The Pre-Start That Found Three Faults
It is the start of the shift and you are doing the pre-start inspection on a stockpicker. You find: (1) the horn does not sound; (2) the emergency lowering valve is stiff and does not return fully; (3) the left drive wheel has a visible flat spot and the tyre pressure gauge reads 20 psi against a specified 90 psi. The machine's logbook shows the last service was 11 months ago against a 6-month interval. The previous operator's note says 'horn intermittent - reported'. Your supervisor says the machine is needed urgently for a 2-hour pick and that 'the horn is not critical'.
1. Decide whether the machine is safe to operate and justify your decision against the faults found.
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The machine is not safe to operate. The horn is a warning device used to alert pedestrians and other operators; without it, movement in shared aisles is unsafe, and the 'intermittent' history shows it is an unresolved fault. The emergency lowering valve is a safety-critical device for rescuing an operator from an elevated platform; a stiff valve that does not return fully may fail when needed. The flat-spotted wheel and the 20 psi tyre against a 90 psi specification affect steering, braking, and stability - under-inflation changes the machine's geometry and can cause a tip-over. The overdue service (11 months against 6 months) means other defects may be undetected. The supervisor's urgency does not override the defects. The machine should be tagged out, the key removed, and the faults reported.
2. Describe the reporting and record-keeping steps you would take.
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Complete the pre-start checklist, recording each defect with a description and the time found. Tag the machine 'out of service - do not operate' and remove the key. Notify the supervisor in writing and enter the defects in the maintenance/fault register. Reference the previous operator's note so the intermittent horn is treated as a recurring fault, not a new one. Record the overdue service and escalate it to the person responsible for fleet maintenance. Keep a copy of the report. Do not operate the machine until it is repaired, re-inspected, and the tag is removed by an authorised person.
3. If the supervisor insists the machine be used for the 2-hour pick, what is your response and what supports it?
Read the worked answer
You should decline to operate the machine and explain why: the faults affect safety-critical functions (warning, emergency lowering, stability), and operating a defective machine breaches your duty to take reasonable care of your own and others' safety. The overdue service adds to the risk. Offer alternatives: use another serviceable machine, split the pick, or delay it until repairs are done. If the supervisor persists, escalate to the WHS officer or manager. Document the refusal and the reasons. The obligation to work safely is not overridden by operational urgency.