material handling – Packaging Expert Witness

Forklift injures worker

By Sterling Anthony, CPP, expert in packaging, marketing, logistics, and human-factors.

Synopsis

The Plaintiff was struck by a forklift truck inside a factory. The Plaintiff had been sent to the factory by a temporary employment agency. Plaintiff sued the factory, alleging negligence owed to breach of standards related to material handling, forklift operations, and safe pedestrian traffic.

I was retained by Plaintiff’s attorney.

Opinions

Defendant breached the standard that a forklift operator must be certified. The fact that the involved operator had experience with forklifts was not an acceptable substitute for certification.

At the time of the accident, the forklift was being operated in reverse, because the height of the load restricted the operator’s vision; however, the back-up alarm, which warns pedestrians, wasn’t working, a condition that had been known by the factory managers but had been allowed to go uncorrected. As a result, Plaintiff was denied the auditory warning that a forklift was operating nearby.

The accident occurred in an area of the factory that did not have convex mirrors stationed at every aisle intersection, including the intersection closest to the accident. As a result, Plaintiff was denied the safety of having his presence detected by properly positioned convex mirrors.

The factory did not have floor markings that delineate pedestrian aisles and pedestrian areas, nor was the floor marked with stencils that identify an area as one in which forklifts operate. As a result, Plaintiff had to carry out his assigned duties, which included traveling to and from parts inventory, without safeguards relative to forklift traffic.

All of the solutions to the inadequacies that contributed to the accident were readily available to the factory and could have been implemented economically and on a short schedule.

Defendant was aware that accidents between forklift and pedestrian carry a high potential for injury and even death. Defendant admitted to knowing that OSHA has requirements aimed at preventing such accidents.

Result

The case settled.

Sterling Anthony can be contacted via 100 Renaissance Center Box 176, Detroit, MI 48243; 313-531-1875; thepackagingexpertwitness@gmail.com; www.thepackagingexpertwitness.com

Packaging fails, worker injured

by Sterling Anthony, CPP, expert in packaging, marketing, logistics, human-factors, and warnings.

Synopsis

A worker for a parcel-post delivery service was manually sorting packages off a conveyor. One of the packages was a corrugated box containing an industrial blade. The blade had cut through the box, resulting in exposure of the sharp edge. Unaware of said exposure, the worker suffered lacerations to one of his hands, causing permanent damage to nerves and ligaments.

The worker sued the manufacturer of the blade, alleging defective packaging, an unreasonably dangerous product, and failure-to-warn.

I was retained by the attorney for the Plaintiff.

Opinions

Because the blade was packaged loose inside the box, the resulting freedom of movement allowed the sharp edge of the blade to contact against the box, eventually cutting through it.

Because the box was oversized relative to the dimensions of the blade, the relationship increased the ability of the blade to move inside the box.

It was reasonably foreseeable that an unrestrained sharp blade can cut through a corrugated box, a common-sense example being a box-cutter instrument.

It was reasonably foreseeable that the size and weight of the blade would give impetus to contacts against the box, sufficient for the blade to cut through the box.

It was reasonably foreseeable that the physical forces (impacts, vibrations, compressions) encountered throughout the parcel post delivery environment would increase the already reasonably foreseeable probability that the blade would cut through the box.

There was no printed warnings on the box that it contained a sharp-edged instrument; as such, Plaintiff was never on notice as to the hazard.

There were alternative ways to package the blade for safety, and such ways were technologically and economically feasible.

Result

The case settled.

Sterling Anthony, CPP, can be contacted through: 100 Renaissance Center, Box 176, Detroit, MI 48243; 313-531-1875; thepackagingexpertwitness@gmail.com; www.thepackagingexpertwitness.com

Packaging expert discusses exhibits

by Sterling Anthony, CPP

Effective demonstrative exhibits leave jurors with a better understanding of the expert’s opinions than what they would have been left with otherwise. Not all demonstrative exhibits meet that criterion. Those that don’t are a waste of time, materials, and energy; worse, they can be counterproductive, if they confuse jurors.

The expert must know his/her opinions thoroughly, but not just in the professional sense; for, demonstrative exhibits should explain in ways that are juror-friendly. Any expert may utilize demonstrative exhibits; however, the more technology-immersed and/or exotic an expert’s field, the greater the need.

Demonstrative exhibits should fulfill their purposes, without competing with the expert; for example, exhibits should not allow jurors to read ahead of the expert’s comments. A good policy in that regard is for any one exhibit to feature only one opinion and to present it succinctly. Jurors won’t resent multiple exhibits as long as the purpose and effectiveness of each are evident. Jurors want to understand the issues. Jurors want to feel intelligent. Demonstrative exhibits should meet those jurors’ wants.

Experts should be mindful that their demonstrative exhibits might end up in the jury room during deliberations; but, of course, experts are not allowed in those sacrosanct quarters. The significance is that the exhibits should be designed to be understandable in the absence of the expert.

Demonstrative exhibits should not be any more hi-tech than needed; for example, transparencies can be just as effective as PowerPoint. Certain equipment, such as laptop computers and flash-drives, can be brought to court by the expert. Anything not as transportable should be arranged well in advance; furthermore, the expert should arrive early to court to confirm that all needed equipment is present.

As advance preparations go, none is more important than that between the expert and the retaining attorney. The expert contemplating demonstrative exhibits should get permission from the retaining attorney; after all, the development of such exhibits represents billable time by the expert. In requesting permission, the expert must explain why demonstrative exhibits would be helpful; after which, the discussion can proceed to the nature and quantity of the exhibits.

Often, the retaining attorney will be able to provide valuable guidance; however, regardless of how involved the attorney is in the development of the exhibits, it’s the attorney who must clear the way for their use, whether by stipulation from opposing counsel or by court approval. The expert who appreciates the time element never takes an eleventh-hour approach.

Depending on the types of demonstrative exhibits, the expert might have to involve other parties, such as graphic artists, animators, model-makers, etc. Here, as with anything that affects billing, the expert must receive permission from the retaining attorney.

No matter who else is involved in the development of the demonstrative exhibits, it’s the expert who should be ever-diligent. That’s because jurors aren’t concerned with the history of the exhibits, and nor should they be. Jurors, nonetheless, will form opinions of the exhibits, and by association, form opinions about the expert, and even the attorney who called him/her to the stand.

In summary, the expert who uses demonstrative exhibits needs to demonstrate mastery over those tools.

Sterling Anthony, CPP, is a consultant and expert, specializing in packaging, marketing, logistics, and human-factors. His contact information is 100 Renaissance Center P.O.B 176, Detroit, MI 48243. 313-531-1875. www.thepackagingexpertwitness@gmail.com

Packaging expert witness on forklift safety

by Sterling Anthony, CPP, expert witness, packaging, warnings, patent infringement, cargo loading & securement, insurance claims

A man was killed at a worksite when a rack of architectural glass fell from a forklift truck, crushing him. At the time, the man was one of two spotters serving as the “eyes” of the forklift driver, whose vision was obstructed by the load.

The ensuing litigation was against the manufacturer of the glass and against the manufacturer of the rack (known as an L-Buck because its side-profile resembles that letter) and alleged that the rack constituted defective packaging and that the rack should have contained warnings.

I was retained by the attorney for the Defendant glass manufacturer.

My opinions:

The direct and proximate causes of the fatality were breaches of standards governing forklift safety. The use of L-Bucks is regarded as a best practice throughout the architectural glass industry and is safe under the aforementioned standards. There is no need for warnings of the type alleged in the Complaint.

In his deposition, the forklift driver testified that obstacles close to the L-Buck prevented him from lifting it from the rear, so that the weight would lean against the mast, as he knew he should have done. He lifted it from the front to position it away from the obstacles; however, he didn’t set it down to reinsert the forks from the back. As a consequence, he traveled with the weight leaning forward, causing the load to rock unsteadily. In contrast, standards mandate that loads be carried low to the ground, forks angled upward, and the weight against the mast.

In his deposition, the forklift driver testified that the size of the load obstructed his vision as he drove the forklift in forward gear; so, he recruited two spotters to direct his travel. In contrast, standards mandate that the driver operate the forklift in reverse when vision is obstructed.

In his deposition, the forklift driver testified that the spotter who got killed was in front of the forklift at the time the load fell forward. In contrast, standards mandate that pedestrians in the vicinity maintain a safe distance from an operating forklift and that the driver remain alert to their presence.

In his deposition, the forklift driver testified that there came a time when the load rocked so violently that it came off the forks, during a time when the spotter who got killed was trying to manually steady the load. In contrast, the load would not have come off the forks had the driver been operating in accordance with standards; furthermore, the spotter would not have been trying to steady the load had standards regarding pedestrians been followed.

The L-Buck did not have a design defect by virtue of it being possible for a driver to carry it in the wrong orientation. There is no feasible way for a device designed for forklift handling to only permit entry of the forks from one direction. OSHA standards dictate that all forklift drivers be certified, meaning that they have been trained in safe operation practices.

The L-Buck did not have a marketing defect by virtue of not carrying warnings as to the correct way to engage the load and travel with it. Forklift drivers are sophisticated users, certified in safe operation practices. Besides, the forklift driver admitted that he knew the correct way to engage the L-Buck.

Result:

The case settled.

Sterling Anthony, CPP, is a consultant to the industrial, institutional, and government sectors and an expert to the legal community. He is a former manager at Fortune 100 companies and a former instructor at two major universities. His contact information is: 100 Renaissance Center-Box 43176, Detroit, MI 48243; (office) 313-531-1875; (cell) 313-623-0522; (fax) 313-531-1972; thepackagingexpertwitness@gmail; www.thepackagingexpertwitness.com

Packaging expert witness discusses stretch-wrap

by Sterling Anthony, CPP, expert witness, packaging, warnings, patent infringement, cargo loading & securement, insurance claims

Stretch-wrapping is the most common method for unitizing cargo onto a platform, typically a pallet. The method involves the tight application of plastic film, in overlapping layers, around the cargo, such that the cargo is held together as a unit that can be handled mechanically. Application can be done manually; however, at modest-to-high production rates, only application by machinery is practical.

Multiple factors play into the proper choice of stretch-wrap, chief among them: manufacturing method, thickness, toughness, aesthetics, and, of course, stretch characteristics. The proper choice, therefore, is application-specific, matching the film to the requirements that the film must fulfill. Another way of stating it is that the film must maintain load integrity (keep the load intact) until intentionally removed at the point of destination.

Throughout its movements in the stream of commerce, a stretched-wrapped load will encounter a variety of forces, induced by the activities of transportation, materials-handling, and storage. The forces are vibration, shock, and compression, and, whether singularly or in combination, can cause stretch-wrap to fail. The result is a load that can shift and even collapse.

Stretch-wrap never is the sole guarantor of load integrity; rather, it is a vital component of a system, which includes the aforementioned activities of transportation, materials-handling, and storage. Stretch-wrapped cargo should be loaded and secured within a transportation vehicle in a manner that renders the cargo immobile throughout transit. Stretch-wrapped cargo should be mechanically handled (by forklift, for example) in a manner that serves to keep the load intact. Stretch-wrapped cargo should be stored in a manner that serves to keep the load intact.

There are forces inherent in transportation, materials-handling, and storage that never can be eliminated, but, nonetheless, can be held within manageable limits. When that’s done, yet load integrity is compromised, it’s justified to investigate stretch-wrap as the possible weak component of the system. That’s because a properly stretch-wrapped load should withstand the forces under all reasonably foreseeable conditions.

Mention should be made of the role of stretch-wrapping machinery. The machinery not only should undergo scheduled maintenance but also should undergo daily calibration checks to assure that it’s operating within specified tolerances. In the absence of such Quality Assurance methods, loads can be stretch-wrapped with insufficient tension, among other negative results.

When stretch-wrap fails due to inadequacies in material or machinery, compromised load integrity is a predictable result. When it leads to damage to cargo or injury to people and litigation ensues, the parties would be wise to retain an expert.

The expert should have knowledge, experience, and training in the specifying and procurement of stretch-wrap and stretch-wrapping machinery, in addition to how they are mated for optimal results.

Sterling Anthony, CPP, is a consultant to the industrial, institutional, and government sectors and an expert who provides services to the legal community. He is a former manager at Fortune 100 companies and a former instructor at two major universities. His contact information is: 100 Renaissance Center-Box 43176, Detroit, MI 48243; (office) 313-531-1875; (cell) 313-623-0522; (fax) 313-531-1972; thepackagingexpertwitness@gmail; www.thepackagingexpertwitness.com

Packaging expert witness discusses pallets

by Sterling Anthony, CPP, expert witness, packaging, warnings, patent infringement, cargo loading & securement, insurance claims

Pallets carry 95% of the world’s cargo, and 90% of pallets are constructed of wood. Those overwhelming percentages establish wood pallets as the linchpin of logistics, affecting the cost, efficiency, and safety with which transportation, material handling, and storage are performed.

The pallet, on surface, is a simple concept, a platform on which items are placed, allowing the now palletized load to be moved mechanically, such as with a forklift truck. On the other hand, pallets should be engineered, designed for structural integrity, under all reasonably-foreseeable conditions encountered from the time they’re loaded until the time they’re unloaded.

Pallets need to embody the requisite combination of strength, stiffness, durability, functionality/compatibility, and affordability.

Strength refers to load-bearing capacity.

Stiffness refers to resistance to undue bending and flexing.

Durability (if not designed for just one trip) refers to the ability to give service across multiple trips.

Functionality/compatibility refers to being consistent with the materials loaded, material handling equipment, transportation regulations, etc.

Affordability refers to FIRST that the pallet be fit for its intended purposes and THEN that it be attainable at the lowest comparable price.

Pallets are of two design categories, referring to how the base is constructed: stringer and block. A block pallet is 4-way, meaning that material handling forks can enter from 4 directions (front, back, and ends). A stringer pallet is 2-way (ends) but can be made 4-way with spaced notches for fork entry, but at the sacrifice of weakening the pallet and making it more vulnerable to damage.

Regardless of design, pallets are different than mass-produced items that (barring a manufacturing defect) are indistinguishable, one from the other. More so than being manufactured, pallets can be said to be assembled and crafted; therefore, there is an inherent potential for variation, even across pallets built from the same design. Some factors that can contribute to said variation include:

Lumber. A pallet’s physical properties are influenced by the type of wood, that is to say, whether hardwood (from deciduous trees) or softwoods (from coniferous trees). Within any one type of lumber are grades, reflecting how free the lumber is from such defects as bark, knotholes, and dimensional irregularities. Yet another important consideration is the degree to which the lumber has been kiln-dried or remains green.

Number and positioning of deck boards. A deck comprised of abutting boards, with no spaces in between——all other things being equal——is sturdier than a deck with spaced boards. Of the latter type of decks, the greater the spacing the less sturdy and the greater the opportunity of an unstable load.

Type, number, and positioning of fasteners. Whether staples or nails are used affect how well the components remain attached, and within each category of fasteners, there are different sizes, with different holding strengths. How many fasteners are used affects how steadfastly the components are joined. Whether the fasteners are patterned in a straight line or staggered not only has an effect on holding strength but also on how likely a board, for example, might split.

By industry standards, any company that loads a pallet is responsible for the fitness of the pallet, and by extension, the fitness of the palletized load.

When pallets fail, the immediate consequence is that the load becomes dangerous to move, prone to tilting on the forks or even falling off. The danger to anyone in the vicinity hardly needs elaboration. Pallet failure also can occur during storage, with the sudden collapse of the load. Failure also can occur during transportation making the unloading——and even the opening of the doors of the equipment——hazardous.

When pallet failure causes or contributes to cargo lost or personal injury and litigation ensues, either party would be wise to retain an expert. The expert should have knowledge of, and experience in, the design, specification, sourcing, inspection, and care of pallets.