While in a local grocery store last week, I heard a floor polisher coming up behind me. I stepped to the side of the aisle so the operator wouldn’t need to steer around me, but there was no operator. That’s when I acknowledged that the Automated Guided Vehicle (AGV) is no longer a tool of the future. Technology has come a long way since the first AGV which was put into service in 1953. This guide-by-wire tow truck was manufactured by Barrett Electronics of Northbrook, Illinois. This was long before the Occupational Safety and Health Administration (OSHA) was established, and I can only guess the hazardous exposures related to those early AGVs.
New AGVs are equipped with laser guidance, artificial intelligence (AI), have self-learning technology, and require little human interaction. Today’s AGVs are designed with flexibility and efficiency. They can now navigate more complex routes, perform numerous tasks, work along with other automated systems within a facility, and most importantly, work safely within the same facility with humans.
The forklift AGV is extremely adaptable in warehousing and shipping environments and can be useful in the pallet industry. When accuracy, safety and timeliness of material movement are important, the AGV is extremely efficient.
These tasks include:
• Handling raw materials
• Work-in-process movement
• Pallet handling
• Finished product handling
• Trailer loading
• Roll handling
• Container handling
Today’s AGV is designed to work safely around humans, with AI, laser guidance, and safety sensors that enable safe coexistence with employees. This does not mean that there are no OSHA requirements for employee safety training. At this point in time, OSHA Standards do not specifically identify AGV safety, safety training, inspections, maintenance, or program requirements. This will certainly be updated in future standards.
What guidelines and standard compliance are required for employers utilizing AGVs?
The current OSHA Standards that encompass AGVs would include:
The General Duty Clause of the Occupational Safety and Health Administration (OSHA) Act of 1970 requires employers to provide a safe workplace for all workers covered by the OSHA Act. Employers must:
• Provide a workplace free from hazards that could cause death or serious injury
• Comply with occupational safety and health standards
• Take reasonable steps to prevent or abate recognized violence hazards
Standard 1910.176 a subpart of Material Handling and Storage
1910.176(b)
Secure storage. Storage of material shall not create a hazard. Bags, containers, bundles, etc., stored in tiers shall be stacked, blocked, interlocked and limited in height so that they are stable and secure against sliding or collapse.
1910.176(c)
Housekeeping. Storage areas shall be kept free from accumulation of materials that constitute hazards from tripping, fire, explosion, or pest harborage. Vegetation control will be exercised when necessary.
1910.176(e)
Clearance limits. Clearance signs to warn of clearance limits shall be provided.
1910.176(g)
Guarding. Covers and/or guardrails shall be provided to protect personnel from the hazards of open pits, tanks, vats, ditches, etc.
Standard 1910.178 Powered Industrial Trucks
1910.178(a)
General requirements.
1910.178(a)(1)
This section contains safety requirements relating to fire protection, design, maintenance, and use of fork trucks, tractors, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric motors or internal combustion engines. This section does not apply to compressed air or nonflammable compressed gas-operated industrial trucks, nor to farm vehicles, nor to vehicles intended primarily for earth moving or over-the-road hauling.
1910.178(a)(2)
All new powered industrial trucks acquired and used by an employer shall meet the design and construction requirements for powered industrial trucks established in the “American National Standard for Powered Industrial Trucks, Part II, ANSI B56.1-1969”, which is incorporated by reference as specified in § 1910.6, except for vehicles intended primarily for earth moving or over-the-road hauling.
1910.178(a)(3)
Approved trucks shall bear a label or some other identifying mark indicating approval by the testing laboratory. See paragraph (a)(7) of this section and paragraph 405 of “American National Standard for Powered Industrial Trucks, Part II, ANSI B56.1-1969”, which is incorporated by reference in paragraph (a)(2) of this section and which provides that if the powered industrial truck is accepted by a nationally recognized testing laboratory it should be so marked.
1910.178(a)(4)
Modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation, and maintenance instruction plates, tags, or decals shall be changed accordingly.
1910.178(a)(5)
If the truck is equipped with front-end attachments other than factory installed attachments, the user shall request that the truck be marked to identify the attachments and show the approximate weight of the truck and attachment combination at maximum elevation with load laterally centered.
1910.178(a)(6)
The user shall see that all nameplates and markings are in place and are maintained in a legible condition.
Note: Standard 1910.178 was written with the assumption that the powered industrial truck was human operated. Therefore, although the terminology within the standard may not specify AGVs, it will certainly encompass much of the same safety requirements of powered industrial trucks.
Standard 1910.147 The Control of Hazardous Energy / LOTO
This standard covers the servicing and maintenance of machines and equipment in which the unexpected energization or startup of the machines or equipment, or release of stored energy could cause injury to employees. This standard establishes minimum performance requirements for the control of such hazardous energy.
The current American National Standards Institute (ANSI) and the Industrial Truck Standards Development Foundation (ITSDF) Include:
Safety Standard ANSI/ITSDF B56.5 Guided Industrial Vehicles.
ANSI/ITSDF B56.5-2019 defines safety guidelines for the elements of design, operation, and maintenance of powered, not mechanically restrained, unmanned automatic guided industrial vehicles and the system of which the vehicles are a part. In addition, this standard applies to vehicles that may have originally been designed to operate in a manned mode, but were since modified to operate in an unmanned, automatic mode, or in a semi-automatic, manual, or maintenance mode.
Read more at the ANSI Blog: ANSI/ITSDF B56.5-2019: Guided Industrial Vehicles https://blog.ansi.org/?p=161983
What safety related documentation and training do I recommend?
• Ensure the company’s safety program administrator, safety manager, supervisors, and safety committee members are familiar with the OSHA Standards and the ANSI / ITSDF Standards.
• Ensure personnel are familiar with the manufacturer’s operation manual for all equipment.
• Ensure the requirements identified by the manufacturer regarding maintenance, inspection, testing, hazards, limitations, posting, clearances, general use, and personnel training are adhered to.
• Complete a job task, safety, and hazard assessment of the equipment.
• Incorporate AGVs into your written safety programs.
• Follow all manufacturer setup and learning requirements for every AGV.
• Maintain safety inspection records for all AGVs.
• Maintain AGV maintenance records.
• Provide and document AGV hazard awareness training for all personnel. Provide at initial hire and at least annually thereafter.
• Provide and document operational safety training in accordance with the manufacturer’s recommendations. Provide at initial hire and at least annually thereafter.
• Post signage for hazard awareness of AGVs in work zones.
• Ensure all operational clearances are maintained.
• Install any perimeter guards suggested by the manufacturer.
• Charge AGVs in areas away from flammables and combustibles.
• Provide first aid supplies, portable fire extinguishers, and an emergency eye wash station near charging and maintenance areas.
• Maintain areas of egress and exits and ensure walking and working clearances around AGV equipment.
• Follow all standards for the control of hazardous energy / LOTO related to AGV maintenance and repair.
• Follow all requirements of the Hazard Communication and The Globally Harmonized System related to the AGV equipment.
In closing, I always recommend that you take advantage of any safety related training provided by your state’s OSHA consultation services, equipment manufacturer, and worker compensation insurance provider. These services are generally provided at no charge to employers.
Editor’s Note: Jary Winstead is a safety consultant, author and trainer who serves a variety of industries including the forest products’ sector. He owns Work Safety Services LLC and can be reached at SAFEJARY@gmail.com.
