In the Summer 2011 IVES Update Newsletter we address operator re-training/recertification, a technical clarification regarding distance off ratios, a lesson plan for operator refresher training, some fun safety quotes, a boomlift What’s Wrong With This? photo, and an answer to Last Month’s photo, a forklift Incident Report, and an Ask Bob regarding using two forklifts for one lift.
So Many “REs” – So Little Time
If you have been training equipment operators for longer than three years, you have probably come across the question of, when is it time to ‘RE’…something them? Many trainers struggle with which word to put behind the ‘RE.’ Should it be certify, train, qualify, fresh, evaluate, assess or something else? If this sounds familiar to you, then you could probably use a bit of a RE-fresher yourself and here it is.
Regardless of regulatory requirements, IVES maintains that it just makes good sense to regularly review the knowledge and skill of operators of all types of equipment, but here are the requirements for operators of forklifts, aerial lifts, loaders and mobile cranes.
Forklifts
There are specific requirements in Canada and the US that call for operators to be re-evaluated at regular intervals after initial training/qualification. In the US, federal OSHA regulations mandate a time interval of three years. In Canada, CSA standards B335-94 and B335-04 address operator training and re-training. CSA B335-94 calls for operator knowledge and skill to be evaluated every two years while CSA B335-04 sets a time interval of 18 months for a skills evaluation only, and 36 months for both knowledge and skill. Canadians must check their provincial OHS regulations to find out which of these standards, if any, they must comply with.
If the re-evaluation of a forklift operator reveals any shortcomings in their abilities, then re-training that addresses those shortcomings must take place before another evaluation is performed. Additional training and evaluation must also take place whenever the operator’s job, environment or equipment changes significantly, or when an operator demonstrates that they need more training like when they are observed driving poorly, causing damage or having near miss incidents.
Aerial Lifts
Operator re-training is required on boomlifts and scissor lifts but when it is required is up to the employer or equipment user based on their observation of the operator.
There is no set time interval. The referenced standards that apply here are:
- In the USA – ANSI/SIA A92.5 for boomlifts and ANSI/SIA A92.6 for scissor lifts.
- In Canada – CSA B354.4 for boomlifts and CSA B354.2 for scissor lifts. Take note that some provincial regulatory agencies in Canada recognize either ANSI or CSA standards.
ANSI and CSA standards also require operators to receive familiarization. Familiarization must take place with aerial lift operators whenever they are directed to use an aerial lift that is significantly different that than any they have used in the past. This familiarization must ensure that the operator:
(1) Knows where the weather-resistant compartment for manual(s) storage is located.
(2) Knows the operating and maintenance manuals supplied by the manufacturer are stored in the weather-resistant compartment and is familiar with them.
(3) Understands all control functions, placards and warnings.
(4) Is aware of and understands all safety devices specific to the model of aerial platform being used.
An important thing to remember about the items above, particularly items 3 and 4 that mention “understanding” on the part of the operator is that understanding is best assessed through demonstration.
Earth Movers
There are very few specific regulations or standards that address the operator training or re-training requirements related to machinery like loaders and excavators commonly called, dirt equipment. In situations where there are no specific applicable regulations, general regulations may be referenced. This is why all regulatory agencies usually include general duty wording within their regulations. General duty requirements put the responsibility of providing a safe and healthful workplace squarely on to employers, stating that they must make every reasonable effort to identify and address safety hazards. Since putting an untrained operator at the controls of 30,000 lb. loader (for example) could be considered hazardous, employers are expected to foresee this and take steps to eliminate or manage the risk. A responsible course of action to take here is to train (or re-train) operators the same way that they would be before using any other type of powered industrial mobile equipment.
Mobile Cranes
The operator training requirements for mobile cranes have changed a lot over the past few years in Canada and the US. In the Fall of 2010, OSHA implemented a requirement for crane operator certification by an “accredited certifying entity” that applies in every state in the USA in addition to the 18 states (and 6 cities) that already had such requirements for several years. Several provinces in Canada consider crane operation to be a trade requiring operators to apprentice for several years before acquiring a “red seal” trade qualification. Operators in Canada can also be trained and certified in accordance with provincial standards that, in most cases, involve certification by an approved or officially recognized testing body.
Across the US and most of Canada, crane operator recertification by an approved certifying body is required every five years and operators must keep a log of their operating hours.
In summary, it really doesn’t matter what you call follow-up operator training and evaluating as long as it gets done on a regular basis, and there’s documentation to prove it. Initial operator training is required on every type of powered industrial equipment. Some of these requirements are direct regulatory requirements and others are industry standards incorporated by referenced. Although direct requirements for dirt equipment operators are few, training and re-training requirements are covered through less direct, general duty regulations.
Rob Vetter
Director of Training
IVES Training Group
Technical Clarification – Distance Off
Recently, there have been some questions over information in some of our Operator Reference Manuals (ORM) regarding the distance off mobile equipment should remain from the edge of a trench. In our current Mobile Crane ORM and some older versions (pre February 2009) of our Loader Backhoe ORM, a distance off ratio of 1:1 (one foot back from the edge for every 1 foot of trench depth) is listed for an unoccupied trench and 1.5:1 for an occupied trench. Please remember that this ratio is not a regulation, it is a safe guideline to use. There are specific regulations that address mobile equipment near trenches but they do not list any distance off ratios, they just have wording that generally states mobile equipment should be kept as far as possible from the edges of trenches. We hope this clears things up a bit and apologize for any confusion.
What’s the Plan?
Sooner or later, you’re probably going to have to do some refresher training and evaluating with operators you have previously trained. In keeping with the theme of the feature article “So many RE’s, So Little Time,” we thought you might find it useful to have a solid guideline to use when that happens so we have provided you with an abbreviated lesson plan here that you can adapt to different types of equipment.
1 – Pre-program preparation (20 minutes)
1.1 – Arrive early and ensure that all required materials are present and in working order.
1.2 – Write title of program and your name on board/flip chart or whichever type of media you are using.
1.3 – Place training materials (pen, highlighter, name tent, etc.) at each place where you want the trainees to sit.
2 – When the operators arrive (5 minutes)
2.1 – Welcome the operators as they arrive and have them sign a roster sheet (12 max. for forklift, 6 for aerial).
2.2 – Introduce yourself and explain the purpose of the program.
2.3 – Collect roster sheet.
2.4 – Point out emergency exits, evacuation/emergency procedures, telephones, restrooms, etc.
2.5 – Discuss class content in detail.
2.5.1 – Explain each phase of the program and what will be expected of the operators.
3 – Classroom Theory Training (40 minutes)
3.1 – Distribute Operator Re-certification Study Guide*
3.2 – Conduct a page by page review while the operators fill in the answers.
* An abbreviated version of the Operator Reference Manual provided by IVES. Available for forklifts, boomlifts and scissor lifts only.
4 – Written Theory Test (15 minutes)
4.1 – Issue Operator Re-certification Theory Test to each operator.
4.2 – Collect tests and grade them.
4.3 – Return graded tests to operators and review.
4.4 – Collect theory tests and file them.
5 – End Classroom Portion
5.1 – Thank operators for their participation. Inform operators that classroom portion of program is over and that you will be moving on to practical portion.
Total Classroom Time – Approximately 60 minutes
6 – Refresher Practical Training (30 minutes)
6.1 – Explain why you are at the machine and what you intend to do.
6.2 – Review pre-use inspection.*
6.2.1 – Select different operators to deliver different parts of the inspection.
6.2.2 – Ask questions of ALL of the operators as you move through the inspection (eg – What is this called? How much can this machine lift? Where are the manuals kept? etc.)
6.3 – Review safe operating procedures
6.3.1 – Physically walk through a mock lift and placement of a load or completion of a task while verbally explaining what you expect to see when they do it.
6.4 – Question period.
6.4.1 – Make yourself available to take any questions from the operators.
6.5 – End practical training portion.
6.5.1 – Inform the operators that the practical refresher training portion of the program is complete and that you will be moving along to practical re-evaluations.
6.5.2 – Draw up an evaluation schedule or just let the operators know when you would like them to return for their evaluation. At this point it may be time for a break, after which they can return to their jobs.
*IVES Certified Trainers may download pre-use inspection checklists and the full version of this lesson plan by logging on at www.ivestraining.com and clicking on the “Free Training Material Updates” button.
Break (10 minutes)
7 – Practical re-evaluations (20-30 minutes per forklift operator, 30-45 minutes per aerial lift operator)*
7.1 – Verbally introduce the evaluation to each operator as they come to you and inform them of what you would like them to do.
7.2 – One at a time, conduct a re-evaluation of each operator’s ability to operate safely.
7.3 – Debrief the operators.
7.3.1 – As operators complete their re-evaluation, let them know how they did, where they are strong, and where they could improve.
7.4 – Continue as per 7.2 and 7.3 until all operators are re-evaluated.
7.5 – Document.
7.5.1 – Complete required re-certification documentation** and file with appropriate department/person.
* Times will depend greatly on how many tasks are assigned. Usually half as many as was assigned during initial training is sufficient however the ultimately decision is up to you.
** IVES can provide Operator Re-certification Notepads that contain enough documentation (theory tests, evaluation forms, wallet cards, certificates of completion and record sheets) for eight (8) operators. Forklifts, boomlifts and scissor lifts only.
End Program
Words of (Safety) Wisdom
Here are some great safety quotes that might just stay with you and the people you train.
- Prepare and prevent, don’t repair and repent.
- Better a thousand times careful than once dead.
- Luck runs out but safety is good for life.
- Working safely may get old, but so do those who practice it.
- There is no safety in numbers, or in anything else.
- Know safety, no injury. No safety, know injury.
- Tomorrow – your reward for working safely today.
Here’s what IVES Staff Certified Master Trainer, Rob MacRae, had to say on safety and training:
Training is awesome when it is taught in compliance with the local regulations and applicable standards. However, employees and employers must also assume the responsibility of continued training and upgrade training to continue meeting the high standards that need to be achieved on a daily basis in the workplace. It is also both parties responsibility when preparing for regulatory certification. A one or two day program gives the trainees the tools to be better prepared for testing however continued use of the tools will assist them in achieving a much more successful result!
What’s Wrong With This?
Look at the photo below and see how many hazards you can spot.
Answer to Last Month’s
Q: In the Spring 2011 edition, we asked if you could see what the operator of the front-end loader was doing incorrectly.
A: We hope you spotted that the operator had not lowered the bucket low enough before dumping the material. This is not good for the stability of the loader or the operator’s co-workers if the spoils get blown around by the wind while falling to the ground.
Incident Report
FORKLIFT
June 2011 – A man was found dead after an accident involving a forklift. The 44 year old victim had been operating a forklift moving books within the warehouse complex, “When the forklift struck an industrial grade shelving unit, traveled under the lower shelf and pinned him between a shelving beam and the forklift,” according to a sheriff’s office news release. Co-workers and rescue personnel from a volunteer fire company worked to free the man who was found dead once the shelving was removed. Officials with the Occupational Safety and Health Administration are investigating.
AERIAL LIFT
May 2011 – An electrical contractor in a bucket truck was killed after being shocked while working on a transformer. He sustained life-threatening injuries when he came in contact with a live wire. He was taken to a hospital where he later died.
Always observe the minimum approach distance (MAD) to power lines when using aerial equipment. -ed.
Ask Bob
Q: Assuming that the capacity of both machines is not exceeded, is it OK to use two forklifts to lift a load?
Lianne.
A: I have never seen any regulations or standards that prohibit it but I would only recommend using two forklifts
to lift a single load as a last resort. A crane would be the right machine to use here if you have access to one. If you have no other choice, I suggest the following:
- Choose two experienced operators.
- Use well maintained forklifts with capacity ratings well above the expected load they will carry.
- Assign a lift supervisor and a signal person (they could be the same person).
- Have a meeting with everyone involved with the lift and discuss what needs to be done and how you intend on getting it done (and write the plan down!).
- Only make the lift in good weather.
- Make sure the forklifts pick up the load so that its weight is distributed evenly across both of them.
- Make sure each operator raises the load at the same speed keeping the load even.
- Keep non-essential personnel out of the area.
- Stop and lower the load immediately if there is even a hint of something going wrong.
Hope this helps!
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