In recognition of National Forklift Safety Day, which occurs each June, we are highlighting Carolina Handling’s continuing focus on improving safety for our associates and our customers. Carolina Handling’s ongoing commitment to delivering the best service ensures that the operating condition of the equipment will not be the cause of serious injuries and compliance violations.
OSHA reports that 70% of forklift accidents are preventable with proper training and policy enforcement.
Each year, forklift operations cause more than 7,000 non-fatal injuries that require days off work. The powered industrial truck standard was number six on OSHA’s top ten list for the most cited for fiscal year 2024, with 2,604 violations.
“The number one cause of forklift accidents is operator error. From my experience, it’s when that operator has limited experience and knowledge of safe operation, which is directly related to training,” said Mark Hernandez, Senior Environmental Health & Safety Manager at Carolina Handling.
“It is essential for a forklift operator never to operate a piece of equipment unless you’re trained, certified, and competent to operate it safely, and you always perform a daily pre-op check to ensure the equipment is safe to operate. In addition to that, the equipment should only be used as designed and within its load ratings. Operators should always remember that forklift operation is critical to their safety as well as the safety of pedestrians. And that can be life-critical,” Hernandez said.
Here is a look at the most common types of lift truck accidents:
- Truck tipped over
- Worker hit by truck
- Worker hit by load
- Truck ran off dock
- Improper maintenance
- Operator lost control
- Truck hit object
- Worker overcome by fumes
Forklift operators must be trained and proficient in the forklift they are authorized to operate.
“Operators must be trained on the certain type and class of equipment, and if that changes, they have to go through an additional training course on that specific type and class to familiarize them with the operation and verify that they can safely operate it before you certify them on that type and class,” Hernandez said.
Hernandez said each forklift operator should be evaluated via refresher training every three years.
Safety training is essential.
Forklift operators must be trained and proficient in the forklift they are authorized to operate.
“Operators must be trained on the certain type and class of equipment, and if that changes, they have to go through an additional training course on that specific type and class to familiarize them with the operation and verify that they can safely operate it before you certify them on that type and class,” Hernandez said.
Hernandez said each forklift operator should be evaluated via refresher training every three years.
Start work with a thorough pre-operational check.
"Pre-operational or pre-op checks should be performed at the beginning of each shift if you are running on a shift schedule. On a single shift schedule, they should be performed at the beginning of the day or at least prior to the use of the equipment,” Hernandez said.
Visual checks, performed while the forklift is off, include:
- Walk around and look for hazards
- Battery compartment: check weight, connectors, gates and clearance
- Hydraulics: check leaks, hoses, fitting and cylinders
- Handles: check for damage or missing parts
- Structure: check for cracks, missing hardware and damage
- Wheels and tires: check mounting hardware and tire surface
- Forks: check to ensure they are not bent or worn
- Mast: check chains, bearings, pulleys, wear and adjustment
Operational checks, performed while the forklift is on, including listening and feeling for hazards:
- Horn/Alarms: confirm that they are working properly
- Controls: test all functions
- Steer: ensure it is smooth, no binding
- Brakes: check stop distance. An incline test is required before operating on a ramp.
- Parking brake: ensure it holds when engaged
- Platform: check fall protection and gate arms
- Control levers: confirm they operate properly and return to the center freely
- Lights: confirm all lights work properly
- Mast: confirm operating properly
Carolina Handling trainers instill best practices for safe operation:
- Always keep a clear view and look in the direction of travel
- Look for overhead obstructions
- Keep forks as low as possible when traveling
- Never drive directly toward anyone
- Remove debris and obstacles from the path
- Use caution on rough, wet, and slippery surfaces
- Keep body parts in the operator compartment
- Give pedestrians the right-of-way
- Never drive up close to anyone
- Look in the direction of travel
- Stop and sound the horn when approaching an intersection or crosswalk or exiting an aisle
- Approach and leave aisles slowly
“We are the subject matter experts in our industry. Our technicians and trainers not only understand how the trucks are designed, how they’re built and operate, but they are also subject matter experts on how to operate them safely,” Hernandez said.
A forklift is dangerously heavy and can be three or four times the weight of a vehicle.
“The battery can weigh up to 3,000 pounds or more, so the forklift itself with the battery can be over 8,000 pounds,” Hernandez said.
Hernandez said pedestrians in areas where forklifts are operating share the responsibility of maintaining a safe environment. Carolina Handling’s pedestrian training program, Steps To Safety ®, teaches pedestrians how to act responsibly around lift trucks to create a more secure and productive environment. Reminders include:
- Use dedicated pedestrian walkways
- Stop, look and listen for oncoming traffic
- Stand clear of lift trucks in operation
- Make eye contact with drivers
- Remember that a forklift needs adequate time to stop
- Understand that a forklift may not be able to see you
Forklift accidents can happen anywhere, but some areas require extra caution.
Extra caution should be used on loading docks, which are often crowded. Common loading dock incidents include trucks falling off the edge or skidding due to wet conditions. Daily dock and trailer inspections are critical to the safety of operators and truck drivers.
Additionally, damage to storage racks is almost always related to misuse and abuse, and forklifts are most often the culprits. The best storage rack systems are configured to allow enough room for workers and lift trucks to move around the facility and access products safely and easily. Providing extra clearance around pallets and in the aisles can make it easier for workers to access products and reduce the risk of accidents.
Forklift safety training helps you maximize productivity.
Safe operation of forklifts will:
- Reduce your downtime
- Increase productivity
- Minimize direct and indirect costs associated with a forklift accident such as:
- Operator out of work due to injuries
- Cost for workers’ comp premiums and medical expenses
- Replacement for damaged forklift
“Training will help you get your associates home safe every day, which should be your first priority. As it relates to your business performance, the safe operation of lift trucks will increase your productivity. If there is an incident, that can take that truck out of operation, and that impacts productivity. I’ve seen trucks quarantined for weeks, if not months, waiting on investigations,” Hernandez said.
Carolina Handling is your partner for forklift safety training, offering industry-leading training programs for everyone in your operation.
- Operator Training: Safety on the Move®, Carolina Handling’s industry-leading forklift operator training program, provides forklift operator certification. The program can assist in satisfying regulatory and required forklift training, including OSHA requirements.
- Pedestrian Training: Our pedestrian training program, Steps To Safety®, can be used independently or as a complement to Raymond’s lift truck operator training, Safety On The Move®, as well as any existing operator training programs.
- Technician Training: Prepare your in-house technicians to effectively diagnose and service Raymond lift trucks to factory standards with our certified instructor-led courses, available in our facilities and at your location.
Safety goes beyond training.
Carolina Handling knows the available technology, and we will take the time to understand your operations and partner with you to find solutions. For example, iWAREHOUSE from The Raymond Corporation is a fleet and warehouse optimization system that provides real-time monitoring, allowing managers to promote accountability and monitor compliance, risk management, and the status of their fleet, operators and batteries. Additionally, our automation group uses data to drive every solution. Our design and engineering teams can help produce custom, conceptual designs to drive efficiency and ROI.
We encourage you to contact Carolina Handling to learn about our products and services that can improve your operation and keep your associates safe.
Related: Automation improves productivity, but also safety, job satisfaction and turnover
