Recommended Forklift Free System Features for Proper Safety and

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Recommended Forklift Free System Features for Proper
                                           Safety and Ergonomic Operation

        When re-designing material handling flow to address restricted use of forklifts (Forklift Free),
        equipment ergonomics and safety play a key role. Following is a list of equipment and
        corresponding features to evaluate during your selection process of material handling equipment
        for use in Forklift Free Systems.

                              FEATURES                                                   BENEFITS
CARTS
         FRAME DESIGN
         All welded steel lower perimeter frame with upper       Designed to absorb greater forces without failure or repair
         deck inside perimeter.                                  when impacted, prohibit or reduce load damage from
                                                                 impacts and allow frame to frame loading in tractor trailers
                                                                 for transport.

         Low floor to deck height.                               Provide proper ergo-height at top layer unload (see Liberty
                                                                 Mutual tables1)

         All external corners or edges where operator's hand     Eliminate or reduce the chance of an operator injury.
         or legs may come in contact should be beveled,
         rounded or provided with rounded contact bumpers.
         Possible pinch points between towbar and handle,
         etc. should be eliminated.


         ROTATIONAL UPPER DECK DESIGN
         Rotational auto-deck lock w/mechanical all steel        Eliminates top rotation and load loss during towing with
         linkage; floor lock activated.                          minimal operator attention. No cables that may loosen or
                                                                 pedals required to activate.

         Soft detent w/locations every 90 degrees of rotation.   Controls "drifting" of loads during operator use w/o wasted
                                                                 motion (no foot pedal release).

         If used for manual movement, cart labeled capacity      Reduce or eliminate the chance for operator injury when
         may or may not reflect maximum deck load that can       manually pushing or pulling a loaded cart.
         be handled ergonomically within acceptable
         push/pull limits (see Liberty Mutual tables1).

         Push / pull forces at actual user loads should be       Positive confirmation that carts meet or exceed safe
         verifiable by actual ergo-test data.                    operation requirements (rather than assumptions that
                                                                 designs meet requirements).
         Frame integrity (under static and dynamic
         conditions) verifiable by FEA2 results or other
         acceptable means.

         Movable or stationary load stop corners and edges       Eliminate or reduce the chance of an operator injury.
         should be rounded or smoothed.




         1
          Manual Material Handling Guidelines, Liberty Mutual Group,
         www.libertymmhtables.libertymutual.com/CM_LMTablesWeb/pdf/LibertyMutualTables.pdf
         2
             FEA, computer based finite element analysis.
                                                                                                                         Page 1 of 5
    Kinetic Technologies, Inc., Phone: 440-973-4111, Website: http://www.ktecinc.com, Email: info@KtecInc.com                 11/07
                            Recommended Forklift Free System Features for Proper
                                     Safety and Ergonomic Operation


                        FEATURES                                                     BENEFITS

    CART HANDLES
    Four bend minimum 1 " diameter steel, one piece         Diameter correct for hand comfort and strength, set at
    ergo-handle.                                             proper ergo-height (~ 36"-42") and designed to angle away
                                                             from cart to allow foot clearance with cart frame when
                                                             pushing / pulling.

    Handles should be rigidly and securely mounted to        Prevents possible injury due to excessively unbalanced
    frame in two places with at least a minimum width        forces on operator during movement.
    of 25". "T" handle design not recommended.


    WHEEL SYSTEMS (caster steering)
    4-wheel chassis design w/two swivel 8" kingpinless       Produces the lowest initial push / pull forces and reduced
    casters, two rigid 8" casters all wheels w/sealed        "skidding" of empty carts on turns which could cause
    precision bearings. Preferred wheel systems              severe contact injury and damage to inventory, equipment,
    incorporate selected swivel lead angles, mixed           etc.
    durometers (hardness ratings) on front and back
    wheels and biased wheel mounting (with respect to
    load).

    Optional 6-wheel chassis design featuring two            6-wheel system significantly improves manual
    swivel 8" kingpinless casters, two rigid 8" center       maneuvering on frames larger than 40" x 40" and corner
    casters and two stabilizer casters.                      turning in long trains (better for tight aisles). Uses MPPTM
                                                             (modified pivot point) steering system.

    Phenolic or steel wheel sets are not recommended         Phenolic wheels are very hard and sensitive to impacts
    for towing. For non-towing applications, OK. High        (cracking and chipping). They are slippery on smooth
    hardness rating of phenolic wheels produces good         concrete floor surfaces and can cause skidding in turns
    push / pull values on clean, smooth floors.              when towing. Steel wheels while rugged, can skid, will
                                                             damage concrete floors and are noisy when towed.


    FLOOR LOCK, TOWBARS and HITCHES
    Heavy duty telescoping tubular structural steel floor    HD design resists wear and tear damage, provides ample
    lock w/large foot activating pedals, replaceable anti-   pedal surface for large shoes. HD spring mechanism and
    skid elastomer floor pad, industrial quality return      anti-skid pad holds cart securely in position. Tow bar
    springs, foot and tow bar activated unlocking            activated auto release prevents "dragging" damage to lock
    mechanism are preferred.                                 and floor if operator forgets to release when towing.

    Floor lock should have a minimum of 2" ground            Reduces the possibility of severe cart impact with floor
    clearance when retracted.                                protrusions and other uneven surfaces when tugging which
                                                             could cause damage to carts and possible load loss.

    Compact 5,000lb rated auto-hitch. Hitch features         Compact size allows rotational frame heights to be lower
    oversized release pedals and structural grade steel      resulting in lower top layer heights. Large pedal design
    tongue (to match towbar eyelet). Rating verifiable       eliminates the need for the operator to bend down to latch
    by FEA2 results or other acceptable means.               or unlatch hitch.




                                                                                                                   Page 2 of 5
Kinetic Technologies, Inc., Phone: 440-973-4111, Website: http://www.ktecinc.com, Email: info@KtecInc.com               11/07
                                Recommended Forklift Free System Features for Proper
                                         Safety and Ergonomic Operation


                            FEATURES                                                      BENEFITS

        Self-stowing HD trapezoidal shaped steel tow bar         Self-stowing feature eliminates the need for the operator to
        featuring reinforced construction and structural         bend down. Reinforced design "bends" without breaking
        grade steel eyelet. Tow bar pivots at base and is        when excessively overloaded so carts remain connected.
        spring loaded for self-level when positioned for         Matching of the eyelet and hitch tongue prevents excessive
        hookup. Tow bar also features auto floor lock            wear.
        release, all mechanical.

        LIFT POCKETS
        Under frame lift pocket built into cart chassis w/       Allows cart w/load to be centered (using limit switch in lift)
        lead-ins at frame back. Lift pocket size should          safely over lift top to avoid tipping issues with unbalanced
        allow the use of a lift with protective 4-sided          loads and use of maximum lift rating. Lift pocket also
        bellows skirting and not allow the skirt to rub on the   prevents lift top from damaging cart wheels / rigs from
        cart frame or be touched by the operator's shoes         impact when pushing cart over lifts and cart wheels from
        when working from the cart.                              damaging the skirt.

        FINISH
        Safety yellow powder coat or other electrostatic         Durable low chipping surface provides protection from rust
        finish.                                                  and contamination of parts.

PNEUMATIC / HYDRAULIC LIFTS

        PERFORMANCE RATINGS
        Both hydraulic and pneumatic lift capacity rating        Proper attention to rating will allow the cart and load to
        should be capable of lifting (to maximum vertical        reach proper heights for ergonomic operator use.
        travel) the maximum load rating of the cart plus the
        cart tare weight.

        Maximum vertical travel plus closed lift height          Provides minimum operator ergo-lift height when working
        (equals total platform height) for most cart lift        from pallets or other containers loaded on a cart deck of ~
        applications should total at least 21".                  31".

        Closed height of lift should allow the cart frame to     Allows top layers on full containers to fit into acceptable
        be as low as possible. With 8" wheel systems,            ergo-lift range for the operator.
        closed lift height should be 7"or lower.

        TOP PLATFORM
        Top platforms shall fit the lift pocket opening with     Requires little or no additional force to load cart over lift.
        acceptable side and top clearance to eliminate           Square edges on top platform provide maximum safety
        jamming and be designed with straight sides (non-        from tipping when deck loads are unbalanced.
        rolled edges).

        Cart should be equipped with a limit switch              Use of contact limit switch allows lift to raise only when
        mounted in the perimeter of the top platform frame       cart is fully in the lift pocket to assure safe lifts.
        that impacts the front of the lift pocket frame.




                                                                                                                          Page 3 of 5
    Kinetic Technologies, Inc., Phone: 440-973-4111, Website: http://www.ktecinc.com, Email: info@KtecInc.com                  11/07
                              Recommended Forklift Free System Features for Proper
                                       Safety and Ergonomic Operation


                          FEATURES                                                   BENEFITS

     LIFT BASE
     Lift base should be secured (lagged) to the floor        Eliminates the possibility of wheel contact when loading
     with legs mounted externally to the short side of the    carts and damage to wheels.
     base frame or internal to the base.

     CONTROLS
     Hydraulic controls: either covered foot or pedestal      Operator must hold down foot pedal or button during entire
     mounted push button controls, 100% contact.              cycle to prevent accidental activation with no operator
     Velocity fuses should be used in line with each          present. Flow valve and 100% contact control prohibits fast
     cylinder, adjustable flow valve to control speed of      drop and trapping of feet or other appendages under the
     table drop.                                              cart. Velocity fuses on each cylinder control table drop in
                                                              case of line rupture.

     Pneumatic controls: pedestal mounted up/down             Operator must hold down hand valve during entire cycle to
     valve control with air filtration. Circuit should        prevent accidental activation with no operator present.
     incorporate excess pressure dump valve and master        Master lockout valve shuts down air to valve when not in
     lockout valve. Additional mechanical travel stops        use and mechanical stops limit closure of unit to protect
     bars should be provided for maintenance.                 maintenance personal from table drop due to bag rupture.


TUGS
     TOWING CAPACITY
     Rated towing capacity should be sized to be              Safe moving of loads without leading to loss of control and
     equal to or greater than the total load to be            possible severe damage to tug operator, equipment and
     towed3.                                                  workers.

     Normal drawbar pull (DBPn) should be equal to
     or greater than the initial rolling force required
     to move the entire train.

     Rule of thumb A: Class III tug normal DBP is ~ 2%
     of rated capacity, e.g.: 10,000lb. rated tug will have
     about 200lb. normal DBP.

     Rule of thumb B: On slopes ranging from 1% to 5%         Tugs sized for proper flat ground performance will not have
     grade, the required normal DBP to handle the grade       the capacity to pull the same load up slopes.
     can be 2-3 times greater than flat grade
     requirements.

     PLEASE CONSULT TUGGER
     MANUAFACTURER FOR MORE DETAILED
     PERFORMANCE AND SAFETY
     INFORMATION.




     3
         Total Towed Load - sum of the cart deck load, cart tare weight and maximum number of carts in a train.

                                                                                                                   Page 4 of 5
 Kinetic Technologies, Inc., Phone: 440-973-4111, Website: http://www.ktecinc.com, Email: info@KtecInc.com              11/07
                            Recommended Forklift Free System Features for Proper
                                     Safety and Ergonomic Operation


                        FEATURES                                                   BENEFITS

    STOPPING CAPACITY
    Stopping capacity of a Class III tugger is designed    Safe stopping of loads without leading to loss of control and
    to be appropriate for the load rating of the tug       possible severe damage to tug operator, equipment and
    within normal operating parameters (charge, tow        workers.
    speed, tread condition, etc.)

    Stopping of the tug on a grade will require that the
    capabilities are de-rated per the Towing Capacity
    discussion above.

    PLEASE CONSULT TUGGER
    MANUAFACTURER FOR MORE DETAILED
    PERFORMANCE AND SAFETY
    INFORMATION.




                                                                                                                 Page 5 of 5
Kinetic Technologies, Inc., Phone: 440-973-4111, Website: http://www.ktecinc.com, Email: info@KtecInc.com             11/07
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