Here is a risk assessment for an order picker, considering potential hazards and control measures:

1. Hazard: Falls from Height

• Risk: Order pickers often work at elevated levels, increasing the risk of falls leading to serious injuries or fatalities.
• Control Measures:
  • Ensure the order picker is equipped with appropriate fall protection, such as guardrails, harnesses, and lanyards. Regularly inspect these for damage [1].
  • Provide thorough training on the safe operation of the order picker, including proper climbing techniques and load handling [1].
  • Establish clear procedures for working at height, including the use of spotters or safety observers when necessary.
  • Maintain a clear and unobstructed work area to prevent trips and falls.

2. Hazard: Collision with Objects/Vehicles

• Risk: Order pickers may collide with racking, other equipment, or pedestrians, resulting in injuries or damage.
• Control Measures:
  • Implement designated traffic routes and pedestrian walkways to separate order pickers from other vehicles and personnel.
  • Use visual aids such as mirrors, warning signs, and flashing lights to improve visibility and awareness.
  • Train order pickers on safe operating speeds and techniques for navigating confined spaces.
  • Regularly inspect and maintain the order picker to ensure proper functioning of brakes, steering, and warning devices.

3. Hazard: Musculoskeletal Injuries

• Risk: Repetitive lifting, bending, and reaching can lead to strains, sprains, and other musculoskeletal disorders.
• Control Measures:
  • Implement ergonomic principles in the design of the order picking process, such as optimizing picking heights and minimizing reaching distances.
  • Provide training on proper lifting techniques and the use of mechanical aids such as dollies or carts.
  • Encourage regular breaks and stretching exercises to reduce muscle fatigue.
  • Rotate tasks among workers to minimize repetitive motions.

4. Hazard: Exposure to Hazardous Substances

• Risk: Order pickers may be exposed to dust, fumes, or chemicals from the products they handle, leading to respiratory or skin irritation [2].
• Control Measures:
  • Ensure adequate ventilation in the work area to minimize airborne contaminants [1].
  • Provide appropriate personal protective equipment (PPE) such as gloves, safety glasses, and respirators, depending on the specific hazards [3].
  • Provide training on the hazards of the materials being handled and the proper use of PPE.
  • Maintain Safety Data Sheets (SDS) for all hazardous materials and make them readily accessible to workers.

5. Hazard: Equipment Malfunction

• Risk: Malfunctioning order pickers can cause accidents, leading to injuries or property damage.
• Control Measures:
  • Establish a regular maintenance program for the order picker, including inspections, lubrication, and repairs.
  • Train order pickers to recognize and report any equipment malfunctions promptly.
  • Take malfunctioning equipment out of service until it can be properly repaired.

6. Hazard: Tip-over

• Risk: Order pickers can tip over if overloaded, operated on uneven surfaces, or turned too sharply.
• Control Measures:
  • Clearly mark the maximum load capacity of the order picker and train operators to adhere to these limits.
  • Ensure that the work area is free of obstructions and that surfaces are level and stable.
  • Train operators on safe turning techniques and the importance of maintaining a low center of gravity.

7. Hazard: Crushing

• Risk: Workers can be crushed by the order picker or by falling objects.
• Control Measures:
  • Ensure that workers are trained to maintain a safe distance from the order picker when it is in operation.
  • Implement procedures for securing loads to prevent them from falling.
  • Use overhead guards or other protective devices to protect operators from falling objects.

Monitoring and Review:

• Regularly inspect the work area and equipment to identify and correct any hazards.
• Review accident and incident reports to identify trends and areas for improvement.
• Conduct periodic safety audits to ensure compliance with established procedures.
• Update the risk assessment as needed to reflect changes in the work environment or equipment.