
• Don’t drive with forks raised.
• Wear safety belts or other restraint
devices.

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Fork Lift Trucks
•No attachment shall be incorporated, without taking necessary precautions

•Fork-lift should be stable

•Fork must be kept 15-20 cm above floor

•If Load is obstructing, drive in reverse gear

•Drive at a slow and safe speed, avoid sudden start and stop

•Avoid driving over any object lying of the path

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Fork Lift Trucks
Be provided with Overhead Protection

Must not

UNSAFE

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Must be fully inside
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FY 17 Q2 Safety Campaign on Material Handling- 30
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Mobile Crane : Mobile crane is a cable – controlled crane mounted on
crawlers or rubber-tired carriers or a hydraulic- powered crane with a
telescoping boom mounted on truck-type carrier or as a self- propelled
models

All mobile crane must have :

a) Load chart
b) Angle indicator
c) Level indicator
d) Load moment indicator
e) Boom back stop ( In case of lattice boom)
f) Sling safety / Safety latches in sheave block or hooks
g) Anti two - blocking devices ( Over hoist protection limit switches)

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 Cranes and Derricks
SAFETY DEVICES

•HOOK LATCH
•BOOM LIMIT SWITCH
•BOOM ANGLE INDICATOR
•OVER HOIST LIMIT SWITCH Over Hoist Limit switch

Boom Limit Switch

Hook Latch

Boom angle indicator

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 Unsafe Practices Remedial Measures

Use Hook latch to

avoid slings from
getting removed
from hook
Non-Use of Hook Latch

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When traveling up a gradient, the When traveling down a gradient,
load shall be derricked out the load shall be derricked into

Position shall be corrected on reaching the level ground

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 ALWAYS OBEY THE NEVERS!
• Never allow more than one person to control
a lift or give signals.
• Never raise the load more than necessary.
• Never leave the load suspended in the air.
• Never work under a suspended load.

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 Center of Gravity
 It is always important to rig the load so that it is stable. Load’s CG must be directly
under the main hook & below the lowest sling attachment point before the load is
lifted.
 Determine center of gravity.
 Place the hook directly above the center of gravity.
 Rig load with pick points above center of gravity.
 If pic point can not be placed above center of gravity, keep sling angle as great as
possible.

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Minimum clearance between the electric lines and any part of crane

3 meters for ≤ 50kV

3 meters plus 1 cm for each 1 kV over 50 kV, for > 50kV

In transit with no load and boom lowered

1.2 meters for ≤ 50kV

3 meters for > 50kV and ≤ 345 kV

4.8 meters for > 345kV and ≤ 750

kV

A person shall be designated to observe clearance of the equipment

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 Thank you

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