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Section 1............................................................................................. 5
Assess risks arising from the relocation of a load .................. 5
Section 2........................................................................................... 25
How do you plan a load relocation and relocate loads?....... 25
This
Learner’s
Guide
is
about
the
skills
and
knowledge
required
to
shift
loads
using
manually-‐operated
mechanical
equipment,
including
assessing
the
risks
associated
with
relocating
the
load,
planning
the
relocation
process
and
carrying
out
the
relocation
with
the
aid
of
the
equipment
in
accordance
with
the
plan.
Persons
achieving
competence
in
this
unit
will
need
to
fulfil
all
of
the
relevant
state/territory
OHS
regulatory
requirements
concerning
the
safe
lifting
and
handling
of
a
load
using
manually-‐operated
load-‐
shifting
equipment.
It
should
be
noted
that
the
use
of
the
term
'SWL'
(Safe
Working
Load)
is
under
review
by
Standards
Australia
and
may
be
replaced
in
the
future
by
the
term
'Rated
Capacity'.
The
Elements
of
Competency
from
the
unit
TLID207C
Shift
a
load
using
manually-‐operated
equipment
covered
in
this
Learner’s
Guide
are
listed
below.
Assess
risks
arising
from
the
relocation
of
the
load
Plan
load
relocation
Relocate
load
This
unit
of
competency
is
from
the
Transport
and
Logistics
Training
Package
(TLI07).
It
is
important
to
plan
your
learning
before
you
start
because
you
may
already
have
some
of
the
knowledge
and
skills
that
are
covered
in
this
Learner’s
Guide.
This
might
be
because:
• you
have
been
working
in
the
industry
for
some
time,
and/or
• you
have
already
completed
training
in
this
area.
Together
with
your
supervisor
or
trainer
use
the
checklists
on
the
following
pages
to
help
you
plan
your
study
program.
Your
answers
to
the
questions
in
the
checklist
will
help
you
work
out
which
sections
of
this
Learner’s
Guide
you
need
to
complete.
This
Learner’s
Guide
is
written
with
the
idea
that
learning
is
made
more
relevant
when
you,
the
learner,
are
actually
working
in
the
industry.
This
means
that
you
will
have
people
within
the
enterprise
who
can
show
you
things,
discuss
how
things
are
done
and
answer
any
questions
you
have.
Also
you
can
practise
what
you
learn
and
see
how
what
you
learn
is
applied
in
the
enterprise.
If
you
are
working
through
this
Learner’s
Guide
and
have
not
yet
found
a
job
in
the
industry,
you
will
need
to
talk
to
your
trainer
about
doing
work
experience
or
working
and
learning
in
some
sort
of
simulated
workplace.
Assessment
of
this
Unit
of
Competency
will
include
observation
of
real
or
simulated
work
processes
using
workplace
procedures
and
questioning
on
underpinning
knowledge
and
skills.
It
must
be
demonstrated
in
an
actual
or
simulated
work
situation
under
supervision.
Section 1
Section outline
The need to assess (judge) risks arising from shifting materials
The
importance
of
correct
manual
handling
to
the
worker
in
the
warehouse
Shifting
materials
safely
may
make
up
the
majority
of
the
work
the
storepeople
do
in
a
warehouse.
‘any
activity
requiring
the
use
of
force
exerted
by
a
person
to
lift,
push,
pull,
carry
or
otherwise
move,
hold
or
restrain
any
person,
animal
or
thing’.
Place a tick in the space that you think is the correct answer to this
question.
Percentage
5% ?
10% ?
20% ?
33% ?
50% ?
There
are
many
small
steps
making
up
the
process
of
risk
assessment
of
a
load
relocation
job.
Firstly,
you
need
to
make
sure
you
have
identified
the
correct
goods
or
materials
to
be
shifted.
Always
make
sure
you
are
looking
at
the
right
load.
Check
your
product
or
stock
numbers
carefully.
A
hazard
is
‘a
source
of
potential
loss
or
danger’.
In
other
words,
it
is
an
accident
waiting
to
happen.
It
is
up
to
everyone
involved
in
the
workplace
to
recognise
hazards
and
fix
them
before
the
accident
can
happen.
In
particular,
this
is
the
employer’s
responsibility.
This
rule
is
the
basis
of
a
safe
and
healthy
workplace.
What is a risk?
A
risk
is
‘the
possibility
of
suffering
harm
or
loss’.
This
means
doing
something
that
is
likely
to
cause
some
sort
of
damage
or
injury
(harm
or
loss).
However,
harm
or
loss
might
not
happen
at
that
particular
time
or
the
injury
might
not
be
immediately
obvious.
This
is
quite
often
the
case,
especially
with
back
injuries,
which
tend
to
develop
over
time
and
with
repetition
of
activity;
for
example,
from
frequent
twisting
and
turning.
Hazards Risks
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
_____________________ _______________________
The
hazards
and
risks
you
face
will
change
from
place
to
place.
As
you
are
moving
around
from
section
to
section
(or
business
to
business),
it
is
important
to
be
constantly
on
the
lookout
for
hazards.
The
risk
of
injury
can
be
reduced
or
removed
by:
• doing
tasks
in
new
ways
that
remove
the
need
for
lifting
and
carrying
• ensuring
that
tasks
beyond
your
ability
are
only
attempted
with
help.
Use
teamwork
and/or
mechanical
aids.
The
key
to
safe
manual
materials
handling
is
in
the
way
you
carry
out
the
tasks.
Tasks
can
be
made
safer
by:
• reducing
lifting
and
lowering
forces
• avoiding
bending,
twisting
and
reaching
• reducing
pushing,
pulling,
carrying
and
holding.
Parts
of
these
problems
can
be
overcome
by
job
redesign.
This
is
largely
a
matter
for
management.
You
can
help
by
suggesting
ideas
to
your
OHS
Committee
or
supervisor.
Job
redesign
can
reduce
the
risk
to
you
by:
• modifying
(changing)
the
object;
for
example,
making
smaller
packages
• modifying
the
workplace
layout
(the
area
you
actually
work
in)
Adjustable work heights. Store heavier and frequently A simple lever and wheels avoids
used items at waist level. stooping and reduces effort.
What do you think are some of the ways to improve your manual
handling methods and reduce risks to yourself and others?
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You
must
be
able
to
accurately
assess
all
the
risks
involved
with
a
particular
load
relocation
task.
This
includes
risks
to
yourself,
the
load
and
any
other
materials
on
your
relocation
route.
You
will
only
become
good
at
assessing
risks
with
practice.
If
you
are
in
any
doubt,
ask
for
help!
Always
adopt
a
careful
attitude.
Always
test
the
weight
of
the
load
before
attempting
to
lift
it.
Many
injuries
are
caused
by
trying
to
lift
a
load
that
is
much
heavier
than
expected.
When
you
know
the
weight
you
will
also
have
a
good
idea
of
the
centre
of
gravity.
If the load seems to heavy or difficult to balance, don’t lift it.
You
also
need
to
consider
the
effect
that
relocating
part
of
the
load
will
have
on
the
original
load
base.
We
have
all
seen
a
cartoon
character
remove
a
can
from
the
bottom
of
a
pyramid
display
in
a
grocery
store.
Sometimes
the
pile
stays
up,
defying
gravity,
but
more
often
the
cans
go
everywhere.
That
is
a
very
obvious
example.
You
will
deal
with
load
relocations
that
are
far
more
subtle.
You must also think about the contents of the load.
Different
load
contents
have
different
behaviour
and
must
be
treated
accordingly.
For
example,
liquids
behave
very
differently
to
solids
when
being
moved.
Dangerous
or
hazardous
materials
require
special
handling
that
is
the
subject
of
regulations
and
workplace
codes
of
practice.
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Yes No
In
most
instances
of
safely
shifting
materials
that
you
will
undertake,
you
are
the
person
who
will
make
the
assessment
of
the
risks
arising
from
relocating
that
load.
You are also the person most likely to suffer from a miscalculation.
The
six
steps
in
lifting
materials
safely
are
as
follows.
1. Size
up
the
load
(described
in
detail
above).
6. Use the muscles in your legs to lift, not the muscles in your back.
The
correct
method
of
lowering
a
load
is
very
similar
to
the
above
rules
for
lifting,
except
done
in
reverse!
This activity is divided into two parts. It is important that you work
through these in order and review your progress on completion of
each part. Refer to the feedback section at the end of this guide.
Part one
Part two
They
help
you
to
remove
or
reduce
the
stresses
that
your
body
suffers
when
carrying
out
manual
handling
tasks.
Aids
and
equipment
to
improve
manual
handling
can
be
quite
simple
and
include:
• safety
stands
• adjustable
bench
heights
• ramps
• roller
conveyors.
You
should
use
an
aid
to
avoid
actions
that
are
hazardous
to
you.
Aids
will
remove
or
reduce
the
risk
to
you
when
carrying
out
tasks
that
involve
bending,
twisting
and
carrying.
The
most
common
types
of
aids
provide
you
with
leverage.
This
increases
the
force
that
you
can
apply
with
a
reduced
amount
of
effort.
Levers
can
come
in
many
forms,
as
shown
in
the
examples
on
the
next
page.
It
is
now
time
to
observe
and
practice
the
correct
use
of
manual
handling
aids
and
equipment
in
your
workplace.
The
rules
that
you
need
to
apply
when
using
these
aids
are:
• Understand
the
principle
involved;
e.g.
leverage
helps
you
to
take
full
advantage
of
the
equipment.
• Know
how
the
item
actually
works.
• Use
the
right
aid
for
the
job
at
hand.
• Check
that
the
aid
is
correctly
maintained
and
in
good
repair.
• Carry
out
the
task
to
the
best
of
your
ability.
• Remember
that
just
because
you
have
a
mechanical
advantage
does
not
mean
that
you
should
over-‐exert
yourself
by
trying
to
do
more.
• Get
help
to
move
the
load
onto
the
device;
e.g.
when
sliding
a
drum
onto
a
trolley
or
lifting
a
heavy
box
down
from
a
shelf
to
place
it
on
a
trolley
jack.
• Position
the
device
where
it
is
easy
to
reach,
especially
if
there
are
a
number
of
items
to
be
moved.
Aim
to
avoid
repetition,
especially
when
the
job
involves
twisting
and
bending
movements.
Identify the correct use of handling aids and try to decide if the best
measures are being used for the tasks that you see.
Jot down your comments below and discuss them with your trainer,
preferably in a group discussion. Your comments should be based
on what you have learnt from this Learner’s Guide up until now.
Section 2
Section outline
Carrying
out
the
task
and
checking
that
the
task
has
been
completed
to
the
relevant
workplace
standards
You
will
need
to
plan
the
relocation
of
the
stock
to
the
correct
site.
Go
to
the
new
site
and
check
exactly
where
and
how
the
relocated
load
is
to
be
placed.
Check
all
documentation
to
ensure
that
you
have
correct
stock
and
have
the
correct
place
for
the
new
location.
You
will
need
to
consider
all
aspects
of
shifting
materials
safely,
including
planning
the
route
for
your
relocation.
You
must
also
assess
all
the
risks
associated
with
the
route
you
are
planning
to
use.
Wherever
possible,
use
a
mechanical
aid.
Ask
yourself
these
questions
when
you
are
planning
to
relocate
a
load:
• Where
are
you
relocating
the
stock
to?
• Which
route
is
the
quickest?
• Is
this
route
the
safest
(taking
account
of
protrusions,
width,
height,
packages
or
pallets
in
aisles,
fragile
goods
along
the
way)?
• How
will
you
place
the
load
in
the
new
location?
• Are
you
adding
the
load
to
an
existing
load?
• How
will
the
existing
load
be
affected?
• Have
you
checked
the
points
of
balance
and
total
resulting
load
weight?
• Can
you
do
the
job
alone
or
do
you
need
help?
• Which
load
shifting
equipment
will
you
use?
For
each
task
you
will
need
to
make
your
assessment
by
close
observation
and
identification
of
the
stock
or
materials
to
be
moved,
the
actual
relocation
site,
the
route
to
that
site
and
the
manual
handling
procedures
most
suitable
to
the
task.
When
you
have
observed
and
considered
all
these
elements
you
need
to
plan
your
relocation.
Whenever
you
are
using
ropes
slings
or
chains
to
lift
a
load
you
need
to
know
the
SAFE
WORKING
LOAD
or
SWL
of
each
piece
of
equipment.
For
a
new
piece
of
equipment,
under
normal
conditions,
the
SWL
will
be
the
WORKING
LOAD
LIMIT
or
WLL,
as
specified
by
the
manufacturer.
The
WLL
should
be
displayed
on
any
rope,
sling
or
chain
you
are
using
for
lifting.
It
is
your
responsibility
to
check
the
SWL
of
your
equipment
which
can
vary
from
the
WLL
because
of:
• wear
• damage
• knots
that
reduce
the
strength
of
a
lifting
rope
by
50%
• angles
it
is
illegal
to
sling
a
load
with
an
angle
over
120
degrees
• hitches
that
can
reduce
the
lifting
strength
by
20
to
50%.
The
working
load
limit
is
equal
to
the
breaking
load
divided
by
the
safety
factor.
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Collect 3 slings from your workplace and fill in the table below:
Types of sling
You
need
to
choose
the
right
type
of
sling
for
your
load.
Chain
is
very
strong
and
durable
but
can
damage
a
soft
load;
natural
fibre
rope
slings
fray
easily
and
should
not
be
used
on
loads
with
sharp
edges.
These
are
the
properties
of
various
types
of
lifting
sling:
• natural
fibre
rope
slings
− easily
damaged
by
cuts,
chemicals,
damp,
heat
and
sunlight
− need
packing
to
protect
against
sharp
edges
− should
be
dried
out
naturally
• synthetic
fibre
rope
slings
− can
stretch
40%
before
breaking-‐the
snap
and
recoil
can
cause
serious
injury.
− can
be
damaged
by
cuts,
chemicals,
heat
and
sunlight
• synthetic
fibre
webbing
slings
− these
include
double
eye
slings,
endless
slings
and
slings
fitted
with
metal
end
pieces
− the
outer
sleeve
should
be
made
of
the
same
material
as
the
inner
fibre
so
that
internal
damage
and
wear
is
not
obscured
− can
be
damaged
by
cuts,
chemicals,
heat
and
sunlight
• flexible
steel
wire
rope
slings
− are
strong
light
and
durable
− require
the
use
of
gloves
− can
be
damaged
by
stretch,
water
(rust),
chemicals
− wire
rope
clips
or
bulldog
clips
must
never
be
used
to
make
lifting
slings
• chain
− long
lasting,
not
damaged
by
sharp
corners,
heat,
water
and
most
chemicals
− expensive
and
heavy;
can
mark
loads
–
needs
to
used
with
padding
− if
SWL
is
hard
to
see,
you
can
calculate
it
using
the
formula:
diameter
x
diameter
x
10
=
SWL
in
kilograms
− if
you
are
sure
that
the
chain
is
alloy
chain
grade
T
or
8,
SWL
in
kilograms
=
diameter
x
diameter
x
30
− you
can
shorten
chain
using
a
grab
hook
or
a
clutch
hook.
Safety of slings
You
are
responsible
for
the
equipment
that
you
use,
so
when
using
any
lifting
equipment:
• check
that
the
slings
are
marked
with
a
readable
WLL
or
SWL
tag
• do
not
use
hand
spliced,
untested
slings
• do
not
use
bulldog
grips
• if
you
find
that
the
sling
has
been
damaged,
remove
it
from
the
working
area
− check
with
the
manufacturer
to
see
if
it
can
be
repaired
− if
it
cannot
be
used,
cut
it
up
and
discard
it
• inspect
slings
before
every
use
• keep
a
sling
register
and
record:
− inspections
(a
thorough
inspection
should
be
done
every
3
months
with
a
check
with
a
full
safe
working
load)
− repairs
− other
relevant
information
such
as
prolonged
exposure
to
heat,
dampness.
List 5 slings that you use in your workplace, their safe working load
and any observations you make upon close inspection of the sling.
An example has been provided to guide you.
Operation
of
this
type
of
equipment
may
require
a
separate
license
or
certificate
of
competency.
This section gives some general points on loading unusual cargo.
The
Load
Restraint
Guide
will
give
detailed
regulations
about
each
type
of
cargo.
If
you
are
moving
unusual
cargo
you
need
to
study
the
regulations
and
follow
the
guidelines
exactly.
You
need
to
take
care
in
preparing
goods
to
be
placed
on
the
vehicle.
Wherever
possible
goods
should
be
packed
into
cases
or
on
pallets
or
in
secure
bundles.
This
makes
loading
and
securing
on
the
vehicle
easier
and
safer.
Most
of
the
types
of
cargo
dealt
with
here
will
also
need
to
be
secured,
protected
or
restrained
in
some
way.
Containers
Most
containers
are
built
to
ISO
standards
and
have
corner
castings
for
lifting
and
for
attaching
to
twist-‐locks
on
specialised
container
carriers.
Remember that an empty container rides higher than a full one.
Use this planning checklist to make sure that you have all the
information you need and have considered all risks associated with
shifting materials and relocating loads. You may like to photocopy
these sheets and use them for several load relocation tasks. If you
are shifting materials with a team, you can complete the checklist
together.
Ask your trainer to check the plan and give you feedback and
suggestions before you perform the task.
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Put
your
plan
into
action
and
follow
the
steps
you
have
outlined.
You
should
not
need
to
make
any
adjustments
to
your
relocation
plan
if
you
have
considered
everything
carefully
beforehand.
Since
you
are
taking
responsibility
for
the
task,
you
should
make
sure
that
all
activities
are
performed
with
due
care
whether
you
are
working
alone
or
with
a
team.
In
particular,
make
sure
that
your
manual
handling
techniques
are
followed
correctly.
If
you
are
working
with
a
team,
make
sure
that
each
team
member
understands
the
plan
and
the
correct
procedures
for
lifting,
carrying
pulling,
pushing
and
setting
down.
Make
sure
you
have
a
set
of
agreed
instructions
for
each
of
the
movements
you
are
making.
Talk
the
team
through
the
plan
and
the
instructions
you
will
be
calling
to
them.
Follow
the
exact
route
that
you
have
selected.
Make
sure
you
have
clearance
beforehand,
especially
if
other
people
are
performing
similar
tasks
in
the
same
area.
When
you
have
set
the
goods
down
in
their
new
location,
check
the
stability
from
all
angles
and
consider
pressures
or
incidents
that
may
affect
the
stability
of
the
load.
Check
that
the
relocated
goods
comply
with
workplace
regulations.
Make
sure
that
you
report
any
changes
to
the
plan
or
to
the
condition
of
the
goods.
When you have shifted the load and set it down, check through the
following items:
Did you:
Additional
resources
Publications:
• Ackerman
K.B.
Practical
Handbook
of
Warehousing,
Van
Nostrand
Reinhold,
New
York
• Lindkvist
R.G.T
Handbook
of
Materials
Handling,
Ellis
Horwood
Ltd,
Chichester,
UK
1985
• Tomkins
&
Smith
The
Warehouse
Management
Handbook,
Megraw
Hill
Book
Company,
USA
• Occupational
Health,
Safety
&
Welfare
Regulations,
1995
• Occupational
Health,
Safety
and
Welfare
Act,
1986.
Regulations
and
Approved
Code
of
Practice.
Manual
Handling
No2
1990
• Workplace
Health
&
Safety
Handbook,
Occupational
Health
&
Safety
Commission,
1992
• Understanding
Manual
Handling,
Occupational
Health
&
Safety
Commission
• Young
Workers
and
Manual
Handling
-‐
Issues
for
Employers,
Occupational
Health
&
Safety
Commission
• Manual
Handling
-‐
Health
and
Safety
Issues
for
Women
Workers,
Occupational
Health
and
Safety
Commission
Videos:
• Manual
Handling
-‐
Safetycare
Series
• Recognition,
Evaluation
&
Control
of
Hazards
-‐
Safetycare
Series
• Slips,
Trips
and
Falls
-‐
Safetycare
Series
• An
easy
guide
to
manual
handling
-‐
Avoiding
back
strains
&
pains
-‐
Workplace
Video
Productions
Feedback on
activities
The responses provided in this section are suggested responses.
Because every workplace is different, your responses may vary
according to your specific workplace procedures, the equipment
available and the nature of the business.
Percentage
5% ?
10% ?
20% ?
33% ?
50% ?
Some of the hazards and risks that you might have thought of are:
Hazard Risk
Some of the ideas that you might have considered to improve your
manual handling methods are:
• plan the movement before you lift, carry, hold, push, etc.
• stand close to the load
• bend your legs, not your back - keep your back straight
• apply a firm grip, keep the load close to your body
• don’t jerk the load; move or lift it smoothly
• use your feet to turn, don’t twist your body
Part one
As you consider all the risks associated with each of the three
loads you will find that a checklist would be very useful.
Part two
• Are the tasks being carried out in a safe manner; are the rules
previously covered in this Learner’s Guide being applied?
• Are suitable protective devices being used as necessary, e.g.
gloves, breathing filters, helmets, safety boots, etc?
• Are manual handling aids being used? If not, could an aid
provide the worker with mechanical advantage? If aids are
being used, are they right for the job, serviceable and used
correctly?
The Safe Working Load is the load limit for that sling taking into
account:
• wear and tear
• knots
• hitches
• angles.