Six Sigma approach to reducing fall hazards among cargo handlers working on top of cargo containers: a case study

Abstract

In Hong Kong, more than 500,000 container units per year are handled by small midstream cargo operators located at the Public Cargo Working Areas (PCWAs). Unfortunately, over 600 fall accidents were reported at PCWAs over the past ten years resulting in more than 45 deaths. This paper reports the results of a Six Sigma study to reduce fall accidents at PCWAs. Work procedures leading to falls of cargo handlers from cargo containers are described and the sigma levels for the rates of such accidents are determined. With help from the Logistics Cargo Supervisors Association and the Hong Kong Occupational Safety and Health Council (OSHC), we conducted focus group interviews and questionnaire surveys at the PCWAs. Data indicated that jumping from one container to another and resting and standing on a lifted container are the most hazardous procedures. The three most critical factors are identified. They are: not concentrating at work; disregarding safety regulations; using worn-out hooks and slings. Detailed improvement actions to reduce the fall accident rates were identified. Control procedures were documented and passed to OSHC.