Genrec - HSEC Risk Assessment (QD 0159 / REV 3 )

Site: Wadeville Genrec Workshop

Section:

Assessment Number GE 22

Task assessed: FORK LIFT OPERATOR

Date: 12 - 07 - 2006

ASSESSMENT GROUP
Name Title Signature Date
Works manager
Works manager
K Burger Safety officer
Safety rep
Supervisor/Foreman

APPROVAL – (Applicable - General Management)

Task specific risk rating: 17 LOW

APPROVAL – (Applicable - General Management)

Name: Title:

Date: Signature: ………………………………………..

H & S COMMITTEE

Name: ………………………………………………….(Chairman) Title:…………………….………………..

Date:………………………………………………………….. Signature: ………….……………………

Risk rating criteria QD 0159 / REV 3
CURRENT CURRENT

1. Frequency of Activity 2. People involved

1 = Once a day or more 1=1
2 = Once a month or more 2 = 2-4
3 = Once a year or more 3 = 5+

CURRENT CURRENT

3. Training in place 4. Safe Work Procedures

1 = Theoretical and Practical 1 = In order
2 = Experienced 2 = To be updated
3 = No training 3 = None available

HISTORY HISTORY

5. Incident History 6. Property Damage

1 = One 1= < R10 000
2 = Less than three 2 = R10 000 - R100 000
3 = More than three 3 = > R100 000

HISTORY CURRENT

7. Severity of history injuries 8. Probability of injury re-occurrence

1 = None / first aid case 1 = None
2 = NDI 2 = Medium
3 = DI / Fatality 3 = High

HISTORY HISTORY

9. Near Miss History 10. Pollution

1 = One 1 = None
2 = Less than three 2 = One Case
3 = More than three 3 = More than one case

CURRENT

11. Work Environment

1= Safe
2= Hazardous
3= Very Dangerous

<17 = Low rating - Review existing control measures to assure relevant effectiveness

18-22 = Medium rating - Review existing control measures. Confirm that task Specific job
procedures is in place and that the worker is competent to conduct the job in a safe manner.
Implement “actions needed to eliminate/lower/control risk.

23 + = High rating - Refer task to Senior Management and involve your Safety department.
Initiate a formal training session to all personnel involved with this task (risk assessment)
GE 22 QD 0159 / REV 3
Activity Fork Risk rating of all activities listed ( 2 ) Total Rating
lift 1 2 3 4 5 6 7 8 9 10 11

1.FORK LIFT 1 2 2 2 1 1 1 2 1 1 2 16

2.SUPERVISION 1 3 2 2 1 1 1 2 1 1 2 17

3.EMERGENCY 2 3 2 2 1 1 1 2 1 1 2 18

4.MANHANDLING STEEL AND EQUIPMENT 1 2 2 2 1 1 1 2 1 1 2 16

Risk Rating 17
GE 22 QD 0159 / REV 3
1- Activitie 2- Risk Rating Item No 3- Potential current Risks Item No 4- Actions needed to eliminate / 5- Responsible 6- Date 7- SIGNATURE
Forklift Driver lower / control risk person completed

SUPERVISOR TO ENSURE THAT

IN-COMPETENT DRIVER OPERATING FORK LIFT COULD
OPERATOR IS FULLY COMPETENT AND
1.FORKLIFT 16 1.1 RESULT IN DAMAGE OF EQUIPMENT,MATERIAL AND 1.1.1
CERTIFICATED TO OPERATE FORK LIFT
CAUSE SERIOUS INJURY TO EMPLOYEE
IN ALL ASPECTS OF HIS TASKS.

OPERATOR TO BE APPOINTED IN
1.1.2
WRITING TO OPERATE FORK LIFT.

RE-EVALUATION OF DRIVER
COMPETENCY TO BE DONE
1.1.3
REGULARLY AS DECIDED BY SAFETY
DEPARTMENT.

IF AT ANY TIME AN INCIDENT

OCCURES RELATED TO THE ABILITY
1.1.4
OF THE OPERATOR A RE -
EVALUATION MUST BE DONE.

EYE TESTS MUST BE CARRIED OUT BY

A SPECIALIZED PERSON ON A YEARLY
1.1.5
BASIS TO ENSURE CLEAR VISION OF
THE OPERATOR.

IF AT ANY TIME THE OPERATOR IS

ISSUED WITH PRESCRIPTION
1.1.6
SPECTACLES A RE-EVALUTION IS
REQUIRED.

DAILY PRE-USE INSPECTION TO BE

OPERATION OF SUB STANDARD OR DEFECTIVE
1.2 1.2.1 CARRIED OUT PRIOR TO OPERATION
EQUIPMENT COULD RESULT IN DAMAGE AND INJURY
OF FORK LIFT.

ALL DEFECTS TO BE LOGGED AND

1.2.2
REPORTED TO SUPERVISOR.
GE 22 QD 0159 / REV 3
1- Activitie 2- Risk Rating Item No 3- Potential current Risks Item No 4- Actions needed to eliminate / 5- Responsible 6- Date 7- SIGNATURE
Forklift Driver lower / control risk person completed

SUB STANDARD OR DEFECTIVE

1.2.3 EQUIPMENT TO BE PLACED UNDER
QUARENTINE.

FORK LIFT TO BE LOGGED IN

1.2.4
REGISTER.

IF DEFECTS ON FORK LIFT IS

REPAIRED ,THIS MUST BE LOGGED
1.2.5 AND SIGNED OFF AS REPAIRED AND
SAFE TO OPERATE BY COMPETENT
PERSON.

MAINTENANCE PLAN TO BE IN ORDER

1.2.6
AND ADHERED TO AT ALL TIMES.

FORK LIFT CAN TIP AND CAUSE INJURY IF OVERLOADED / MAXIMUM ALLOWABLE LOAD TO BE
1.3 1.3.1
LOAD IS NOT SECURE / FORKS NOT CORRECTLY LIFTED CLEARLY DEMARCATED ON FORK LIFT.

SUPERVISOR AND OPERATOR TO

1.3.2 ENSURE THAT MAXIMUM ALLOWABLE
LOAD IS NOT EXCEEDED

OPERATOR TO ENSURE LOAD IS

1.3.3
SECURE BEFORE TRAVELLING

ENSURE FORK LIFT IS PARKED ON

1.3.4
SOLID ,STABLE GROUND.

OPERATOR TO ENSURE THAT FORKS

1.3.5 ARE WELL CLEAR FROM THE GROUND
WHEN TRAVELLING.

SUPERVISOR AND OPERATOR TO

1.4 INJURY COULD RESULT IF PPE IS NOT WORN. 1.4.1 ENSURE THAT PPE IS WORN AT ALL
TIMES.
GE 22 QD 0159 / REV 3
1- Activitie 2- Risk Rating Item No 3- Potential current Risks Item No 4- Actions needed to eliminate / 5- Responsible 6- Date 7- SIGNATURE
Forklift Driver lower / control risk person completed

ONLY THE APPOINTED FORK LIFT

NON APPOINTED AND INCOMPETENT PERSON
OPERATOR MAY RECEIVE OR BE IN
1.5 OPERATING FORK LIFT COULD RESULT IN SERIOUS 1.5.1
POSESSION OF THE IGNITION KEYS OF
INJURY OR DAMAGE TO EQUIPMENT
THE FORK LIFT

THE SUPERVISOR MUST COLLECT THE

KEYS AT THE END OF THE SHIFT FROM
THE OPERATOR WHEREBY THE NEXT
APPOINTED PERSON TO COLLECT THE
KEYS FOR THE MOBILE LIFT MUST
1.5.2
SIGN AS ACCEPTANCE OF THE
KEYS.AT THE END OF HIS SHIFT THE
KEY WILL BE HANDED BACK TO THE
SUPERVISOR AND SIGNED OFF.THIS IS
PART OF THE LOCK-OUT SYSTEM.

SUPERVISOR MUST KEEP KEYS IN A

SAFE PLACE THAT IS ONLY
1.5.3 ACCESSIBLE BY HIM AND THE
SUPERVISOR ON THE FOLLOWING
SHIFT.

SUPERVISOR AND OPERATOR TO

SLINGS FASTENED INCORRECTLY RESULTING IN INIJURY
1.6 1.6.1 ENSURE THAT LOAD IS SECURE AND
AND DAMAGE
SLINGS ARE HOOKED CORRECTLY.

IF AT ANY TIME THE SUPERVISOR OR

ANY OTHER EMPLOYEE SUSPECTS
OPERATOR OPERATING MOBILE LIFT WHILST THAT THE OPERATOR IS INTOXICATED
1.7 1.7.1
INTOXICATED COULD CAUSE INJURY AND DAMAGE IT IS THE DUTY OF THE SUPERVISOR
NOT TO HAND OVER THE KEYS AT THE
BIGGING OF THE SHIFT.

IF AT ANY TIME THE SUPERVISOR

SUSPECTS THAT THE OPERATOR IS
INTOXICATED OR UNDER THE
INFLUENCE OF ILLEGAL
1.7.2
SUBSTANCES ,HE MUST IMMEDIATELY
STOP THE OPERATION AND FOLLOW
COMPANY DISCAPLINARY
PROCEDURE.
GE 22 QD 0159 / REV 3
1- Activitie 2- Risk Rating Item No 3- Potential current Risks Item No 4- Actions needed to eliminate / 5- Responsible 6- Date 7- SIGNATURE
Forklift Driver lower / control risk person completed

IF THE OPERATOR IS ON PRESCRIBED

MEDICATION FROM A MEDICAL
PRACTITIONER AND THE OPERATOR
REALISES THAT THE MEDICATION IS
1.7.3
CAUSING ANY SIDE EFFECTS THAT
COULD EFFECT HIS JUDGEMENT HE
MUST NOTIFY HIS SUPERVISOR
IMMEDIATLEY

OPERATOR MAY NOT GIVE ANOTHER

1.8 PERSON FALLING OFF LOAD / FORKLIFT. 1.8.1
PERSON A LIFT ON THE FORK LIFT.

GAS CYLINDER ON FORK LIFT CAN CAUSE GAS BUILUP OPERATOR TO ENSURE THAT GAS IS
1.9 AND THEREFORE EXPLODE AND CAUSE DAMAGE AND 1.9.1 CLOSED ONCE FORK LIFT IS NOT IN
INJURY USE.

OVER SPEEDING WITH FORKLIFT COULD CAUSE INJURY OPERATOR MAY NOT OVERSPEED
1.TEN 1.10.1
AND DAMAGE FORKLIFT.

FORKLIFT MAY NOT PARK AROUND A

FORK LIFT PARKED IN BLINDSPOT AREA / AROUND CORNER WHERE OTHER VEHICLES
1.11 1.11.1
CORNER. COULD COLLIDE INTO THE BACK OF
IT.

IF FORKLIFT IS PARKED AROUND A

CORNER / BEND DUE TO BREAKDOWN
OR ANY OTHER EMERGENCY, THE
OPERATOR MUST PLACE WARNING
1.11.2
TRI-ANGLE A SAFE DISTANCE BEHIND
FORKLIFT TO WARN OTHER MOVING
VEHICLES OF HIS PRESENCE AROUND
CORNER.

OPERATOR MUST NOT DELAY HIS

STAY AROUND A CORNER AND
1.11.3
ENSURE TO MOVE TO A SAFER
PARKING AREA AS SOON AS POSSIBLE
GE 22 QD 0159 / REV 3
1- Activitie 2- Risk Rating Item No 3- Potential current Risks Item No 4- Actions needed to eliminate / 5- Responsible 6- Date 7- SIGNATURE
Forklift Driver lower / control risk person completed

FORKLIFT TO BE PARKED AT A SAFE

1.11.4
OR VISIBLE AREA WHEN NOT IN USE.

REFLECTIVE TAPE TO BE INSTALLED

ON ALL SIDES OF FORKLIFT AS WELL
AS THE OUTER SIDES OF THE FORKS
1.11.5
TO ACCOMMODATE FOR EASIER
NIGHT VISION BY OTHER VEHICLES
WHEN NOT IN MOTION.

FORKS TO BE LOWERED TO THE

1.11.6
GROUND WHEN FORKLIFT IS PARKED.

OPERATOR TO ENSURE THAT

REVERSE HOOTER IS IN WORKING
EMPLOYEE NOT AWARE OF FORKLIFT COULD CAUSE
1.12 1.12.1 ORDER SO THAT EMPLOYEES COULD
INJURY AND DAMAGE
BE NOTIFIED OF ITS DIRECTION OF
TRAVELL.

IF OPERATOR IS TRAVELLING IINTO A

BEND / BLINDSPOT AREA OR CORNER
1.12.2 HE MUST SLOW DOWN AND USE HIS
HORN TO NOTIFY TRAFFIC /
PEDESTRIANS.

ALL ACTIVITIES TO BE SUPERVISED BY

2.SUPERVISION 17 2.1 INSUFFICIENT SUPERVISION 2.1.1 COMPETENT APPOINTED
SUPERVISORS.

SUPERVISORS TO ENFORCE SAFETY

2.1.2 RULES AND ENSURE COMPLETE
COMPLIANCE.
GE 22 QD 0159 / REV 3
1- Activitie 2- Risk Rating Item No 3- Potential current Risks Item No 4- Actions needed to eliminate / 5- Responsible 6- Date 7- SIGNATURE
Forklift Driver lower / control risk person completed

ALL EMPLOYEES TO BE TRAINED IN

THE WORKSHOP EMERGENCY
PROCEDURES AND EMPLOYEES TO
CONFUSION DURING EMERGENCIES DUE TO
3.EMERGENCY 18 3.1 3.1.1 SIGN AS PROOF OF
INSUFFICIENT TRAINING OF EMPLOYEES
TRAINING.EMPLOYEES TO BE
RETRAINED ON AN ANNUAL BASIS AS
REFRESHER TRAINING.

ALL EMPLOYEES TO BE TRAINED TO

3.1.2 RECOGNISE THE SOUND OF THE
EMERGENCY ALARM.

ALL EMERGENCY CO-ORDINATORS TO

BE TRAINED AND FOUND
3.2 INCOMPETENT EMERGENCY CO-ORDINATORS 3.2.1
COMPETENT.SAFETY DEPARTMENT TO
FOLLOW UP ON COMPETENCY.

ALL EMPLOYEES TO FAMILIARISE

THEMSELVES WITH THE EMERGENCY
3.2.2 CO-ORDINATOR IN THEIR RESPECTIVE
AREAS AS WELL AS THE LOCATION OF
THE EMERGENCY ASSEMBLY POINTS.

SUFFICIENT FIRST AIDERS SHOULD BE

3.3 INSUFFICIENT FIRST AIDERS 3.3.1 APPOINTED AND ALLOCATED TO FIRST
AID BOXES IN THE WORKSHOP.

ALL EMPLOYEES TO KNOW THE

RESPECTIVE FIRST AIDER IN HIS AREA
3.3.2
AND THE LOCATION OF THE FIRST AID
BOX.

RESPONSIBLE FIRST AIDER TO HAVE A

CHECK LIST OF CONTENTS IN HIS
FIRST AID BOX AND THIS MUST BE
3.4 INSUFFICIENT CONTENTS IN FIRST AID BOXES 3.4.1
CHECKED ON A DAILY BASIS AND
LOGGED ON THE CHECKLIST AND
SIGNED.
GE 22 QD 0159 / REV 3
1- Activitie 2- Risk Rating Item No 3- Potential current Risks Item No 4- Actions needed to eliminate / 5- Responsible 6- Date 7- SIGNATURE
Forklift Driver lower / control risk person completed

IF CONTENTS IS REMOVED FROM

FIRST AID BOX A SHORT NOTE MUST
BE MADE DESCRIBING REASON FOR
REMOVAL OF ITEM AND HANDED IN
3.4.2 WHEN ITEM IS RE-ISSUED OR RE-
ORDERED.THIS COULD ASSIST THE
SUPERVISOR AND SAFETY
DEPARTMENT AND MINIMISE UN-
REPORTED INJURIES.

NO EMPLOYEE IS TO REMOVE ANY

ITEM FROM THE FIRST AID BOX
3.4.3
WITHOUT THE AUTHORIZATION OF
THE FIRST AIDER OR SUPERVISOR.

SUPERVISOR AND EMPLOYEE TO

INCORRECT/LACK OF PERSONAL PROTECTIVE ENSURE THAT CORRECT PERSONAL
4.MANHANDLING STEEL AND EQUIPMENT 16 4.1 4.1.1
EQUIPMENT (P.P.E) BEING USED COULD CAUSE INJURY. PROTECTIVE EQUIPMENT FOR HIS
TASK IS BEING USED AT ALL TIMES.

INJURIES COULD BE SUSTAINED IF EMPLOYEES ATTEMPT HEAVEY OBJECTS TO BE MOVED OR

4.2 4.2.1
TO HANDLE HEAVEY OBJECTS HANDLED BY CRANE OR TROLLEY.

CORRECT LIFTING TECHNIQUES TO BE

4.2.2 APPLIED WHEN LIFTING OR MOVING
EQUIPMENT.

IF CRANE REQUIRED IT MUST BE

4.2.3 OPERATED BY AN APPOINTED CRANE
OPERATOR.
GE 22 QD 0159 / REV 3
1- Activitie 2- Risk Rating Item No 3- Potential current Risks Item No 4- Actions needed to eliminate / 5- Responsible 6- Date 7- SIGNATURE
Forklift Driver lower / control risk person completed
GE 22 QD 0159 / REV 3
1- Activitie 2- Risk Rating Item No 3- Potential current Risks Item No 4- Actions needed to eliminate / 5- Responsible 6- Date 7- SIGNATURE
Forklift Driver lower / control risk person completed