ManuaL HanDLing SOLutiOnS in tHE

Transcription

MANUAL HANDLING SOLUTIONS
IN THE SAWMILLING INDUSTRY
1ST EDITION
NOVEMBER 2005
Manufacturing
CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Manual handling and musculoskeletal.
disorders (MSD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
The legal framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
How to use this Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Reasonably practicable control measures . . . . . . . . . . . . 5
Plant and other hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tasks
1. Handling timber - green chain. . . . . . . . . . . . . . . . . . 6
2.Destacking – Handling dry timber
at the start of the dry chain . . . . . . . . . . . . . . . . . . . 12
3. Handling timber – dry chain . . . . . . . . . . . . . . . . . . 13
4.Saw benches and finishing –
handling timber for further processing. . . . . . . . . . 16
5. Strapping packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6. Pushing trolleys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
7. Handling and sharpening saw blades . . . . . . . . . . 23
Acknowledgements. . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
The information presented in Manual Handling Solutions in the Sawmilling Industry
is intended for general use only. It should not be viewed as a definitive guide to the law,
and should be read in conjunction with the Occupational Health and Safety Act 2004.
Whilst every effort has been made to ensure the accuracy of this Guide, the advice
contained herein may not apply in every circumstance. Accordingly, the Victorian
WorkCover Authority cannot be held responsible, and extends no warranties as to:
• the suitability of the information for any particular purpose
• a ctions taken by third parties as a result of the information contained in Manual
Handling Solutions in the Sawmilling Industry.
The information contained in Manual Handling Solutions in the Sawmilling Industry is
protected by copyright. The Victorian WorkCover Authority hereby grants a non-exclusive
licence in this publication to the recipient of this publication on the condition that it is not
disseminated for profit. The Victorian WorkCover Authority encourages the free transfer,
copying and printing of the information in this publication if such activities support the
purposes and intent for which the publication was developed.
WorkSafe Victoria is a division of the Victorian WorkCover Authority.
Foreword
Victoria’s sawmill industry comprises more than 135 workplaces and represents
hundreds of employees involved in hardwood and softwood timber processing.
When it comes to workplace health and safety, manual handling tasks are a major
contributor to workplace injuries in this industry.
In the sawmill and processing timber industry, manual handling is the primary
cause of musculoskeletal disorders (MSD), such as sprains and strains and joint
problems, which account for more than half of all injury claims.
Manual handling covers activities such as lifting, pushing, pulling, holding and
carrying timber or processing equipment such as saw blades and trolleys. It occurs
with both green wood and dry timber.
In addition to the pain and suffering experienced by workers with these injuries,
there have been more than 550 standard claims which cost the industry more than
$13-million between July 1997 and September 2005.
WorkSafe Victoria and the forest industry joined forces to form the state-wide
Forest Industry OHS Stakeholder Forum in October 2002. It focuses on workplace
health and safety hazards and the development of shared solutions to reduce the
risks faced by forest industry workers.
In June 2005, three Manual Handling Solutions consultative workshops were held
involving more than 100 people from the sawmill and timber processing sectors.
to discuss a range of acceptable risk control solutions.
To help reduce the risk of MSD, WorkSafe has produced this publication which
describes the main manual handling tasks attributed to these injuries.
It provides practical guidance for workplaces to consultatively work out how best
to perform these tasks in the safest and most practicable way.
WorkSafe encourages everyone involved in the sawmill and timber processing
sectors to read this publication as it will assist employers (duty holders) to comply
with Victoria’s health and safety requirements. WorkSafe acknowledges the
contributions from the employers, employees, industry associations, unions and
occupational health and safety representatives involved in the development of this
important publication.
WORKSAFE VICTORIA / MANUAL HANDLING SOLUTIONS IN THE SAWMILLING INDUSTRY
INTRODUCTION
Information contained in this Guide is derived from the results of three Sawmilling
Solutions workshops held in June 2005. The workshop brought together unions,
workers, industry associations, employers, training organisations, ergonomists,
industry safety consultants and health and safety representatives to share ideas
for addressing the risks in sawmills due to manual handling tasks.
The Guide demonstrates both WorkSafe’s and the industry’s expectations on how
to best reduce the risk of musculoskeletal disorders (MSD) arising from manual
handling in sawmills.
MANUAL HANDLING AND MUSCULOSKELETAL DISORDERS (MSD)
Manual handling
For the sawmilling industry, manual handling covers a wide range of activities such
as lifting, pushing and pulling timber, twisting and turning timber, strapping packs,
handling saw blades and pushing trolleys. Many of these tasks can result in
musculoskeletal disorders and other types of injury.
Musculoskeletal disorders (MSD)
Musculoskeletal disorders (MSD) are often referred to as ‘sprains and strains’..
It is a term used to describe a wide variety of injuries to the musculoskeletal
system. This includes injuries to joints, ligaments, intervertebral discs and other
structures in the back and injuries to joints, ligaments, tendons and nerves in.
the wrist, arms, shoulders, neck, abdomen and legs. Some of these conditions
are sometimes described as repetitive strain injury (RSI), occupational overuse
syndrome (OOS), cumulative trauma disorder (CTD) and work-related
musculoskeletal disorder (WRMSD).
In the Occupational Health and Safety (Manual Handling) Regulations 1999,.
all of these conditions are referred to as musculoskeletal disorders (MSD).
INTRODUCTION
THE LEGAL FRAMEWORK
There is a legislative framework around controlling risk in the workplace. This Guide
shows ways to comply primarily with the Occupational Health and Safety (Manual
Handling) Regulations 1999.
Under the Manual Handling Regulations the employer has a duty to:
• Identify tasks involving hazardous manual handling
• Assess the risk of developing a musculoskeletal disorder associated with the task
• Control the risk by eliminating the risk or reducing it so far as is reasonably
practicable.
Hazard identification
This Guide identifies 7 manual handling tasks that the sawmilling industry agrees
are hazardous and have resulted in MSD.
Risk assessment
Guidance is given based on the common risk factors seen in the sawmilling
industry. This Guide follows the risk assessment format as used in the WorkSafe
publication ‘Manual Handling’ (Code of Practice No. 25, 2000). It will give you
some indication as to which risk factors may be in your workplace. In particular it
demonstrates those that result in high risk work practices that put people at risk of
developing an MSD.
It cannot replace the requirement for risk assessment and risk control under the
Manual Handling Regulations as the risk of developing an MSD will vary depending
on the circumstances in your workplace.
Risk control
Risk controls are shown in the Guide. The duty of an employer to carry out risk
control under the Manual Handling Regulations requires the following actions to.
be taken:
1. eliminate the risk (eg; automate or redesign so as to eliminate handling) or;
2. if it is not practicable to eliminate the risk, reduce the risk so far as is practicable.
In either case, the risk can be controlled by any of the following ways:
a. altering the workplace or environmental conditions (eg; adding rollers to
conveyors, using flippers to turn timber, using overhead hoists, changing
conveyor heights)
b. altering the systems of work (eg; adjusting work rates, regular maintenance.
on equipment, job rotation, team handling)
c. changing the objects (eg; using trolleys to transport blades)
d. using mechanical aids (eg; height adjustable trolleys, using overhead hoists)
Provision of information, training and instruction in manual handling techniques
cannot be used as the sole or primary way of controlling the risk unless all other
ways to control risk are not practicable.
A combination of controls often gives the best solution.
Consulting with employees and a trial of the solution can often help decide
whether it is right for your workplace or whether further adjustments or controls
are required.
You should always check the legislation referred to in this material and make your
own judgement about what action you may need to take to ensure you have
complied with the law.
INTRODUCTION
HOW TO USE THIS GUIDE
The red (High Risk), amber (Reduced Risk Solution), green (Preferred Solution) ‘Traffic Light’ format will help you identify
high risk activities and assess your workplace to implement safer work practices. The rationale is simple. To reduce injury
rates and compensation claims, high risk situations must be addressed.
Companies with work practices falling into the red, high risk area, who fail to implement risk control measures for these
practices, are likely to be in breach of the legislation. More importantly they are placing the health and safety of their
employees at risk. The red, high risk, column is split into two sections. One is for the actions (postures, movements.
or forces) that may give rise to the risk of an MSD and the other is for potential sources of that risk. A better understanding
about what is causing the risk of an MSD will result in a better risk control. Potential sources of the risk are listed,
although your workplace may discover other reasons why those actions are being undertaken and should control
accordingly. If high risk practices are used in your workplace, you should immediately determine if you can implement
the solutions in the green column. If this isn’t practicable, you should put in place the comparable practice in the amber
column as an interim solution.
The manual handling solutions in the amber and green sections in this Guide provide a number of different options. This is
because the tasks, and hence the risk, will vary according to the specifics at your workplace. It’s important to ensure that
any controls that you implement address the risk factors in the task.
HIGH RISK
REDUCED RISK SOLUTION
PREFERRED SOLUTION
The practices in the red column
should not be used in workplaces;.
an employer who allows these
practices to be used is likely.
to be in breach of OHS legislation
The solutions in the amber column.
are less effective in reducing risk,.
as compared to the green column,.
and would generally be treated as
interim solutions
The solutions in the green column.
are the most effective at reducing.
risk and should be regarded as the
target for all workplaces
Red, High Risk, column
Solutions
should continue
to be reviewed
as higher order
controls become
more practicable
Are any solutions from
the green column
reasonably practicable
for the workplace?
YES
Implement a
solution from the
green, Preferred
Solution, column
NO
Implement solutions
from the amber,
Reduced Risk, column
Note: In most cases the solutions in the green, Preferred Solution, column reflect the most effective control and the amber,
Reduced Risk, column provides interim solutions. However, if you are able to demonstrate that an appropriate risk
assessment process has been undertaken and you are able to verify that the ‘reasonably practicable’ test has been applied
to the controls you implement, then control measures falling within the amber range may be practicable in some
circumstances. However, the Reduced Risk solutions (amber) should be reviewed as Preferred Solutions (green) become
more practicable.
INTRODUCTION
REASONABLY PRACTICABLE CONTROL MEASURES
The Occupational Health and Safety Act 2004 explains the factors you must take
into account when deciding if something is ‘reasonably practicable’. These are:
• the likelihood of the hazard or risk eventuating
• the degree of harm that would result if the hazard or risk eventuated
• what you know, or ought reasonably to know, about the hazard or risk and any
ways of eliminating or reducing the hazard or risk
• the availability and suitability of ways to eliminate or reduce the hazard or risk
• the cost of eliminating or reducing the hazard or risk
This Guide has persuasive status on what you know, or ought reasonably to know,
and therefore what you should reasonably do. It is expected that employers,
employees and WorkSafe inspectors will use the Guide to form an opinion about
suitable health and safety risk controls, under the test of ‘reasonably practicable’.
PLANT AND OTHER HAZARDS
Ensure that introducing risk controls to reduce risk of an MSD from manual
handling does not introduce other risks into your system of work. For example;
• the introduction of a forklift will require implementation of a traffic management
plan to segregate pedestrians from forklifts.
• when using cranes to handle items, ensure loads are carried within the capacity
of the safe working load (SWL) and implement a program to monitor damage.
to slings and cranes etc.
• changes to equipment will require that a plant risk assessment is conducted
and controls put in appropriately to ensure that employees are not injured by
trapping points, in-running nip points or by timber ejected from the equipment.
1
Handling timber
– Green chain
✗
Timber is manually handled from a chain or a carousel and then placed onto.
a pallet or trolley for drying.
The main risk factors are repeated pulling, lifting, carrying and bending with.
lengths of timber and sticks, repeated gripping of sometimes awkwardly shaped
timber and high force, particularly to get the timber moving. The frequency.
of the actions and duration of the task will vary at each workplace and even
between days.
A fixed height conveyor will not suit everyone, but can be fixed to suit most
employees. It should be fixed somewhere in a range between elbow height.
and standing knuckle height or around 800mm to 1000mm. Consulting employees
and trialling the height will get the best result. There is a range of mechanical.
aids available to raise the height of the pallet or trolley.
HIGH RISK
Action
Back bending
• >twice per
minute
PREFERRED SOLUTION
Handling timber with the height raised
using scissor lifts, spring lifters, fixed
height dollys, trolleys or pallets
Automation, such as ‘pocket sorter’.
or ‘auto stacker’ mechanical aids
Potential
source of risk
Pallets are filled
at ground level
With long duration.
(>30 minutes
continuously or
>2 hours over
the whole shift)
These actions
may occur in the
situations listed
under ‘source.
of risk’ or in
combination.
with other work
activities
Rollers and a scissor lift are used to assist two
employees handle the timber.
Autostacker and autostick placer eliminates
manual handling.
This guide should be used in conjunction with the Occupational Health and Safety (Manual Handling) Regulations 1999 and Manual Handling Code
of Practice 2000
Handling timber – Green chain
HIGH RISK
Action
PREFERRED SOLUTION
Potential
source of risk
Purpose built trolleys with a simple spring/
scissor mechanism to keep the load at a good
height.
Fixed height stands or trolleys which
raise the bottom level to reduce back
bending
Autostacker with semi-auto stick stacker
eliminates most manual handling. Sticks are
manually placed into the stick stacker.
Appropriately designed job rotation
implemented to reduce duration.
of time on the task in combination.
with other risk controls to improve
postures and movements
Two different types of semi-auto stackers with
manual stick placement, above and below.
of Practice 2000
HIGH RISK
Action
PREFERRED SOLUTION
Potential
source of risk
Use mechanical aids
Vacuum lifter for use on heavy slabs.
Purpose-built lifter with hinge attachment allows
placement of slabs without bending.
Conveyor too low
Consult with your employees to raise
the height of the conveyor. It should
be somewhere in a range between
standing elbow height and standing
knuckle height (between 800 and.
1000 mm). Trialling the height will get
the best result. This guide should be used in conjunction with the Occupational Health and Safety (Manual Handling) Regulations 1999 and Manual Handling Code
of Practice 2000
HIGH RISK
Action
Carrying with one
hand or side of
the body
• >twice per
minute or
• >30 seconds
at a time
With long duration.
(>30 minutes
continuously or
>2 hours over
the whole shift)
These actions
may occur in.
the situations
listed under
‘source of risk’.
or in combination
with other work
activities
Twisting and
turning actions
with the fingers,
hands or arms
PREFERRED SOLUTION
Position and orientate packs to reduce
carrying distances and handling, as
shown in the photo below
Automation or mechanical aids.
(see above)
Potential
source of risk
Long distances
between chains
and trolleys or
packs
Example of layout to reduce carrying distances.
Team handling in combination with
other risk controls to improve
postures and movements
Requirement to
turn board for
visual inspection
• >twice per .
minute
With long duration.
(>30 minutes
continuously or
>2 hours over
the whole shift)
These actions
may occur in.
the situations
listed under
or in combination
with other work
activities
Use mirrored waterfall grading
stations, as typically used with
optimising fault docking saws
Automated turning equipment.
eg: flippers
Two different types of board turning devices,
above and below.
of Practice 2000
HIGH RISK
Action
Repetition and
very fast
movements
PREFERRED SOLUTION
Ensure there are enough employees to
perform the task, including enough
employees to cover absenteeism
Automate or use mechanical aids.
(see above)
Potential
source of risk
Frequency of
timber needing to
be stacked is fast
due to:
• Not enough
employees
• Working to a
cutting rate
rather than a
packing rate
• Excessive
speed of chain
with no
opportunity for
rest breaks
when
physically
fatigued.
• No ability to
alter the pace
of the chain
• No buffer to
allow timber to
rest whilst
workers keep
up
High force –
lifting and
lowering.
heavy boards
Alter the production rate: e.g. by
stopping a docker
Reduce work pace when handling
heavier boards
Implement rest breaks
Use appropriately designed job rotation
Introduce buffers to allow a safe area
for timber to rest whilst employees
keep up
A large buffer area.
Pallets filled at
ground level
Solutions as above
Automate or use mechanical aid
solutions as above
Weight of timber
Solutions as above
Automate or use mechanical aid
solutions as above
other risk controls to improve postures
and movements
Poor fitting
gloves or no
gloves provided if
requested by
employees
leading to higher
grip force
Glove management program in place
eg: appropriate, well fitting gloves, flat
palm gloves or fingerless gloves that
retain ‘feel’
of Practice 2000
10
HIGH RISK
Action
High force –
pushing and
pulling objects
that are hard.
to move
PREFERRED SOLUTION
Reduce the force by:
Automation or mechanical aids.
(see above);
Potential
source of risk
No rollers are
provided
Pulling timber on
timber creates
higher forces due
to friction of
wood on wood
• Reducing the surface area
• Using low friction edges
• Using rollers
Sap build up on
rollers reduces
the effectiveness
of the rollers
Weight of timber
limits the motion
of the rollers
Rollers provided
but employee
pulls timber
against the
direction of the
rollers
Rollers assist in handling timber.
Different types of rollers, above and below.
• Using cleats
• Using chains
• Ensuring all equipment is well
maintained and appropriate for the
timber
• Performing regular housekeeping to
reduce effects of sap
• Training to ensure timber is handled
in the direction of the roller
Start implementing risk controls for your heaviest and highest volume timber first.
of Practice 2000
WORKSAFE VICTORIA / MANUAL HANDLING SOLUTIONS IN THE SAWMILLING INDUSTRY11
Destacking – Handling
dry timber at the
start of the dry chain
2
✗
HIGH RISK
Action
Back bending
• >twice per
minute
With long duration.
(>30 minutes
continuously or
>2 hours over
the whole shift)
Dried timber needs to be transferred to the dry chain for further processing..
This can involve repetitive back bending, pulling, pushing, high force and.
twisting and turning actions.
PREFERRED SOLUTION
Keep the timber around waist.
height: e.g.
Automate the process
Potential
source of risk
The position.
of the timber.
is below knee
height
• redesign the trolley or pallet or
• use a pallet/trolley stand
• use a mechanical aid
These actions
may occur in the
situations listed
under ‘source.
of risk’ or in
combination.
with other work
activities
High force –
lifting and
lowering boards
Dry chain destacker used to eliminate manual
handling.
Scissor lifter used to keep the timber around
waist height.
This pack is being lowered onto two spring
operated scissor lifters by forklift for further
handling.
of Practice 2000
12
3X
Handling
NEW
SECTION
timber
– Dry chain
• Lorper adiamet la facillan heniscidunt
• Heniscidunt il ing eros orperet
• La facillan heniscidunt il ing eros
✗
Dried timber is handled from a chain to a trolley or pallet in preparation for
strapping and transport.
The main risk factors are repeated pulling, lifting, carrying and bending with
lengths of timber, repeated gripping of sometimes awkwardly shaped timber and
high force, particularly to get the timber moving. The frequency of the actions
and duration of the task will vary at each workplace and even between days.
A fixed height conveyor will not suit everyone, but can be fixed to suit most
employees. It should be fixed somewhere in a range between elbow height and
knuckle height or around 800mm to 1000mm. Consulting employees and trialling
the height will get the best result. There is a range of mechanical aids available
to raise the height of the pallet or trolley.
HIGH RISK
Action
Work above
shoulder height
or back bending
• >twice per
minute
PREFERRED SOLUTION
Trolleys or pallets designed to keep
pack between shoulder and knee
height eg:
Packs on height adjustable trolleys
Potential
source of risk
Packing
repeatedly above
shoulder height
or below knee
height
With long duration.
(>30 minutes
continuously or
>2 hours over
the whole shift)
These actions
may occur in.
the situations
listed under
or in combination
with other work
activities
Purpose-built trolleys with a simple spring/
scissor mechanism.
of Practice 2000
Handling timber – Dry chain
HIGH RISK
Action
High force –
lifting and
lowering heavy
boards
PREFERRED SOLUTION
Trolleys or pallets designed to keep
pack between shoulder and knee
height eg:
Mechanical aids
Potential
source of risk
Pallets filled at
ground level
and movements
Vacuum lifter for use on heavy slabs.
Packs on height adjustable trolleys
Purpose-built trolleys with a simple spring/
scissor mechanism.
Weight of timber
Solutions as above
Solutions as above
and movements
Poor fitting
gloves or no
gloves provided.
if requested by
employees
leading to higher
grip force
Glove management program in place
eg: appropriate, well fitting gloves, flat
palm gloves or fingerless gloves that
retain ‘feel’
of Practice 2000
14
Handling timber – Dry chain
HIGH RISK
Action
High force –
pushing and
pulling objects
that are hard to
move
PREFERRED SOLUTION
Reduce the force by:
Mechanical aids (see above)
Potential
source of risk
No rollers are
provided
Pulling timber on
timber creates
higher forces due
to friction of
wood on wood
• Reducing the surface area
• Using low friction edges
• Using rollers
Sap build up on
rollers reduces
the effectiveness
of the rollers
Weight of timber
limits the motion
of the rollers
Rollers provided
but employee
pulls timber
against the
direction of the
rollers
Rollers assist in handling timber.
Different types of rollers, above and below.
• Using cleats
• Using chains
• Ensuring all equipment is well
maintained and appropriate for the
timber
• Performing regular housekeeping to
reduce effects of sap
• Training to ensure timber is handled
in the direction of the roller
Start implementing risk controls for your heaviest and highest volume timber first.
of Practice 2000
4
Saw benches and
finishing – handling
timber for further
processing
✗
Handling of timber by sawyers and other operators may include reaching, twisting,
pushing and pulling actions.
Turning boards for inspection at machines is repetitive and involves other risk
factors such as reaching, grasping and turning actions of the forearms and hands.
Attempting to loosen timber that piles-up, jams or becomes stuck on chains and
tables may require high force and awkward postures.
Clean up and removal of dropped waste product from floor level involves awkward
postures and forward bending.
Wearing gloves may require a greater force to be applied to handle the timber.
HIGH RISK
Action
Twisting, turning
actions with the
fingers, hands
and arms
• >twice per
minute or
• >30 seconds
at a time
With long duration.
(>30 minutes
continuously or
>2 hours over
the whole shift)
These actions
may occur in.
the situations
listed under
or in combination
with other work
activities
PREFERRED SOLUTION
Potential
source of risk
One employee
allocated to task
involving frequent
turning and
twisting of timber
using one hand
for inspection
Job rotations to tasks involving
different muscle groups to provide
some opportunity for recovery
Ability to reduce chain speed
Use of a laser to scan timber.
Use mirrored waterfall grading
stations, as typically used with
optimising fault docking saws
Well designed task layout with
deflection devices to keep boards
square and assist in turning eg:
•
•
•
•
•
make full use of conveyors
board turners
flippers
‘L’ shaped turners
rubber flaps or hair brushes to keep
boards square
of Practice 2000
16
Saw benches and finishing –
handling timber for further processing
HIGH RISK
Action
PREFERRED SOLUTION
Potential
source of risk
Automated board turning equipment, above
and below.
Pushing timber
Employees
manually push
• >twice per
timber on rollers
minute
all day at docking
With long duration. saw
(>30 minutes
continuously or
>2 hours over
the whole shift)
These actions
may occur in.
the situations
listed under
or in combination
with other work
activities
Rotation of employees through tasks
provides some opportunity for recovery
Automatic in-feeds
Dock ends of packs whilst packed firm
Pack being compressed and docked.
of Practice 2000
Saw benches and finishing –
handling timber for further processing
HIGH RISK
Action
Back bending
• >twice per .
minute
PREFERRED SOLUTION
Waste needs to
be picked up
from floor level
Waste bins within reach are provided
and used to prevent waste being
thrown on the floor
Automated waste handling using a
conveyor to take waste to bins
Timber jams or
entanglements
need to be
cleared manually
Plant is isolated and team handling is
used
Automated ‘straight mill’ design
Potential
source of risk
With long duration.
(>30 minutes
continuously or
>2 hours over
the whole shift)
High force
‘Cant hook’ or similar tools are used if
levering by hand
Proximity switches, conveyor design
and flow pattern segregate the timber
lengths and ensure gaps occur to
prevent build-ups
Power driven rollers or conveyor with
forward and reverse capability for
unscrambling jam ups
Overhead hoists or other mechanical
aids used to eliminate manual handling
One employee
carries timber
back for re-saw
The carrying distance is minimal and
heights are on the same level
Layout of conveyor and trolleys minimises
required carrying.
Forces required
to handle timber
increase due to
poorly fitting
gloves
Conveyors to return timber for re-saw
Mechanical board lifter.
There is a program in place to ensure
proper fitting gloves are provided such
as ‘flat palm’ gloves or fingerless
gloves that retain ‘feel’
of Practice 2000
18
5X
NEW SECTION
Strapping
packs
• Lorper adiamet la facillan heniscidunt
• Heniscidunt il ing eros orperet
• La facillan heniscidunt il ing eros
✗
HIGH RISK
Action
Work with hands
above shoulder
height, back
bending, reaching
>30cm from the
body, excessive
bending of the
wrist, exerting
force while in an
awkward posture
and hitting actions
Banding can involve awkward postures when reaching and force when tightening
the packs using manual strapping machines.
PREFERRED SOLUTION
Provide a longer lever arm to reduce
the force required to ratchet
Auto-strapping
Potential
source of risk
One employee
allocated to
strapping with
steel requiring
force to ratchet
Job rotation to reduce the frequency of
exposure
Appropriate PPE – face protection and
full-length gloves
Weight of ratchet
• >twice per
Hitting the pack
minute or
with a mallet to
compress it
• >30 seconds
at a time
With long duration.
(>30 minutes
continuously or
>2 hours over
the whole shift)
Powered ratchet, eg battery operated
Plastic strapping used where it is
assessed as safe (eg in transport)
Smaller, lighter ratchet
Suspend ratchet or strapping machine
Job rotation
Auto stackers with hydraulic
compression devices
These actions
may occur in.
the situations
listed under
or in combination
with other work
activities
of Practice 2000
6
Pushing trolleys
✗
Trolleys are often pushed manually to transfer packs of green or dry timber into
areas where they can be mechanically removed.
High force is often required to initiate the movement of the full trolleys.
Some factors that may need to be addressed when controlling the risk are:
• Traffic management issues – separation of pedestrians from forklifts
• Using mechanical aids to do the work
• Implementing effective administrative procedures if mechanical aids.
are not practicable
• Limiting the distances over which the trolleys are pushed
• Appropriate trolley and castor selection
• Implementing effective maintenance procedures for trolleys, castors.
and housekeeping
of Practice 2000
20
Pushing trolleys
HIGH RISK
Action
High force
PREFERRED SOLUTION
Team handling – ie two employees
assigned for the task, adequately
trained and capable with standard size
packs on trolleys, or on a dolly.
on wheels
Use an overhead gantry to move packs
Potential
source of risk
Heavy, fully
stacked trolley
Various sources
of risk as outlined
in following table
Using a mechanical aid
The use of a ‘tug’ to move trolleys, above
and below.
Poor work
practices.
allowing trolleys
to become
overloaded.
and heavier
Work practices allow for more frequent
clearing of trolleys or packs
Provide a sufficient number of trolleys
A system is in place to ensure forklifts
or other mechanical aids are available
when needed
of Practice 2000
Pushing trolleys
Issues that affect the force required to manually move trolleys
Trolley design
and number
Caster choice
Potential hazard source
Risk control
Poor trolley design results in a high centre.
of gravity
A height adjustable spring or scissor trolley will
allow loading at a good height and provide a
low centre of gravity for stability when pushing
No handles provided or the handles provided
are too low
Good handles provided, eg vertical
Insufficient trolleys resulting in over stacking
the available ones
Sufficient number of trolleys also allows.
for maintenance
Flat tyres or flat spots make the trolley
difficult to get moving
Solid tyres or ones with adequate tyre
pressure
Small diameter castors
Low resistance bearings
Large diameter castors
Floor surfaces
Housekeeping
Cracks, uneven or non smooth floors can
make the trolleys harder to move by
increasing the pushing forces
Inspections and regular maintenance to keep
floor surfaces clear and well maintained
Steep gradients on ramps
Ensure trolleys are handled on flat or low
gradient surfaces
Dirty floors or tracks due to sawdust, wood,
mud or stone make it harder to move.
the trolley
Regular housekeeping results in work areas
kept clean and free of obstructions and trip
hazards
For example: implement a programme to
conduct additional housekeeping during
breakdowns
Maintenance
Damaged trolleys and castors make it harder
to move the trolley
Immediate removal of damaged trolleys
Implementation of a systematic preventative
maintenance system for trolleys and castors
An example of a good reference guide on pushing trolleys is: ‘The Ergonomics of Manual Material Handling – pushing.
and pulling tasks’. This is also known as the Darcor and Ergoweb white paper on trolleys. It may be viewed online at.
http://www.darcor.com/library_wp.htm
of Practice 2000
22
7
Handling and
sharpening
saw blades
The manual handling of saws includes installing, removing, transporting,
sharpening and re-tipping. Replacing and maintaining saws, including transporting
them in and out of storage, should be done using mechanical aids.
Bandsaws might be changed at a minimum of every 5 hours; circular saws every.
1–2 weeks; rip-saws every 4 hours in some sawmills. The saw change over tasks
may be scheduled to occur during lunch breaks or between shifts.
Handling saws can involve a combination of high risk actions for the one task..
For example, a change-over might require sustained reaching above shoulder
height to access a saw, exerting high force while in an awkward posture followed
by lifting, lowering and carrying a heavy or bulky load. Effective solutions may
eliminate a number of these actions together.
HIGH RISK
PREFERRED SOLUTION
Using X-rays to scan for foreign
objects and knots that can damage
blades to reduce breakdowns and the
frequency of saw changes
Action
Potential
source of risk
High force.
in awkward
postures
Handling or
changing large
saws
Appropriately trained employees
allocated to the task using a block and
tackle, a sling and clear access
Handling large
and heavy
circular saws,.
chipper blades
Use the right blade in good condition
to reduce frequency of change overs
Handling 30.
foot bandsaw,
removal and
tensioning
Carbide tungsten tipped saw blades to
reduce the frequency of changing blades
Powered mechanical aids to reduce
manual handling
The position.
of the saw is
difficult to access
Gantry crane, hoist and cradle.
of Practice 2000
Handling and sharpening saw blades
HIGH RISK
Action
High force.
in awkward
postures.
(continued)
PREFERRED SOLUTION
Ensure adequate access platforms are
provided, eg ‘fold-away’ platforms to
reduce reaching and handling distances
Introduce electronic, gantry-mounted
lifting winch or other suitable
mechanical aids
Potential
source of risk
Twin bandsaw
removal and
fastening
The position of
the saw, eg twin
‘Canadian’, is
difficult to access
Gantry-mounted lifting winch.
Heavy saw
blades stored flat
on floor level or
in positions that
force awkward
postures, such as
forward bending
and reaching
Heavy objects are stored systematically,
eg up off floor to reduce forward
bending with a heavy load
An example of a simple but effective storage
system.
Trolley used to store circular saws.
of Practice 2000
24
HIGH RISK
Action
High force.
in awkward
postures.
(continued)
PREFERRED SOLUTION
Removing and
handling guards
Appropriately trained employees are
allocated to the task, using suitable
tools
Automation, use of pneumatic rams,
balancers or other mechanical aids.
to assist
Transporting
saws
Introduce simple lifting equipment
such as trolleys to assist in saw
transport
Reduce the distance over which saws
need to be manually transported
Potential
source of risk
One person
rolling bandsaws
up or down
steps, across
uneven floors
Examples of trolleys for bandsaws above and
circular saws below.
Manually lifting
saw blades up
onto vehicle to
go to saw doctor
These photos above and below, show a hole in
the floor to raise and lower saws through, using
suitable lifting equipment.
Blades are boxed and forklifts used.
to place them onto vehicles
Use of monorails, hoists or other
mechanical aids
of Practice 2000
HIGH RISK
Action
High force.
in awkward
postures.
(continued)
PREFERRED SOLUTION
Sorting out of larger pieces before the
in-feed and using appropriate tools to
reduce reaching or twisting
Appropriate equipment for the volume
of chip wood
Potential
source of risk
Manually clearing
blockages at infeeds of chippers
The employee in the photo above is using a tool
to reduce the need to reach and clear blockages.
Ensure an isolation procedure exists
and is enforced and supervised
Use of automation such as reversible
belts and shakers
This is an example of a shaker. Distance prevents
access to hazards from potential nip points.
A longer and wider in-feed conveyor reduces
blockages.
of Practice 2000
26
HIGH RISK
Action
Twisting and
turning actions
with the fingers,
hands or arms,
exertion of force
in an awkward
posture or.
holding of tools
PREFERRED SOLUTION
Use appropriate equipment with
sufficient opportunity for breaks
Task outsourced to saw doctors with
appropriate equipment
Manual check setting at an appropriate height.
Automatic sharpening equipment.
Manual check setting at an appropriate
height with sufficient rest breaks for
recovery, or rotation to other tasks
using different muscle groups
Reducing the frequency of sharpening
by moving to tungsten carbide tipped
saws, where applicable
Manual tensioning with supervised
breaks and task rotation
Air assisted automatic swaging
Potential
source of risk
Sharpening saws
by manually filing
or check setting
One person
benching a.
band saw
• >twice per
minute or
• >30 seconds
at a time
With long duration.
(>30 minutes
continuously or
>2 hours over
the whole shift)
These actions
may occur in.
the situations
listed under
or in combination
with other work
activities
Sustained manual
tensioning and
swaging without
breaks or
appropriate
rotations
Manual swaging requires appropriate breaks and
task rotation.
Changing riving
knives or other
equipment with
no powered tool
assistance
Appropriately trained employees.
are allocated to the task, using
suitable tools
The semi-automatic swager is supported with an
overhead hoist.
Use powered tools, such as pneumatic
‘air guns’, wherever practical
Allow sufficient rest breaks for
recovery, or rotation to other tasks
using different muscle groups
Ensure an isolation procedure exists
and is enforced and supervised
of Practice 2000
acknowledgements
WorkSafe Victoria and the Victorian Forest Industry have formed a peak body to address OHS hazards and provide.
solutions to reduce risks faced by forest harvesting and sawmilling workers.
WorkSafe would like to acknowledge the following contributors to this publication:
Forest Industry Occupational Health and Safety Stakeholder Forum members and organisations who participated and
contributed in the consultative workshops conducted during June 2005 and subsequent industry reference group.
Forum Members:
The peak body is drawn from all sectors of the forest industry and includes representatives from:
Carter Holt Harvey
Hancock Victorian Plantations
Tree Felling Safety Group
CFMEU Forestry Division
Midway Pty Ltd
Vic. Assoc. of Forest Industries
Department of Sustainability
and Environment
Neville Smith Timber Industries
VicForests
Employee Representatives
Plantation Timber
Association of Victoria
Vic. Forest Harvesting
and Cartage Council
Forest & Forest Products
Employment Skills & Co
Syndicated Harvesting
Companies
WorkSafe Victoria
Special thanks to all who participated in the publication development workshops and in particular organisations who
contributed to providing images for the publication.
Alex Demby Timber Co. P/L
H. Waterhouse & Son Pty Ltd
Radial Timber Australia P/L
Bedggood Sawmills P/L
McCormack Timbers Pty Ltd
Ryan & McNulty P/L
Carter Holt Harvey Radius
Merriwa Industries LTD
Timber Training Creswick Ltd
CCA Pine
N.F. McDonnell & Sons
Warburton Timber Company
Drouin West Timber Pty Ltd
Neville Smith Timber Industries P/L
Yarra Valley Saws
J.L. Gould Sawmills Pty Ltd
Powelltown Sawmills Pty Ltd
28
WorkSafe Victoria
Advisory Service
222 Exhibition Street.
Melbourne 3000
Phone . . . . . . . . . . . . . . . 03 9641 1444.
Toll-free. . . . . . . . . . . . . . 1800 136 089.
Email. . . . . . [email protected]
Head Office
222 Exhibition Street.
Melbourne 3000
Phone . . . . . . . . . . . . . . . 03 9641 1555.
Toll-free. . . . . . . . . . . . . . 1800 136 089.
Website. . . www.workcover.vic.gov.au
Local Offices
Ballarat. . . . . . . . . . . . . . .
Bendigo. . . . . . . . . . . . . .
Dandenong . . . . . . . . . . .
Geelong. . . . . . . . . . . . . .
Melbourne .
(628 Bourke Street). . . . .
Mildura. . . . . . . . . . . . . . .
Mulgrave. . . . . . . . . . . . .
Preston . . . . . . . . . . . . . .
Shepparton . . . . . . . . . . .
Traralgon . . . . . . . . . . . . .
Wangaratta . . . . . . . . . . .
Warrnambool. . . . . . . . . .
VWA989/01/11.05
03
03
03
03
5338
5443
8792
5226
4444.
8866.
9000.
1200.
03
03
03
03
03
03
03
03
9941
5021
9565
9485
5831
5174
5721
5564
0558.
4001.
9444.
4555.
8260.
8900.
8588.
3200

ManuaL HanDLing SOLutiOnS in tHE

Transcription

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