Workplace Transport Safety

DHL – Workplace Transport Issues and Solutions Oct 1 st 

2009

Agenda 

1. Introduction to DHL Operations 

2. Specific Issues and Solutions 

‣Trailer Nose Dives 

‣Trailer Supports 

‣Bay Pull Offs/Roll Offs 

‣Bay Controls 

‣Chocks, Locks and Blocks 

‣Automatic Off Loading 

‣Wheel Locks 

‣Site Transport Safety Message & Rules 

3. Improving Vehicle & Trailer Safety 

‣Engineering and Safety Partnership 

4. Any Questions 

Safety, Health & Environment – “Make it happen” – Stronger through collaboration Page 2

DHL - Background 

DHL – German based – second largest Transport/Logistics company in 

the World – 650,000 employees worldwide. 

UK and Ireland – sub groups – Retail, Tradeteam, NHS, Automotive, 

Industrial. 

DHL UK and Ireland is made up of a number of businesses that have 

been merged/taken over – Tibbett & Britten, Exel Logistics, Power 

Logistics, amongst others 

Due to the various standards, processes, procedures that these 

businesses had in place, it’s a big job standardising – especially with 

over 400 operating sites. 

DHL clients include M&S, Tesco, Sainsburys, Primark, Debenhams, B&Q, 

Homebase, Unilever and many more. 

Workplace Transport issues within DHL UK & Ireland are very diverse. 


Trailer Nose Dives 

Due to a number of reasons product change (heavier) and an 

unfamiliar trailer, incidents such as a trailer nose dive can happen 

Because of operational requirements, transport costs etc, it is not 

always possible to load a trailer whilst still connected to a Unit 

Dependant on yard gradients, type of load, loading requirements etc 

solutions are needed to support some trailers whilst being loaded 


Nose Dive Solutions 

Mobile Trailer supports used in addition to landing legs 


Nose Dive Solutions 


Bay Pull Offs/Roll Offs 

Bay “pull offs” and “roll offs” can happen due to a number of 

factors: 

‣Non-compliance with a Safety process/procedure/system 

‣Human Error 

‣Mechanical Failure 

‣Environment – gradients/slopes 

And whilst processes and procedure are necessary, if they are 

not followed incidents and accident can happen – see next slide 

Equipment such as Bay Lights/Traffic Light Controls are 

provided, but other “physical” barriers may be required. 


Bay Pull Offs 

Driver pulled away on a Red Light 


Bay Controls - Chocks,Locks and Blocks 

Traffic Lights 

Bay Door Controls 

Air Line Locks 

Wheel Chocks 

Vehicle Key Controls 


Homemade Controls 


Automatic Off Loading 

Some sites have automatic off loading systems, which can remove a 

load of approx 20 pallets at a time 

It is vital that pull offs/roll offs are prevented 

The damage that could occur to the automation could be extensive and 

extremely costly to repair and in some cases could have a serious 

effect on the operations ability to function correctly 

Conventional systems such as traffic lights, chocks etc are suitable for 

most operations, however these could be deemed as insufficient if as in 

the previous slides failures occur 

Through the risk assessment process it was highlighted that a more 

robust system was needed to prevent pull offs 

Automatic Wheel Locks, controlled by the off loader were fitted in this 

instance 


Automatic Off Loading – Wheel Locks 


Site Transport Safety Message & Rules 

Sometimes it is difficult to get the message 

across regarding site transport safety. 

Language barriers, unfamiliar with the site 

layout/rules etc 

These are typical examples of Notices and 

handouts given to drivers – in different 

languages 


Improving Vehicle & Trailer Safety 

Engineering & Safety Partnership 

2008/09

Why have we done this? 

Why? 

Reduce the risk of accidents to drivers 

Improve vehicle safety specifications 

Standardise safety features on new equipment across the UK 

Scope 

Currently only applies to owned vehicles and trailers 

Working with Hire and Leasing Suppliers to adopt these safety features 


How have we organised this? 

How? 

UK Forum involving Engineering & Safety created 

Agreed scope of vehicles & trailers 

Agreed different approach for existing and new equipment 

Identified & prioritised issues 

Sense checked findings with Driver Groups across the UK 

Proposal agreed by UK Board 


What are we doing to Existing Vehicles & Trailers? 

Compulsory 

Ensuring all vehicles have unique audible “Park Brake Off” warning 

Warning system must work on the opening of the drivers door in all 

vehicle states (engine on/off, keys in/out) 

Where no current warning system is fitted advising voice warning 

Park Brake application reminder sticker to be placed in cab 

All trailers to have “Apply Trailer Park Brake” sticker placed by 

couplings 

Recommended 

Front & Rear proximity sensors 

Forward facing in cab camera 

Coming to a vehicle near you soon 


Voice & Dashboard Park Brake Warning 

“Warning Park 

Brake Not Applied” 


What will we be fitting to All New Vehicles? 

Compulsory 

“Park Brake off” voice warning in cab (to work in all vehicle states) 

Front & Rear proximity sensors 

Vehicle Reversing warning for pedestrians 

Seat belt audible warning system & all belts to be red in colour. 

Catwalks – One level, full width & 3 point contact for access/egress 

Susie stowage points 


What will we be fitting to All New Trailers? 

Compulsory 

Fail safe trailer “Park Brake On” application system 

Park brake to be positioned by Landing Legs 

Park Brake warning sign by trailer coupling points 

Considered 

Access and Egress – Safest method to be established jointly by 

Operational Management and Engineering 


Catwalk Example 

• Level Cat Walk Platform / Full Width / 

With Chassis Infill 

• Punched Aluminium or Other Surface 

Offering Suitable Grip 

• Factory Grab Handles (3 Points of 

contact needed at all times) 


Catwalk Example 

Top Left - Poor Design 

Exposed Open Areas 

Varying Platform Levels 

Bottom Left & Right – Good Designs 

Full Width with Chassis Infill 

Level Platform 

Punched Aluminium or Other Surface 

Offering Suitable Grip 

Factory Grab Handles (3 Points of 

contact needed at all times) 


Vehicle Access Example 


Vehicle Access - Egress Example 

Steps have wider and deeper tread plates with 3 points of contact 


Vehicle Access - Egress Example 

Steps have wider and deeper tread plates and slide under 

trailer to reduce damage if inadvertently not stowed 


Curtain Operation – New Designs 

Old 

Design 

New 

Design 

(Adds £170 

to standard 

trailer cost) 

Highest possible bodies 

New design curtain rollers used 

Comments passed:- 

“ Effortless curtain movement” 

“ Can slide curtain with one finger” 


Ground Coupling R&D 

Early designs providing inadequate solution – part of the development process 


The DON-BUR “Safe Suzie” Coupling 

Features: 

Fully automatic, air-powered rotating coupling plate 

Auto-lock in coupling position 

Coupling plate positioned beyond side of trailer for coupling 

process 

Safety lights (White to front, red to rear) 

Failsafe link to EBS braking system 

Female connectors aligned with tractor configuration 

Durable construction 

Benefits: 

Eradicates need for driver to access catwalk 

Comfort-reach height & position for all drivers 

Enables vertical force to be applied to air line connectors 

Coupling plate retracts to parked/ transit position 

Vehicle cannot be moved while arm is in coupling position 

Prevents line tangling 

Transit Parked Coupling 



Operation 

Coupling: 

1) Pull down arm from parked position 

to coupling position 

1) 

1) 

3) 

4) 

2) Connect electric and air lines 

3) Unlock arm 

2) 4) 

4) Press “Up” button on side rave to 

retract to transit position 



Operation 

1) 4) 

Un-Coupling: 

1) Press “Down” button on Side Rave 

2) Pull down arm to coupling position 

2) 

5) 

3) Disconnect all lines 

4) Unlock arm 

3) 

5) Lift arm to parked position 



When is this be happening? 

Existing Fleet (Owned) – Retro Fit 

Survey started on to understand current status of vehicle Park Brake 

Warnings (to ensure unique audible warning exists) 

UK Retro fit program planned for non compliant vehicle Park Brake 

Warning systems May to Dec 2008 – Managed by Field Engineers 

Vehicle & Trailer Park Brake Stickers purchased – Sites to apply 

Assessment on vehicles requiring proximity Sensors underway 

New Fleet (Owned) 

All new owned vehicles & trailers ordered from now on will comply 

with revised specifications 

Making our Fleet Safer 


Safety Features to Date 

“Park brake off” voice warning in cab (to work in all vehicle states) 

Automatic fail-safe: Trailer Park Brake Application System 

Park brake application reminder sticker to be placed in cab 

All trailers to have “Apply Trailer Park Brake” sticker placed by couplings 

Park brake to be positioned by Landing Legs 

Front & rear proximity sensors 

Vehicle reversing warning for pedestrians 

Seat belt audible warning system & all belts to be red in colour. 

Catwalks – One level, full width & 3 point contact for access/egress 

Susie stowage points 


Trailer Parking Brake Surveys 

Checks for Trailer Park Brake Application is a continuous 

programme 

‣Trailers Checked 578 

‣Park Brakes Applied 565 

‣Park Brakes Applied % 98% 


Other Information 

DHL SHE Strategy 

Transport Road Risk Workgroup to produce findings on: 

Suitability of Equipment 

Driver Training/Assessment 

Point of Delivery Assessments 

Divers CPC 


Workplace Transport Assessments – EHO advice 

DHL hold SHE Forums mainly attended by site/operations based H&S Managers 

and Officers etc usually approx 100 persons attend. 

In 2008 we invited Glynis Buckley from Warrington Borough Council to attend and 

present on Workplace Transport 

Glynis very kindly provided us with the Workplace Transport Assessment 

paperwork that she uses on site visits/inspections 

We have base our Workplace Transport Assessments on this document. 

Housing, Protection and Community 

Trading Standards, Food Safety, Health & Safety 

Workplace Transport Questionnaire 


Roadscan – another possibility 

Roadscan is a camera system fitted in vehicles. 


Any Questions ?

Workplace Transport Safety

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