Case Study IV The Plant is approximately 100,000-sq. ft. and produces automotive parts on 12 lines with a separate Press Department, located at the rear of the plant, that produces parts for the lines. There are 15 forklifts that service the lines and the Press Department. All of the aisles in the plant are used for both pedestrian and forklift traffic. The aisleway between Shipping/Receiving is used by all of the Forklift Operators as they service their lines. It also is used by all of the employees working on lines at the rear of the plant, to access their work areas. This incident occurred five minutes prior to the start of First Shift. A female Press Operator, Mary, was walking from the Womens Locker Room, at the front of the plant, to the Press Department at the rear of the Plant. She was at the last of a group of 20 employees headed for her workstation. A Third Shift Forklift Operator was delivering parts to a line on the Shipping/Receiving Aisle. This was his last assignment before the end of his shift, which had to be completed prior to the start of First Shift. He stopped to talk with the Third Shift Lead on the line, after he had made his delivery. The female employee saw the Forklift Operator stopped to talk with the Lead. She assumed that the operator saw her and proceeded to walk behind the forklift. The Forklift Operator finished talking with the Lead and looked behind him. He saw the large group of people who had walked past him, but he didnt see anyone behind him. He put the forklift in reverse and backed up. He had gone about a foot when he heard screaming. That is when he realized that someone had been behind him. He stopped and pulled the forklift forward and parked it. The female employee sustained major trauma to both of her legs and feet and required months of treatment and therapy to recover from her injuries. The Forklift Operator said that he looked but didnt see anyone behind him. His ability to see directly behind the forklift is hampered by the placement of the propane fuel tank and the design of the roll cage. He had completed his last assignment and was going to drop his forklift off at the rear of the plant and then punch out. The employee who was injured said that she had always taken the same route to her workstation, and that she had walked behind the same Forklift Operator on numerous occasions, and that he had always seen her before. For years prior to the accident there had been numerous near misses between pedestrians and forklifts, most of which had been reported. The management was aware of the problems that existed, and had completed several studies. These studies recommended restricting forklift operation or pedestrian.traffic, warning systems and safety training, but no actions were ever taken prior to the accident

Question :

Major Safety Systems Training & Procedure Goals / Hazard Identified 3/7 Sub Safety Systems / Control Measures Major Safety Systems Training & Procedure Goals / Hazard Identified 3/7 Sub Safety Systems / Control Measures