Check credentials.  Make sure a trainer is qualified both on paper and has experience before contracting with an outside firm.  Ensure that the trainers are certified.  Many trainers have earned their certifications through trainer certification programs offered by major lift truck manufacturers and third-party training organizations.  Be wary of one-size-fits-all training programs as OSHA rules require training to be specific to the vehicle and to the application, something a one-size-fits-all program would be unlikely to meet.

Require a site visit.  Developing a specific client training program requires a site visit since operation conditions vary significantly.  Only when a trainer talks with the customer can he gain a full understanding of the issues and obstacles that need to be considered.  When a trainer visits your site he can also gather fleet composition data, the shift it operates, and current operator qualifications.  Such specific knowledge empowers trainers to design a program that addresses a customer’s specific needs.  Often individual vehicle classification courses are offered since operators must be specifically trained for the manufacturer and the machine because each machine has its own application and capacity.

Look for a thorough program.  Your lift truck operators should learn far more than just starting, driving, steering, and manipulating forklifts.  Effective programs should also cover an overview of OSHA regulations, daily inspections, pre-shift inspections, training on inclines and ramps, operating in hazardous environments, loading and unloading, fuel handling and storage, battery safety and handling, stacking and manipulating loads, safe storage of material, negotiating sharp turns, and pedestrian traffic.

Classroom instruction.  Depending on operation requirements, class size and operator experience, classroom instruction can vary from a few hours to a full day.  Trainers should use a wide variety of media including printed material, safety videos, PowerPoint presentations and lectures.  Classes should begin with basic concepts like the dangers of speeding, awareness of pedestrians and safe load handling before moving on to accident prevention, driving skills, fueling and charging, truck inspection, the dangers of complacency and dock hazards.

Hands-on training.  Safe load handling and maneuvering can only be learned on the equipment.  Trainees should observe an experienced person first before practicing on their own.  Hands-on training can be conducted off site or after hours in a relatively quiet portion of an active distribution center.  There’s no substitute for doing it in the work environment and it’s crucial that your employees receive training on the specific brand of truck they’ll operate.  Assuming that you can drive a Crown truck, if you drive a Raymond truck is naïve.  Not only does the make and type of truck matter, but the model matters too.  Within brands, upgraded and new models of existing trucks require vehicle-specific training.

Evaluate Your Operators.  It’s important to evaluate each operator’s skills and skill level.  An evaluator who is forthcoming about whether or not a lift truck operator is up to the job can make the difference between life and death situations.  Remember that while professional trainers offer all components of training programs, certification is up to the employer.

Train pedestrians.  People who work around lift trucks but do not operate them also face hazards and for this reason safety training is important for all employees working in distribution centers, especially busy ones.  To reduce the risk of accidents and pedestrian injuries, look for special safety training for these employees as well.

For the full OSHA standards, refer to document 1910.178 Powered Industrial Trucks.  Training is addressed in the first paragraph.

Before you get in the driver’s seat, walk around the forklift and check for any fluid leaks.  Search the surrounding floor for small puddles.  Examine hydraulic line hoses for splits and leaks around the fittings.  A line burst during operation could seriously injure the operator and fluid on the tires will cause the vehicle to slip and slide out of control.  Refer to the owner’s manual for the location of fluid reservoirs and safe operating levels.  Also check for loose bolts on the roll cage and that the warning light is functioning properly.  Roll cages prevent serious injury should you tip over.  In poorly lit areas forklifts warn people of the forklifts operation.

Inspect the forklift for any cracks in the steel or bends in the fork’s length.  A damaged fork could result in an accident while lifting a load.  If a bent fork catches on the floor, the vehicle could stop suddenly.  Bent forks can also catch and tip over a load when a forklift moves in for a pick up.

OSHA requires seatbelt use and if you’re not wearing the seatbelt during an inspection, your company will face a fine.  If the forklift tips over during operation, the seatbelt will prevent you from being ejected and crushed.  Make sure to securely fasten the seatbelt around your waist once you’re seated.  Once you have powered up the forklift, apply the brake pedal, checking for softness.  Move forward and look for hydraulic line leaks you may have missed before.  Shift the forklift into reverse and remain stopped, listening for the alarm to sound that warns the forklift is backing up.  Test the horn as it too is critical to forklift safety.  Report and repair any defects or safety hazards.

Wheels in the back of the forklift are used for turning and may take new operators time to get used to forklift’s tighter turning capabilities.  Operators should never drive forward with forks raised and should lift them off the ground a few inches before proceeding.  Use a wide open space to familiarize yourself with forklift operation and before you attempt to lift a load, be aware of lift capacity.  A load that’s too heavy can raise the forklift’s rear off the ground and create a safety hazard.  When picking up a load, be cautious.  Driving too fast may cause the forks to strike something and tip the load over or cause the forklift to suddenly stop.  With the forks placed under the pallet, tilt the load back slightly and then lift it off the ground.  Before moving with the load, determine the load’s height.  If the load extends beyond halfway up the mast, drive in reverse.  Below that, you’ll have a clear line of sight.  Be sure to always use the horn when backing up and traveling around corners.

Unfortunately, knowing forklift safety procedures is not enough.  Operators must also practice them.

Before loading a forklift, first check the load.  Ask yourself if the load is stable or if parts will slide or fall during transit and secure the load as necessary.  The most common way to secure a load is to stack it in a block fashion, encircling the upper level with wire or strapping.  A second way is to interlock the load in a brick fashion, turning each level 90 degrees.  A third way is using the pinwheel method, especially when the brick pattern is unstable.  To stabilize castings, bags and additional irregular shapes, use an irregular stacking pattern by placing wood strips, plywood or heavy cardboard between layers.  The dimensions and weight of the load should fall within the capacity rating of the forklift at the highest elevation and extension.  If they don’t, consider breaking the load into smaller parts.

If the load meets the forklift’s capacity guidelines, move the forklift squarely into position in front of the load.  To keep the load balanced, position the forks wide apart and drive the forks fully under the load.  Raise the bottom of the load to the proper traveling height before tilting the mast backward slightly to stabilize the load and lift.  Check for pedestrians and other traffic behind and on both sides of the forklift before you back up.

Before you place the load, check to see if the destination is flat and stable, that the load won’t rock, tilt or lean.  Abide by the maximum stacking quantities and orientation on printed cartons and never place heavy loads on lighter ones.  You should also know the load bearing capacity of your rack and storage loft destination.  Look for rack legs or support members that are bent or disconnected.  The damaged component should be replaced before guessing its load bearing capacity!  If racks are arranged back to back with stock behind the area where you plan to place the next load, you’ll need someone to control access in the next aisle.  Make sure any wooden stringers or decking that’s been laid between the front and rear rack beams are in good condition.  Check other pallets in the stack, ensuring they are in good condition and capable of supporting additional loads.

With the safety of your load’s destination verified, squarely position the forklift in front of the rack or stack and tilt the mast to level when ready.  When the load is over the spot where you wish to place it, tilt the mast forward and lower the forks.  Visually inspect the area to verify that the load is stable and check for pedestrians and other traffic before backing away.  No one should ever walk, stand or pass under a raised load.

Operating a forklift is dangerous when safety regulations are ignored.  Don’t risk your life or those around you.  Follow these guidelines and those specified by forklift manufacturers for the safest results.

Choosing the right tires significantly impacts forklift handling and safety characteristics.  But before you start searching for tires, see if your forklift gives you the option to choose different tires.  The majority of forklifts have frames that will only accept a specific tire type.  This is why choosing the right tire really means choosing the right machine for the work you plan to do.

If most of your lifting will take place indoors or with light outdoor usage on asphalt, then cushion tires will do the job.  Cushion tire forklifts have a smaller chassis and sit much lower to the ground than pneumatic forklifts.  With little ground clearance, it’s easy to see why cushion tire forklifts can get hung up so easily outdoors.  To combat this dilemna, many cushion tire forklift users put traction tires on the front of their forklifts rather than on the back.  Not only do their tires last longer and have better outdoor maneuverability, but their outdoor use is more safe and economical.  A big advantage to using cushion tire forklifts is their smaller turning radius, making them ideal for manufacturing facilities that have less space than a warehouse. Cushion lifts are less expensive and are much easier to come by than pneumatic lifts.

Similar to the tires on a car, pneumatic tires have air in them, and are most useful outdoors on gravel or in yard work, though they can be used inside as well.  Pneumatic tires are longer and wider than cushion tire lifts which is why they are primarily used outdoors.  There are two types of pneumatic tires – solid and air.  Solid pneumatic tires are made of solid rubber.  These are more expensive than air pneumatic tires because you can’t pop, puncture or gouge them as they are 100% rubber.  They’re ideal for lumber yards and scrap yards where there is a lot of sharp metal scrap debris and nails.  Like solid pneumatics, air pneumatics work well outdoors on asphalt, in gravel and in yards, but they can be punctured so you’ll want to make sure your work area is free of any sharp objects before you begin making your lifts.  Many air pneumatic users foam fill their tires, giving themselves a smoother ride than the one experienced on solid pneumatic tires.

Both cushion and pneumatic tire forklifts can be obtained with almost any load capacity (from less than 2,000 pounds to more than 200,000 pounds).  But pneumatic Tire Forklifts are in high demand.  Brand new Pneumatic Tire Forklifts pricing ranges between $20,000 and $25,000.  For this reason, pneumatic tire forklifts sell quickly in the used market.  Forklift America’s pre-owned forklifts are dependable, good running, quality machines, so you really do get what you pay for.

Before you decide on cushion or pneumatic tires for your forklift, determine the type of work you plan to do.  While cushion tire forklifts are ideal for indoor lifting, pneumatic forklifts are better suited for outdoor lifting.  But both offer almost any load capacity.  For answers to more questions about forklifts and the one that’s best for you, please contact us.

There is, unfortunately, a number of different dumb (and unsafe) things people do with forklifts. Some of these things are intentional while some are accidental; some are the result of laziness and others the result of pure ignorance or poor decision making.

While many forklift operators and other warehouse employees may walk away from unsafe forklift operations or stupid forklift stunts unscathed, many others are not so fortunate. Unsafe forklift operations can lead to accidents, which can cause injury, illness, and even death. Therefore, it’s important to learn what dumb, unsafe forklift behaviors to avoid so you can help prevent unnecessary workplace accidents.

Here is a list of some of the common unsafe practices employed during forklift use:

Allowing untrained or unauthorized employees to operate or ride on forklifts

Allowing untrained, uncertified, unauthorized, or unskilled workers to operate a forklift is probably the most common unsafe practice regarding forklift operations. Proper training and certification is REQUIRED for someone to be able to operate a forklift, and only those people who are trained/certified (and demonstrate the proper knowledge, skills, and safety precautions) should be able to drive a forklift.

Further, designated forklift operators must always be properly trained and certified. Failure to train/certify forklift operators is unfortunately, common. Knowledge and skill aren’t enough; proper training and certification is necessary.

Related to this unsafe practice is allowing other people to “ride” on a forklift as if they were passengers in a vehicle. Forklifts are not meant to carry or lift people; they are meant for cargo!

Operating forklifts that require repair

Another unsafe forklift practice is operating a forklift that requires repair. Just like someone wouldn’t (or shouldn’t) operate a car that needs repairing, so should forklift operators avoid driving and using a malfunctioning forklift until it is repaired.

Leaving forklifts running while not in use

Some people lack the common sense to actually turn off the forklift when it’s not in use—or perhaps they’re just lazy. This is a very dumb, unsafe practice that is almost “asking” for an accident, and should always be avoided.

Using forklifts as “tow trucks” to tow very heavy objects

Some companies or manufacturers may suggest that it’s okay to use forklifts as “tow trucks” to tow heavy objects around a warehouse or farm, but this is generally considered an unsafe practice.

Driving a forklift under the influence

This should go without saying, but people continue to do dumb and unsafe things. Forklift operators should never attempt to operate a forklift while under the influence of alcohol, recreational drugs, or certain medications that may cause drowsiness, dizziness, etc.

Forklift racing

It may seem fun and exciting, but forklift racing [forklift operators driving different forklifts down the aisle(s)] is really just asking for trouble. It’s a dumb idea, it’s incredibly unsafe, and it’s also just plain unprofessional. Heavy-duty machinery should never be used for racing.

Forklift “jousting”

Forklift “jousting” has become a popular (although dumb and unsafe) forklift pastime for bored and unsupervised warehouse employees. It’s essentially “bumper cars” using forklifts.

Using the forklift for anything other than its intended purpose

Forklifts should be used only for what they were designed to be used for: to lift and transport weight-appropriate cargo and materials.

Common sense, knowledge, and follow-through are powerful weapons when it comes to safety around forklifts and safely operating forklifts. If you are a forklift operator, warehouse supervisor, or otherwise around forklifts or involved with forklift operations, avoid doing any of the above dumb (and unsafe) things people do with forklifts, and learn proper forklift safety policies and procedures and follow them. You’ll be doing your part to ensure a safe work environment for you and your coworkers.

However, warehouse workplace accidents and injuries can be reduced simply by having all warehouse personnel follow some basic warehouse safety tips, rules, and precautions at all times. It’s important that everyone involved in warehouse operations know, understand, and follow proper warehouse safety precautions to help prevent and reduce workplace accidents and injuries.

Warehouse Safety Training

The best way to ensure everyone is on board with the warehouse’s safety rules is to hold mandatory warehouse safety training for all warehouse personnel. This can be done in a half-day session, a full-day session, or extended to last a week (with, for example, just a few hours of training per day), depending on what works best for the warehouse staff. This training should be a mandatory component of employment with the warehouse, and should include a safety test afterward to help determine who is ready and who needs to be retrained and retested.

So what type of warehouse safety precautions should be covered in the training and should be followed on a day-to-day basis? Here are some warehouse safety tips and topics that are important to cover, understand, and—most importantly—follow:

Hazardous Materials Safety

All warehouse employees must learn how to follow proper safety precautions when handling any hazardous materials that are stored and used in the warehouse. This should be covered as part of the training, and all material-handling procedures followed judiciously.

Machinery Operations Safety

Learning how to operate all warehouse machinery properly and safely is an important component of overall warehouse safety. Each employee should learn the proper procedures for operating all the machinery in the warehouse, which will go a long way in preventing workplace accidents and injuries.

Forklift Safety

One of the most important safety tips to follow in a warehouse is forklift safety. Because forklifts are used regularly and frequently in warehouses, and are linked to numerous warehouse accidents and injuries, learning about and following forklift safety procedures is essential. For example, warehouse personnel must actually be certified to operate a forklift before driving one. Untrained personnel should not operate a forklift, even for “just a few minutes.” An incorrect maneuver can lead to an accident—sometimes a fatal one—in just a few seconds. Certified forklift drivers should also operate a forklift only when the path is clear from debris, spills, and other workers.

Dock Safety

Dock safety refers to following safety precautions in and around the docking area of the warehouse, which is where cargo is delivered and shipped and is typically a very busy area.

Hardhat Safety and Falling Items

Falling items and cargo is a potential hazard throughout the warehouse. All warehouse employees should be required to wear hardhats when working in any part of the warehouse. Coupled with this warehouse safety tip is including safety training on how to properly and safely stack and store items on racks and shelves to help reduce the potential of falling items in the first place.

Lifting Safety

Warehouse personnel can prevent or reduce painful back injury to themselves by following proper lifting procedures for lifting, carrying, and otherwise handling heavy items in the warehouse.

First Aid and Fire Safety

All warehouse personnel should be trained in First Aid and CPR (Cardiopulmonary Resuscitation) and should know where to find and how to use First Aid kits. Workers should also know where to find and how to use fire extinguishers, and there should be a fire evacuation plan (including fire drills) in place.