OCP for Handling Of Materials

1.PURPOSE: To minimize the risk of accidents while handling materials manually and also during the visual inspection

2. SCOPE: This work instruction is applicable to during Heat treatment

3. RESPONSIBILITY:  Departmental HOD’s


  1. Ensure that proper PPE’s are worn by operators during handling of materials
  2. If a load is too heavy to lift by one person, he should ask for help from others
  3. If a load is too heavy to lift by one person, he should ask for help from others.
  4. While shifting heavy materials by more than one person, the job should be carried out under the direct supervision of a responsible person.
  5. The material should be gripped firmly and then lifted when all are ready and each person has a firm footing.
  6. Hand gloves should be worn while handling sharp materials. Proper rubber hand gloves should be worn while handling corrosive liquids and acids. Hand gloves should be worn while handling hot materials.
  7. While handling cylinders they should not be dropped or allowed to strike each other.
  8. Cylinders should never be lifted by the magnetic crane.
  9. Cylinders should be laid horizontally on the floor of the track and should be properly fastened. Those cylinders, which are kept vertical, should be secured with special fastening. The tailgate of the truck should be closed and secured during transport.
  10. While handling forklift care must be taken to avoid collisions of each other or against other objects.
  11. Dropping of the materials from the truck should be avoided.
  12. Overturning due to unsafe loading or rash driving should be avoided. Forklifts must be provided with canopy guards.
  13. Only authorized persons should operate Cranes.
  14. All must keep away from the load during lifting or lowering the load or during swinging the boom and the cab.
  15. Only one person should give signals during lifting or lowering or transporting the load.
  16. Load heavier than the SWL of the crane must not be lifted.
  17. The load should not be moved or the crane should not be shifted unless the floor and way are clear.
  18. The load should not be allowed to swing.
  19. The load should not be suspended from the crane unnecessarily for a long time.
  20. The operator should see that loads are not carried over men working on the shop floor and men on the workshop floor must be warned of the passage of a suspended load so that they may keep clear off it.
  21. The operator should not perform more than one crane operation at a time.
  22. Brakes, hoisting cables and hook block, drums, limit switches, controllers and alignment of bridges must be thoroughly and regularly inspected by the operator and maintenance engineers.
  23. Broken or cracked or chipped rails or trolley or runway should be immediately repaired.
  24. Safety guards and foot-walks, side rails and toe boards should be regularly inspected and defects rectified.
  25. End stops and bumpers on the bridge should be regularly inspected.
  26. Over lubrication should be avoided.
  27. While handling materials under cranes, helmets must be worn.
  28. Safety shoes must be worn while handling steel, and scrap.
  29. While using ladders, it should be ensured that the top and bottom of the upright members are secured properly. Men using the ladder should not carry anything in his hand. The material should be hoisted and handled by suitable equipment such as pulley blocks, chains, ropes, etc.
  30. Workmen should be at a safe distance from the handling area while crane or forklifts are in operation.
  31. Smoking is strictly prohibited on the premises.
  32. The floors of the stores must be kept clear and absolutely free from oil, grease, lubricants, paints, etc. The empty packing cases and packing materials such as straw, paper, etc. should be removed every day.
  33. Sawdust, firewood, sludge oil, and other materials must not be allowed to accumulate and should be disposed of quickly.
  34. SWL should also be painted in yellow color on the guard flange of the chain block-pulley and on other tested gears.
  35. All lifting tackles and grabs should be regularly tested.
  36. All overhead and other cranes should be periodically tested and the drum wire should be thoroughly inspected and a record on such test should be maintained.
  37. All records of testing of lifting machinery such as overhead cranes, free mobile cranes, track mobile cranes, etc. should be centrally maintained in the Maintenance Department. A copy of such test records should be kept with the department concerned. Another copy of such test records should be sent to the Safety Officer.
  38. If any sparking is noticed between the crane hook and the wire sling, while using an overhead crane, it should be immediately reported to the Head of the concerned department and to the Safety Officer. The lifting work should be stopped until the fault is rectified and failure to inform as mentioned above may warrant strict disciplinary action against the defaulters.
  39. It should be ensured that the loading is properly supported in the bowl of the hook.

5     RECORD REF.: Crane, Lifting Tackle inspection records, Training of Operators

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