Rank: Forum user 
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I have never before had to deal with the operation of manned order pickers and would welcome some thoughts on an issue we have, as follows.
Our order picker had the safety equipment that came with the machine removed as the management were unhappy with our staff having to use a rope to evacuate. A evacuation procedure has been put in place that relies on others manually lowering the operator who has access to a whistle to summon help.
The HSE have issued a bulletin advising that rope evacuation should only be considered a last resort so what we have in place fits with their guidelines, however, the following situation prevails:
1) we have removed a supplied safety system form the machine and
2) our external training provider advises our staff each time they have refresher training that he should be training them to evacuate using the rope method and our original safety equipment.
3) the risk assessment for the machine is rather generic and does not address that the original safety equipment has been removed.
Question: What would you do in this instance?
Any advice would be appreciated
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Rank: Super forum user
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Linda, The fact that the employer has removed the evacuation gear supplied with the machins is of some concern to me. Does the employer have any experience in the use of this equipment in an emergency situation that makes them better qualified than the equipment supplier? How are you to ensure that the help of others is carried out safely and what training in this activity have you provided? How long does it take to undertake this revised evacuation process against that involved with the original method? Does it mean that the length of time it takes is longer if so how is this juastified when a fire evacuation is called for? Am I right to assume that the use of the original emergency kit is included in the original training programme for the machine users? You can see from my response that there are several weaknesses in the use of the system you have introduced and this is simply on the wish of your management!
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Rank: Super forum user
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Sorry had not finished with the most important bit of your question, the risk assessment should be reviewed as a matter of urgency as it seems to me that it is out of date and therefore non compliant with the law.
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Rank: Super forum user
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I wouldn't say they have removed a "safety system" (that infers it is required for the safe normal operation of the machine), more a method of evacuation.
This seem similar to the method to lower a MEWP if the operator gets stuck at height, clearly a over using a rope to ascend down.
You need to make sure that:
- the communication system is adequate (i.e. can you guarantee the whistle will always be heard or may you need to look at walki talkies / mobile phone etc.)
- The persons on the ground have received appropriate training in the lower technique.
I would suggest you revisit the provision of a rope for getting down, as this is a fall back option. What if the ground controls also malfunction? (maybe due to the same faulty that caused it to be locked at height). I'd say keep the rope as an ultimate back up. Staff would need training in how to use the rope.
lastly, your risk assessment would need to be updated to reflect the current arrangements etc.
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Rank: Super forum user
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Does anyone have a link that takes me to a picture of this equipment? Don't understand the need for the rope.
We used an order picker that looked similar to a forklift. A platform raised with the driver. In front of the driver was a forklift arrangement that held the pallet being picked onto.
The driver could lower the platform from the platform or it could be lowered from ground level.
There was a ladder available if the equipment ever broke down but never happened.
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Rank: Super forum user
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Linda G - the rope is there for use in the event that the machine fails while the forks are located within a rack.
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Rank: Super forum user
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Linda
I am guessing this is the "bulletin" you are referring to
http://www.hse.gov.uk/lau/lacs/20-3.htm
Others may find it interesting. As you will read in the document HSE makes reference to a number of injuries and fatalities using such systems. I recall reading an incident a few years ago where such an accident occurred during a training session cannot remember if it was the instructor or trainee that was involved and have been unable to locate the details.
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Rank: Super forum user
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Rank: Super forum user
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If there are anything like the ones we had, they go up about 13 meters and you had to climb out and around as not all have an escape hatch in the bottom. You really do no want people abseiling down (had one guy lose all the skin of his hands whilst being trained one).
All of these truck have an hydraulic release valve at the bottom which will control the decent, very simple to use. Another option is to use a second orderpicker (if you have one) to get the person out. I supplied the operators with air horns to signal if they were stuck, was effective enough (of course will depend on how far away the pick desk is or other personnel etc)
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Rank: Forum user
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Linda,
Order picker is a broad term talking about a wide range of equipment, and if the forks stick straight ahead of the driver like a fork truck and the truck is only used to pick within aisle then rope evacuation equipment may not be necessary and emergency lowering training would suffice.
If the forks reach and turn picking pallets from racking then the two emergency systems are complementary and are for different scenarios. Emergency lowering can be facilitated from the ground only when the truck is not engaged within the racking, the rope evacuation system is to permit the operator to escape when there has been a failure and the forks are extended in the racking rendering the emergency lowering ineffective.
In this case your procedures should include training personnel in emergency lowering procedures and rope evacuation techniques unless you can suggest alternative methods which would be deemed acceptable.
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Rank: Forum user
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Thank you everyone for your feedback and Alistair in particular.
BR Linda
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