order picker operator test setup

Setting up the test course for testing order picker operators

This section describes, in detail, how to set up the practical test course for order picker operators. This should be read in conjunction with the plan of the course

Test Course Materials

The test course has been designed to utilise the order picker based on an operating environment which include the use of pallets, loads and high bay racking.  All loads handled by the order picker during the test should be of identical width, length and weight to simulate realistically the candidate’s work.

Locating and engaging an aisle safely, while ensuring efficiency of loading and retrieving a load.

Chicane

The chicane may be constructed using hurdles, empty pallets or existing features and consist of the minimum one left and one right turn in either sequence. Care should be taken during construction to create the correct distance between each turn to be negotiated (see plan of course). Due to the size of the machine, the creation of a chicane may not always be possible, so the use of alternative methods may be required to create sure accurate steering and manoeuvring, including the use of transit aisles and actual aisles if permitted by the site.

Traffic cones and other materials which permit gaps in the chicane are not suitable for this purpose. The distance from the chicane to the test aisle is not critical. However, care should be taken to allow sufficient separation distance so that the candidate, when emerging from the chicane, may position the truck correctly prior to undertaking the first picking operation.

Note: If using empty pallets, care must be taken to ensure that the pallets are secured and stable, this is in order to reduce the risk of damage or injury to persons in the event of a pallet falling over.

Critical Dimensions

The width of the chicane will be the practical minimum negotiating width for the laden order picker plus a clearance of 75mm at the critical points, (pivot point, truck and load extremities) of each turn (see plan of course).

Main Aisle

The width of the main aisle will be the manufacturer’s minimum aisle width for that particular truck. The theory minimum aisle width may be obtained from the manufacturer if not already published in the technical literature supplied with the truck.

Empty and palletised loads, simulated ready for picking, should be stacked or racked in line at the appropriate levels with 75mm spacing between the loads or the racking uprights where applicable. The space at ‘D’ should likewise allow for the width of the load with 75mm spacing on either side.

Load ‘A’: The part of the course forming the vertical face should be sufficiently wide and high to permit the candidate to see it load leading. The laden pallet  should be positioned square, central within 150mm of, but not touching the vertical face.

High Level ‘B’: Refers to the maximum picking height normally to be found in the candidate’s working environment for the particular truck and loads in use. High level is a minimum of 3m picking height, in situation where the maximum picking height is less than 3m the certificate must be clearly and suitably endorsed.

Medium Level ‘C’: Refers to the stacking position situated between high and low level to be found within the candidates own working environment.

Low Level ‘D’: Refers to the picking position at, or about, ground level.
Load at ‘A’ (see plan of course)

The part of the course forming the vertical face should be sufficiently wide and high to permit the candidate to see it load leading. The pallet should be positioned square, central within 150mm of, but not touching the vertical face.

High Level at ‘B’ (Not applicable for E1 category trucks)

Refers to the maximum picking height normally to be found in the candidate’s working environment for the particular truck and loads in use. High level is a minimum of 2501mm picking height. Whilst using an E2 category truck in situations where the picking height is less than 2501mm any certification issued for successfully completing the basic operating skills test must be clearly and suitably endorsed

Medium Level at ‘C’

Refers to the picking position situated between high and low level to be found within the candidates own working environment.

Low Level at ‘D’

Refers to the picking position at, or about, ground level. (Approx 299mm). Note: Should racking be involved, the levels referred to will correspond as closely as possible to the above requirements, depending on the level of beams available.

4.2 Alternative Test Construction.

Every effort should be made to construct the course in one continuous area as shown in test course, but, where the area is insufficient to construct the complete test course, the chicane may be entirely separate from the main aisle, effectively dividing the test into two parts.

Pre Use Checks | Written Test | Practical Test