FORKLIFT OPERATIONS

OSHA Standard 29 CFR Part 1910.178

Requires all forklift operators receive safety training before operating any type of forklift

The term “forklift” is used to identify all powered industrial trucks, including those where the operator rides on the unit and those where the

operator walks with the unit.

A forklift is any mechanical device used for the movement of supplies, materials or finished products that is powered by an electric motor or

internal combustion engine. Does not include a farm vehicle or vehicles used primarily for earth moving

It is a violation of Federal law for anyone under 18 years of age to operate a forklift

The OSHA act of 1970 requires all employers to provide a place of employment which is free from recognized hazards that are causing

or are likely to cause death or serious physical harm to his employees.

Under this act employees are also required to comply with occupational safety and health standards and all rules, regulations, and orders issued pursuant to this Act which are applicable to his

own actions and conduct.

Each year, tens of thousands of forklift-related injuries occur in U.S. workplaces. Most employee injuries and property damage can be attributed to:

•lack of safe operating procedures

•lack of safety-rule enforcement

•insufficient or inadequate training.

Employers must ensure operators are:

•Trained•Competent•Documented

Training must consist of a combination of:

•Formal instruction•Practical training •Evaluation

Management / Supervisor Responsibilities

•Make sure that workers do not operate a forklift unless they have been trained and licensed.

•Develop, implement, and enforce a comprehensive written safety program that includes worker training, operator licensure, and a timetable for reviewing and revising the program.

•A comprehensive training program is important for preventing injury and death.

•Operator training should address factors that affect the stability of a forklift—such as the weight and symmetry of the load, the speed at which the forklift is traveling, operating surface, tire pressure, and driving behavior.

Management / Supervisor Responsibilities

•Inform operators of sit-down type forklifts that they can be crushed by the overhead guard or another part of the truck after jumping from the overturning forklift.

•The operator of a sit-down type forklift should stay with the truck if lateral or longitudinal tip over occurs.

•The operator should hold on firmly and lean away from the point of impact.

•Train operators of stand-up type forklifts with rear-entry access to exit from the truck by stepping backward if a lateral tip over occurs.

Management / Supervisor Responsibilities

•Ensure that operator restraint systems are being used on sit-down type forklifts.

• Since 1992, forklift manufacturers have been required to equip new sit-down type forklifts with operator restraint systems. Many manufacturers of these forklifts offer restraint systems that can be retrofitted on older forklifts.

•Many of the fatalities resulting from overturns of sit-down type forklifts might have been prevented if the operator had been restrained.

•The overhead guard of the forklift is generally the part that crushes the operator's head or torso after he or she falls or jumps outside of the operator's compartment.

Management / Supervisor Responsibilities

The risk of being crushed by the overhead guard or another rigid part of the forklift is greatly reduced if the operator of a sit-down type forklift remains inside the operator's compartment.

Because many forklifts are not equipped with a restraint system and operator compliance is less than 100% on forklifts equipped with a restraint system,

Operators of sit-down type forklifts should be instructed not to jump from the operator's compartment but to stay inside by leaning in the opposite direction of the overturn.

Management / Supervisor Responsibilities

•Enforce safe driving practices such as obeying speed limits, stopping at stop signs, and slowing down and blowing the horn at intersections.

•Separate forklift traffic and other workers where possible.

•Limit some aisles to workers on foot only or forklifts only.

•Restrict the use of forklifts near time clocks, break rooms, cafeterias, and main exits, particularly when the flow of workers on foot is at a peak (such as at the end of a shift or during breaks).

Management / Supervisor Responsibilities

• Install physical barriers where practical to ensure that workstations are isolated from aisles traveled by forklifts.

• Evaluate intersections and other blind corners to determine whether overhead dome mirrors could improve the visibility of forklift operators or workers on foot.

• Make every effort to alert workers when a forklift is nearby. Use horns, audible backup alarms, and flashing lights to warn workers and other forklift operators in the area. Flashing lights are especially important in areas where the ambient noise level is high.

Management / Supervisor ResponsibilitiesINSPECTIONS

•Ensure that workplace safety inspections are routinely conducted by a competent person who can identify hazards and conditions that are dangerous to workers.

•Hazards include obstructions in the aisle, blind corners and intersections, and forklifts that come too close to workers on foot.

•The person who conducts the inspections should have the authority to implement prompt corrective measures.

•Enforce safe driving practices such as obeying speed limits, stopping at stop signs, and slowing down and blowing the horn at intersections.

Comparing Forklifts to Automobiles

Forklifts use a three-pointsuspension system

Rear wheel steering

Has triangular stability, not four point

Rear of forklift swings outon turns

Performance Testing

Each operator must demonstrate their proficiency in forklift operations as part of the required training.

The following slides will explain what is required in this phase of training

FORKLIFT TRUCK OPERATOR PERFORMANCE TESTOPERATOR’S

NAME_________________DEPT._____________DATE_____________

Operator’s ability to perform check-sheet inspection for safe operation of truck prior to use.

Uses check-sheet satisfactorily Failed to check safety items

2. Proper use of controls (understands proper technique and proper direction of movement of control to get desired direction of movement).

(a) Clutch operation. Yes No

(b) Inching control (auto transmission). Yes No

(c) Tilt control. Yes No

(d) Lift control. Yes No

(e) Attachment controls. Yes No

(f) Steering techniques for type of machine being used by operator. Yes No

(g) Proper positioning of all controls, switches, parking brakes when leaving machine unattended. Yes No

(h) Service brake. Yes No

(i) Parking brake. Yes No

3. Maneuvering skills

(a) Smooth starting and stopping

Acceptable Needs practice Poor control

(b) Sharp turns forward and reverse.

Proper speed. Yes No

Looks in direction of travel. Yes No

Carries forks low. Yes No Clears obstacles by safe distance. Yes No

4.Selecting loads.

(a) Proper capacity for truck used. Yes No

(b) Proper size load for visibility and safety of handling. Yes No

(c) Load tilted back against back rest. Yes No

(d) Carries load low (just high enough to clear floor obstacles) Yes No

5. Driving with load. (a) Smooth start and stopping. Yes No

(b) Proper speed. Yes No (c) Sounds horn at intersections and corners. Yes No

(d) Keeps to the right in aisles used for two-way traffic. Yes No

(e) Travels at least three lengths behind other vehicles. Yes No (f) Handles load in manner to prevent product damage. Yes No

6. Stacking.

(a) Approaches loads squarely. Yes No (b) Stacks straight and squarely. Yes No

(c) Does not tier to high. Yes No

(d) Deposits load safely; does not use excessive tilt action. Yes No

(e) When selecting top load for pickup, uses proper form spread for load.

Yes No (f) Removes load and lowers to safe level before making turn to proceed

in direction of desired travel. Yes No

7. Dock Safety.

(a) Checks bridge plates (dock boards) before crossing. Yes No (b) Checks trailers for proper wheel chocking before entering and proper jack installation of trailers where required. Yes No

(C) Checks rail freight cars for proper positioning and safe loading conditions. Yes No

REFERENCES

Forklift Operator Training, J.J. Keller & Associates 1999

Accident Prevention Manual for Business & Industry, 12th Edition, National Safety Council

http://www.cdc.gov/niosh/2001-109.html#3

http://www.osha.gov/dcsplotr/trng-materials/pit/pit.html

http://wisha-training.lni.wa.gov/traning/trainingkits/forklift/sldo19.htm