Forklift Safety  
 

FORKLIFT SAFETY AND OPERATION

Forklifts are an integral part of material handling in many industries. They are also a source of serious accidents. All personnel who operate forklifts must be trained and certified in safe operation at least once a year. The training includes both classroom and vehicle operation. Written and driving tests are administered by the instructor.

Operator Responsibilities
The operator is in charge of his/her own vehicle. As such they are responsible for their own safety, vehicle, load, company property and equipment and other employees or pedestrians.
Only qualified drivers may operate forklifts. This will be determined by their supervisor and be based upon experience and training.
Wear hard hat, safety glasses, hearing protection and safety shoes as required.
Horseplay is prohibited.
Report all accidents immediately.
No riders are allowed.

Operators should be knowledgeable of:

> Operation of all controls for the lift truck.
> Capabilities of the lift truck. ( weights, fork shifting, etc. ) This can be found on the placard in the cab and/or in the operations manual.
> Fueling / battery recharging procedures.
> Visibility barriers and back-up alarms.
> Operations in tight aisles, loading ramps, high picks, and on inclines.
> Driving procedures. Corners, carrying loads, material placement, lift truck speed.

These topics, as well as others, should be covered in a comprehensive training program. The program should also include a written outline of training topics, a self test or evaluation for the driver, a practical field test, and a signed certificate of completion for the course.

Traffic Safety
In general, observe the usual traffic rules and regulations whenever possible. These include:

> Keep to the right on roadways and wide aisles.
> Drive at a reasonable speed depending on location and condition of surface.
> Slow down at intersections, corners, ramps and other danger points.
> Leave plenty of space between forklifts when moving.
> Use your horn in blind spots, but don't overdo it.
> Watch in turning that you don't cut too short.
> Be alert for wet and slippery surfaces while driving.
> Give pedestrians the right of way. Assume they are not aware of forklift traffic.
> Stop at all stop signs.
> When parking, do not block traffic
> Park with the forks lowered to the floor

Turn off the power and take the key with you.

Lifting Personnel
Forklifts (or powered industrial trucks) were never intended by manufacturers as a means of lifting personnel to perform job tasks at heights. Through the years, however, it became apparent, as evidenced by the number of injuries occurring, that this was, indeed, a method being employed for getting to light fixtures, top storage racks, elevated motors and other items too high to reach from the floor or from a ladder. It was viewed as a quicker way to accomplish tasks. Instead of going to the storage area and retrieving a ladder, riding the forks to the upper level would take less time.

In an attempt to reduce this exposure, regulatory groups, manufacturers and other interested parties decided that developing a "safe method" of elevating personnel would be the best course of action.

Presently, forklifts may be used to lift personnel only if the following guidelines are followed:

> A work platform equipped with standard guardrails or equivalent means, and firmly secured to the lifting carriage or forks, must be used.

> The hydraulic system must be so designed that the lift mechanism will not drop faster than 135 feet per minute in the event of a failure in any part of the system.

> An operator must attend the lift equipment while workers are on the platform.

> The operator must be in the normal operating position while raising or lowering the platform.

> The vehicle must not travel from point to point with the work platform elevated at a height greater than 4 feet while workers are on the platform. When necessary, at heights greater than 4 feet, inching is permitted provided it is done at a very slow speed.

> The area between workers on the platform and the mast must be guarded to prevent    contact with chains or other shear points.

> A safe and adequate access/egress must be provided for workers entering and exiting the work platform.

Material Stacking
An alarming number of employee accidents and injuries are associated with forklift operations. Many of these are a result of poorly stacked materials that topple and damage property or injure people.

The stability of a stack is probably the number one concern. If a stacked load is going to be moved, with a forklift or pallet jack for example, you can see that the inevitable jostling may cause items to fall. But what about stacks that are not to be moved? Stability is still important. An earthquake or an accidental bump could cause something to fall.

For a load to be stable, its base must be stable. This means you have to start building the stack on a firm, level surface. If a pallet is used, inspect it to be sure it's in good repair. If not, it should not be used. Though it seems obvious, make sure everyone on the crew knows the difference between "good" and "bad" pallet repair.

Place larger and heavier objects at the bottom. If the packaging material is compressible, pay attention to the printed instructions on the box that advise how many units can be stacked. If you go higher, the weight could cause the lower boxes to crush, creating an unstable stack and damaging goods in the boxes. If the product is bagged, be sure the contents are evenly distributed in the bag as you lay it down. This creates a flat surface for the next tier. Interlock the units as you build the load. Your supervisor can show you how this is done.

Some stacks are going to be inherently stable. An example would be a stack of rectangular, interlocked boxes with the base of the stack wider than the height. Other stacks are inherently unstable. An example would be square boxes that cannot be interlocked. Such stacks must be tied or wrapped to increase stability.

Watch the total weight of objects or containers you stack. If the load is going to be moved by a forklift or pallet jack, the total weight must not exceed the capacity of the equipment. Also know the weight bearing capacity of floors and shelves, and do not exceed these capacities. Spread the load out so the weight is not concentrated in one area.


Dock Safety
An accident in a warehouse can injure you or your co-workers, damage equipment, and ruin merchandise. It is a potential for a multiple loss. The most common warehouse accidents involve forklifts and manual material handling.

The forklift is one of the most important mechanical devices you have. It can also be one of the most dangerous if not properly used. Statistics show that forklifts are involved in only about 1% of lost time accidents, yet they account for about 10% of the serious injuries. Some of those injuries occur when:

A forklift strikes a pedestrian.
A load falls on a pedestrian or the driver.
A forklift falls between a trailer and dock or off a truck.
A forklift turns over.

The key to forklift safety is the skill in operating the equipment, the ability to anticipate hazards in the warehouse and the concentration regarding the task at hand.

You can prevent traffic incidents while operating the forklift, by using the same safe practices that apply to traffic driving. Observe the rules regarding speed, maneuvering, and loading and unloading. Keep your arms and legs inside the guard and wear your seatbelt. The seatbelt will keep you inside the forklift in the event it tips over. Odds are you won't be able to jump clear! Unfortunately too many people have tried…unsuccessfully.

The dock plate is all that is between you and an accident when transferring cargo between a trailer and the dock. Damaged plates should not be used. Check for cracks or if curbs are missing or broken, report it. Makeshift plates should not be used, not even for a one-time job. Make sure the plate is properly anchored in place before loading or unloading.

The trailer can also contribute to an accident. The impact of lift trucks moving in and out can cause the trailer to inch away from the dock. Trailers should be chocked and frequently checked to insure they have not shifted. When the trailer is parked, jacks should be placed to prevent the trailer from tipping over.

As a pedestrian in the warehouse, stay clear of moving loads. When palletized cargo is being picked up, it can topple. Be alert. The rear of a forklift swings wide, since the steering axle is in the rear. So stay clear, and give the equipment plenty of room to maneuver.

Before you attempt to lift, move or shift heavy items in the cramped confines of a trailer, assess the situation. Do you need assistance from one of your co-workers, or do you need mechanical assistance from a forklift? Without assistance, you may injure your back or damage the cargo.

Forklift Guidance

OSHA Powered Industrial Truck Standard (29 CFR 1910.178)

Training Roster

Forklift Training Acknowledgement