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Board contacts grading machine photoeye

Safety Alert Type: 
Sawmills and Reman
Location: 
Castlegar, BC
Date of Incident / Close Call: 
2019-01-11
Company Name: 
INTERFOR
Details of Incident / Close Call: 

The Lineal High Grader (LHG) operator went to pull the LHG out in order to clean the scanner. At the same time, the Planerman was doing an adjustment to the Planer.

As the LHG was being backed out to be cleaned, the Planerman jogged a board forward, pushing it into the LHG. The board made contact with the infeed photo eye.

The LHG was shut down, stop button pushed, and permissive button pressed to prevent the rolls from moving. The PLC controls stopped the “planer feed auto” but did not stop the “jog” function. The PLC controls did not allow this fuction previously and had been changed at some point to allow this to happen.

This procedure did not require a lockout because employees were never entering the bite and only cleaning from outside of the area using an air wand. Potential for LHG damage or possibility of boards protruding from the feed line exist.

Learnings and Suggestions: 
  • The Safe Work Procedures for the LHG now requires a full lockout of the LHG when cleaning or inspecting. This means that a lockout is required any time the LHG main frame is moved to the “out” position or out of the feed line.
  • The LHG frame acts as a safety barrier and when in the “out” position, the potential for someone to enter the bite exists. Serious injury could occur.
  • PLC Controls cannot be used as a safe guard when removing guards or barriers, where potential for injury or damage exists.

 

For more information on this submitted alert: 

Tony Mackie, Safety Coordinator Tony.Mackie@Interfor.com

File attachments
Safety_Alert_Interfor_Castlegar-Board_Contacts_Machine_Photoeye-01-11-2019.pdf

Packaging worker's thumb gets stapled

Safety Alert Type: 
Sawmills and Reman
Location: 
Castlegar, BC
Date of Incident / Close Call: 
2019-01-09
Company Name: 
INTERFOR
Details of Incident / Close Call: 

At the mill's paper wrap station, there was a package of mixed length lumber to tag. The economy packages do not require to be paper wrapped, only tagged. The tags are required to be stapled to the package.

The operator stapled the top of the tag and the tag curled up from the bottom. The operator held the bottom of the tag. When he was attempting to staple the bottom left corner, he inadvertently put a staple into his left thumb.

The operator had the trigger depressed while he was applying staples. He was wearing Gander Brand Ninja X4 gloves.

Learnings and Suggestions: 
  • OMER Brand tools are equipped with a safety mechanism and can only fire when the safety and trigger are depressed at the same time.
  • Operator was holding trigger and using the safety to fire the tool.
  • Cap Staple Tools were used on all products except for cedar and for “tag only” packages.
  • Ensure proper hand placement while stapling and using the trigger to fire OMER tools.
  • Cap Staple Tools function the same as OMER Staple tools. Cap tools automatically place caps, and will now be used to staple tags on all packages.
  • Cap Staple Tools require less manual hand use for opposite hand and have a wide safety mechanism that helps to keep the tool farther away from the opposite hand.

 

For more information on this submitted alert: 

Tony Mackie, Safety Coordinator Tony.Mackie@Interfor.com

File attachments
Safety_Alert_Interfor_Castlegar-Stapled_Thumb-01-9-2018.pdf

Log loader mechanical failure on boom and stick hinge point

Safety Alert Type: 
Yarding and Loading
Location: 
Adams Lake Woodlands (Chase, BC)
Date of Incident / Close Call: 
2019-01-10
Company Name: 
INTERFOR
Details of Incident / Close Call: 

A log loader was swinging a grapple of long logs onto a truck trailer and a mechanical failure in the boom hinge occurred resulting in the load of logs dropping.

The steel pipe on the stick side of the boom/stick hinge-point broke away. After the break, the boom and stick assembly were supported by the cylinder and hoses. A post-incident inspection found that only half the pipe was welded --- there was not a continuous weld all the way around.

During regular greasing of the hinge point, this location is greased remotely near the grapple end as there is no practical method to regularly service or inspect this location.

The truck driver was in the clear and not at risk of being struck by a log.

Learnings and Suggestions: 
  • Always stay in the clear around active equipment and overhead hazards.
  • At regular intervals, a qualified person should thoroughly inspect and test machine components and welds that regularly receive heavy loads.
  • Operators using a 2015 Tigercat 875 log loader should inspect the hinge for weld defects.

 

For more information on this submitted alert: 

Evan Hauk, Area Supervisor  Evan.Hauk@Interfor.com

File attachments
Safety_Alert_Interfor-Adams_Lake_Woodlands-Mechanical_Failure_Log_Loader-01-10-2019.pdf

Lockout violation due to unfamiliarity with disconnect locations

Safety Alert Type: 
Sawmills and Reman
Location: 
Acorn Sawmill (Delta, BC)
Date of Incident / Close Call: 
2019-01-10
Company Name: 
INTERFOR
Details of Incident / Close Call: 

A sawmill lockout violation occurred when an employee entered the barker infeed conveyor to conduct maintenance work.

Although the employee had sufficiently locked out the barker, locking out of the hydraulic log loaders located on another MCC was missed. The Lockout verifier was also unaware that the disconnect for the log loaders had to be locked out at a different location.

Both employees are relatively new to their positions, however they have been trained. Prior to the actual work commencing, the violation was discovered and the employee in the barker infeed was pulled from the work area.

Learnings and Suggestions: 
  • Take the required time to identify all pieces of equipment, energy sources and disconnect locations when locking out. Multiple locations and energy sources could be required to lockout one piece of equipment.
  • Ask more experienced employees to explain the different lockout locations and energy sources of each piece of equipment.

 

For more information on this submitted alert: 

Sia Bouseh, Safety Coordinator Sia.Bouseh@Interfor.com

File attachments
Safety_Alert_Interfor-Acorn_Sawmill-Lockout_Violation-01-10-2019.pdf

Operator sustains injury as loader drops log, shakes violently

Safety Alert Type: 
Heavy Equipment
Location: 
Coastal Woodlands (Vancouver Island)
Date of Incident / Close Call: 
2019-01-09
Company Name: 
INTERFOR
Details of Incident / Close Call: 

A Front End Loader Operator sustained a serious cut between fingers, requiring surgery. The loader (966H) was travelling on a dry land sort carrying a very heavy load of 3 Hemlock logs (max. load or overweight). Operator was wearing seat belt.

The operator slowed and turned on the approach to a log bunk. Inertia caused the front of machine to dip with the grapple hitting pavement. The back end of loader lifted off the ground and the operator released a large log from the grapple. This caused the rear to abruptly drop.

The loader violently shook and the operator’s hand flung approximately 8 inches, catching a finger in a metal latch (originally hood latch type, with after market change made).

Learnings and Suggestions: 
  • Equipment must be inspected and records kept for unsafe working conditions. This includes: sharp objects, guarding, escape hatches and other safety devices, hazards from modifications, ergonomics and maintenance issues.
  • Manufacturer’s specified payloads must not be exceeded and operators must travel at safe speeds. Extra time is required to stop when carrying loads.
  • Supervisors must regularly observe equipment for care and control while logs are handled/moved.
  • Unsafe equipment must be locked out immediately, with repairs done and/or hazards removed prior to operating.

 

For more information on this submitted alert: 

Gary Bauer, Safety Coordinator: Gary.Bauer@Interfor.com

File attachments
Safety_Alert_Interfor-Coastal_Woodlands_Loader_Operator_Suffers_Hand_Injury-01-9-2019.pdf

Pup trailer detached while leaving loading area

Safety Alert Type: 
Loading and Shipping
Location: 
Grand Forks Sawmill
Date of Incident / Close Call: 
2019-01-02
Company Name: 
INTERFOR
Details of Incident / Close Call: 

A driver entered the yard with his rear trailer on top of the front trailer and had attached the two trailers before he was loaded.

The fifth wheel had some accumulation of grit and ice which the driver tried to remove before attaching the trailer. After being loaded and driving forward 60 metres, the fifth wheel detached between the two trailers of the Super B and the rear trailer brakes locked up (photos in attached pdf).

The rear trailer slid 4 metres and stopped, resting on the landing gear. A post incident inspection determined that grit and ice in the locking mechanism prevented the “dogs” from fully locking into place and securing the connection.

Learnings and Suggestions: 
  • A Supervisor must complete a Hazard Assessment on trailers that are stacked and have to be attached before loading to ensure fifth wheel connections are free of debris
  • Trailers that are stacked must have their fifth wheel covered to prevent dirt and debris from building up on the locking mechanism.

 

For more information on this submitted alert: 

Darrell Whelan, Safety Coordinator: Darrell.Whelen@Interfor.com

File attachments
Safety_Alert_Interfor-Grand_Forks-Pup_Trailer_Detached-01-2-2019.pdf

Forklifts collide in lumber yard

Safety Alert Type: 
Heavy Equipment
Location: 
Chase, BC (Adams Lake Sawmill)
Date of Incident / Close Call: 
2018-12-19
Company Name: 
INTERFOR
Details of Incident / Close Call: 

Forklift 2 was loaded and travelling through a lumber yard in reverse heading towards the planer infeed. Forklift 2 came around a blind corner and collided with loaded forklift 1 who was travelling, also in reverse, into the lumber yard.

Forklift 2 collided into oncoming forklift 1’s load, narrowly avoiding a direct collision with the operator cab (see photos in attached pdf).

This incident had the potential for a head on collision at a combined relative speed of 36 km/h, as indicated on the dash cam footage of both forklifts.

Learnings and Suggestions: 
  • Lumber runways are not to encroach into roadways causing large blind spots
  • Slow down, stop, and look prior to proceeding around blind spots in lumber yards
  • Use additional care and attention when merging from secondary roadways to primary roadways
  • Drive at safe speeds! Loaded mobile equipment takes longer to slow down and stop
  • Maintain communication when entering congested areas
  • Outfit mobile equipment with blue lights or safety whips/flags for better visibility.

 

For more information on this submitted alert: 

Daniel Ruzic, Safety Coordinator: Daniel.Ruzic@interfor.com

File attachments
Safety_Alert_Interfor-Adams_Lake-Forklift_Collision_12-19-2018.pdf

Forestry worker falls through ice while snowshoeing on a day off

Safety Alert Type: 
Other
Location: 
Wilson Lake (near Peachland, BC)
Date of Incident / Close Call: 
2019-01-06
Company Name: 
Gorman Bros. Lumber Ltd.
Details of Incident / Close Call: 

While enjoying a day off, a forestry worker fell through ice and into the lake. He was leading a group of people snowshoeing when he suddenly fell though the ice, ending up chest deep. He had crossed this same location many times throughout the years, but never had fallen through the ice. Fortunately, people in his group were able to reach him with their hands from the edge and pull him out.

It is not easy to extract yourself with snowshoes on and felt packs full of swamp water (not to mention feeling a bit panicky, as he could not touch the bottom). Had he been alone he quite possibly would not have been able to escape.

Another factor on his side was the outside temperature of minus -3. Any colder and the 1.5 kilometre walk out would have been dangerous, being soaking wet from the extremely cold water.

Learnings and Suggestions: 
  • Avoid waterways unless absolutely sure of ice conditions
  • Don’t trust any ice conditions when working alone
  • Always pack extra socks and some small plastic bags to put over your feet if they do get wet.

Lake Ice Conditions:

  • 7 cm (3 inches) or less - STAY OFF
  • 10 cm (4 inches) - ice fishing, walking, cross country skiing
  • 12 cm (5 inches) - one snowmobile or ATV
  • 20 - 30 cm (8 - 12 inches) - one car or small pickup truck • 30 - 38 cm (12 - 15 inches) - one medium truck (pickup or van)

 

For more information on this submitted alert: 

Doug Campbell, Gorman Bros. Lumber Ltd. (250) 768-5131

File attachments
Hazard_Alert-Worker_Through_Ice_While_Snowshoeing-Gorman_Bros-Jan_6-2019.pdf

Snowplow goes through shop door

Safety Alert Type: 
Mechanical Service (Shop)
Location: 
Gilchrist, OR
Date of Incident / Close Call: 
2018-12-14
Company Name: 
INTERFOR
Details of Incident / Close Call: 

Vehicle was parked inside the truck shop with the bay doors closed. Employee opened door of the sander / snowplow truck and reached in and started the vehicle.

The truck was in gear and lurched forward, crashing through the garage door. The truck traveled approximately three truck lengths before the employee was able to catch the truck and reach in and turn off the key.

Learnings and Suggestions: 
  • The clutch depression relay that requires that the clutch to be depressed in order to start the vehicle had been jumped and by-passed. It is not known when or by whom the relay was by-passed.
  • A new harness has been ordered and installed by the mechanic.
  • Employee was coached on the hazards of carbon monoxide poisoning.
  • Employee was reinstructed on safe vehicle operation according to the Job Safety Analysis.
  • Never chase down runaway vehicles or equipment as there is a high risk of being pulled under and / or crush injuries.

 

For more information on this submitted alert: 

Dave Johnson, EHS Coordinator Dave.Johnson@interfor.com

File attachments
Safety Alert-Interfor-SnowplowThroughShopDoor-Gilchrist-Dec 14-2018.pdf

Lift truck fork strikes kiln track, worker impacts steering assist knob

Safety Alert Type: 
Heavy Equipment
Location: 
Port Angeles, WA
Date of Incident / Close Call: 
2018-12-12
Company Name: 
INTERFOR
Details of Incident / Close Call: 

A lift truck traveling at 14.8 km/h stopped immediately when the right fork struck a kiln track. The operator’s chest impacted the steering assist knob. As a result, the employee was taken to the emergency room and diagnosed with internal bruising to the sternum area.

Learnings and Suggestions: 
  • Forklift operators need to know where their forks are at all times.
  • Forks should be carried approximately front axle height or a reasonable minimum distance from the operating surface (Hyster 155FT front axle height is about 16 inches high – this is at or below knee height and should be adjusted to a reasonable minimum distance).
  • Never travel with the mast tilted forward.
  • Make a production plan. A safe and acceptable production pace can be maintained to reduce pressure for crew members. Pre-staging or increasing manpower during fast product runs needs to be addressed before every production run.

 

For more information on this submitted alert: 

Sean Murphy, EHS Coordinator, Port Angeles Sean.Murphy@interfor.com

 

File attachments
Safety Alert-Interfor-Lift Truck Fork Height-Port Angeles-Dec 12-2018.pdf
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