Incident Investigation: Young Worker Falls From Forklift | WorkSafeBC

Summary

A young worker suffered a severe head injury after falling from an order-selector style forklift due to inadequate training and unsafe work practices. The incident highlights the importance of proper training, adhering to safety standards, and avoiding makeshift work platforms. The script urges employers to ensure equipment safety, supervise new workers, and follow manufacturer's instructions to prevent such accidents.

Takeaways

• 🚜 New equipment like an order-selector forklift can introduce unexpected dangers to the workplace.
• 🔍 Inadequate training on new equipment can lead to serious accidents, as seen with the new worker who had no prior forklift experience.
• 👷‍♂️ The Lead Hand, who was also inadequately trained, provided insufficient instruction on forklift operation and fall protection.
• 🚨 Employers must ensure that all workers are properly trained and authorized to use equipment before allowing them to operate it.
• 📐 The workplace setup, with protruding wood shelving and boxes, created an unsafe distance for workers to operate the order selector safely.
• 🛠️ The makeshift plywood-covered pallet used as a work platform was not compliant with safety standards, posing a serious hazard.
• 🔐 Using the makeshift platform compromised fall protection, as the safety lanyard was too short to reach into the racks.
• 💡 The incident highlights the importance of maintaining proper racking systems and following manufacturer's instructions for equipment operation.
• 👨‍🏫 Comprehensive training for workers and supervisors is crucial, including adherence to the CSA standard for lift truck operators and fall protection regulations.
• 👀 Supervisors must be knowledgeable about safe work procedures and regularly verify that workers are following them.
• 👶 Special attention is required for new and young workers, who may not recognize hazardous conditions in the workplace.
• 🛡️ While new equipment can offer benefits, it is essential to prioritize worker safety and protection against potential hazards.

Q & A

What was the main incident described in the script involving the new worker?

The main incident was a young worker falling from an elevated platform of an order-selector-style forklift, sustaining a serious head injury.

What type of equipment was involved in the incident?

An order-selector-style forklift was involved, which is different from a typical forklift as it has a designated operator’s platform that self-elevates to the desired height.

What were the two main roles of the workers in the warehouse?

The two main roles were the Lead Hand and the 'New Worker,' both of whom were responsible for hand-picking items out of boxes to fill orders.

What was the initial reason for the company to purchase the order selector?

The company purchased the order selector to make order-picking safer by giving workers easy access to all levels of racking in the warehouse.

What was the issue with the training the new worker received on the forklift operation?

The new worker had never run a forklift before and received minimal instruction from the Lead Hand, who was also inadequately trained on forklift operation and fall protection.

Why was the makeshift work platform on the forks unsafe?

The makeshift work platform was unsafe because it was not built to comply with required safety standards for work platforms mounted on forks, and it created a serious hazard to workers.

What was the consequence of using the plywood-covered pallet as a work platform?

Using the plywood-covered pallet as a work platform forced workers to forego using fall protection, as the safety lanyard was too short to allow them to reach into the racks.

What was the situation that led to the new worker's fall?

The new worker's fall was caused by an unsafe work platform with unguarded edges, no appropriate fall protection in use, and a gap to reach across while trying to access items on the racks.

What was the immediate action taken by the Lead Hand after hearing the noise from the new worker's area?

The Lead Hand immediately went to where the New Worker was working to see what had happened and found her on the floor, unresponsive.

What are some of the key lessons learned from this incident as outlined in the script?

Key lessons include always wearing fall protection, not using makeshift work platforms, maintaining racking systems, following manufacturer's instructions, training workers and supervisors to standards, and ensuring special care for new and young workers.

What additional measures should be taken to prevent similar incidents according to the script?

Additional measures include developing safe work procedures for new equipment, ensuring supervisors are knowledgeable and regularly check compliance with procedures, and considering the hazards of new equipment along with its benefits.

Outlines

00:00

🚜 Forklift Hazards and Worker Safety

The script discusses a workplace accident involving a new worker who sustained a serious head injury while operating an order-selector style forklift. The incident occurred due to inadequate training and unsafe working conditions. The company had introduced the new equipment to improve safety but failed to consider the proper use and training. The script emphasizes the importance of using fall protection, adhering to safety standards, and following manufacturer's instructions. It also highlights the need for proper training and supervision, especially for new and young workers, to prevent such accidents.

Keywords

💡Order Selector

An order selector is a type of forklift with a designated operator's platform that can be elevated to the desired height, allowing workers to easily access all levels of racking in a warehouse. In the video, the introduction of this equipment was intended to enhance safety by providing a safer way to pick orders, but it also introduced new hazards due to inadequate training and unsafe modifications.

💡Fall Protection

Fall protection refers to safety measures designed to prevent workers from falling from heights or to minimize the distance of a fall if one occurs. In the video, the importance of using fall protection is highlighted when a worker falls from an elevated platform, underscoring the necessity of proper training and equipment use.

💡Lead Hand

A Lead Hand is a worker who supervises and trains other workers, often in a specific area or task. In the video, the Lead Hand's inadequate training on forklift operation and fall protection is a contributing factor to the accident, emphasizing the role's responsibility for proper safety instruction.

💡New Worker

A new worker is an employee who has recently joined a company and is still in the process of learning the job's requirements and safety procedures. The video's incident involves a new worker who was not adequately trained on the use of the order selector, illustrating the risks associated with insufficient orientation and supervision of inexperienced staff.

💡Racking System

A racking system is a structure used in warehouses to store goods in an organized and space-efficient manner. The video mentions that the racking system was not properly maintained, which contributed to the accident by obstructing the safe operation of the order selector.

💡Makeshift Work Platform

A makeshift work platform refers to an improvised or temporary structure used to elevate workers for tasks such as order picking. In the video, the use of a non-compliant plywood-covered pallet as a work platform is identified as a serious hazard, highlighting the dangers of using non-standard equipment.

💡Fall Arrest Harness

A fall arrest harness is a personal protective equipment designed to catch a falling worker and limit the distance of the fall. The video discusses the importance of using a fall arrest harness properly, as the worker's failure to do so led to a severe injury.

💡Safety Standards

Safety standards are guidelines or regulations that outline the minimum requirements for safe work practices and equipment. The video emphasizes the importance of adhering to safety standards for work platforms mounted on forks, which were not met in the case of the makeshift platform.

💡Training

Training in the context of the video refers to the process of educating workers on the safe operation of equipment and adherence to safety procedures. The video stresses the need for comprehensive training to the CSA standard for lift truck operators and fall protection requirements, as inadequate training was a key factor in the incident.

💡Supervisor

A supervisor in the video is a person responsible for overseeing workers and ensuring that safety procedures are followed. The role of supervisors in training, regular checks, and enforcement of safety protocols is highlighted, emphasizing their critical part in preventing workplace accidents.

💡Hazardous Conditions

Hazardous conditions are circumstances that pose a risk of harm or injury to workers. The video describes the various hazardous conditions present in the workplace, such as the unsafe work platform and the lack of proper fall protection, which ultimately led to the worker's fall.

Highlights

New equipment in the workplace can introduce unexpected dangers.

A young worker suffered a serious head injury after falling from an elevated platform of an order-selector-style forklift.

WorkSafeBC’s investigation revealed inadequate training and safety measures in the workplace.

Workers were using a rolling scaffold staircase and ladders to access higher shelves.

The company introduced an order selector to improve safety in order-picking.

The new worker had no prior experience operating a forklift.

The Lead Hand, with insufficient training, instructed the new worker on forklift operation and fall protection.

The new worker was authorized to use the forklift with minimal instruction.

Wood shelving and boxes obstructed the order selector's path, complicating safe operation.

A non-compliant plywood-covered pallet was used as an unsafe work platform.

Using the makeshift work platform required workers to forego fall protection.

The incident occurred when the new worker was moving boxes without proper safety measures in place.

The Lead Hand found the new worker unresponsive on the floor after hearing a fall.

Key lessons include the importance of wearing fall protection and staying on designated platforms.

Makeshift work platforms should not be used as they compromise safety features.

Racking systems must be maintained for smooth operation of order selectors.

Manufacturer’s instructions and safe work procedures are crucial for new equipment.

Training to CSA standards and fall protection requirements is mandatory for lift truck operators.

Supervisors must be knowledgeable and ensure workers follow safety procedures.

Special attention is needed for orienting, training, and supervising new and young workers.

The importance of considering both the benefits and potential hazards of new equipment.

Transcripts

New equipment can introduce something unexpected into the workplace: danger.

A young worker, just 3 weeks on the job, fell from an elevated platform of this order-selector-style

forklift sustaining a serious head injury.

These are the findings of WorkSafeBC’s investigation.

Two young workers were employed in this warehouse: a Lead Hand, and the “New Worker.”

Their job was to fill orders by hand-picking items out of these boxes.

Workers used a rolling scaffold staircase to access the third level of racking and ladders

to access the upper shelves.

Thinking it would make order-picking safer, the company purchased an order selector.

Unlike a typical forklift, an order-selector has a designated operator’s platform that

the operator self-elevates to the desired height.

This new equipment gave workers easy access to all levels of racking in the warehouse.

The new worker had never run a forklift before.

The Lead Hand, inadequately trained on forklift operation and fall protection herself, showed

the new worker what she knew about operating the forklift and how to put on the fall arrest

harness.

With minimal instruction, the new worker was authorized to use the forklift.

That wasn’t the only problem.

The wood shelving and the boxes on them protruded from the racking frame into the aisle, preventing

the order selector from running closer than 12 to 17 inches away from the racking.

This added distance made it difficult for any operator, while properly wearing the required

fall protection, to reach items on the racks.

The employer introduced a plywood-covered pallet to be mounted on the forks.

Workers used it as a work platform to stand on, at elevation, to access items in the racks.

This work platform was not built to comply with required safety standards for work platforms

mounted on forks.

This created a serious hazard to workers.

In order to step onto the work platform from the designated operator’s platform, a worker

would have to forego using fall protection because the safety lanyard, designed to keep

the operator on the designated operator’s platform, would be too short to allow them

to reach into the racks.

With a gap to reach across, an unsafe work platform with unguarded edges, and no appropriate

fall protection in use, the stage was set.

On the day of the incident, the Lead Hand directed the New Worker to move all the boxes

on one set of racks to make way for new stock.

The Lead Hand then went to work in a different aisle.

After lunch, she heard the forklift running.

A short time later, the Lead Hand heard a box and then something else hit the floor.

She immediately went to where the New Worker was working to see what had happened and found

her on the floor, unresponsive.

She had fallen nearly 13 feet onto a concrete floor.

There are many lessons to be learned here: Always wear fall protection and remain on

the designated operator’s platform when using an order-selector style forklift.

Don’t use makeshift work platforms.

Doing so defeats the built-in safety features of a designated operator’s platform and

the fall protection system.

Maintain racking systems to ensure smooth and proper operation of order selectors

Follow manufacturer’s instructions for equipment and develop safe work procedures for equipment

new to the workplace.

Train workers and supervisors to the CSA standard for lift truck operators and to the fall protection

requirements in the Regulation.

Ensure supervisors are knowledgeable in the procedures and that they regularly check that

workers are following them.

Special care must be taken to orient, train, and supervise new and young workers.

Young and inexperienced, these workers just did not realize the hazardous conditions they

were working in.

Don’t just look at the benefits new equipment can provide, make sure workers are protected

against its hazards.