Safety First September 2010

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Solutions Guide

September 2010

INSIDE: Body Protection Height Safety Materials Handling ● Production Line Safety ● Waste & Hazardous Environments ●

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>>> A SPECIAL SUPPLEMENT PRODUCED BY REED BUSINESS INFORMATION

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CONTENTS

SafetyFirst.

Editor Sarah Falson Tel: (02) 9422 2480 Fax: (02) 9422 2722 E-mail: sarah.falson@reedbusiness.com.au Victoria sales Project Manager Michael Northcott Mobile: 0448 077 247 E-mail: michael.northcott@reedbusiness.com.au New South Wales sales Anthony Head Tel: (02) 9422 2368 Fax: (02) 9422 2966 E-mail: anthony.head@reedbusiness.com.au Queensland sales Sharon R. Amos Tel: (07) 3261 8857 Fax: (07) 3261 8347

E-mail: sharon.amos@reedbusiness.com.au Associate Publisher Michelle Graves Tel: (02) 9422 2391 E-mail: michelle.graves@reedbusiness.com.au Production Co-ordinator Mary Copland Tel: (02) 9422 2738 Fax: (02) 9422 2655 E-mail: mary.copland@reedbusiness.com.au Graphic Design Nicolle Lawson Tel: (02) 9422 2714 E-mail: nicolle.lawson@reedbusiness.com.au Circulation/Customer servicce Tel: (02) 9422 2666 E-mail: customer.service@reedbusiness.com.au

contents Body Protection

Manager’s Occupational Health and Safety

Solutions Guide

September 2010

INSIDE: G

G Body Protection G Height Safety G Materials Handling Production Line Safety G Waste & Hazardous Environments

>>> A SPECIAL SUPPLEMENT PRODUCED BY REED BUSINESS INFORMATION

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Height Safety

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Falling clearance when working from heights Guard rails versus roof anchors Self-retracting safety line

Materials Handling

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Mixed-case palletising solutions Forklift safety solutions Safety packaging knife

Production Line Safety

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Automation meets safety Integrated safety, motion controller Non-invasive fluid detector Welding facial protection

Waste & Hazardous Environments

Contents Copyright. Published by Reed Business Information, a division of Reed Elsevier Pty Ltd (ABN 80 132 719 861) Tower 2, 475 Victoria Avenue, Chatswood NSW 2067 Locked Bag 2999, Chatswood Delivery Centre Chatswood, NSW 2067 Tel: (02) 9422 2999 Fax: (02) 9422 2922 web: www.reedbusiness.com.au Printed by Offset Alpine Printing All rights reserved. No part of this publication may be reproduced or copied in any form or by any means without the written permission of the publisher. Utmost care is taken to ensure the accuracy of editorial matter. Product specifications and claims are those of the manufacturers.

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Avoiding chemical accidents Flexible earplugs Versatile hand protection Dust detector system

Versatile handlamps Drum dolly for increased safety Solvent-free parts washer Chemical storage unit

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Behind the cover The ExoFit NEX full-body harnesses range provides comfort, function and durability that have never been experienced with a fall protection harness, until now! With first-of-its-kind features and benefits, the ExoFit NEX provides the highest level of safety and the utmost comfort with technologically-advanced hardware, soft yet extremely durable anti-absorbent webbing, strategically-placed padding, and protective elements that prolong the service life of the harness. The ExoFit NEX introduces a series of industry firsts that have been developed from user needs, such as: Duo-Lok quick connect buckles, Revolver vertical torso adjusters, Tech Lite aluminium D-rings, hybrid comfort padding, REPEL Technology webbing and integrated suspension trauma straps, to name just a few. For more information regarding DBI-SALA’s NEW ExoFit NEX harness range, or to request a free information pack, call us on 1800 245 002 (AUS), 0800 212 505 (NZ) or visit www.capitalsafety.com.au

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BODY PROTECTION

Avoiding chemical accidents Chemicals in the printing industry can result in some nasty ailments, and manufacturing plant managers would do well to heed current occupational health and safety warnings, Ray Schaeffer advises. he printing industry in Australia is one of the largest manufacturing sectors employing some 115,000 workers, according to the Printing Industries Association’s figures. Smallto-medium businesses (SMEs) dominate the industry, with over 85% employing less than 20 people.

Though in recent times the industry has commenced substituting many, very toxic chemicals – under three headings, namely inks, adhesive and solvents – the problem is that printing businesses are less than efficient in discarding the countless residues in containers that frequently litter the shop floor. And remain there for extended periods of time.

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Printing problems The occupational health and safety (OH&S) problems involved focus on three aspects. First, the often volatile fumes that can go off, with gas from these containers filling the working environment atmosphere. Second, the actual contact exposure affecting both skin and eyes. Third, often employees arrive to work in the industry out of school and spend the rest of their working lives if not in one place of employment then nevertheless in a print business. What this means is that they can be exposed to the print industry’s toxic chemicals over the greater part of their working lives.

The key printing processes include: lithographic printing, screen printing, gravure printing, flexographic printing, digital printing and laminating. The range of printing tasks normally performed includes ink mixing, colour matching, manual cleaning of presses, on press cleaning and more. What this adds up to for employees is a potentially-serious risk exposure to some very bad chemicals. And this can occur on a daily basis over an extended period of time.

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| Safety First | September 2010

Toxic chemicals in the printing industry can affect workers over the short- and long-term.

Serious ailments Isocyanates (products labeled R42) have potential to cause occupational asthma.

Those labeled R42 /43 may cause sensitisation by way of inhalation and skin contact. Employers should remember that though these might have been removed from use, they were used over many years.

Employers are well advised with workers exposed to this chemical to adopt the risk management procedure of: having a suitably-qualified medical doctor assess the workers’ lung function; repeat this assessment annually; monitor absences from work; and keep records.

All are essential steps, the employer is to comply with the mandatory Duty of Care obligation.

Regarding skin dermatitis, this may be generated by the combined exposure of workers to hazardous solvents and then printing inks. The solvent on the skin can facilitate skin damage by inks. Workers using UV–curable inks or the chemicals listed above may demonstrate skin dermatitis by way of rashes, itching,

redness and skin peeling.

It is the role of the employer to have supervisors monitor this with all workers and conduct periodic inspections.

The problem can be exacerbated by substitution of these toxic solvents by what appear to be benign substitutes that may be made from synthetic chemicals whose long-term exposure is simply not known.

Employers should regularly meet with their chemical suppliers to canvas what new non-toxic chemical substitutes have become available.

This should be recorded.

Action plan Where to start? Print shops have a number of characteristic OH&S and ‘other’ problems. One of the most serious relates to wastewater disposal. Print shops characteristically use large volumes of water. After the printing is completed, then comes the washing down and Continued on page 6

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BODY PROTECTION

Continued from page 4

cleaning up. And this produces large volumes of contaminated water.

Disposal of this water to sewer is controlled by way of a Trade Waste Agreement between the business and the Water Authority. Often, the Local Council.

It frequently happens that the print chemicals in the wastewater cause the waste liquid to be non-conforming with the parameters in the Agreement. It is really important this issue be properly managed as a matter of priority.

The OH&S issue related to this wastewater occurrence is that of the washdown bays being operated, both OH&S-responsibly and environmentallyresponsibly. Operators must be made aware of the need to use Personal Protective Equipment (PPE) which must be supplied by the employer at no cost to the employee. Failure to properly protect the hands, arms and eyes can lead to exposure to the chemicals mentioned above.

Another key exposure here is noise. A compressor drives a water jet that is used to do the cleaning of the plates. Noise levels from the jet frequently exceed 85dBA. This means a risk assessment must be conducted in order to check the noise reduction equipment is suitable. Various risk assessments such as this are an essential part of the management system.

The method recommended as a start point with establishing a due diligent print chemicals management system is to organise a clean-up date. Commencing with a collection and disposal of all and every residue of ink, solvent and adhesive container stored anywhere on the shop floor and in and under and above every cupboard.

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| Safety First | September 2010

The next step is to establish methodically for every single chemical in use a chemicals register as required under the NSW OH&S Regulations 2001 Chapter 6, Part 6.4. A Material Safety Data Sheet (MSDS) must be obtained from every supplier and placed in a Manual which should be located on the shop floor, so that it is immediately available when needed. A good location is adjacent to the First Aid kit.

The working environment is a very important print shop OH&S issue that also needs risk assessing. The extraction capability of the system must be checked according to a program. The atmospheric chemicals level must be assessed and recorded as per a set plan. A chemicals labelling system must be in place – one that covers every container with a residue.

Alternatively, it must go to disposal.

Just as with noise, manual handling and eye protection safety posters should be used extensively throughout the shop, drawing attention to skin hygiene and the correct use of suitable gloves.

Documentation recording all of the above including training to be given by supervisors comprise the employers evidence of due diligence and the meeting of the employers’ mandatory Duty of Care obligations.

Finally, a warning about ultra violet (UV) lamps use, UV-powered equipment and UV-cured inks: employers need to understand the risks posed by this relatively new range of OH&S threats in the print shop and to ensure they properly manage these.

Ray Schaffer is the principal consultant with R M H Schaffer & Co. Contact him at schaffer@environmentdiy.com.au or visit www.environmentdiy.com.au

Flexible ear-plugs Choosing the appropriate type of earplugs is an important part of effective hearing protection in the workplace. Earplugs that offer too much hearing protection are reportedly just as harmful as earplugs that offer too little protection, according to hearing protection equipment provider, Howard Leight.

The company is now providing a range of new foam earplugs, including the Laser Lite and 300 Series, which are said to provide adequate protection when they are rolled and inserted into the ear.

Using clean hands, the units should be rolled down into a small crease-free cylinder, and inserted into the ear canal.

According to Howard Leight, insertion of earplugs is much easier and effective if the outer ear is pulled outward and upward to straighten the ear canal. Once the earplug has been properly inserted, users should hold the earplug in position for 30 to 60 seconds while the foam expands and holds the earplug in place.

A practical alternative to roll down foam models, new hybrid push-in style earplugs such as the company’s Pilot feature a moulded ‘navigation’ stem which glides the earplug into the ear canal for a quick, snug and comfortable fit.

Workers should remember to always check if their earplugs are either roll-down or push-in types, and should always read instructions on the packaging before insertion, the company advises.

There is no one size fits all earplug, says Howard Leight.

Sperian Protection, 1300 139 166, www.sperianprotection.com.au

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®

Are You Compliant?

AS/NZS 1891.4 - 2009 Industrial Fall Arrest Systems & Devices Selection, Use & Maintenance is now in effect.

New Training Requirements Training requirements for supervisors & operators working at height has now been defined in AS/NZS 1891.4 as

Height Safety Theory Basic height safety for all people associated with harness based work at heights. At the basic level it is pitched to operators up to and including supervisor level to height safety technologists and to equipment inspectors.

Height Safety Operator Training in the skills to perform harness based work at heights under direct supervision of a height safety supervisor.

Height Safety Supervisor Training and assessment in skills needed to perform harness based work at heights unsupervised, to supervise entry level and other operators, and to participate in first responses rescue

Height Safety Equipment Inspector Training in the skills needed to detect faults in equipment and to determine remedial action.

Height Safety Manager Training for people involved in the selection, design, manufacture or installation of height safety systems or equipment, or the development of control measures or work practices, in the technical skills appropriate to their tasks together with, as appropriate, training in risk management and systems management.

Nationally Accredited Courses offered by SpanSet Note: All Practical Courses Include Rescue Work Safely at Heights:- MNMG237A Work Safely at Heights:- CPCCCM1006A Nationally Recognised Work Safely on Roofs:- CPCPCM2105A Training Competent Person Practical Inspection & Record Keeping:- MEM15004B Tower & Pole Rescue:- PUAOHS001B, PUASAR001A, PUASAR004A Vertical Rescue:- PUAOHS001B, PUASAR001A, PUASAR004A Enter Confined Space:- MSAPMPER205B, MSAPMPER200B Operate Breathing Apparatus:- MSAPMOHS216A Confined Space Vertical Rescue:- PUAOHS001B, PUASAR001A, PUASAR004A N S W Vo c a t i o n a l Education & Training Accreditation Board

Height Safety Equipment Inspector June 18 July 12, 29 August 19, 31

(License No: 91173)

Public Course Dates 2010 Work Safely at Height June 17, 25, 30 July 9, 15, 21, 30 August 6, 12, 20, 24

Confined Space Entry June 21-23 July 7-9, 19-21 August 3-5, 16-18

Corporate or bulk bookings and dates easily accommodated Venues: NSW - Emu Plains, Botany QLD - Brisbane, Townsville WA - Welshpool VIC - Moorabbin Bookings: Gillian Duncan Ph: 02 4735 3955, Email: gilliand@spanset.com.au

www.spanset.com.au/training

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BODY PROTECTION

Dust detector system The Dust Detect 1000 is a single device dust detector designed to continuously-monitor the flow of particulate emissions from small stacks and emission points being passed through an air filtration system. It is said to be easy to install in the exhaust ductwork and can be used with several types of filtration systems.

The probe on the Dust Detect 1000 is able to recognise abnormal particulate levels outside user-defined parameters and initiates an alarm when changes in emission exceed these levels.

The unit uses Triboelectric technology, whereby the collision and interaction of particles with the probe rod cause a small electrical charge transfer to occur. This small electrical charge provides a signal that is monitored by the electronics.

It is designed to prevent false readings, even if an accumulation of dust forms on the sensor rod. Emissions readings are reportedly averaged, not smoothed, to eliminate false alarms.

The unit can also be set to make pre-warning indicator alerts to potentially-hazardous situations or be set to provide an instantaneous alarm or one-minute averaged readings.

Pacific Sensor Technologies 1300 662 720, www.pacificsensortech.com.au

Safety message Tri-Cones Workplace safety equipment manufacturer, Industroquip Safety, has developed a new Safety Message Tri-Cone designed specifically for the local mining industry – however the company claims the unit can be used in almost any industrial landscape.

The Tri-Cone is manufactured from lightweight and durable plastic for the harsh mining landscape.

The unit is stackable, which makes it easy to transport. Once on-site, the unit can reportedly be easily moved-around by one person due to its moulded handle.

Industroquip specialises in manufacturing rotational moulding signs for manufacturing facilities. The company can also offer flexibility when in the form of different colours including yellow, red, orange, purple, blue and black.

The company also offers a glow-in-thedark option for ambient environments; the colour is not painted on to the cone, but rather moulded into the product.

The cones can carry messages for different industrial safety scenarios.

Messaging on the cones includes safety, traffic, information, directional, marketing, promotional and more.

The unit features a lip around the base which can be filled with dirt or rocks to help weigh it down to prevent it from being blown by heavy gusts of wind often found on mine sites around Australia.

Industroquip Safety 1300 303 249, www.industroquip.com

UGLY JOB. PROTECTION WITH ATTITUDE.

Designed to optimise and protect your vision so you can get the tough jobs done, safely. The extensive range of Ugly Fish protective eyewear are shatterproof, impact resistant and have permanent anti-fog and anti-scratch coatings. In a range of modern designs that offer superior comfort and fit, including prescription options, you’ll bring the Ugly attitude to every job you tackle.

EVERYONE’S UGLY. uglyfisheyewear.com

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Mongrel SP Range Because what you do makes a difference to the boots you wear Our Mongrels SP Series was designed to incorporate the most significant technological, comfort and safety features into one premium range. Now Mongrels have expanded the SP designation to meet the requirements of different work conditions.

For example the mining industry and light manufacturing industries have very different needs. Now, along with SP originals we offer SP>Z, SP>R, SP>S ranges. Take a look on our website or call for a Mongrel salesman for more information.

A range of 35 styles incorporating Airzone Comfort Sole, Roller Sole, Toughsider etc.

Zipsiders provide superior ankle support with ease of access

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The Aussie born and bred work boot designed to work best for you

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BODY PROTECTION

Versatile hand protection love manufacturer Ansell says many workers in industries that require a high level of dexterity often avoid using gloves, despite the risk of scrapes, blisters and minor injuries.

To address the need for hand protection in this work environment, the company has developed the HyFlex 11-618 glove.

Designed for a wide range of lightweight applications in dry or slightly oily environments, the new glove is said to be ideal for workers who need a high level of touch and precision.

The thin construction of the HyFlex 11-618 glove was designed to offer comfort and sensitivity for the most delicate

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The gloves are thin, yet strong enough to withstand scrapes.

tasks, Ansell claims. Made with palm-coated nylon/

polyurethane and an elasticised knitwrist, the glove is

reportedly Ansell’s lightest lined and coated glove available on the market.

The glove is said to be 20% lighter in weight than Ansell’s other nylon/ polyurethane gloves, yet provides light mechanical protection, the company says. Testing is compliant to AS/NZS 2161 and abrasionresistance rating is EN level 3 and level 1 for cuts.

Ansell says this glove is ideal for light assembly applications requiring a high degree of precision, such as final assembly, air conditioning, electrical engines, wire harness assembly or picking and fitting small pieces such as bearings and springs.

Ansell Limited 1800 337 041, www.ansell.com.au

Sales – audiometers and tympanometers Workplace hearing screening equipment Audiometric booths Calibration & Service Noise Surveys Maintenance Agreements – for peace of mind Equipment solutions from world rldd leading brands

1800 809 321

Phone: Email: equipesales@phonak.com

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| Safety First | September 2010

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HEIGHT SAFETY

The importance of fall clearance It’s not enough to assume the correct fall-protection equipment will keep you safe: taking into account fall clearance is a crucial occupational health and safety requirement for your team. Gordon Cadzow writes. alls from height continue to be an all-too significant statistic when it comes to fatalities, according to the latest Safe Work Australia Notified Fatalities Report (2008–09). In 2009, 20 people were fatally-injured when falling from height.

Where the need for a person to work at height has been identified, the first step is to look at the Hierarchy of Control to see if the risk can be eliminated or isolated. If not, focus then turns to the selection of the best personal protective equipment (PPE) for the task. However, it’s not enough to assume that PPE will keep you safe.

Roofsafe Industrial Safety (RIS) managing director, Michael Bermejo, who is a member of the Fall Protection Manufacturers Association (FPMA), says that one of the key factors in this process is the operator’s fall clearance.

“This must encompass accessing and returning from the work site as well as whilst executing the actual task. The theoretical fall clearance required must always be less than fall distance available,” he said.

difference in the overall lanyard length and the vertical distance from the anchor point and the connection to the harness will give a measure of the free fall distance.

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Vertical and swing falls Vertical and swing falls need to allow for clearance below the operator so that he will not strike the ground or other objects after a fall. There is no point providing fall arrest equipment if the operator could hit other objects. There are two conditions that need to be considered: the straight vertical fall; and the risk from a swing fall where the connection between the

3. Self Retracting Lifeline These usually operate on a fixed arresting distance. Where these are used, Australian Standards recommends a fixed allowance of 700mm.

4.Anchor point location Where the anchor point is not vertically above the operator, an additional allowance equivalent to the lateral offset needs to be added to the fall distance.

5.Shock absorbing Lanyard The tear webbing can be activated with the length of the extension depending on the distance of the initial free fall. The table below shows the average extension based on the initial free fall distance: The number of fatalities from falling from height has grown year-on-year.

operator’s harness and the anchor point may be deflected, or where the operator may swing against another structure. For any operation, there are a number of factors that need to be considered.

1. Deflection of the anchor point Where this is a fixed anchor point, the deflection may be small. However, if the operator is connected to a horizontal lifeline system, the deflection in the lifeline could be significant.

2. Length of connection Where the anchor point is above the harness fall arrest connection, the

Free Fall Distance

Extension

600mm 1000mm 1500mm 2000mm

300mm 500mm 600mm 900mm

6.Operator height The final allowances for required fall clearance relate to the actual height of the operator, from his feet to the attachment point between the full body harness and lanyard connection.

7. Safety Distance The recommended additional safety distance in any calculation is 1000mm.

Gordon Cadzow is the FPMA secretary.

Contact him at at info@fpma.com.au

Self-retracting lifeline for fall protection use Capital Safety’s DBI-SALA Ultra-Lok RSQ Self Retracting Lifeline (SRL) with Rescue was designed for the fall protection market and offers both the traditional ‘fall arrest’ and ‘rescue/descent’ rescue options.

If a fall occurs while in the rescue/descent mode, the Ultra-Lok RSQ will arrest the fall and then automatically lower the worker safely to the ground or next level. This operation allows the device to be optimised for the work site while providing worker safety, claims Capital Safety. If a fall were to occur while the device is in the fall arrest mode, a speed-

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| Safety First | September 2010

sensing brake automatically stops the fall, reducing the forces exerted on the user to safe levels of 6kN or less.

The fall arrest mode also allows for assisted rescue to take place by means of a First-Man-Up Pole and Assisted Rescue Tool. This mode is designed for fall protection in situations where the user is working over dangerous objects, such as moving machinery or traffic, or when the next level below the work area is more than 15 metres away.

Capital Safety 02 8753 7600, www.capitalsafety.com

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HEIGHT SAFETY

Guard rails versus roof anchors Australia's roof tops bristle with horizontal life lines and roof anchors but, says fall prevention specialist Carl Sachs of Workplace Access & Safety, most should be replaced with guard rails. he case for guard rails over roof anchors begins with the law.

WorkCover NSW’s Code of Practice for Safe Work on Roofs and Victoria's Compliance Code for the Prevention of Fall in General Construction for example, both detail a rigorous selection process for fall prevention measures.

The familiar hierarchy of controls that sets-out the order of control measures goes further in the case of fall prevention – authorities also specify the controls.

The first step is to eliminate the hazard by reorganising the job so that work is undertaken from ground level or on a solid construction. If neither is practicable, the next best alternative is to use a passive fall protection device. In fact, the Victorian OHS (Prevention of Falls) Regulations

T

provide an exemption from many duties if equipment complies with AS1657 – 1992 Fixed Platforms, Walkways, Stairways and Ladders. Controls listed in both AS1657 and in Level 2 of the hierarchy of controls include guard rails and fixed platforms, which are the most viable permanent solutions for safe maintenance access of all the level 2 controls. Guard rails have a lifespan of perhaps 20 years and are always in place when needed. They require a low level user skill, few administrative controls and virtually no maintenance.

It is only if these ‘passive fall protection devices’ are not practicable that ‘work positioning systems’ may be used. These systems prevent workers falling over an unprotected edge and are harnesses attached by lanyards to roof anchors or

static lines, or harnesses with ropes and friction devices.

Maximising safety Statis lines and anchors can be easily misused. High skill levels are demanded from users and both of these anchor-based systems rely on equipment being suitable, compatible, carefully maintained and regularly tested.

The consequences of the misuse of work positioning or fall arrest systems can be catastrophic. System misuse or the incorrect placement of roof anchors can also mean level 3 fall restraint systems effectively become level 4 fall arrest systems. As a result, the site's safety standards are lowered.

Continued on page 14

September 2010 | Safety First |

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HEIGHT SAFETY

Continued from page 13

Table 1: Cost of ownership: Guard rails and roof anchors

Because fall arrest systems only aim to minimise injury once a fall has occurred, they also risk the potentially deadly pendulum effect and suspension trauma.

Consequently, use of level 3 or fall controls requires supervision and planning.

STATIC LINE

ANCHORS

GUARDRAIL

A 25m static line, 8 x anchors or 30m of guard rail Administrative controls/roof permit system/consultation Initial training for two operators

$2,500

$2,000

$3,500

$500

$500

$0

$1,000

$1,000

$0

TOTAL INSTALLED COST

$4,000

$3,500

$3,500

$4,400

$4,400

$0

$5,000

$5,000

$0

1500 1000

900 1000

$0 0

$15,900

$14,800

$3,500

Less maintenance and less training The cost of maintaining roof anchors and the matching fall arrest or prevention systems means that a guard rail quickly pays for itself (see Table 1, above right).

According to AS1891, roof anchor systems must be labelled with their rating and commissioning date. They must be recertified and inspected every six months in Victoria, Queensland and South Australia, and every 12 months elsewhere.

Roof anchors and static lines also make labour sourcing more complex. Using work positioning and fall arrest systems safely requires high skill levels and anyone accessing the roof needs to have completed specialised competency-based training. In contrast, guard rails do not need to be regularly inspected.

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| Safety First | September 2010

COSTS OVER 10 YEARS Retraining of 2 operators every 2 years @ $220 each 6 monthly inspection and recertification (@$500 p/a) Recertify, or replace in year 10 PPE (Harnesses, lanyard, shock absorbers etc) TOTAL COST AFTER 10 YEARS

The cost of maintaining roof anchors and the matching fall arrest or prevention systems means that a guard rail can pay for itself.

Roof anchors and static lines Roof anchors and static lines have their place – as one of the last resorts when guard rails are not practicable. When the need for access to the roof is very rare, they can be an attractive option,

particularly on heritage buildings where guard rails might look out of place.

Carl Sachs is managing director of Workplace Access & Safety. Contact him at carls@workplaceaccess.com.au or call 1300 552 984.

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MATERIALS HANDLING

Mixed-case palletising solutions Due to occupational health and safety concerns, there is an increasing demand for smart mixed-case palletising solutions that take warehousing management in a new direction, writes David Rubie. ntil recently, the only way to assemble a pallet containing many different SKUs (stock keeping units) was to do it manually. But as logistics professionals know, repetitive and heavy tasks are both physically demanding and costly. And, unless mixed case pallets are carefully assembled by experienced personnel, the resulting stacks of goods may be unstable.

Driven by occupational health and safety (OH&S) concerns and skills shortages, there is an increasing demand for smart solutions that take mixed case palletising in a new and exciting direction.

To provide high volume distributors with smarter, safer, more cost-efficient alternatives to manual mixed case palletising, Dematic has developed two solutions – ErgoPall Ergonomic High Rate Palletising Stations and AMCAP (Automated Mixed Case Palletising). Both systems employ a combination of automated storage, buffering and sequencing systems, advanced software and automated materials handling

U

The ErgoPall palletising stations enable operators to ergonomically build mixed SKU pallets.

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MATERIALS HANDLING

equipment, the main difference being that ErgoPall still uses people to build the pallets, and AMCAP uses sophisticated robotic palletisers.

Facilitating high rates To process and palletise mixed cases accurately at high speeds, products need to be fed into the system in the correct sequence to suit pallet assembly. Key to the development of the ErgoPall and AMCAP solutions was the evolution of smart product storage, buffering and sequencing systems such as the company’s Miniload and Multishuttle automated storage and retrieval systems (ASRS). The storage buffer and sequencing technology allows manual mixed case order assembly to be done more safely and with greater efficiency, accuracy and productivity when goods are presented for palletising.

Mixed-case palletising The distribution centre’s warehouse management system (WMS) interfaces with Dematic’s WCS (warehouse control system), which controls all aspects of the order assembly process including pallet breakdown or delayering, storage, buffering, picking, sequencing, transport and palletising.

When the WMS releases orders, the WCS sorts the data and sends the pallet stock information to Dematic’s PalletGenDirector software, which uses different attributes of the product (length, width, etc) and stacking criteria factors including crushability and family group rules unique to stores, departments, aisles and aisle sections to determine the optimum build sequence for each pallet.

Pallets of stock for the orders are then automatically delayered or manually broken

down and conveyed to Dematic’s high-speed Miniload or Multishuttle storage buffer and sequencing system. When required for an order, the necessary SKUs are automatically picked and transported in the exact sequence required to facilitate pallet assembly.

High-rate palletising ErgoPall Ergonomic High Rate Palletising Stations enable operators to ergonomically build mixed SKU pallets.

The ErgoPall stations are built on a mezzanine with integrated conveyors delivering a constant flow of mixed cases to the operator, enabling them to slide the sequenced cases into position on the pallet.

Lifting is almost eliminated and, as each layer of cases is completed, the pallet automatically lowers, enabling assembly of the next layer to begin, reducing the physical effort required, and improving the safety, speed and quality of order assembly. As the pallet is being lowered, it is stretch wrapped for stability. When all of the goods required for an order have been placed on the pallet and the stretch wrapping completed, the pallet has a label applied to it as it exits the system on a conveyor.

Palletising continues even while the built pallet is being removed from the ErgoPall station, with only a few seconds lost in the transition.

After the pallet continues down through the mezzanine, slider plates close above it to form a solid surface upon which the ErgoPall station operator(s) can immediately begin stacking cases for the next pallet to be built.

Concurrently a new empty pallet is raised by the lift to the underside of the slider plates, which open gently transferring the already picked cases to the surface of the new

pallet, as the operator(s) continue assembling the order.

Automated palletising Automated palletising is an efficient solution to building pallets in high volume distribution applications.

New advances in software, product storage, buffering, sequencing and recognition systems, and high-speed articulated robots with more versatile product gripping tools, have enabled the development of automated palletising systems capable of handling a diverse range of SKUs and packaging types.

Capable of building a higher, more stable pallet, these accurate and fast systems can handle tens-of-thousands of SKUs.

Optimised efficiency Each AMCAP cell comprises two six-axis, servo-driven

articulated arm robots installed on a mezzanine. Two conveyors automatically deliver the SKUs to the work cell, at which point they are aligned, oriented and presented to the robots for pick up, with the two robots building each pallet cooperatively. The combined dual-robotic cycle of feeding, grabbing and placing the SKUs enables the system’s high throughput rate of greater than 1,000 mixed SKU cases per hour.

One of the unique aspects of AMCAP is the multi-axis, endof-arm-tool (EOAT) attached to the robots’ articulated arms.

This universal tool can handle all standard types of packaging without stopping or changing tools.

David Rubie is Dematic’s industry logistics manager. Contact Dematic on 02 9486 5555 or www.dematic.com.au

September 2010 | Safety First |

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MATERIALS HANDLING

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Forklift safety solutions

Safety knife for package unwrapping

A WorkSafe document called People and forklifts don’t mix contains tips for the separation of pedestrians and forklifts. The document states there must be at least three meters distance between a pedestrian and forklift or a suitable permanent physical barrier must be installed.

Warehouse Safety Solutions (WSS) has reportedly dedicated years to developing products to aid customers in the separation of forklifts and pedestrians, such as tour safety barriers and gates.

The Australian Standard AS1657 (Standard for ballastrate railing) calls for a minimum of 50mm diameter upright. WSS has gone beyond the Australian Standard and uses a minimum of 100x100mm uprights. The company has reportedly installed its gates and rails in countless warehouses with great success. These gates can be linked to WSS’s Early Alert system that will magnetically lock when a forklift approaches or have a flashing light activate when a pedestrian uses the gate.

WSS in conjunction with NMIT offers full traffic management audits that are designed to help companies comply with the new requirements.

Warehouse Safety Solutions 1300 927 372, www.waresafety.com.au

Reducing hand injuries caused by conventional packaging knives has become a priority in many workplaces.

Exposed blades means exposure to hazard, says Vision Safe.

The company’s range of Safety Knives has been engineered to reduce the risk of personal injury caused by exposed blades.

The latest addition to the range is the versatile Sword Fish Safety Knife. Based on the company’s Fish series of knives, the Sword Fish is a heavy duty safety knife for use in both rescue and warehouse/packaging situations.

It features a concealed blade enclosed in an impact-resistant nylon casing with a textured surface for grip, even when wet. Strapping, banding, wrap, seatbelts, The safety knife features a concealed blade rope, clothing and cable ties slide into enclosed in an impact-resistant casing. the mouth of the ‘sword fish’ where it contacts the blade and is cut.

It also features a hook blade which can be positioned for automatic or manual retraction to further reduce the risk of injury.

| Safety First | September 2010

Vision Safe 08 9295 0624, www.visionsafe.com.au

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Materials Handling Solutions for a Safe, Productive & Efficient Workplace...

SAFETY??? — DON”T DIE WISHING YOU HAD USED A MATHAND LADDER LIFT MatHand Ladder Lifts These are the ideal lift for various operations in the construction & solar technology industries, whilst lifting onto roofs. MatHand Ladder Lifts are top quality, with first class components and available in 150 & 250kg capacities.

They are extremely lightweight, safe and versatile lifting solutions. Thanks to various platforms and other accessories these lifts meet virtually all demands on any construction site.

The compact drive simply latches on

Adjustable angle bend section Bend section - Adjustable from 20°- 45°. Heavy duty hardened steel pulleys for long life of rope.

Set up inclined on the roof Bend section

Wire rope

MatHand 150 Solar ensures safe lifting solar panels & hot water systems With the versatile load-bearing ladder style lifting rails, the MatHand 150 Solar is the ideal choice to safely lift solar panels & hot water systems onto roofs. It is a sophisticated lifting system with a special platform fixed to the carriage that ensures safe transportation of the panels onto the roof. Rubber rests protect them from being damaged while the clamping device fastens the panels safely to the platform.

Rail 2m

Standard carriage

Foot section 2m with large foot plates to spread the load

Uni platform - Used for the transport of roof tiles.

MatHand 150 Solar inclined to building without bend section (compulsory safety rails have been removed for this promotional image)

Standard solar platform with solar panel.

Note the compact drive.

Drive unit MatHand 150 Hoisting speed 25m/min, suitable for standard and tilting carriage, maximum payload 150kg.

Standard carriage - For use when there is no need to tilt for unloading. A broken rope device prevents the carriage from falling in the event of a rope failure.

An optional module fitting platform SMV150 ensures safe transportation of panels when on the roof. This device can easily be moved by smooth running rollers & is conveniently hooked in the existing aluminium rails of the solar panels, so no additional assembly work is necessary.

Adjustable solar platform Standard solar platform 600 x 850 x 350mm

SMV150 Solar panel transport trolley with a solar panel (compulsory safety rails have been removed for this promotional image)

Our website: www.materialshandling.com.au Phone us: 1300 65 00 35 Fax us: 1800 68 68 96 SIA1008 Email us: result@materialshandling.com.au

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PRODUCTION LINE SAFETY

Standard control meets safety A new software platform combines IEC 61131-3 programming languages and software blocks in one tool, writes Frank Schrever. odern hardware can’t get by without software. Often there is one fundamental decision to make: whether to use individual, complex, in-depth programming or simply drag and drop with ready-made software blocks.

An automation system from Pilz called the PSS4000 combines these two seemingly conflicting methods in one tool.

The software platform PAS4000 accommodates a wide range of programming abilities: from first-timers to professionals.

The market reveals a trend towards universal, complete solutions, in which programmable safety technology is linked ever closer with standard control technology. And this is where the new automation system comes in. With PSS4000, Pilz claims to be the first to combine the safety and standard sections, making safety technology easier to program in the process.

The automation system can be used to build control structures that are very complex, and yet are still easy for the user to operate. The PSS4000 enables you to reap the benefits of a decentralised control structure without having to face the higher complexity that this would normally

M

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| Safety First | September 2010

The market reveals a trend towards universal, complete solutions, in which programmable safety technology is linked ever closer with standard control technology.

involve. Thanks to the software platform PAS4000, users can not only retain an overview of a decentralised automation system with distributed control functions, but also have a tool to hand which enables them to create applications.

Ready-made software blocks The graphics editor PASmulti enables the necessary functions to be configured with ease. The editor has been developed from the user-friendly configuration tool for the PNOZmulti safety system, which has been extended to incorporate standard automation technology. The software platform provides the IEC 61131-3 languages for proprietary programming.

The full, standardised instruction set is available for standard control functions and, for the first time, safety functions too.

This merges a variety of levels within the software platform: a pure programming level for experts and a superimposed level on which the

complexity is virtually hidden, enabling functions to be configured with ease.

On less complex machines with straightforward safety functions, the whole safety solution can be created simply and quickly using the software blocks supplied by Pilz. On larger applications with more demanding safety requirements, the user is able to structure his application very clearly through configuration with PASmulti; individual sections can then be programmed in accordance with IEC 61131-3. Parameters for these self-written safety functions can then be set and linked very easily.

Another special feature is the fact that programming is independent of the hardware. Each function can be used with total flexibility, whether it’s from the Pilz block library or from the library that the customer has created himself.

Frank Schrever is the managing director of Pilz Safe Automation. Email safety@pilz.com.au or phone 03 9544 6300.

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Non-invasive fluid detector Custom Fluidpower has produced a market-first prototype of a handheld non-invasive fluid detection device. The device was designed as an answer to workplace injuries involving fluid under pressure. According to the company, there have been recent fatalities in longwall scenarios related to contact with fluid under pressure, as high pressure fluid or oil in hydraulic systems is lethal if a fluid line connection point is opened or hose failure occurs.

The portable detection device was also developed to bridge a gap in the market for handheld, non-invasive pressure detection devices for ascertaining whether a hose, tube or pipe is under pressure.

The prototype project, funded by the Australian Coal Association Research Program (ACARP), commenced in and has resulted in the invention of a working prototype.

“The principal use of the Portable Detection Device for Pressure in Hydraulic Hoses (PDD) is to inform an operator using the device on a hydraulic hose if there is high pressure or low pressure in the hose,” said Custom Fluidpower engineer Liviu Schintee.

“This information is critical in performing isolation procedures in hydraulic circuits where it is not possible to connect a pressure detecting device to measure the pressure in contact with the medium or hydraulic oil. In a complex hydraulic circuit with long lines not all the lines are provided with test points to allow pressure measurement. The invention addresses this aspect by allowing an operator to have a portable device that indicates if there is high pressure or low pressure in that hose following a simple non-invasive procedure.”

Custom Fluidpower 07 3307 8227, www.custom.com.au

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Integrated safety, motion controller

The controller provides safety, motion, discrete- and drive-control functions.

Rockwell Automation has introduced a new controller to provide integrated safety, motion, discrete- and drive-control capabilities for midrange applications, all in a single unit.

Available in two models – L43S and L45S – the Allen-Bradley Compact GuardLogix programmable automation controllers (PACs) extend capabilities previously available only in the larger Allen-Bradley ControlLogix platform, including diagnostics and information capabilities that help reduce nuisance shutdowns and prolonged restarts, as well as a single programming environment for enhanced design and development.

The controllers integrate standard and safety control into a single platform. As part of the Rockwell Automation Integrated Architecture system, the controllers use the same configuration, networking and visualisation environment as the company’s larger-scale systems. This is designed to provide machine builders and end-users with cost-effective integration of a machine or safety application into the plant-wide control system.

“The introduction of the Compact GuardLogix PAC opens a new door for many manufacturers with midrange applications who previously did not have the means to implement an integrated architecture,” said Rockwell Automation product manager architecture and software South Pacific Region, David Black.

“The scalability of the Integrated Architecture system means that manufacturers and machine builders can design their applications using a single control engine and a single development environment, regardless of the application size.”

The Compact GuardLogix PACs can control as many as eight axes of integrated motion over the Serial Real-time Communication System (SERCOS) communication network. When used in combination with the Allen-Bradley Kinetix 6200 servo drive, machine builders have advanced safety options, including safe-speed and safe-direction, Rockwell Automation says.

Rockwell Automation 1800 762 593, www.rockwellautomation.com.au

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LED strobe lights The Pulse range of high-output strobe lights from Narva is said to bring LED technology together with reliability and performance.

Suited to a broad range of applications from harsh mining and construction sites to use by local councils, the new strobes have been made to last, the company claims.

Their strong construction, including a polycarbonate lens, die-cast powder-coated aluminium base and solid-state LED circuitry, makes them resistant to shock and vibration.

An ‘O’-ring seal is fitted between the polycarbonate lens and the die-cast base to provide protection against the ingress of dust and water and an internal heat sink effectively dissipates heat from the high output LEDs, allowing maximum brightness and performance, Narva says.

The Pulse range offers 360-degree rotating flash patterns, simulating the performance of a rotating beacon. Eight specific light patterns are built into the strobes, including three different rotator patterns Brown & Watson International 03 9730 6000, www.narva.com.au

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Welding facial protection With welding and grinding responsible for over 29% of all eye injuries both at home and in the workplace, the use of suitable protective welding headwear is essential to minimise these preventable injuries, says Sperian Protection.

Sperian offers a range of face and head protection products including high-impact welding helmets and accessories that protect welders against injuries like flash burns, UV/IR radiation and fine particles and vapours. Designed with a range of safety features including a sensor bar and slide, sensitivity function, delay function,

shade level and girding mode, the range is said to provide comfort and on-the-job performance for the professional welder.

The units were engineered to meet the demands of professional welders, with the Optrel Galaxy High Impact Welding Helmet model reportedly the only passive flip front, high-impact-approved welding helmet on the market.

The units were tested to Australian Standards, and are approved by SAI Global.

Sperian Protection, 1300 139 166, www.sperianprotection.com.au

Safety compressed air blowing nozzles A recent installation of Silvent low noise, highefficiency blowing nozzles on a high-speed beverage packaging line has reportedly seen increase in output and a reduction in rejection rates of barcode printing.

According to Silvent, its safety compressed air blowing nozzles make drying operations prior to labelling, printing and packaging more efficient.

Due to their patented design, they reportedly use less air and reduce noise compared to open pipes and cannot be dead-ended against the skin. Silvent reportedly has solutions to suit most packing application and line speeds, each contained within the company’s new catalogue.

Spray Nozzle Engineering 03 9583 2368, www.spraynozzle.com.au

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WASTE & HAZARDOUS ENVIRONMENTS

Solvent-free parts washer he Alsco Ecosafe Washer is a waterbased parts washer that uses bioremediation to remove oil and grease from the cleaning solution, without using harmful solvents.

The specialised design features a wide sink with an angled brush and flexible nozzle. The washer has an automatic timer that allows the fluid to flow continuously for 10 minutes, removing oil and dirt from the part while users attend to other areas of the business. The unit is mobile and can be moved anywhere in the workshop.

The Ecosafe Washer employs a process called Bioremediation, which incorporates a unique filter system and a solvent-free solution called Ozzy Juice. The filter mats in the unit are freeze-dried with microbes, which come alive when warm Ozzy Juice passes through them.

The microbes eat away at the oil and grease, and convert them into non-toxic

T

substances such as water and carbon dioxide. Over time the microbe colonies continue to expand ensuring that the effectiveness of the cleaning solution never drops away.

The Ozzy Juice solution is water based, meaning it is gentle on the hands and won’t cause skin irritations, dermatitis or other health problems.

Alsco 1300 136 784, www.ecosafewasher.com.au

The washer uses a solvent-free solution using freeze-dried microbes.

Gas monitoring alarm ANRI Instruments & Controls’ GDS404 is a one to four-channel gas alarm for monitoring any combination of oxygen, combustible and toxic gases in hazardous industrial areas including chemical processing plants.

The unit is designed for economical and reliable monitoring of gas levels, and is designed in a smart steel housing, suitable in any type of environment from commercial premises through to heavy industrial and hazardous area applications.

The monitor incorporates a range of sensors, including infrared, electrochemical, catalytic combustion, thermal conductivity and MOS. The unit is suitable for monitoring O2, CO, H2S, SO2, NO, NO2, CL2, H2, HCN, HCl, NH3, O3, C2H4O, CO2 and LELs. Other controllers are available for larger installations.

Alarm features include two alarm stages, with a delay to alarm option, selectable alarm relays, visual LED displays and audible warnings.

Digital alarm settings are fully-adjustable, and the unit features an IP52 housing with the option of IP65 housing if required.

Typical monitoring locations are public buildings, underground car parks, boiler plant rooms, swimming pools, water treatment works, H&V control systems, landfill sites, laboratories, hospitals, food packaging, manufacturing and processing plants.

ANRI Instruments & Controls 03 9752 3782, www.anri.com.au September 2010 | Safety First |

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Chemical storage unit Many industries require a small number of chemicals to be stored and dispensed safely, ranging from water treatment dosing to chemicals for cleaning food plants – and all these need to be stored safely, yet still be accessible for manual or automatic decanting.

Spilldoktor has released a new Chemstation storage unit for up to six 20-litre containers. The unit is available with a separate bund for incompatible liquids.

The product comes in kit form for quick and simple assembly, according to distributor Skilldoktor, and includes a sturdy shelf and safety features including emergency eyewash, sorbent wipes, MSDS folder and signage.

The 150-litre base tray projects around the footprint of the shelving unit, offering protection from accidental leaks and spills.

Chemstation is constructed from Polyethylene and stainless steel for use in demanding environments.

Spilldoktor 1800 365 867, www.spilldoktor.com

The unit can store up to six 20-litre containers.

Drum dolly for increased safety In today’s industry, many 200-litre drums are still in use, causing problems with removals and decanting. However, according to Spilldoktor, the same problems are experienced on a smaller scale with 20litre drums, which are used more prevalently in industrial areas.

The normal method of moving large and small drums is to manually slide them on and off pallets and then decant the liquid.

Spilldoktor’s new drum dolly is designed to eliminate this process. Designed for use with 20 to 200-litre drums, the unit also offers a recessed section in the centre for 20-litre containers. The units are available with or without a handle, and include four heavyduty wheels for maneuverability, making it easier to access in tight factory areas.

The double-skinned construction reportedly offers superior strength, and incorporates a bund for drips and spills.

Spilldoktor 1800 365 867, www.spilldoktor.com

Versatile handlamps NHP is now distributing a range of STAHL hazardous area equipment (HAE) products to the Australian market, including the STAHL 6149 Toughlux Series of handlamps.

The range is said to be unique in that units are compact, lightweight and ergonomically-designed. The units reportedly ensure light is always in the right spot thanks to the integrated anti-roll profile and suspension hook.

The handlamps are suitable for Zones 1 & 2, 21 & 22, as well as a wide variety of mounting accessories. According to NHP, prior to the 6149 Toughlux being released in Australia, the only options for hazardous area handlamps used fluorescent lamps which made them vulnerable to breakages in rough areas.

The Toughlux uses cold cathode technology, which is said to give a better product without compromising on light output.

NHP Electrical Engineering 03 9429 2999, www.nhp.com.au

The handlamps can be used with a range of mounting accessories.

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WASTE & HAZARDOUS ENVIRONMENTS

Airborne particles removal Fanquip has developed a new fan technology and safety monitoring system for use when handling asbestos and other substances that are harmful when airborne.

The Fanquip Negative Air Fan is designed for applications where contaminated airborne particles must be removed to create a clean/safe working environment.

These fans have a ‘dust load monitoring system’ and have reportedly been developed in response to strong calls from professionals holding specific licences for removal of product likely to cause harmful or toxic conditions when being handled.

The Fanquip Neg Air Unit is configured with a HEPA filter, tested to AS 1324 to achieve minimum efficiency of 99.99%.

The unit is fitted with a dust load monitoring system which notifies the operator when the filter is dirty. It does so by means of two-stage alarm and flashing light.

Fanquip 1800 224 308, www.fanquip.com.au

The fan removes airborne particles including asbestos.

September 2010 | Safety First |

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