Hi everyone — for a glass‑manufacturing factory (cutting/polishing/tempering + cranes + forklifts), best‑practice controls to manage high‑risk glass breakage and suction‑lifter failures are:

Planning & competence

• Task‑specific risk assessment + lift plan for each lift type (sheet size/thickness/coatings, route, landing, people/traffic).

• Only trained/authorised operators for vacuum lifters, cranes and forklifts (include failure factors + emergency actions).

Engineering controls for suction lifters (critical)

• Use vacuum lifters rated for the glass type (SWL, surface condition, temperature limits).

• Fit/require: vacuum gauge visible to operator, low‑vacuum alarm, and vacuum reserve / non‑return valves (where applicable).

• Correct pad type and condition; keep pads/seals clean, undamaged, and compatible with coated/low‑E surfaces.

Pre‑use checks (every shift)

• Check pads/seals, hoses/fittings, filters, gauge/alarm function, power/battery, controls.

• Confirm glass surface is clean/dry (dust, oil, water, condensation = loss of grip).

• Do a brief hold test per procedure; any defect → tag out immediately.

Maintenance & inspection

• Planned preventative maintenance to manufacturer instructions.

• Formal inspections/thorough examinations and records for lifting accessories (per your country’s legal requirements).

Exclusion zones / “drop zone” control

• Establish lifting exclusion zones with barriers/signage and enforce them.

• Never travel a vacuum‑lifted load over people; keep loads as low as practicable.

• Use a banksman/spotter for blind moves and tight areas.

Controls to reduce glass breakage

• Safe storage on purpose‑built A‑frames/stillages on level floors; prevent unstable stacking.

• Good housekeeping: remove strapping/offcuts, control dust, keep routes clear and dry.

• Avoid impact/edge damage: use edge protection, controlled set‑down, and correct handling tools.

Forklift/crane interaction

• Segregated traffic routes, speed limits, clear crossings and visibility controls.

• Use only approved glass attachments/stillages; no improvised lifting/balancing.

PPE (last line)

• Cut‑resistant gloves/sleeves, eye/face protection, safety footwear, and task‑appropriate clothing.

Emergency response

• If vacuum alarm triggers: STOP → secure area → lower to a safe surface → isolate equipment → report/investigate.

• Treat breakage as an emergency: stop traffic, cordon, safe clean‑up, investigate root causes.