HAS9002 02 - Powered Industrial Trucks (PIT) and Aerial Lifts 11

EU EHS Procedure | HAS9002.
02
Powered Industrial Trucks (PIT) and Aerial Lifts
Issue Date Description of Changes

01 Jan. 2019 Initial document
Document Details Role

Author(s): EHS Manager, CEE FC EHS
Owner: Process and Standards Manager, EU EHS
Regional EHS Managers
EHS
Design in Safety and PM, EU EHS
Verifier(s):
Senior EHS Manager
Director, EU RME
Director, EU Ops Engineering
Director, EU Ops Engineering Services
Stakeholder
Director, EU Ops L&D
Verifier(s):
Director, EU Ops HR
Director, EU Ops Security/LP
Director, EU Ops Procurement
Snr Manager, EU FC Infrastructure
Legal
Corporate Counsel, EU Compliance
Verifier:
Approver: Director, EU EHS
1. Purpose
The purpose of this procedure is to prevent personal injury to operators and nearby pedestrians and to prevent
property damage resulting from the use of Powered Industrial Trucks (PIT) and Aerial Lifts, by ensuring correct
equipment specification, maintenance, operation and operator training are in place.
2. Scope
This procedure applies to all areas of Warehouse where PIT’s (including pedestrian controlled pallet trucks) and
Aerial Platforms are in use. This policy is not intended to cover new construction, which is outlined in the Design–In
Safety Policy, but rather to cover inspection and maintenance criteria for existing structures and equipment.
Each location is responsible for complying with the legal requirements currently in force in their country. This
procedure sets out the minimum requirement that are applicable in all Warehouse. Where local regulations are more
stringent than this procedure, then the local regulation will supersede this procedure.
3. References
3.1. Internal
WW EHS Standards:
EU EHS Standards and Procedures -
Other Published References:
3.2. External
 PIT manufacturer manual instructions
 EN 1175-1:1998+A1:2010 - Safety of industrial trucks. Electrical requirements. General requirements for battery
powered trucks
 EN 16307-1:2013+A1:2015 - Industrial trucks. Safety requirements and verification. Supplementary
requirements for self-propelled industrial trucks, other than driverless trucks, variable-reach trucks and burden-
carrier trucks
 EN 16307-5:2013 - Industrial trucks. Safety requirements and verification. Supplementary requirements for
pedestrian-propelled trucks
Created: Jan 2019
Date of Last Revision: Jan 2019
1 Next Revision Planned: Jan 2020
EU EHS Procedure | HAS9002.02
 EN 16307-6:2014 - Industrial trucks. Safety requirements and verification. Supplementary requirements for
burden and personnel carriers
 EN 1726-2:2000 - Safety of industrial trucks. Self-propelled trucks up to and including 10000 kg capacity and
industrial tractors with a drawbar pull up to and including 20000 N. Additional requirements for trucks with
elevating operator position and trucks specifically designed to travel with elevated loads
 EN ISO 3691-1:2015 - Industrial trucks. Safety requirements and verification. Self-propelled industrial trucks,
other than driverless trucks, variable-reach trucks and burden-carrier trucks
 EN ISO 3691-5:2015 - Industrial trucks. Safety requirements and verification. Pedestrian-propelled trucks
 EN ISO 3691-6:2015 - Industrial trucks. Safety requirements and verification. Burden and personnel carriers
 ISO 13564-1:2012. Powered industrial trucks. Test methods for verification of visibility. Sit-on and stand-on
operator trucks and variable-reach trucks up to and including 10 t capacity
 ISO 22915-1:2016 - Industrial trucks - Verification of stability - Part 1: General
 ISO 6055:2004 - Industrial trucks — Overhead guards — Specification and testing
 ISO 6292:2008 - Powered industrial trucks and tractors. Brake performance and component strength
 EN 12053:2001+A1:2008 - Safety of industrial trucks. Test methods for measuring noise emissions
 EN 12895:2015 - Industrial trucks. Electromagnetic compatibility
4. Acronyms, Abbreviations, Terms and Definitions
Acronym Description
TUG Tow truck
STACKER Electric pedestrian stacker
RT Reach truck
OP Order picker
Turret truck PIT dedicated for VNA
PIT Operator training External/Internal theoretical and practical training on how to safety drive PIT
PIT Leaders training Familiarization training for all supervisors of PIT drivers
Aerial Lift Any vehicle-mounted device, telescoping or articulating, or both, which is used to position
personnel, including extensible boom platforms, aerial ladders, articulating boom platforms,
vertical towers, scissor lift.
Rabbit / Turtle Function The rabbit / turtle switch allows the operator to quickly set speed and performance profiles
to suit conditions.
5. Roles and Responsibilities / RACI Matrix

RME Manager
L&D Manager
Dep. Manager
EHS Manager
Ops. Manager
HR Manager
Procurement
Committee /
Tasks / Activities
Associate
Manager
Sr. Ops.
General
EHS
PIT and Aerial Lifts requirements

Ensure that procured or leased equipment meets the minimum
C A I I I - I C R R I
local and Warehouse afety requirements.
Ensure PIT modifications are completed by competent persons -
and that all modifications conform to health and safety C A I I I - I C R I
requirements and certifications set by governing authorities.
Ensure that battery charging areas are designed in accordance C A I I I - I C R - I
Created: Jan 2019

with local and Warehouse standards.

Managing PIT inventory C A I I I - I C R - -
PIT and Aerial Lift driver requirements
Providing medical examination standards regarding EU safety
C A I I I R I C - - I
requirements.
Operation
Ensure that each PIT and Aerial Lift operator possess the
required certifications and are authorized by employer or a C A R R I C C I - - R
person designated by an employer prior to operating any PIT.
Ensure that each PIT and Aerial Lift Operator follows all safety
C A I I R - C C R - R
rules from this procedure.
Ensure that a PIT and Aerial Lift preventive maintenance
C A I I I - I C R - I
program is developed, implemented and maintained.
Managing misbehaviour of Associates regarding driving -
ensure investigation is held regarding all PIT or Aerial Lift A I C C - C C I C - R
incidents.
Training-
Establish the -site’s PIT training and certification programs to
ensure it meets the requirements of this policy and EU laws and C A I I I I R C I - I
regulations.
PIT regulations regarding contractors
Ensure only qualified contractors who received permission and
completed authorized PIT training held by Warehouse Learning C A I I I I C C R - R
department are using PIT in the FC.
6. Procedure
6.1. General PIT requirements
PIT/ Aerial Lifts must only be operated according to the manufacturer’s manual which must be kept on site by the
RME department. Modifications and additions that may affect the capacity and safe operation of PIT/Aerial Lifts
must not be performed without the manufacturer’s prior written approval. Upon approval, the rated capacity,
operation and maintenance instruction plates, tags, or decals must be modified accordingly. Nameplates and markings
must be in place and maintained in a legible condition. The manufacturer identification nameplate must contain load
capacity.
Picture 1. OP name plates
Created: Jan 2019

Picture 2 PPT name plates
The RME Department must maintain an inventory of all PITs and Aerial Lifts currently in use within the FC,
including Power Pallet Trucks. All PITs must be numbered and have at least two visual identifiers, with the number
present on both sides of the PIT.
Each site must have a dedicated and segregated area for repairs to be carried out in. Only contractors qualified and
trained to repair PIT/Aerial Lifts may perform repairs and adjustment. Contractors intending on performing work on
PIT/Aerial lifts will be assigned a RME liaison who will oversee the work conducted by the contractor. It is strictly
not permitted for any Warehouse employee to perform repairs and adjustments to PIT fleet equipment. Where a
contractor is required to undertake a High Risk Operation (HRO) in order to perform the work, then HAS9005.13 –
High Risk Operation and Permit to Work procedure must be implemented.
PIT maximum speed must be limited to 6km/h (this does not apply to PIT that are dedicated to operate in VNA aisles
where their speed can be increased to a maximum of 12km/h due to wire guidance, which will be subject to the
outcome of a risk assessment conducted by the FC). Only adjusted types of PIT are to be operated in the Yard and
any other area outside the FC. PIT maximum speed must be limited to 6km/h and 4km/h for Powered Pump Pallet
Trucks.
Pedestrians are allowed in VNA aisles subject to the outcome of a risk assessments conducted by the FC.
Specific, and stricter safety rules regarding PIT/Aerial Lifts may be defined by each FC, in the specific details
contained in SLLS 17033 concerning VNA aisles and pedestrians.
6.2. Design Standards and Features

The minimum design standards and features to be included in PIT/Aerial Lifts procured/contracted for use at
Warehouse premises are detailed in ‘HAS9002.07- PIT Safety Requirements (Procurement Guidance)’.
6.3. PIT/Aerial lift risk assessment

Further to the guidance set out in ‘HAS9001.08 - Risk Assessment and Risk Reduction’, each FC must conduct risk
assessments and develop a ‘Risk Register’ for their FC, that they can refer to in order to help eliminate, or reduce as
low as reasonably practicable, the risk of injury and/or
illness from occupational workplace activities.
Site risk assessments must detail the potential for injuries

and illnesses as a result of working with PIT/Aerial lifts; the
potential for property damage and consequences of related
PIT events; the consideration of Legal and other Regulatory
Body requirements; potential mitigation measures; and
corrective steps to take in conformance with this procedure
and in line with the Hierarchy of Controls.
Risk assessments and the site risk register must be updated

on an annual basis at a minimum; reviewed following the
occurrence of serious incidents on site and execution of
Created: Jan 2019
corrective/mitigation actions; and/or whenever there is a change that could affect risk on site i.e. new/modified
procedure, equipment, task, layout change, and or regulation (whichever occurs soonest).
At a minimum, the PIT/aerial lift risk assessment shall:

 Determine where physical barriers are needed to protect pedestrians and structures, including but not limited to:
 Along pedestrian walkways and doors in, and adjacent to PIT/aerial lift operating space;
 Workstations in and adjacent to PIT/aerial lift operating space; and
 Building structures in and adjacent to PIT/aerial lift operating space;
 Determine where low-clearance overhead protection is needed to protect structures such as sprinkler and gas
lines, heaters, and roof drains;
 Confirm there are no places within the facility where there is a potential for fire explosion hazards due to the
presence of flammable gases, vapours, dusts, fibres, or other materials requiring consideration for rated PIT.
Minimum distance of combustible materials from charging area is 2m;
 Confirm there are no physical requirements within the facility that exceed the selected PIT/aerial lift capabilities
relative to grade or surface integrity;
 Establish documented controls accordingly.
 Evaluate whether the facility/operation receives pallets that have potential for exceeding the rating of the
PIT/aerial lift;
 Establish documented controls accordingly sufficient to prevent exceeding PIT/aerial lift rated capacities.
 Determine if there are areas within the facility that require PIT maximum speed to be limited below 5 MPH (8
Km/h)
 Evaluate all conditions pertaining to stacked and irregularly shaped product, documenting:
 Specific product/items allowed;
 Stacking and stack height limitations; and
 Specific locations under which stacking is allowed/prohibited.
6.4. Legal Register

Each FC must identify and take required steps to ensure compliance with the Legal and other Regulatory Body
requirements for their region, state, country. See section 3.2.
6.5. PIT/Aerial Lift Driver Requirements

1.
2.
3.
4.
5.
6.
6.1.
6.2.
6.3.
6.4.
Medical examinations by a suitable person (depending upon national standards) must be completed prior to initial
operator training. Refresher medicals will follow national standards. Sites must establish the specific legal
requirements regarding medical documentation based on the national standards.
All PIT/Aerial Lift operators must possess the required certifications and be trained and authorized by employer or a
person designated by an employer prior to operating any PIT.
Created: Jan 2019

Operators must possess and be able to present their Warehouse PIT Operator badge at all times during operation of
PIT and Aerial Lift. PIT badge can’t cover associate badge at any time. If an associate does not possess the PIT
badge, a one-day license can be issued to the operator after checking by safety team, if all required documentation is
in place.
They do require the full internal PIT training, the medical pre-checks shall be done in compliance with local law
regulations. Contractors are required to be appropriately trained and certified by their employer to the appropriate
national standard with copies of this training and certification to be given to Warehouse . The Warehouse Point of
Contact (PoC) for the contractor is responsible to notify the need of internal training session to Learning department.
The Learning department will provide training for contractors if all required documentation is given to Warehouse.
Only contractors who have been given permission via contract to operate Warehouse PIT equipment are permitted to
operate them (for example, MITIE, Crown). All other contractors must provide their own PIT equipment necessary
to complete activities on site.
6.6. PIT/Aerial Lift Usage

1.
2.
3.
4.
5.
6.
6.1.
6.2.
6.3.
6.4.
6.5.
6.6.
6.6.1. Pre-Operational (Pre-Use) Inspection
6
6.4
6.4.1
Inspections of PIT/Aerial Lift must be completed before every use and must identify any conditions that may
affect the safe operation of the PIT/Aerial Lift. PIT equipped with fleet management system have to have set up
time to fill the pre-checklist and do all required checks. The time set up to fill checklist have to be maximum 6
minutes.
6.4.1.1
Upon completion of a pre-use inspection, the operator must complete the pre-operational checklist and use the
sign-in system. Each FC have to implement WEBTOOL system. Each department must identify a storage
location for the completed pre-start inspection forms. The pre-operational checklist must be kept in the vehicle
at all times or be easy to find and presented. The historical pre-checklist have to be retained for a minimum of
six (6) months in area defined by local team.
Where any safety defects are found they must be marked on the pre-operational checklist, as well as in the sign-
in system, if one is in place. Operators must mark the defected PIT/Aerial Lift and then the RME Department
must be notified. Under no circumstances must PIT with identified defects be operated.
RME will ‘tag’ the PIT/Aerial Lift as “Out of Service” and apply LOTO until repairs or improvements can be
made.
6.6.2. Pedestrian Awareness

Created: Jan 2019
In accordance with, and further to the EU Operational Safety Rules (OSR):

 PIT / Aerial Lift Operators must stop at all pedestrian walkways, look both ways, sound horn and then
proceed if there are no pedestrians. If a pedestrian is present, the operator must make eye contact and
communicate verbally to give the pedestrian “right of way” before proceeding safely after them.
 Pedestrians must remain a minimum of 2 meters from travelling PIT/Aerial Lift.
 Where PIT forks are elevated above 1.8m all pedestrians and PITs must remain at a distance of at least 6
meters.
 PIT / Aerial Lifts must not travel in identified, marked, or signed “Pedestrian Only” areas unless
accompanied by a spotter.
 PIT/Aerial Lift must never be driven toward anyone standing in front of a bench or fixed object like a guard
rail.
 Cones to be use at both sides of pallet staging lane to warn PIT drivers of pedestrian’s presence in those
areas.
6
6.4
6.4.1
6.4.2
6
6.5
6.6.3. Key/Code control
Only authorized and trained PIT operators shall be allowed access to PIT keys or PIT cards. Physical key/card
controls shall be implemented where training or administrative controls prove ineffective as defined by any
unauthorized access.
Permission in Fleet Management system to drive PIT have to base on list of authorized PIT drivers from L&D.
A central PIT key locker will be available within the FC. Location to be decided by the FC. There can be a
number of lockers controlling keys assigned to different areas if required for operational reasons. Each Area
Manager (AM) or designated lead who requires PIT drivers will issue PIT keys to their PIT drivers as required.
To issue keys, the AM is to visually check the driver’s PIT badge and check the truck type and expiry date is
valid before signing out the key. Each key issued, is to be signed out using the PIT Key Issue Log by both the
AM and the PIT driver. The driver is to sign the key back in upon completion of use.
Where a vehicle key is lost or broken, raise a trouble ticket with engineering to obtain a replacement.
6.6.4. PPE Usage

Any person operating PIT/Aerial Lift that requires or allows them to be elevated from the ground must wear fall
protection equipment (lanyard and harness connected to appropriate anchor point). The height above which
using fall protection equipment is required may vary depending on national or Warehouse standard, whichever is
the stricter.
Fall protection equipment must be inspected pre-use daily by the operator. PPE have to be without any visual
damages, the inspection timeframe have to be visible and up-to-date. Annual inspections are to be completed by
an authorized company. A fall protection equipment register, including annual re-inspection dates, is to be kept
by local non-inventory department, or other departments if agreed locally within the FC.
6.6.5. Operator Safety Rules
In accordance with, and further to the EU OSR:

 Operators must not dismount PIT until it has come to a complete safe stop.
 Operators must keep all body parts inside PIT/Aerial Lift while in motion at all times.
Created: Jan 2019

 PIT/Aerial Lift must come to a complete stop in a safe location before the use of a phone or radio.
 Operators must use the horn at the end of every aisle, intersections, blind corners and when exiting trailers
and swap bodies.
 In areas where Aerial Lifts or Elevating Devices do not usually operate, operators must segregate the area to
a minimum of 6 meters exclusion zone using the visual signage (ex. cones and white/red tape).
 In pallet racking areas where no barrier exists between adjacent pallet racks a visual (lights pointing 6m
distance installed on the not movable part of PIT and floor marking within the area to facilitate recognition
of the 6m distance) and/or audible (sounding the horn) notification must be used to warn pedestrians in
adjacent aisles when storing or retrieving pallets from elevated pallet racking.
Picture 3 Blue lights fitting system
 When vision is obstructed, the operator must travel with the load trailing. Otherwise, a spotter is required
and the operator is to proceed slowly and with caution.
 Overtaking any kind of PITs, Aerial Lifts or pedestrians is banned. It is only possible to pass when PIT,
Aerial Lift or a pedestrian are stationary and the passage does not interfere with the movement from the
opposite direction.
 Overtaking in the high rack aisled is forbidden, unless site has a specific risk assessment which permits this.
 The PIT operator must look in the direction of travel at all times.
 The PIT operator must slow down for wet and slippery floors.
 Speed must be reduced during turning.
 PIT must only be used for specific work related tasks. PIT must not be used for personal transportation or
horseplay. A passenger must never be carried on the forks or load.
 Under no circumstances are PIT allowed outside during inclement weather (e.g. ice, rain or snow)
 PIT operators must wear a seatbelt where one is present on the equipment.
 Trash, corrugate, or any other material must not be stored on the overhead guard of a PIT.
 PIT must not be used as a towing or push device, unless appropriate attachments are fitted for this intended
purpose.
 Persons must not stand or walk under the elevated forks or a platform, even when a load is not being
carried.
 PIT must not be left unattended with the engine running, power on or with keys in the ignition without the
operator in the immediate area.
 PIT traveling in high rack aisles must drive single file and have at least 6 meters between equipment.
Tailgating is prohibited.
 Sites must strictly enforce a no smoking policy in a refuelling or battery charging area.
 Hooking, wrapping cables or chains around the mast of the equipment to pull objects is strictly prohibited.
 Minimum distance to be observed between PITs are as followed:
 6m – in the high rack area
 3m – on the main PIT lanes
 2m – on the docks, in the buffers and in the charging station area
Note - Distances can be stricter based on the results of site risk assessments.
Created: Jan 2019
 Written instructions are to be created within the site and must include at least the following requirements:
 Respect of the implemented traffic visual display,
 Maintain the access to the emergency exits which must be permanently free of any obstacle.
 No handling of equipment without formal authorization.
 No obstruction of traffic routes and more generally no blocking of the traffic flow.
 No parking (even for a short time) out of the specially dedicated and identified areas.
 It is forbidden for pedestrians (except for previously established service reasons) to enter manoeuvring
areas
As much as possible, these instructions are to be written under understandable pictograms to avoid
language barrier (for example: multiplicity of the heavy trucks driver’s languages).
6.6.6. Traveling Safety

Passengers are strictly prohibited on all PIT, with the exception of the scissor lift or when equipment and work
platforms are specifically designed and approved for use with two or more persons. This exception must also be
supported with training and Risk Assessment.
PIT must not travel with forks or load in front unless the PIT is designed to travel with forks first (e.g. Sit down
forklift) or when positioning, entering a staging lane / drop zone or loading and unloading a trailer. Traveling or
turning while the operator, forks, or load are elevated is prohibited (with the exception of positioning a load or
pallet and operating in VNA). PIT equipment in transit must keep forks to 10 - 15cm from the ground.
The act of ‘snowploughing’ is strictly prohibited. Snowploughing is defined as using a PIT to push pallets or
materials on the ground without the operator having a clear view of their path or having complete control to
steer or stop the materials e.g., pushing pallets along the floor to reduce the space between them. Similarly,
operating PIT in two directions at the same time is prohibited i.e. ‘roller-coasting’, ‘air-plaining’ or ‘drifting’ are
common terms for this behaviour. (Exception: This is permitted on Order Pickers and Turret trucks while on
wire guidance). All instances of snowploughing, roller-coasting/air-plaining/drifting must be reported I&M
application as a PIT event and corrective actions must be documented in ATS, including disciplinary actions for
the PIT operator in accordance with the EU Safety Code of Conduct.
6.6.7. Parking
 When PIT/Aerial Lift is not in use it must be parked in designated PIT parking areas, marked in accordance
with the FC Safety Signage Standard. When parking PIT, operators must safely lower the load, turn off the
power and apply the parking brake if one is present. Where PIT equipment cannot be parked in a designated
parking area ensure forks are lowered to the ground and covered (e.g. with a pallet and safety cone)
 In emergency situations (evacuation etc.) PIT should be parked immediately, not blocking an escape route
and keys should left in vehicle to allow emergency services to move equipment if required. RME will keep
master card for PIT equipped with fleet management system.
6.6.8. Load Safety

 PIT operators must not move double-stacked pallets taller than 1.8 m outside the immediate vicinity of the
dock door. Double-stacked pallets greater than 1.8 m must be down stacked before further transport.
 Loads intended for transport by PIT must never exceed the weight limit posted on the data plate of the PIT.
 All loads must be stable and safe to transport, lift or carry. Operators must inspect them first and restack or
secure them if necessary.
 All pallets stowed in reserve locations must be shrink wrapped or banded.
 Floor-stacked pallets must not be stacked in higher than 1.8m.
Created: Jan 2019

 Transporting product or totes (without a pallet) on the forks of PIT equipment is not allowed. Product and
totes must be placed on a pallet first.
 When transporting pallets, all items must be secured with shrink wrap (minimum three layer of shrink wrap)
or at least two pieces of banding. (Exception: When transporting empty stacked totes at floor level banding
is required).
 When transporting a stack of pallets this must only be done using PIT with operator protection guards. The
height of transported pallets must not exceed the height of the protective bar.
6.6.9. Pallet staging

 Mark pallet staging lanes.
 Prohibit associates from occupying or performing tasks (e.g. product check-in, ICQA functions, put away) in
any lane or adjacent lane (unless protected by physical guardrail) to that which is in process of being
loaded/staged by PIT.
 Mark readily available procedures and visual cues to manage PIT and pedestrian activities relative to how
product is to be properly stored, stacked and stocked.
 Train as appropriate associates (e.g. dock, ICQA and stock/stow) whose job requires work on the dock. These
associates shall be subject to the requirements of pallet staging.
6.6.1. Traffic Requirements

The site’s traffic plan shall be designed to minimize the risks of traffic accidents, but most importantly it should
minimize the number of traffic flows, separate pedestrian lanes from vehicle lanes, minimize the areas of
intersection and interference of flows, secure the routes and establish all the site’s traffic rules, considering the
following:
 Lane widths shall be adapted to the nature of the flow (pedestrians, impaired mobility people, vehicles, etc.)
and to the intensity of the traffic flow during normal or exceptional periods (personnel evacuation). This
shall be controlled at each modification of the site’s layout.
 When designating the lanes, the wider type of the PIT must be taken into consideration. The traffic lanes
will have the following minimum widths as shown on picture 5.
 Pedestrian lanes must be separated from the ones dedicated to vehicles and equipment,
 Blind corners and hazardous intersections are to be equipped with mirror(s) to ensure a visibility between
the various traffic directions,
 Dangerous elements such as docks, difference of levels, obstacles shall be signalized
 Permanent obstacles on the ground which can generate falling risks are coloured to distinguish them easily
(cable ducts, rollers guide rails, etc.)
 Level differences shall be prohibited as far as possible, but when there are level differences, access ramps
shall be preferred to move from one level to another. The slope of the ramps shall not exceed 5%. The ramps
are visually signalled (colour on soil, posting etc.).
 Doors and exits whose opening may generate a risk shall have a window or sufficient transparent surface
area to allow seeing any presence on the other side.
 Additionally, doors that open into an active PIT aisle shall be equipped with a guard, such as a bollards,
guardrails, chains and/or railing, to protect Associates from unintended contact with PIT.
Created: Jan 2019

Picture 5 – Minimum requirements for traffic routs widths.
 Pedestrian restricted areas must be clearly visualized (ex. VNA aisles). Only people with a service need are
authorised to enter these areas.
Based on the traffic plan and a risk analysis, the site shall install collective safety equipment allowing secure
pedestrian and vehicle traffic on site. Recommended are:
 Anti-slipping surfaces;
 Barriers or obstacles separating the various flows (notably the pedestrians and equipment or vehicles ones)
 Traffic lights,
 Mirrors at intersections,
Based on the traffic plan, the site must defines its own traffic rules resulting in:
 Implementation of adapted visual signposting,
 Written instructions completing the signposting.
6.6.10.PIT Shutdown Procedure

 PIT must be returned to the designated location(s), in good clean condition and all personal belongings
(including PPE) and waste must not be left inside.
 Forks must be lowered to ground level.
 Steering wheel must be left in neutral position.
 PIT must be signed off the in the system
 Keys are to be returned to department manager at the end of each shift or returned to a designated location.
Created: Jan 2019

If PIT incident occurs, the PIT must be marked with the defective label and signed off in the system if one is in
place and marked as “involved in incident”. All PIT incidents must be reported immediately without exception.
If any safety defect(s) occurred during the operation of the PIT, they must be marked with defective label and
marked in the system accordingly and the same process followed as outlined in 6.5.1 above regarding the
escalation to RME and the action that RME must take to LOTO the vehicle and arrange inspection/repairs. If
PIT equipment is involved in a collision, even if there is no obvious visual sign of damage, a report must be
obtained from the supplier to confirm that the equipment is safe to be returned into operation.
6.6.11.Maintenance
Only trained and qualified persons may inspect, maintain or repair a PIT. PIT must be kept clean at all times so
it is easier to identify worn or defective parts. Detailed records of every inspection, service, maintenance, repair
and modification must be retained by RME throughout the whole time the truck is in use within the FC.
6.6.2. Safe Aerial Lift Operations

 Operators must pay attention towards the direction of travel, clearances above, below and on all sides of the
Aerial Lift.
 Persons must not sit or climb on the guardrails of the Aerial Lift.
 Planks, ladders or other devices must not be used on the work platform.
 Aerial Lift must not be moved when it’s elevated in a working position with employees in the basket unless
ground area is safe, distances are short and minimum 6m and area have to be cordoned off. Distance from the
device and segregation must be maintained.
 Aerial Lifts must not be placed against another object to steady the elevated platform.
 Aerial Lift must not be used as a crane or other lifting device.
 Aerial Lift must not be operated on grades, side slopes or ramps that exceed the manufacturer's
recommendations.
 Brakes shall be set and outriggers, where available, must be positioned on pads or a solid surface.
 The speed limit of Aerial Lifts is 6km/h but must be limited according to the conditions of the ground surface,
congestion, visibility, slope, location of personnel and other factors that pose hazards to personnel.
 Stunt driving and horseplay is prohibited.
 Booms and elevated platform devices must not be positioned in a way to jack the wheels off the ground.
 The immediate area surrounding the elevated platform must be cleared of personnel and equipment prior to
lifting and lowering the elevated platform.
 All materials must be secured inside the aerial lift and their weight must not exceed the rated capacity of the
machine.
 Operators must call for assistance if the platform or any part of the machine becomes entangled or in an
unsafe situation.
 Safe shutdown is achieved by parking in a designated area, placing the platform in the stowed position,
placing controls in neutral, idling engine for gradual cooling, turning off electrical power and taking the
necessary steps to prevent unauthorized use.
 Operators must not wear any loose clothing or accessory that can catch in moving parts.
 Aerial Lifts must not be operated from trucks, scaffolds, or similar equipment.
 Condition of ground and weather must be checked prior to carrying out aerial lift and starting the usage and
strictly follow with requirements from manufacturer manual, like wind limits etc.
 Before use or activity should be done visual check of overhead obstructions.
 The site have to have rescue plan for work at height activities in compliance with procedure HAS9005.05
- Fall Hazard Control.
6.7. Battery Charging Requirements

6.7.1. General Requirements
Created: Jan 2019
Only trained personnel (authorized PIT operators) are authorized to perform battery charging activities as well
as electrolyte backing. Battery charging activities must only be performed at the designated locations provided
for this purpose, which have good ventilation and where suitable means are available to counter the electrical
risk.
Operators must:
 Strictly adhere to the posted instructions. All signs have to be in compliance with FC Safety Signage
Standard. Minimum signage in the area should be
 Smoking forbidden
 Warning signs - corrosive substances
 Required PPE
 Emergency shower
 Explosion zone – if needed, explosion protection analysis
 Never ignite a naked flame close to a charging equipment,
 Never discharge a battery by more than stated in manufacturer manual of the battery,
 Check that the battery lead connections are clean and well-greased,
 Never leave tools or metal parts on the battery or at proximity during the loading, and
 Always shut down the battery loader at the end of the loading/charging activity
 The distance from combustible materials should be min 2m,
 Charging cable can’t lying on the floor. Hangers for charging cables are recommended.
For dry-charge batteries or batteries with gel, the charging must be realized at the end of each shift. You should
always follow with manual of battery manufacturer
6.7.2. Maintenance of batteries (electrolyte top up)

This operation must only be performed at the locations provided for this purpose, which have good ventilation
and where suitable means are available to counter the electrical risk.
If possible, use single point watering as shown on diagram below to minimalize risk of acid splashes.
Operators must:
 Always wear the required PPE in accordance with section 6.7.5 (below) and ‘HAS9002.01 – Personal
Protective Equipment (PPE)’
 Strictly adhere to posted instructions,
 Conduct the electrolyte refilling in accordance with the instructions,
 Wipe up any electrolyte spillages immediately and dispose of spill materials appropriately
Picture 6 – Single fill watering system.
The FC RME team must routinely validate the proper functioning of the safety shower and eye washes made
available in the area
6.7.3. Maintenance areas and the charging of acid batteries.

The battery charging areas are designed and operated according to local regulations. They are built and operated
in order to reduce the risk of hydrogen accumulation and are, if necessary, equipped with explosion-proof
installations. The room is duly ventilated and protected. The hazards are identified and clearly signalized, the
assessment of charging station. Minimum signage requirements are: ex zone (if needed), no smoking, corrosive
substances, and no hot works. The storage of combustible materials in the loading areas and around the
perimeter area is prohibited. The prohibition to bring in any form of fire is indicated. The battery maintenance
areas (acid batteries in particular) are clearly identified. It’s recommended that the floor is sealed and covered
with an anti-acid-type resin.Eliminate areas near the ceiling where hydrogen could accumulate or form pockets.
Created: Jan 2019

If the pocket cannot be eliminated, provide ventilation in these areas and ensure there are no ignition sources in
these areas. The floor of the battery charging room shall be resistant and impenetrable to the electrolyte
(acid/alkali). Follow battery charger manufacturer's recommendations for safe operation and ventilation
requirements.
Open flames are strictly forbidden in the battery charging area. Therefore, never permit sparks, open flames, hot
works or lit cigarettes near a battery charging area. The size of the classified area where hydrogen could be
present should be determined by conducting a risk assessment based on local requirements and is dependent on
the dimensions of the charging area, the hydrogen release rate and the availability and type of ventilation. Post
clearly visible signs to prevent open flames in the vicinity of the battery charging area.
Batteries operate at their optimum at room temperature. This is the recommended temperature for battery
charging. Keep battery cap vents clear. If the released hydrogen is not vented, it can build up pressure and burst
a cell. Also when charging batteries ensure that the vent caps are in place to avoid the potential of spray of
electrolyte.
Avoid arcing at the battery. Therefore avoid the use of metal tools, which could accidentally be placed across
the battery, causing a short circuit. Use only insulating tools in the battery charging area and avoid the use of
larger metal objects such as aluminium ladders or scaffolding tubes, which pose the same short-circuit risk.
There shall be touch protection for all active parts at voltages > 50 volts DC with insulation, covers or shrouds
and distances.
Operators shall be trained about the hazards associated with batteries and battery charging.
Proper water levels in the battery cells must be maintained. Batteries can be topped up with distilled or
demineralized water. When lifting a battery, use an approved lifting beam. This beam has a non-conducting
barrier between the two hooks, which prevents short circuiting.
6.7.4. Battery exchanging requirements

Operators shall be trained about the hazards associated with batteries and battery charging and o nly trained
personnel can change batteries in electric industrial trucks. In addition to training in battery changing and
charging procedures, these employees should be trained on emergency procedures in the event of an acid splash,
including how to use eyewash and shower facilities. Potential hazards include:
 Batteries are very heavy and pose a dropping hazard–some batteries weigh as much as 1000kg or more
 Batteries contain sulfuric acid that is highly corrosive and could be splashed on personnel servicing or
changing batteries
 Toward the end of the battery charging process, batteries can give off highly explosive hydrogen gas. This is
commonly called “out gassing”
 Contact with battery cells may cause electrical short circuits in certain situations, which can burn
unprotected skin
Specific procedures and risk assessment must be conducted by the site to establish the required safe process also
following the recharger manufacturer's recommendations for attaching and removing cables and for proper
operation of the equipment.
6.7.5. PPE for Battery Charging Areas

 When handling electrolytes, wear face shields (face shields should not have metal reinforcing rims, which
could cause a battery to short circuit if dropped on to the battery metal contacts), rubber aprons and rubber
gloves. Avoid splashes, but if splashes occur to eyes or skin, flood with water for at least 15 minutes and
get medical attention. In the case of valve regulated or gas-tight sealed batteries, a minimum of protective
glasses and gloves shall be worn.
 Electrostatic discharge shall be prevented by wearing antistatic clothing and footwear in the battery charging
area when conducting maintenance on the batteries. Absorbing cloth moistened with water shall be used for
Created: Jan 2019
battery cleaning, other cleaning agents may result in buildup of static or may damage the battery cases.
Responsible for cleaning batteries is external company providing service for PIT.
6.7.6. Emergency Showers

 Safety showers and eyewash shall be located within 6 m (20 ft) of the battery charging area.
 Safety showers and eyewash stations must be inspected regularly, minimum once a month.
 It’s recommended to equip charging station with eye wash suitable for chemicals (if acid batteries)
6.7.7. Spill Response

Each charging area must be equipped with appropriate visually marked spill kit along with the necessary PPE.
 White (it can be also blue) - for use with oils
 Yellow coloured - for use with chemicals
 Grey - maintenance standard spill kit, this can be used on oils and chemicals
In case of a spill, Operations management and RME must be informed immediately and spill removal to be
handled according to local instructions only by trained personnel. Spill instances must be recorded I&M
application as a Spill/Release Event.
6.8. Audits
6.9. Safety Incident; Property Damage; Power Outage and Emergency Situation Reporting
6.9.1. Safety Incidents or Property Damages
The PIT/Aerial Lift Operator is responsible for reporting all safety incidents, damage to merchandise, equipment
or stationary objects immediately to their Manager. If involved in an incident the following steps must be
followed without exception:
1.
2.
3.
4.
5.
6.
6.1.
6.2.
6.3.
6.4.
6.5.
6.6.
 Do not move the equipment (unless an unsafe situation requires movement of PIT) and notify manager
immediately.
 Shutdown PIT immediately and leave everything as it came to rest.
 If PIT has come into contact with a pedestrian and they are trapped by the equipment - do not move the
equipment and immediately contact first aid response provision or Emergency Medical Services (EMS).
 Only move PIT if there are no trapped persons or something is being spilled or leaking (water lines,
sprinkler system) then use extreme caution and move slowly to a safe location.
1.
2.
3.
4.
Created: Jan 2019
5.
6.
6.9
6.9.2 Emergency Events
Further to, and in accordance with’, in the event of:
 Power outage, the use of PIT equipment must cease. Operators will lower forks, move to a safe area and
outside of any designated pedestrian path, and leave the work lights on. Equipment operated in VNA will
be moved outside of VNA if it is safe to do so.
 Fire Alarm/ Site Evacuation, the PIT operator will lower forks, park in an area not to block any emergency
exit routes, turn off and leave PIT/Aerial Platform with keys inside the ignition and go outside through the
nearest exit.
 Fall (including partial fall) from elevated work platforms such as order picker, turret truck, scissor lift or
other aerial lift, the site fall rescue plan will be initiated. Equipment must be taken out of service until it is
deemed safe to use again by the manufacturer (subject to any restrictions on use imposed by the EHS team,
Legal, and regulatory and law enforcement authorities).
 Tip over, associates will be trained on how to respond. Always follow the operator’s manual guidance on
such an event.
 Battery Acid Spill, refer to site Emergency Action Plan to properly clean the affected area.
 Incapacitating Injury/Unconsciousness of a Person at height and/or PIT/Aerial Lift struck at height, the
RME team are the principle point of contact and must be contacted without delay to responsibly lower the
equipment safely etc.
6.9.3 Reporting
In addition to the reporting obligations noted above and in the Global EHS Incident Reporting and Investigation
Standard, all injuries and events must be reported without exception.
6.10 Managing Misbehaviour and Investigation

Each PIT / Aerial Lift incident must be reported by the Department Manager to EHS, Learning and HR department.
Safety violations of PIT/Aerial Lift Operators and any associated disciplinary action, up to and including termination,
must be considered strictly in line with the EU Safety Code of Conduct (SCOC). The decision on the severity of the
infringement will be made by the investigation team in accordance with the guidance set out by the SCOC.
1.
2.
3.
4.
5.
6.
6.1.
6.2.
6.3.
6.4.
6.5.
6.6.
6.7.
The investigation should start immediately and end within 2 weeks. After recommendation from EHS Department
and Legal confirmation, HR department should prepare the final document which is delivered together with Area
Manager to Associates. Learning will organize any retraining accordingly.
6.10.1 PIT Incidents – Investigation
Created: Jan 2019

Where a person has been involved in a PIT / Aerial Lift incident where there is either injury to people, damage
to equipment or product - the driver’s PIT authorization to drive badge must be immediately removed pending
the outcome of the investigation (the badge must be submitted to the EHS team).
The supervising manager must immediately commence an incident investigation. If during the initial incident
investigation the investigating manager finds that an associate’s conduct is below standard, then the
investigating manager should recommend to HR that a conduct investigation is required. The incident
investigation should not determine the outcome of this but merely state that a conduct investigation is
recommended. The investigating manager should then liaise with HR to commence this separate conduct
investigation. The incident investigation documentation then becomes part of the conduct investigation and is
separate.
The scene of the incident must be photographed prior to any movement of PIT / Aerial Lift. The PIT Pre-Use
Inspection check sheet must be attached to the incident investigation for review and retention. The investigating
manager must arrange for the vehicle to be moved to a safe location, if possible depending upon the
circumstances of the incident. Facilities Department to be informed of the issue and a request for a maintenance
visit and inspection report made.
7. Contractor Management
Establish a program for managing contractors who are authorized to operate PIT to ensure they are competent prior to
operating the equipment. The facility/operation is responsible for ensuring they are competent through training and
evaluation on the use of the specific type of PIT. If a contractor is operating a PIT at the facility that is owned and under
the control of the contract company, the contractor shall follow the facility operation and safety requirements.
Independent RME contractors are permitted to use Warehouse equipment if they have completed and present the
documentation:
 Contractor acknowledgment (release of liability and site EHS rules)
 Contractor pre-task checklist and risk assessment or safe work method statement
 Provide evidence of their training to RME and H&S
 Driving license acc local law requirements
 Warehouse internal training
 Work permit
 Provide evidence of their training to RME
 Carry out a pre-use check.
Additional considerations may include, but are not limited to:

 competence and capability (e.g. designers or contractors);
 sufficiency of time and resources for the work to be done safely;
 information needed to arrange for any gaps in information to be filled (e.g. commissioning an asbestos survey);
 responsibilities for overseeing communication and work cooperation and coordination; and
 Management arrangements to handle issues and concerns.
8. Training
8.1 Training Documentation and Retention
FC Learning in cooperation with the EHS department must establish the site’s PIT training and certification program
to ensure it meets the requirements of this policy and EU laws and regulations. Electronic training records that
include the course name or code, the trainee’s name, the date, and the trainer’s name must be retained.
Documented training records, including certificates, must be maintained for the whole length of the trainee’s
employment, and 5 years after the termination. Based on local requirements each FC to establish the place
(department) and method of storing the documentation (electronic or paper version).
Created: Jan 2019

8.2 Permanent On-Site Contractors

Warehouse expects permanent on-site contractors to fully comply with this document, including medicals and
authorized PIT training, according to local requirements. On-Site Contractor have to organize all required documents.
L&D have to conduct PIT internal training.
8.3 Training Types and Required Frequency

FC Learning department is responsible to select suitable personnel as Warehouse PIT trainers or competent external
training providers to evaluate operator competence.
1.
2.
3.
4.
5.
6.
7.
7.1.
7.2.
 Basic PIT Awareness Training - All associates employed within FC’s using PIT must have basic PIT
awareness training. This is contained within the safety school induction training session. There is no refresher
training requirement.
 PIT Operator Safety Rules Authorized Training – All Trained PIT Operators. The operational safety rules
document is to be briefed either during PIT operator driver training or before being issued a PIT authorization to
drive badge. Learning department must maintain a training matrix to identify the date all PIT authorized drivers
completed this awareness training and when the annual refresher is due. Learning manager is responsible for
ensuring all PIT operators are re-briefed on the operator safety rules annually and documentation retained.
 Authorized training types: Theoretical part – to be completed before the practical part. Must end
with the knowledge test, which is then stored in the Learning department – Based on local requirements
each FC to establish the place (department) and method of storing the documentation (electronic or
paper version).
 Practical part – must end with the practical exam. If an associate does not pass the practical exam,
trainer can decide about providing another internal training session to improve the skills. If associate
will not pass the exam at the second attempt PIT license will not be issued.
 Refresher training. To be provided annually to all PIT operators (PIT safety rules) and when a condition in the
workplace changes in a manner that could affect safe operation of the truck or after three months gap without
using of any PIT.
 Retraining. Must be provided when the operator has been observed to operate the machine in an unsafe manner;
has been involved in a PIT Incident or PIT near miss incident; has received an audit that reveals that the operator
is not operating the truck safely; or is assigned to drive a different type of truck.
 PIT Operators Driver Training – Selected Associates (this is dependent upon national standards).
 Battery exchange training – to be provided to all operators authorized to exchange the battery. The training is
held by Facilities team in accordance to PMV. The content of the PMV must be consulted with EHS and
Learning departments.
 Spill Training – All PIT Operators. Each newly trained PIT operator must have the spill response training
awareness course as part of the PIT training package. If the site does not have a PIT trainer, the EHS team will
provide this training awareness package. Refresher training is due every year. FC RME team and the site
cleaning contractor must also be trained in spill response and clean up and attend to all large spills.
 PIT Leadership Awareness Training - all Supervisors of PIT Drivers (Ops Manager, Area Manager and
Leads), EHS team. All supervisors of drivers must undertake the PIT Supervisor awareness session, split in two
parts. This gives basic knowledge of safe driving practices to enable adequate supervision of PIT driving
standards and to complete PIT Operator audits. First training session is held by the PIT trainer in-house (where
Created: Jan 2019

there is no PIT trainer on site, the EHS team will carry out the awareness session). PIT Operator Audits can be
carried out by any person who has completed this awareness session or is an appropriately trained PIT operator
(e.g. Area Managers (AMs), EHS team, leads, Learning associates). Refresher training is due annually. Second
part must be completed in KNET session.
 PIT Trainers must complete training sessions for EHS teams where necessary to enable them to complete the
PIT Supervisor Awareness Training. The details are presented in Table one.
At a minimum, the following requirements shall be included:

Job Title Job Description Type Training Content Required Frequency
Affected Perform work in Awareness - Basic awareness training on the Initial on assignment
associates areas where operation and hazards of PIT/Aerial
PIT/Aerial Lifts are use
in operation - Proper procedures when entering
areas where PIT’s are in use.
PIT/Aerial lift Operator PIT/Aerial Authorized - Affected associates training content - Initial on assignment
operators Lifts - 1-year Refresher
Theoretical: - Quarterly evaluation/
- A prerequisite for the practical hands assessment of using PIT
on training) training regarding the
types of PIT/Aerial Lifts and Retraining:
operational safety requirements. - If Operators have not
- Must end with a competency operated any PIT/Aerial
verification. Lift in 3 consecutive
- required regulatory content months
- involved in a PIT
Practical/hands on training: related near miss,
- For each specific type of incident or accident
equipment/attachments to be used. cause by operator error
- Must end with a practical hands on -assigned a different PIT
competency verification. than previously trained;
- PIT badge or license shall not be - workplace conditions
issued until both theoretical and changes that affect safe
practical training competency operation safety;
verification are complete. - observed to operate in
- Battery exchange training (if an unsafe manner; and
applicable) - received an evaluation
- Emergency and spill response training that show operator is not
- Operational safety rules operating safely
PIT/Aerial lift Oversees workers Leadership - Affected associate training content - Initial on assignment
operation who operate PITs - Authorized associate training content - Annual refresher
leadership within the facility - Auditor program/procedure training
requirements and assessment by PIT
manager
- Equipment specific training for each
type of PIT in use
PIT/Aerial lift Trainer of PIT Authorized - Trained by equipment manufacturer - Initial on assignment
trainers operators or certified by a third party course as - Annual refresher
competent in the knowledge and - Quarterly provide
demonstrated ability to train PIT/Aerial coaching to PIT
Lift operators and evaluate their operators related to
competence on a quarterly basis. assessment/
evaluations
Table 1: PIT/aerial lift training matrix
1.
2.
Created: Jan 2019
3.
4.
5.
6.
7.
8.
8.1.
8.2.
8.3.
8.4.
8.5.
8.6.
8.7. Practical Training Guidance

A PIT trainer/trainee shall not, for any reason, stand or walk in front of, behind, or around the PIT, unless the PIT is
turned off and keys removed. Where possible, PIT and observers (trainer/trainee) should be separated by a guardrail.
9. Documented Information
At a minimum, the following records shall be kept on file for the time period specified unless country specific regulations
require a longer retention period.
Record type Retention period minimum

Audits (e.g. pre-use inspection) 6 months or can be retained electronically e.g. fleet
management systems
Procedural forms (can be stored electronically) 1 year
Local regulatory documentation (e.g. copy of driver’s 5 years or length of employment (whichever is longer)
license, medical evaluation, etc.)
Training records 5 years or length of employment (whichever is longer)
Original equipment documentation The operational lifetime of the PIT/aerial lift
Repair and Preventative maintenance records The operational lifetime of the PIT/aerial lift
Risk Assessments 5 years or length of employment (whichever is longer)
Table 2: Documented information retention schedule
1.
2.
3.
4.
5.
6.
7.
8.
10. Appendixes
Created: Jan 2019


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EU EHS Procedure | HAS9002.

Issue Date Description of Changes

Document Details Role

4. Acronyms, Abbreviations, Terms and Definitions

5. Roles and Responsibilities / RACI Matrix

PIT and Aerial Lifts requirements

Created: Jan 2019

with local and Warehouse standards.

Picture 1. OP name plates

Created: Jan 2019

Picture 2 PPT name plates

6.2. Design Standards and Features

6.3. PIT/Aerial lift risk assessment

Site risk assessments must detail the potential for injuries

Risk assessments and the site risk register must be updated

At a minimum, the PIT/aerial lift risk assessment shall:

6.4. Legal Register

6.5. PIT/Aerial Lift Driver Requirements

Created: Jan 2019

6.6. PIT/Aerial Lift Usage

6.6.2. Pedestrian Awareness

In accordance with, and further to the EU Operational Safety Rules (OSR):

6.6.4. PPE Usage

6.6.5. Operator Safety Rules

In accordance with, and further to the EU OSR:

Created: Jan 2019

Picture 3 Blue lights fitting system

6.6.6. Traveling Safety

6.6.8. Load Safety

Created: Jan 2019

6.6.9. Pallet staging

6.6.1. Traffic Requirements

Created: Jan 2019

Picture 5 – Minimum requirements for traffic routs widths.

6.6.10.PIT Shutdown Procedure

Created: Jan 2019

6.6.2. Safe Aerial Lift Operations

6.7. Battery Charging Requirements

6.7.2. Maintenance of batteries (electrolyte top up)

6.7.3. Maintenance areas and the charging of acid batteries.

Created: Jan 2019

6.7.4. Battery exchanging requirements

6.7.5. PPE for Battery Charging Areas

6.7.6. Emergency Showers

6.7.7. Spill Response

6.10 Managing Misbehaviour and Investigation

6.10.1 PIT Incidents – Investigation

Created: Jan 2019

Additional considerations may include, but are not limited to:

Created: Jan 2019

8.2 Permanent On-Site Contractors

8.3 Training Types and Required Frequency

Created: Jan 2019

At a minimum, the following requirements shall be included:

8.7. Practical Training Guidance

Record type Retention period minimum

Created: Jan 2019

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