Focus
Safe stacking initiative
by Chris Alderson
Bulk stacking practices in Fonterra's global warehouse operations have been the subject of a specific project, that has lead to a dramatic reduction in the number of falling pallets.
It has been common practice in the dairy industry to stack pallets of milk powder without supporting racking. The powder is packed into a 25 kg bag and then up to 80 bags placed on a 2.2 metre wide pallet. This aids packing operations as the powder can then be loaded directly into a shipping container for export.
Stacking the powder over the years has not been without issue and there were a worrying number of incidents being reported where powder had fallen over in the warehouse resulting in loss of product and damage to building walls. The risk associated with falling powder pallets – which can weigh up to two tonnes – is obvious. Although Fonterra forklift operators have strong safety cages for protection it was still a substantial hazard.
In response to this risk Fonterra formed a team who devised a strong set of procedures and controls that when applied almost eliminates the risk associated with product falling in a bulk stacking environment. Time was spent talking with experienced forklift operators, whose opinions helped define what product was safe to stack, how high it could be stacked and the safe creation of rows of stacked powder. A height limit of five pallets was mandated and the formation of ëanchor stacks', at a lower height at the back of the row, created a much more stable stacking formation.
The rules around the minimum requirements, which included supervisor checking and a link to ongoing audits were agreed and published globally earlier this year.
The application of the safe stacking rules has resulted in an approximate 70 per cent reduction in the number of stack collapses.
One of the challenges for Fonterra is in training forklift operators and warehouse supervisors in the new stacking rules.
To assist with this a set of animated training videos were created which transmit the main messages in a highly visual way. Applying this training technique through the upcoming season will further reduce the number of high risk incidents.
Four training animations were created with the assistance of Revisia who specialise in industrial training and animation solutions.
The four training modules cover the following:
- how to assess product for stacking
- how to create row
- how to de-stack for export
- warehouse supervisors' duties
The animations can be played on standard windows PC s or as iphone/ipad applications.
Fonterra in New Zealand already has an in-house training programme called Forklift Code of Practice – or FCOP. The safe stacking videos will be used to supplement the FCOP training in New Zealand but are also available to international Fonterra operators – given that subtitles can be easily created to cover non English speaking audiences.
Chris Anderson is general manager of safety frameworks at Fonterra.
3M awards polytechnic for innovation in health and safety
Otago Polytechnic has won the 3M Award for Innovation in Health and Safety for an iPhone and iPad application it has developed called OP Tools. The interactive app uses video, text and audio to demonstrate the correct and safe way to operate different power tools and other equipment.
OP Tools was developed by third-year IT students Nolan Ratu, Anton Smith and Taua Piri, and design student Matt Norrish, with guidance from staff - Peter Sinclair, Matt Thompson, Mark Miller.
The application uses the latest technology to provide a rich interactive method of delivering content and measuring the learning outcomes for staff and students across multiple departments.
For their success, the team receives $3,000 from 3M towards professional development.
Saya Wahrlich from 3M Safety, Security and Protection Services says 3M and the judging panel were impressed by the Otago Polytechnic’s technological advancement, and that their entry epitomised what the 3M award is all about.
Otago Polytechnic health and safety advisor, Terry Buckingham, was delighted with the win.
“I would like to thank 3M for sponsoring this award, and we are excited to be recipients. It is encouraging to be recognised for our hard work in helping to improve and promote health and safety.”
The team from Bioworks and Greater Wellington Regional Council was awarded second place for their ‘Muzzle’ innovation - a new motorbike exhaust port guard which helps to prevent serious burns from bike accidents.
BioWorks specialises in possum and other predator control and their 17 staff cover about 200,000 hectares of the Wellington Region each year.
Contract co-ordinator, John Hopkirk, says, “Our guys are working on farmland or in bush and it can get pretty steep and rough. They use motorbikes to get around their traps and bait stations, and minor falls at low speed happen from time to time.
We can’t stop that happening, but we can stop them getting burnt, when it does.
“The problem started when two staff suffered painful burns, in separate incidents, after falling off motorbikes and getting a leg trapped against a hot exhaust pipe. Both staff had to have several weeks off while the burns healed.
“The damage was done by a piece of unprotected pipe where the exhaust pipe leaves the engine.
“We’ve got 20 of these motorbikes, so we had to do something to make sure this didn’t happen again.
“When the first guy burnt his leg we wrapped all the pipes in exhaust tape. The bikes are constantly under attack from mud, sand, cow dung and the tape was disintergrating quite quickly and was getting blown off when they washed down their bikes.
“After the second burnt leg, we needed a permanent solution right away. That’s where the idea for exhaust muzzle came in.
“We put our heads together, came up with an idea and shot across to Langlands to see if they could make something to suit. “They put together an exhaust muzzle and we tried it out. It worked brilliantly. It gets warm, but not scorching like the exhaust it’s covering.
“Now we have an exhaust muzzle on every bike.”
Safety NetWorx was awarded third place for their commitment to providing essential and relevant health and safety information for their communities through free-to-attend seminars and workshops.
Ian stretton, one of the founding members of Safety NetWorx and health and safety advisor for Taupo District Council said:
“Most community-based providers and employers know their needs, obligations and responsibilities to effectively manage safe and healthy workplaces for their employees.
“For many, the prohibitive costs and time spent away from the job, meant that many employers could ill-afford to send their health and safety representatives and other staff to training opportunities.
“We sent out invitations and requests for presentations and workshops to the best professional health and safety–related speakers available. The requests and invitations were readily accepted and quickly filled, with others requesting the opportunity to present at subsequent seminars.
“Most speakers gave of their services free of charge, as they, too, recognised an opportunity to do good and give something back to the community. Many presentations and workshops were designed as interactive sessions.
“Case studies and examples of applying the information presented, made the application of the subjects meaningful and of value to attendees.
“By pooling resources, allocating tasks to each member of the Safety NetWorx Team and each member giving freely of their own time, meant that costs could be reduced to a minimum, as there was little budget available to fund the venture.”