Fall Prevention and Protection
Policy Key Points
- The Fall Protection Program consists of two core elements: 1) Fall hazard elimination and prevention, and 2) Use of personal fall protection equipment.
- Falls are 100% preventable.
- Fall hazard elimination utilizes job hazard assessments and proper equipment (scaffolds, aerial lifts, guardrails, step stools) to eliminate height hazards.
- Mandatory Triggers: Fall protection is required on unprotected walking/working surfaces with unprotected edges/sides when elevated 4 feet or more above lower levels.
- Hazardous Equipment Exception: Fall protection is required regardless of height if a worker can fall into or onto dangerous machinery, live electrical components, or sharp/piercing objects.
Table of Contents
Policy
Responsibilities
EHS Risk Mitigation: Perform Job Hazard Assessments (JHA) to identify fall hazards and evaluate worksite modifications where new height hazards may exist.
Affected Associate's Immediate Supervisor: Take proactive steps to eliminate fall hazards; provide fall protection where hazards cannot be eliminated; ensure associates are trained and certified before accessing fall restraint/arrest systems; inspect and maintain fall protection equipment per manufacturer standards.
Yaskawa Associate: Notify management immediately of fall hazards; use climbing equipment only for intended design purposes; place ladders strictly on clean, dry, level surfaces; maintain 3 points of contact on stairs/ladders; use certified fall restraint/arrest systems when required; keep loading dock doors closed unless a truck is docked or secondary fall protection is deployed.
Ladders
As part of Job Hazard Assessments and Manufacturing Engineering evaluations, alternative work-at-height methods should be integrated to eliminate the need for ladders wherever feasible.
While Working on a Ladder:
DO
- Hold on securely.
- Maintain 3 points of contact with the ladder at all times (2 feet + 1 hand, or 2 hands + 1 foot).
- Keep centered with your belt buckle always between the side rails.
- Stay straight and close to the ladder.
- Use a tool belt or hoist rope to transport tools.
DON'T
- Lean too far outside the rails.
- Reach too high above the top rung.
- Attempt to reposition or "hop" the ladder while standing on it.
Ladder Inspection & Safety Rules
- Inspect ladders for visible defects prior to every use. Tag and destroy damaged ladders immediately so they cannot be retrieved from trash.
- All ladders must meet OSHA/ANSI standards with equally spaced rungs. Ladders shall not be painted, as paint hides structural cracks and defects.
- Keep rungs free of oil, grease, mud, and ice. Clear shoe soles before climbing.
- Set extension ladders on solid, level footing at a 4-to-1 pitch ratio (1 foot back for every 4 feet of vertical height).
- Extension ladder side rails must extend at least 3 feet above the upper landing surface and be secured at the top.
- Ladders used near electrical conductors must feature non-conductive side rails (fiberglass/wood).
- Keep top and bottom landing areas completely clear of debris and tools.
Scaffolds & Scissor Lifts
OSHA defines a scaffold as any temporary elevated platform (supported or suspended) and its supporting structure used for supporting employees, materials, or both.
Scissor lifts are classified as mobile scaffolds. All scaffold safety rules apply directly to scissor lifts.
Scaffold Requirements
Yaskawa associates shall NOT erect or dismantle scaffolds. Scaffolds must be erected exclusively by certified contractors. Associates working on scaffolds must be fully trained and qualified.
Scaffolds must be inspected daily by a competent person checking for cracks, bent parts, loose connectors, missing bracing, missing guardrails, damaged access ladders, or unstable footings. Never use damaged equipment.
- Guardrails (top-rail 39"–45" high) and toeboards (≥4" high) are mandatory on open sides/ends 4 feet or more above ground/floor.
- Planking must be scaffold-grade, fully decked, and extend 6"–12" over end supports.
- Keep platforms clear of rubbish, snow, ice, oil, and grease.
Scissor Lift Requirements
- Yaskawa scissor lifts shall not be operated outdoors.
- Operators must be certified in both Powered Industrial Vehicles (PIV) and Mobile Scaffold standards.
- No modifications shall be made to scissor lifts without prior written permission from the equipment manufacturer.
- If a rental or contractor lift lacks an entry toeboard:
- No tools or materials may be stored on the lift floor.
- The area below must be barricaded, and personnel below must wear an approved Type 2 Class A hard hat.
Scissor lift with entry toeboard present.
No entry toeboard: Barricade area below and mandate hard hats.
Task Support Vehicles (Big Joey): No loose objects stored at operator feet. Personnel below must wear hard hats.
Boom lifts are governed by OSHA Aerial Lift Standards.
No Yaskawa associate is certified or permitted to operate a boom lift.
Guard Rails
Floor openings, roof edges, wall openings, open platforms, and runways elevated 4 feet or more (or at any height above hazardous equipment) must be protected by standard guardrails.
Standard Guardrail Specifications:
- Consists of top rail, mid-rail, toeboard, and vertical posts.
- Top rail height: 39" to 45" above working surface.
- Mid-rail positioned halfway between top rail and floor.
- Toeboard height: Minimum 4" vertical height.
- Must withstand a minimum top-rail outward/downward force of 200 pounds with minimal deflection.
Fall Hazard Elimination
Good housekeeping is essential to maintaining secure footing and avoiding falls. All associates must:
- Keep walkways and aisles free of extension cords, materials, and trip hazards.
- Immediately clean up oil, grease, water, or chemical spills.
- Maintain proper lighting in work areas.
- Never stand on chairs, crates, boxes, skids, or barrels. Use approved step stools or platform ladders.
Hierarchy of Fall Protection
Personal Fall Protection
Only certified, qualified Yaskawa associates may use fall restraint and fall arrest systems. Body harnesses must be worn wherever free-fall potential exists. Body belts are strictly prohibited for fall protection.
Shock-absorbing lanyards (½" nylon equivalent) must limit free-fall distance to 6 feet or less, feature a 5,000 lb breaking strength, and connect to anchorages rated for at least 5,000 lbs per attached worker.
Records
Scissor lift inspection logs are maintained by the Cost Center Manager for the life of the equipment.
Training
General Fall Protection Awareness is assigned via Yaskawa LMS. To achieve Active Qualification for personal fall protection PPE, associates must complete classroom instruction, hands-on fitting, and prompt rescue procedure training with a qualified instructor.
Revision History
| Rev # | Description | Release Date | Approved by |
|---|---|---|---|
| 0 | Initial Release | 4/14/2016 | Thurwanger |
| 1 | Added scaffolding requirements | 7/16/2017 | Thurwanger |
| 2 | Grammatical corrections | 9/12/2022 | Thurwanger |
| 3 | Added "No modifications shall be made to scissor lifts without manufacturer permission" | 3/26/2025 | Thurwanger |
| 4 | Added "When other methods of fall are not utilized" to meet Veriforce requirement | 7/9/2025 | Thurwanger |
Program Review
| Review Date | Reviewed by | Changes Required (Yes/No) | Revision # if updated |
|---|---|---|---|
| 2/15/2017 | Thurwanger | Yes | 1 |
| 1/12/2018 | Thurwanger | No | — |
| 1/18/2019 | Thurwanger | No | — |
| 1/14/2020 | Thurwanger | No | — |
| 1/26/2021 | Thurwanger | No | — |
| 1/18/2022 | Thurwanger | Yes | 2 |
| 1/13/2023 | Thurwanger | No | — |
| 1/16/2024 | Thurwanger | No | — |
| 1/21/2025 | Thurwanger | Yes | 3 |
| 2/9/2026 | Thurwanger | No | — |
