1. EQUIPMENT SPOTTER TRAINING
Welcome class and remind them of bathrooms, emergency exits, and be prepared for discussion.

2. What you will leave with:
WHY ARE WE TAKING TIME TO TRAIN SPOTTERS?
WHO IS A SPOTTER? DEFINITIONS
WHEN AND WHERE IS A SPOTTER NEEDED?
WHAT DOES A SPOTTER DO?
WHAT ARE THE EQUIPMENT OPERATOR RESPONSIBILITIES?
Explanation of slides:
The questions will remain green throughout the slides and be repetitively seen to remind the class of why we are here.
The answers will usually be in purple with additional notes in yellow, included between the questions.
Instructor notes have recommended comments and questions in bold.
Recommended Comments:
The answers to these questions are what we want to be able to answer confidently and execute consistently in the field.

3. WHY ARE WE TAKING TIME TO TRAIN SPOTTERS?
Recommended Comments:
This is not only an incident that may have been avoided with a spotter; but the spotter must also be aware of where the equipment could fall if an incident occurs.
AS A SPOTTER - NEVER PLACE YOURSELF IN THE LINE OF FIRE.

4. Because We Want to Avoid Incidents Such as this…
The crane operator deviated from the established work plan when he decided to position the crane without the assistance of the designated spotter.
Recommended Comments:
Operators also need to be aware of spotter responsibilities and coordinate all questionable moves with their spotter.
This incident occurred in July 2009.
Three individuals were on the scaffold at the time of impact. (all left uninjured and able to safely exit scaffold)
THIS COULD HAVE BEEN A LOT WORSE!

5. And This…. Measurements were taken.
But, the attached I-beam was taller and resulted in shutting down a unit.
Could have been a lot worse.
Spotter – you are the last line of defense!
Recommended Comments:
We plan and prepare for big moves like this, but even the best laid plans can come up short.
As a spotter, you will have an opportunity to be the last line of defense
With a keen eye and quick use of your equipment and training, you will prevent an incident like this.
You can save equipment, production, and lives!
You must take this job seriously and realize you are vital to the safety of you and those around you.

6. SO…WHY ARE WE TAKING TIME TO TRAIN SPOTTERS?
Historically incidents have been prevented by using spotters (the eyes and ears for operators of equipment moving in congested or awkward areas)
Historically incidents have been attributed to not using a spotter (or insufficient spotting).
Results from these incidents are damaged equipment, loss of production, injured people and ultimately loss of life.
What have you seen? Could you share an incident that resulted from “the lack of” or “poor” spotting?
Recommended Comments:
Here are the answers to our first question.
Here is an incident I remember related to spotting…...
Recommended Question:
Can anyone in the class share an incident you saw or heard about involving mobile equipment?

7. WHO IS A SPOTTER? DEFINITIONS
YOU
(AFTER THIS TRAINING)
Spotter-
Person whose responsibility is to watch equipment movements and to verify that proper clearances are maintained during equipment operations. The spotter will be on foot while equipment enters and during travel inside of unit boundaries or any time proper clearances are questionable. The spotter will have visual or radio communications with the operator with the ability to stop operations if movement of equipment is not safe.
Ask someone in the class to read the Spotter definition

8. Definitions continued…
Supplemental Spotter-
Person whose responsibility is to watch equipment movements and to verify that proper clearances are maintained during equipment operations. The supplemental spotter will be on foot while equipment enters and during travel inside of unit boundaries or any time proper clearances are questionable. The spotter will have visual or radio communications with the lead spotter and the ability to stop operations if movement of equipment is not safe.
Ask someone in the class to read the Supplemental Spotter definition

9. Definitions continued…
Equipment Operator -
Qualified and experienced person assigned to operate mobile equipment. This person should be knowledgeable of equipment operations, interpreting load charts, and be familiar with site procedures pertaining to working in the proximity of power lines, crane matting, and hand signals as they pertain to Equipment Operations. Equipment Operators should be qualified to inspect and ensure the equipment is safe to operate and all safety devices are functioning properly.
Ask someone in the class to read the Equipment Operator definition

10. WHEN AND WHERE IS A SPOTTER NEEDED?
Recommended Comments:
Now that we know who and what a spotter is; let’s answer our third question, a must know for the spotter and operator.

11. When equipment is moving in an operating unit
Recommended Comments:
An operating unit is typically a live unit and within the boundaries of the fire suppression equipment. (Fire Monitors and Hydrants)

12. In Material Laydown Yards
Recommended Comments:
Lay-down yards are not only tricky with people walking the area, but low lying pallets and other supplies can cause damage to the mobile equipment.

13. In Congested Work Areas
Recommended Comments:
Time should be taken to reduce congestion when possible, however some worksites are necessary to complete jobs.
As a spotter, you may need to slow the operator down if necessary to move your view of travel and catch unsightly objects.
Just remember to never put yourself in the “line of fire”, between the moving object and the stationary object.

14. When Equipment has the Opportunity to Strike Nearby Hazards.
Recommended Comments:
A non-ExxonMobil incident, which shows the importance of knowing your clearance.
Consider all opportunities for striking stationary objects.

15. During Unusual Activities in a Warehouse
Recommended Comments:
Warehouses typically have safeguards in place for routine moving of forklifts and mobile shelf retrieving equipment.
However, if non-routine tasks involve mobile equipment, LPSA should be used to determine the need for spotters.
Get your supervisor involved if in question.

16. On Narrow Roads, Low Clearances, or Tight Turns
Recommended Comments:
Congested areas are not the only potential places for mobile equipment incidents.
Narrow roads require slowing the operation down and allowing a spotter to be the eyes of the operator.
Low clearances can be easily overlooked outside of unit boundaries.
Tight turns will require good communication between spotter and operator, as different equipment has different turn radius characteristics.
Recommended Questions:
When are the times or places a spotter is required? – wait for answers before the next slide

17. SO…WHEN AND WHERE IS A SPOTTER NEEDED?
When moving equipment is:
In an Operating Process Unit
In a Material Laydown Yard
In a Congested Work Area
During Unusual Activities in a Warehouse
Driving on Narrow Roads
Driving in Questionable Clearance Areas
Driving where Tight Turns are Required
Recommended Comments:
Summary of our third question and answers.
Recommended Questions:
Have any incidents come to mind?

18. WHAT DOES A SPOTTER DO? Recommended Comments:
Ready for the answer to question 4?
Seems like an obvious answer.
But, since we have incidents, we need to be clear and consistent on the spotter actions.

19. Give Attention to Spotting ONLY!
If you cannot give all your attention to Spotting; Stop the movement until you can or until you get a trained replacement spotter!
Recommended Comments:
You, as a spotter, are the eyes and ears of the operator, where they are blind.
If you cannot perform your job effectively, stop the operation and get assistance.
Don’t assume it will be ok, or tolerate a risk that may cause a significant incident.
Lastly, LPSA your personal travel path as you spot.
Look for changing conditions that may cause you to trip, bump into something, or slip.
But with all this attention on SPOTTING EQUIPMENT–
LPSA YOUR TRAVEL PATH

20. The NO-ZONE Determine Need for Supplemental Spotters by Knowing the:
Recommended Comments:
The “No Zone” is a good reminder for what may seem obvious.
This is a visual description of the blind spots for an operator.
As a spotter, you must constantly be looking not only where the operator can see, but especially in the shaded areas of the following slides – where the operator cannot see.
This part of the answer to “what does a spotter do?” will take a little time but is very important.
THE SHADED AREA SURROUNDING EACH VEHICLE REPRESENTS THE DANGER ZONE or “NO-ZONE” IN WHICH THE VEHICLE OPERATOR’S VIEW OF PEDESTRAN TRAFFIC IS GREATLY REDUCED OR OBSCURRED ALTOGETHER.

21. Manlift The Operator cannot see in the shaded areas
Anything that is in this area could be in danger of being hit.
Eye level 10 ft - 0 in above
ground level
34’ 0”
36’ 4”
Recommended Comments:
From the operators vantage point, many obstacle from the mobile equipment block their view
Look for large parts of the machine that block the operator’s view.
Recommended Questions:
Any Personnel Lift operators in the class?
Any comments to help spotters?
68’ 0”
95’ 0”
Manlift

22. Hydraulic Crane Area of fully obstructed view
Eye level 7 ft - 0 in above ground level
25’ 5”
17’ 8”
15’ 9”
10’ 0”
3’ 0”
Recommended Comments:
Consider the difference of eye level from the ground that the operator is dealing with as well.
The operator is seeing from not only a different position but different elevation as well.
Recommended Questions:
Any Crane operators in the class?
Any comments to help spotters?
16’ 4”
27’ 2”
Hydraulic Crane

23. The backhoe operator’s focus is many times on the task at hand…
Make sure eye contact is made if moving in a shaded area.
Eye level 7 ft - 7 in above
ground level
8’ 4”
29’ 1”
9’ 1”
Recommended Comments:
Remember the extended parts of equipment.
In a turning operation, consider these extensions just like walking through Lowe’s or Home Depot.
Imagine carrying a 10 foot pipe horizontally; creates many potential objects or people to get hit.
Those extended parts also cause blind spots.
Recommended Questions:
Any Backhoe operators in the class?
Any comments to help spotters?
7’ 7”
18’ 5”
Backhoe

24. Equipment parts greatly affect the areas of visibility for the operator.
Always ask yourself - where might the blind spots be?
Eye level 6 ft - 3 in above
ground level
16’ 0”
8’ 2”
8’ 2”
3’ 10”
Recommended Comments:
The ability for the operator to turn his head is impaired as well.
When operations go forward and reverse, be prepared to give spotting assistance.
Recommended Questions:
Any Bulldozer operators in the class?
Any comments to help spotters?
12’ 5”
12’ 1”
18’ 7”
Bulldozer

25. Bobcat/Skid Steer While the rear visibility is obviously low…
Remember the bobcat can make quick sharp turns, look for low lying front and side obstacles
Eye level 5 ft - 5 in above
ground level
11’ 7”
11’ 5”
21’ 8”
4’ 10”
6’ 1”
Recommended Comments:
Bobcats can move very quick, so attention needs to be given to all shaded areas and keeping yourself out of the way.
Recommended Questions:
Any Bobcat operators in the class?
Any comments to help spotters?
3’ 1”
6’ 3”
Bobcat/Skid Steer

26. Look at the view obstructed due to the high reach arm on this forklift – up to 85 feet.
Detail to spotting is essential, and especially in a right turn.
85’ 0”
Eye level 7 ft - 3 in above
ground level
18’ 2”
10’ 9”
7’ 9”
39’ 0”
3’ 0”
Recommended Comments:
The parts of the equipment that make it unique and necessary also cause significant operator blind spots.
Recommended Questions:
Any High-Reach Forklift operators in the class?
Any comments to help spotters?
21’ 2”
14’ 10”
High Reach RT Fork Lift

27. The front mast assembly obstructs front and corner visibility.
Help spot those sharp turns that forklifts typically make
Eye level 8 ft - 9 in above
ground level
26’ 8”
15’ 5”
4’ 8”
4’ 5”
Recommended Questions:
Any Forklift operators in the class?
Any comments to help spotters?
What is the main difference in taking turns is with this equipment?
13’ 6”
8’ 8”
14’ 1”
17 Ton Forklift

28. Semi-Truck & Trailer 27’ 1” 6’ 5” 42’ 8” 40’ 6” 36’ 8”
Keep non-spotting personnel out of the dark shaded area when the truck is moving.
Eye level 6 ft - 10 in above
ground level
Area of fully
obstructed view
27’ 1”
Recommended Questions:
Any Semi-Truck and Trailer operators in the class?
Any comments to help spotters?
Besides clearance issues – what operation is most hazardous with a semi –truck/trailer?
6’ 5”
42’ 8”
40’ 6”
36’ 8”
Semi-Truck & Trailer

29. HiVac Truck Eye level 8 ft - 0 in above ground level Area of fully
obstructed view
(more than 300 ft)
Area of fully
obstructed view
from Eductor Hose
(more than 100 ft)
29’ 0”
24’ 0”
37’ 4”
8’ 7”
Recommended Comments:
Remember, the Eductor hose blind spot moves as the truck moves.
Recommended Questions:
Any HiVac operators in the class?
Any comments to help spotters?
31’ 0”
24’ 6”
41’ 0”
HiVac Truck

30. The shaded area is fully obstructed when the vehicle is full
Eye level 7 ft - 0 in above
ground level
49’ 9”
28’ 9”
31’ 6”
Recommended Comments:
Remember even when a bus is not full the blind spots are significant.
Recommended Questions:
Any School Bus operators in the class?
Any comments to help spotters?
When would a spotter be especially important to a bus driver in a plant situation? Make sure Tight turns comes up
22’ 8”
22’ 8”
21’ 3”
22’ 2”
School Bus

31. Spotter Activities Continued….
A transition slide from the “No Zone” description back into answering the question “What does a spotter do?”
Recommended Comments:
Let’s move back into our list of “What a Spotter Does…”

32. Communicate with Operator and Supplemental Spotters Tasks and Hazards
Take time before the task to ensure all involved know what the travel path and movements will be.
Recommended Comments:
Meeting face to face with operator and other spotters is critical to a successful move.

33. Communicate and Use Consistent Hand Signals
(Description of Each Found in the SSS – Take time to LEARN THEM now!)
Forward -Backward
STOP
Turn
Recommended Comments:
These hand signals have been standardized for the use of spotters and operators.
Many incidents have been caused by a simple misunderstanding of hand signals.
Take time to review with the operator and other spotters to ensure clear communication.
Clear
to Leave Area
Distance to Stop
Emergency STOP

34. Wear High Visibility Vest
Wear it with Pride!!!
Recommended Comments:
If you are not easily seen, you can easily become a statistical and painful injury.
Especially the supplemental spotter, as the operator will not have his eyes on you.
Recommended Questions:
What are other times we need to wear a high visibility vest?

35. Carry and Use Operating Air Horn
Test it
Use it to stop the operator’s movement
Recommended Comments:
A dead air horn is like having no brakes.
If you cannot stop the operator quickly, you may be watching (and in the middle of) a huge mess.
Not a bad idea to test it with the operator before the move to make sure he can hear you.
But do not play with the air horn - an unexpected blast can make a person jump and hurt themselves or others.
The air out of the horn is extremely cold, as well. Keep it away from your skin.

36. Maintain Eye Contact with the Equipment Operator
If you cannot see the operator’s eyes, the operator cannot see YOU!
Stop the movement with the horn, if needed.
Recommended Comments:
The operator should stop the operation if he looses sight of the spotter; however, if this does not happen and you cannot see the operator – use your horn and get back in focus.
Recommended Questions:
When is a time the spotter and operator must have eye to eye contact when the equipment is still? Looking for putting outriggers down. (Keep people way away from outrigger operations.)

37. Clear Communication with Supplemental Spotters
Now even more eyes to make sure you can see!
Stop the movement with the horn, if needed.
Recommended Comments:
With supplemental spotters, the attention is spread even more.
Do not let up on your attention to communicating with both the operator and supplemental spotters.

38. Position Self to Clearly Spot Clearances
If in question… MEASURE!
If measuring… MEASURE AGAIN!
Do not let the equipment determine if clearance is good!
Recommended Comments:
Remember the incident at the beginning. Measurements are critical.
If clearances are in question always stop and measure, do not use the equipment as a “Go” – “No Go” gauge.
Recommended Questions:
How will you be able to spot equipment going under low clearances? Have discussion to include getting good vantage point of tightest clearance – even if needing supplemental spotter for that area only.

39. Position Self and Others out of “Line of Fire” Potential
Can you see the problem?
Remember the “No Zone” and move the people!
Recommended Comments:
There is a person between the trailer and forklift load (in it’s path of travel).
A good formula for an incident!
Recommended Question:
When have you seen “line of fire” situations in spotting?

40. Immediately STOP Operator if Contact is Lost Between Spotters
Do not assume that your lead or supplemental spotter is out of the way!
Recommended Comments:
If communication is hindered, stop the show and re-establish communication.
Never assume for a second that all is clear.
Recommended Questions:
What does a spotter do? – wait for answers before the next slide

41. SO…WHAT DOES A SPOTTER DO?
Perform LPSA Before Beginning
Give Attention to Spotting ONLY!
Determine Need for Supplemental Spotters by Knowing the “No Zone”
Communicate with Operator and Supplemental Spotters Tasks and Hazards
Communicate and Use Consistent Hand Signals
Wear High Visibility Vest
Carry and Use Operating Air Horn
Maintain Eye Contact with the Equipment Operator
Clear Communication with Supplemental Spotters
Position Self to Clearly Spot Clearances
Position Self and Others out of “Line of Fire” Potential
Immediately STOP Operator if Contact is Lost Between Spotters
Summary slide to provide the entire list of answers to “What does a Spotter do?”
Take time to make sure all in attendance know the answers.
Maybe have each line read by a different person.

42. THE GOAL: USE TEAM-WORK TO SAFELY COMPLETE EACH TASK
Recommended Comment:
This is what we are looking for with all involved, confident, trained, and looking out for each other.
You are what keeps us going home the way we came to work. Keep it up!