traffic management warehousing 5856

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New South Wales Governmentmaking a difference

TRAFFIC

MANAGEMENTIN WAREHOUSING

PLAN AND CHECKLIST

March 2009


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Disclaimer

This publication may contain occupational health and safety and workers compensation information. It may include some of your obligations under the

various legislations that WorkCover NSW administers. To ensure you comply with your legal obligations you must refer to the appropriate legislation.

Information on the latest laws can be checked by visiting the NSW legislation website (www.legislation.nsw.gov.au) or by contacting the free hotline

service on 02 9321 3333.

This publication does not represent a comprehensive statement of the law as it applies to particular problems or to individuals or as a substitute for legal

advice. You should seek independent legal advice if you need assistance on the application of the law to your situation.

WorkCover NSW

Acknowledgement: This is a NSW Wholesale Industry Reference Group project in partnership with WorkCover NSW.


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CONTENTS PAGE

INTRODUCTION 2

TRAFFIC MANAGEMENT PLAN CHECKLIST 4

Loadshifting Equipment 4Barricades/Barriers/Bollards 6

Layout/Line Marking 7

Signage/Warning Devices 8

Training, Systems, Policies, Procedures 9

Personal Protective Equipment 11

External Traffic Management Requirements 12

Sample Warehouse Traffic Management Action Plan 13

RISK ASSESSMENT MATRIX 14

DEFINITIONS 15

MORE INFORMATION 17


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INTRODUCTION

The consequences of being hit by loadshifting equipment and other vehicles can be serious,

resulting in injury or even death. There is a significant cost to the victim, the employer, the

victims family and the community.

This Traffic Management Plan Checklist provides guidance to managers and supervisors

of small to medium businesses on how to develop, implement and maintain safe systems

of work, intended to eliminate or control the risks of collision in a warehousing and/or

storage environment.

An important part of managing your business is to ensure the health and safety of your

employees and other people, such as customers, visitors or tradespeople who visit your

workplace.

To ensure you fulfil your obligation for a safe workplace, you need to be aware of what can

cause harm and then take action to ensure no one is at risk while they are in your workplace.

The following questions will help you evaluate how well you are currently managing safety in

your workplace:

Do you talk with your employees about safety issues? Yes No

Do you encourage your employees to report safety problems? Yes No

Do you regularly inspect your workplace to identify safety problems? Yes No

Do you fix identified problems? Yes No

Do you supervise and train employees so that all work is carried out safely? Yes No

If you answered no to any of these questions, you may not be meeting all of your

obligations under theOccupational Health and Safety Act 2000(the OHS Act).

Even if you answered yes to all these questions, this Traffic Management Plan Checklist will

help you to systematically identify the traffic management safety risks in your workplace and

take the necessary steps to make your workplace safer.

When using the Traffic Management Plan Checklist, it is important to involve your

employees, as they are the people most affected by safety issues and can help to identify the

best safety solutions. Involving your workers is one of your obligations under The OHS Act,toconsult with your employees on workplace safety issues, including when developing safe work

procedures.

When you complete the Traffic Management Plan Checklist, it is important to determine how

often it needs to be reviewed. As a guide, it is a good idea to review the Traffic Management

Plan Checklist at least once a year. However, you may also need to review the Traffic

Management Plan Checklist if there are changes to your workplace that may impact on

safety, eg when new equipment is introduced into the workplace, in situations where plant/

processes are modified and during seasonal peak periods.


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By completing this Traffic Management Plan Checklist, identifying and controlling any

problem areas and reviewing it regularly, you will be well on your way to meeting your legal

obligations to provide a safe and secure workplace.

Instructions

Simply tick Yes or No to each question and add any comments you consider appropriate.

If the question does not apply to your workplace, tick N/A. If you tick No to any question

you will need to take action to rectify the issue. An action plan template is provided in this

Traffic Management Plan Checklist and may be used to map the necessary steps required to

make your workplace safer.

For more information or assistance, go to www.workcover.nsw.gov.au or contact the WorkCover

Assistance Service on 13 10 50.


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TRAFFIC MANAGEMENT PLAN CHECKLIST

Date checklist completed: _______ /_______ /_______

Date checklist to be reviewed

(if not reviewed earlier due to a change to the workplace): _______ /_______ /_______

Name(s) of person(s) who completed checklist: _________________ Title: _________________

Name(s) of person(s) who completed checklist: _________________ Title: _________________

1. LOADSHIFTING EQUIPMENT

Issue YES NO N/A POSSIBLE Control Measure Action to be taken

1.1 Is a forklift requiredfor this job?

substitute forklift withmore pedestrian friendlyloadshifting equipment (egpallet jacks, walker stackers)

if the above is not

practicable, design theworkplace to eliminate theneed for pedestrian access inthe vicinity of a forklift.

1.2 Have you studiedthe loadshiftingequipment andpedestrian movementin the workplaceto identify the riskof collision with apedestrian?

study the loadshiftingequipment and pedestrianmovement in the workplace

identify the potential forcollisions with loadshiftingequipment and pedestrians,columns, racking and othervehicles.

1.2a Have you

implemented controlmeasures to addressthe risks identified inthe above study?

mark No Go for exclusion

zones for both pedestriansand powered loadshiftingequipment based onpedestrian and equipmentmovements, brakingdistance, stability and loadsbeing handled

change layout

change equipment.

1.2b Have youimplementedappropriate measuresto monitor the

effectiveness of thecontrols?

ensure there is anappropriate level ofsupervision provided to seecontrol implemented

ensure there are appropriatearrangements in place sothat incidents and nearmisses are reported

ensure arrangements arein place to modify controlswhere necessary based onfeedback from incident andnear miss reports.


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1. LOADSHIFTING EQUIPMENT (CONTINUED)


1.3 Have you determinedparking areasfor loadshiftingequipment?

ensure loadshiftingequipment has its ownclearly marked parking and/or recharging areas

design work processesso that no loadshiftingequipment is required topark on pedestrian walkways.

1.4 Are dailypre-operationalchecks beingcompleted for thesecomponents?

falling object protection

brakes

seat belts (where fitted)

lights

warning devices

steering

tyres

controls

horn

mast and hydraulics

chains

hand brake

load capacity plate

NOTES

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2. BARRICADES/BARRIERS/BOLLARDS


2.1 Are physicalseparation structuresinstalled to keeppedestrians out

of loadshiftingareas? (they may beessentially visual innature or only strongenough to resistaccidental actions bythe pedestrian)

enclose designatedloadshifting equipmentoperating areas with physicalbarriers to prevent pedestrian

access if employees work within

loadshifting equipmentoperating areas eg desks,counters, goods dispatchareas or workstations:

relocate them away fromtraffic areas

erect physical barriersto protect such areas,eg steel railings.

2.2 Are pedestriancrossings clearly

marked?

clearly designate pedestriancrossings by installing inward

opening pedestrian gates asa calming device to ensurepeople stop and look beforecrossing

have right of way proceduresin place and enforced,clearly indicating who mustgive way

pedestrian crossings on thepavement.

2.3 Are adequate bollardsand safety railingsbeing used to reduce

the risk of vehicleand pedestriancollision in thebattery charging areaand waste bin workzones?

clearly delineate the batterycharging area for electricloadshifting equipment by

installing adequate bollards/safety railings

separate access paths forvehicles and pedestrians,eg vehicles access from theend and pedestrians fromthe side barricading andmarkings to match

ensure clear visibility aroundwaste bin areas to avoidpedestrians stepping out intotraffic from blind spots

install barriers/bollards toprotect other vulnerableequipment, pits or placeswhere employees work.

2.4 Do entry and exitpoints to the buildingprotect pedestriansfrom being struck byvehicles?

install barriers or bollardsat the entry and exit pointsof the building to preventpedestrians walking into thepath of oncoming vehicles

where buildings or walkwaysopen directly onto roadwaysor traffic zones, erectpermanent barriers to ensurepedestrians do not step intothe path of passing vehicles

use bollards/barriers toprevent vehicles obstructingemergency exits.


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3. LAYOUT/LINE MARKING


3.1 Is there aneffective workplacelayout to separatepedestrian and

powered loadshiftingequipment traffic?

clearly line mark pedestrianwalkways, roadways andloadshifting equipmentoperating areas based on

speed limits, stoppingdistances and efficientworkflow

minimise the cross flow oftraffic, intersections andblind spots

line mark customer pick-upparking areas

make sure customer pick-upparking areas are positionedclose to pedestrian walkwaysand provide access withoutcrossing driveways or loadingdock vehicle paths

clearly define areas wherepowered loadshiftingequipment is used aspedestrian exclusion zonesand clearly exclude poweredloadshifting equipment frompedestrian walkways/workareas

use line markings and/ormarker posts in docking areasto indicate distances fromdock, ie 1 metre incrementsadvising driver of proximity todock, reducing the need for

assistance reversing provide line marking for:

traffic flow markings

loadshifting equipmentparking

driver designated safeareas

car parking

keep clear zones

lane numbering wheremultiple docks exist

speed humps.

3.2 Is there effective linemarking to separatepedestrian andpowered loadshiftingequipment traffic?


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4. SIGNAGE/WARNING DEVICES


4.1 Is there adequatelighting and visibilityto minimise the riskof collision?

install eye ball convexmirrors to provide clearvisibility of approachingloadshifting equipment and/

or pedestrians all loadshifting equipment

to carry high visibility and/orreflective markings

pedestrians within vehicleaccess areas to wear highvisibility clothing or vests

provide additional lighting.

4.2 Is there clear warningof loadshiftingequipment hazards?

loadshifting equipmenthave fitted and maintainedreversing beepers and/orflashing lights

clearly mark such things ascabling or ducting with highvisibility materials

have signs conforming to theAustralian Standard AS1319 Safety Signs for theOccupational Environment

prominently display clearwarning signs in relevant,well lit areas to remindpersons of the trafficmanagement hazards andrequirements.

Signage examples:

Pedestrians Prohibited Loadshifting EquipmentOperating Area

Loadshifting EquipmentProhibited

Pedestrian Safety Zone

Beware loadshiftingequipment operatingwithin the area

Vehicles must give way topedestrians or a priorityor right of way procedurethat applies to pedestrian

crossings.


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5. TRAINING, SYSTEMS, POLICIES, PROCEDURES


5.1 Are operatorsadequately trainedand licensed whererequired?

make sure operators areadequately trained andcompetent, even formachines that do not require

a Certificate of Competency do NOT allow other people

(eg visitors, delivery drivers,etc) to operate machinerywithout assessing theircompetency and sightingrelevant Certificates ofCompetency

make sure learner operatorsare properly supervised andcomplete logbooks

induct operators into theoperation of new plant

have operation manuals forplant available for operatorsto read

keep copies of loadshiftingoperators Certificates ofCompetency.

5.2 Have employeesundergone a sitesafety induction priorto being permittedto use loadshiftingequipment?

conduct a work environmentinduction

conduct a trafficmanagement site induction.

5.3 Are safe work

procedures inplace for operatorsof loadshiftingequipment?

Consult with staff and consider

incorporating the following intoyour safe work procedures:

pre-use inspectionprocedures to check forobvious defects

means to ensure loads do notexceed the capacity of theequipment

loadshifting equipment keycontrol procedures to ensureonly competent operators usethe equipment

loadshifting equipment to

cease work if pedestriansenter a pedestrian exclusionzone

loadshifting equipmentoperators to keep the tynesas close to the floor aspractical when travelling andoperating within the site

loadshifting equipmentoperators to ensure that theirload (mast) has appropriaterearward tilt prior to movingpallet/stock and not travelwith tynes extended

loadshifting equipmentoperators should lower theirloads before turning in thedirection of travel


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5. TRAINING, SYSTEMS, POLICIES, PROCEDURES (CONTINUED)


5.3 Are safe workprocedures inplace for operatorsof loadshifting

equipment?(cont)

sound loadshiftingequipments horn (warningdevice) when crossingintersections, pedestrian

walkways and access andegress points for pedestrians

no loadshifting equipment isto be used to move or shuntanother piece of equipment

no tampering or modifyingof loadshifting equipmentby staff

Out of Service/Danger tagsystem clearly understoodand carried out byloadshifting operators

ensure operators ofloadshifting equipmenttravel in reverse if the loadobstructs their view.

5.4 Have procedures andtraining on trafficmanagement beengiven to employeesand any visitors tothe workplace?

ensure pedestrians are awareof traffic management rules,including not walking behindloadshifting equipment whenin operation and staying ondesignated walkways andpedestrian areas

ensure all contractors andvisitors working on sitereceive induction regardingtraffic management and are

signed in ensure non-inducted visitors

are supervised at all timeswhen walking through the site

monitor and assessemployees compliance withthe traffic managementprocedures.

5.5 Have you clearlyidentified pedestrianwalkways and trafficdirections?

develop a site plan clearlyidentifying pedestrianwalkways and trafficdirections

review the site plan regularly(at least annually), haveit dated and signed offby the OHS Committee/Representative and SiteManager.

5.6 Are external deliverydrivers aware of yoursites traffic safetyprocedures?

develop a truck dockingprocedure to ensure deliverytrucks engage trailer braking,chocks and parking brakes atall times during unloading

ensure risks of drive-offsduring loading and unloadingare minimised (eg driver

not permitted to stay insidevehicle while being loaded/unloaded or ignition key puton a hook inside the dock).


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6. PERSONAL PROTECTIVE EQUIPMENT


6.1 Do pedestrians anddrivers (internal andexternal) wear highvisibility clothing in

traffic areas?

provide high visibilityclothing that meets theAustralian StandardAS/NZS 4602 High

Visibility Safety Garmentsand is appropriate for theirspecific use day or night

ensure pedestrians anddelivery drivers wear highvisibility clothing (day ornight) in traffic areas

provide high visibilityclothing (eg vests) for visitorsor other employees accessingtraffic areas from other areasof the workplace, eg officestaff entering warehouses.

6.2 Do you have a policyregarding appropriatefootwear in theworkplace?

write a policy regardingappropriate footwear inthe workplace and clearlydefine the term AppropriateFootwear for each area ofthe workplace

ensure persons accessingvehicle areas wear closed-inand/or safety footwear.

NOTES

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7. EXTERNAL TRAFFIC MANAGEMENT REQUIREMENTS


7.1 Do you have externalcontrolled speedlimits in place fortrucks, customers or

visitors vehicles tothe site?

install traffic-calming devicesto reduce the speed ofvehicles, especially whenapproaching pedestrian

or loadshifting equipmentoperating zones eg boomgates and self closing gates.

7.2 Have you providedsafe access andegress to andfrom your site forpedestrians?

provide line markings,signage and barriers for safepedestrian walkways.

7.3 For common areaswhere pedestriansand vehicles arerequired to operatewithin the same area,have you providedadequate safetycontrol measures?

provide line markings onthe ground to indicateappropriate parking lanes,driver safe zones andwalkways for drivers ofvehicles being loaded andunloaded

clearly define safety zonesprotected by bollards/barriersso that drivers or unloadingcrew can supervise unloadingat a safe distance fromloadshifting equipment andfalling loads.

NOTES

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SAMPLE WAREHOUSE TRAFFIC MANAGEMENT ACTION PLAN

Action

Required

Priority Person

Responsible

Est Completion

Date

Completed by

Signature/Date

Comments

1. Re-do linemarking ofall pedestrian

walkways

HighMedLow

M. Brown January 2009 Check allpedestrianwalkway areas

within thewarehouse

HighMedLow

HighMedLow

HighMedLow

HighMedLow

HighMedLow

HighMedLow

High

MedLow

HighMedLow

HighMedLow

HighMedLow

HighMedLow

HighMedLow


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RISK ASSESSMENT MATRIX

HOW DANGEROUS IS THE HAZARD YOU HAVE IDENTIFIED?

FOR EACH HAZARD THINK ABOUT THE FOLLOWING:

WORKCOVER HAZPAK MATRIX HOW LIKELY IS IT TO HAPPEN?

HOW BAD IS IT LIKELY TO BE? VERY LIKELY:

Could happenat any time++

LIKELY:

Could happensome time+

UNLIKELY:

Could happen,but very rarely

VERY

UNLIKELY:Could happen,but probablynever will

Kill or cause permanent

disability or ill health

1 1 2 3

Long term illness or

serious injury

!!!

1 2 3 4

Medical attention and

several days off work

!!

2 3 4 5

First aid needed

!

3 4 5 6

The numbers show how important it is to do something.

1 top priority: immediate action required

6 low priority: take action when possible.

Example

Hazard:Plate glass door at foot of steps

Judge severity:Someone falling down the steps could smash through the glass and be

very seriously injured. So it is a !!! hazard. (Look in the second row of numbers.)

Judge likelihood:This could easily happen at any time. So it is ++ very likely. (Look in

the first column of numbers.)

Second row, first column is priority number 1.So it is extremely important to fix this

hazard soon.


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DEFINITIONS

WHOLESALE TRAFFIC MANAGEMENT

Traffic Control Bollards, Barriers, Railings and Barricades

A physical barrier installed to separate pedestrians or property from loadshifting equipment

and other vehicles.

Competent Person

A person who has acquired through training, qualification or experience, or a combination of

them, the knowledge and skills to carry out that task.

Personal Protective Equipment (PPE)

Safety devices or safeguards worn by workers to protect against environmental hazards. PPE

includes such items as helmets, safety goggles, hearing protectors, face shields, sun screens,

respirators, harnesses and lanyards, arm guards, smocks, gloves, high visibility clothing and

safety boots.

Plant

Any machinery, equipment (including scaffold), appliance, implement or tool and any

component or fitting thereof or accessory thereto.

Risk Assessment

A process that estimates the effects or consequences of hazardous events on people,

property and the environment. The process would consider the likelihood of occurrence and

the severity of the consequences.

Safe Work Method Statement or Job Safety Analysis

A statement that:

describes how work is to be carried out

identifies the work activities assessed as having safety risks

identifies the safety risks

describes the control measures that will be applied to the work activities, and includes

a description of the equipment used in the work, the standards or codes to be complied

with, the qualifications of the personnel doing the work and the training required to do

the work.


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Scheduled Work

Scheduled Work is defined in the Occupational Health and Safety Regulation 2001,Part 9.1,

Clause 266 and includes some types of cranes and loadshifting equipment used in warehouses.

Pedestrian

A person travelling on foot.

Loadshifting Equipment plant designed to lift and/or move loads

Powered: eg motorised pallet mover/jack, forklift truck, walk-behind forklift, stock picker/

order picker, overhead crane, vehicle mounted crane

Manual: eg manual pallet jack, trolley, wheeled pallet.

Dock

Any area designated for the physical receipt and/or despatch of goods.

Delivery Vehicle

Any vehicle delivering or picking up items from a workplace (eg bicycle, motorcycle, car, van,

ute, truck etc).

Safety Zone

Designated work area protected by a physical barrier separating pedestrians and loadshifting

equipment.

Certificate of Competency

Certification determining competency to operate specific machinery, which is scheduled

under Clause 266 of the Occupational Health and Safety Regulation 2001(eg specified

types of forklift, crane, hoist etc). Also commonly called a Ticket or a Licence.

Site Plan

Building and perimeter layout detailing the flow of work processes and all necessary movements

of people, loadshifting equipment, vehicles, material and equipment of different types.

Traffic-calming Devices

Methods used to bring traffic movement to a momentary halt or reduce the speed of vehicles

eg boom gates, self closing gates, speed humps, chicanes.


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MORE INFORMATION

GUIDE TO OBTAINING MORE INFORMATION

WorkCover NSW

Phone: 13 10 50http://www.workcover.nsw.gov.au/

WorkCover NSW publications are available on the WorkCover website or by calling the

Publications Hotline on 1300 799 003. Some useful publications are:

Making your forklift work for you

Forklift Truck: National Certificate of Competency

Plant Guide 2001

OHS Legislation

Occupational Health and Safety Act 2000

Occupational Health and Safety Regulation 2001

http://www.legislation.nsw.gov.au/

Australian Standards

Standards Australia

Phone: 1800 035 822

http://www.standards.org.au/

Australian Standards are available from SAI Global www.saiglobal.com/shop

Email: [email protected] or phone 13 12 42

WorkSafe VIC

Forklift Safety Reducing the Risk

http://www.worksafe.vic.gov.au/wps/wcm/resources/file/ebcad2435c446c8/forklift_safety.pdf

ACT WorkCover

A Guide to Forklift Safety July 2005

http://www.workcover.act.gov.au/pdfs/guides_cop/Forklift_Safety_Booklet.pdf

Worksafe WA

Guidance Note Safe Movement of Vehicles at Workplaces

http://www.docep.wa.gov.au/worksafe/PDF/bulletins/safe_movement_vehicl.pdf

Shop, Distributive and Allied Employees Association (NSW Branch)

InfoSheet8 Working with Forklifts

http://www.sdansw.org.au/www/forms/forklifts.pdf

Safety-Engineer.com

Forklift Safety by Design

http://www.safety-engineer.com/forklift.shtml


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Health & Safety Executive UK

Improving the Safety of Workers in the Vicinity of Mobile Plant

http://www.hse.gov.uk/research/crr_htm/2001/crr01358.htm

Workplace Transport Safety

http://www.hse.gov.uk/pubns/indg199.pdf

Monash University Accident Research Centre (MUARC)

Forklift Trucks and Severe Injuries: Priorities for Prevention

www.monash.edu.au/muarc/reports/muarc030.html

NOTES

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NOTES

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Catalogue No. WC05856 WorkCover Publications Hotline 1300 799 003

WorkCover NSW 92-100 Donnison Street Gosford NSW 2250

Locked Bag 2906 Lisarow NSW 2252 WorkCover Assistance Service 13 10 50

traffic management warehousing 5856

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