OLD WAY: Refresher training was a "classroom only" review of initial new operator training.

PROBLEMS:

1. Costly - 8 hours of lost production time per operator
2. Effectiveness - Unknown. No assurance of safety or skills retention.
3. Redundant -Good operators don't need retraining and are antagonized by unnecessary classroom time. No method of assuring that poor or "borderline" operators improved proficiency.
4. Compliance - May be questionable. There is no indication of skills retention or individual areas of operator weakness to meet the voluntary OSHA guidelines ref. Booklet #2254.

NEW WAY: Re-certification and refresher training is based upon demonstrated operator skills.

BENEFITS:

1. Effective - Individual operator performance data is generated.
2. Precise - Computer scoring is objective and consistent.
3. Less Costly - Operators receive only training needed. Less time off job.
4. Effective - New skills must be demonstrated before re-certification.
5. Efficient - Only deficiencies are attended. Safe and skilled operators are re-certified.
6. Attitude - Operator respect and support for system is motivated. Certification becomes a matter of pride.
7. Compliance - All aspects of OSHA voluntary guidelines are attended.
8. DataBase - Special cause failures are highlighted for management attention. Common cause failures are handled within the program.

FORKLIFT EVALUATION & TRAINING DEVELOPMENT PROGRAM

Objectives: (Long term)

• Eliminate unsafe behaviors (incident & accident)
• Increase retraining effectiveness
• Improve safety attitude & behaviors
• Determine presence & frequency of unsafe behaviors
• Prevent operator injury
• Reduce/control training costs
• Maintain operator skill level in control range

Tactics:

• Determine absolute operator norm (time over designated course)
• Penalize major/minor safety errors
• Determine "weighted" operator performance
• Determine type & frequency of safety errors
• Design retraining to focus on: skills/classroom training to bring operator into control
• Eliminate unnecessary training

Benefits: (Operator)

• Accident/injury potential reduced
• Training for indicated needs only
• Operator knows his area of focus
• System/equipment deficiencies highlighted
• Certification more meaningful

Benefits: (Employer)

• Assumption & subjectivity replaced with data
• Continuous improvement begins
• Operator unfamiliarity with new equipment/methods is notable
• Safety awareness is improved
• Retraining investments refines
• Loss prevention begins
• System weaknesses noted
• Special cause cases highlighted
• In-control assured
• Effective system in place
• Needless training expense eliminated
• Less training time = productivity improvement

TIME BASED JUSTIFICATION

1. Simulate actual working conditions.
2. Ability to determine operators familiarity with each type of machine based on:
   (a) Frequency of use of a particular type of machine
   (b) Job description, criteria and frequency for total use
   
3. Continuous Improvement
   (a) Provides baseline for comparison for each re-certification
   (b) Allows setting of realistic goals and/or ideals
   

Safety Systems & Solutions, Inc.

412 Main Avenue
P.O. Box 66
Wynantskill, New York 12198
(518) 283-8228, FAX: (518) 283-3331
e-mail: info@safetysystems.com