A TRAINING FOR THE

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SAFE OPERATION OF FORKLIFT
A TRAINING FOR THE METALWORKING INDUSTRIES
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Table of Contents

• Introduction
• Risk management on forklift
• Common forklift hazards
• Route plan
• Training for forklift operators
• Pre-operation checks
• Load assessments
• Common safe practices
• Forklift traffic control

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Introduction

• Forklift can be hazardous if not handled
  properly
• Forklift accidents can cause serious injury,
  death, property and product damage
• This poses a serious problem
• for everyone
• Accidents can be prevented if risk assessment
  and safe work procedures (SWP) are followed.

Picture source http//www.thompsonandjohnson.com/
images/accident1.jpg
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Forklift Fatalities in Singapore
Source Ministry of Manpower
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Potential Forklift Accidents
Picture source http//marbella.to/humour/sep00/fo
rklift.jpg
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Potential Forklift Accidents
Picture source http//www.facelift.co.uk/images/r
oguesgallery/forklift_no-no1.jpg
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Forklift Accidents
Picture source http//siri.uvm.edu/graphics/Indus
trial_Operations/Forklift_accident.gif
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Forklift Accidents
Picture source http//www.jicosh.gr.jp/english/ca
ses/cases/case105.gif
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Forklift Accidents
Picture source European Industrial Gases
Association
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Risk Management on Operation of Forklift

• Required to manage risks under WSH (risk
  management) regulations
• Assess the risk
• Take all reasonably practical steps
• Eliminate any risks

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Risk Management on Operation of Forklift

• Step 1 Identification of hazard

Picture source http//www.safetyworld.com/images/
101.gif
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Common Forklift Hazards

• Overloading
• Unsafe stacking
• Speeding
• Raised forks
• Unauthorized operation of forklift
• Untrained forklift operators

Picture source http//www.iqsdirectory.com/info/f
ork-lift-trucks/images/fork2.jpg
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Common Forklift Hazards

• Lifting of persons on forks
• Pedestrians and forklifts moving in the same
  place
• Travelling on slope
• Obstruction in the path e.g. overhead, blind
  corners
• Poor ground conditions e.g. slippery, uneven,
  potholes

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Common Forklift Hazards
Source Ministry of Manpower

• Body/limbs caught in moving parts of the
  forklift
• Falling loads
• Poor condition tyres e.g. without thread
  markings
• Electric Shock (Battery operated forklift)

Picture source http//www.cdc.gov/niosh/face/imag
es/96nj062.jpg
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Common Forklift Hazards
Pedestrians and forklift moving in same place
Picture source http//www.safetyworld.com/images/
67.gif
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Common Forklift Hazards
Forklift traveling on slope
Picture source http//www.sandhillquilting.com/im
ages/M-16-SYS-8436-L.jpg
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Common Forklift Hazards
Poor ground conditions
Picture source http//eternitycaptured.com/blog/w
p-content/uploads/2007/04/bigstockphoto_Road_Crack
s_And_Potholes_606173.jpg
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Common Forklift Hazards
Worn out tyres
Picture source http//www.riverina.coop/depts/Rea
lestate/Other/forsale_auctions/whybro/RIMG2040.JPG
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Common Forklift Hazards
Unsecured load
Picture source http//www.locknpop.com/images/img
_fork.gif
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Common Forklift Hazards
Electric shock from battery
Picture source http//www.ubuyme.com/img_prod/679
/pic1.jpg
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Common Forklift Hazards
Lifting Persons on Forks
Picture source http//www.ttt-services.co.uk/Heal
thandsaftey/forklift_web.jpgc
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Risk Management on Operation of Forklift

• Step 2 Assess the risk
• Dependent on severity of risk and likelihood of
  hazards occurring
• severity X likelihood risk level
• Risk Level Low, Moderate or High

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Risk Management on Operation of Forklift
Severity
Minor  
Moderate  
Major  
Likelihood
Low
Remote
Low
Medium
Occasional
Low
Medium
High
Frequent
Medium
High
High
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Risk Management on Operation of Forklift

• Step 3 Select Measures to Control and Reduce
  Risk
• Based on hierarchy of hazards control
• 1st Remove the hazard (E.g. Forklift
  operations route separated from workers)
• 2nd Guard the remaining hazards (E.g. Erect
  physical protective barriers)

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Risk Management on Operation of Forklift
HIERARCHY OF HAZARDS CONTROL
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1st Remove the Hazards Forklift Route Planning
Picture source http//maaw.info/images/Figure8-10
.gif
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Route Plan

• Efficient workplace layout/plan
• Floors and surfaces in good condition
• Fixtures which are clearly visible
• Forklift operating and pedestrian paths
  identified and clearly marked
• Designated maintenance, parking and battery
  charging areas

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Forklift Operation Separated from Worker Area
Forklift operation area
Picture source Hi Tech Coatings, Inc
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Allocated Goods Area
Goods sitting area
Picture source Hi Tech Coatings, Inc
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Designated Battery and Parking Area
Forklift battery charging and parking area
Picture source Hi Tech Coatings, Inc
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2nd Guard the Remaining Hazards Protective
Barriers
Brightly coloured barriers
Picture source Hi Tech Coatings, Inc
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Risk Management on Operation of Forklift

• 3rd Mitigate impact of hazard (E.g. Operator
  to wear an seat belt)

Source Ministry of Manpower
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Risk Management on Operation of Forklift

• Risk assessment to be done for every forklift
  tasks
• To identify the risk and control measures
• Establish safe work procedures (SWP)
• Inform staff of SWP
• Staff to follow SWP

Source Ministry of Manpower
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Risk Management on Operation of Forklift

• Forklift Safe Work Procedures (SWP)
• Forklift Training
• Pre-Operation Check
• Load Assessment
• Common Safe Practice
• Traffic Control

Source Ministry of Manpower
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Forklift Training

• Under Factories (Safety Training Courses)
  Order, all forklift operators shall undergo a
  Forklift Drivers Training Course
• Conducted by a MOM Accredited Training Provider
• Consists of 1-day theory course
• And 4 or 2 days practical course

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Why Conduct Forklift Training

• Ensure forklift drivers are competent
• To train driver in basic forklift operation
• To provide knowledge of safe operating
  practices for forklift

Picture source http//www.crowndfw.com/training.h
tml
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Why Conduct Pre-operation Checks?

• Ensure efficient and safe operation of
  forklifts
• Prevent workplace injuries
• To remove inefficient forklift practices

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Under WSHAC Forklift Checklist, Pre-operation
Checks Includes

• Tyres and wheels
• Forks/attachments
• Chains, cables and hoses
• Safety devices (e.g. seat belts, warning
  devices, rear mirror and etc.)
• Leaks
• Hour meter
• Battery/LPG system
• Battery connector
• Guards
• Structural damage

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Pre-operation Checks 1
Source http//www.thefabricator.com/Images/96/fo
rklift-truck-diagram.jpg
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Pre-operation Checks 2 Propane Forklift
Picture source http//www.osha.gov/dcsp/ote/trng-
materials/pit/images/pitchklistimg2.gif
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Pre-operation Checks 3 Electric Forklift
Picture source http//www.osha.gov/dcsp/ote/trng-
materials/pit/images/pitchklistimg2.gif
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Pre-operation Checks 4 Yard Forklift
Picture source http//www.osha.gov/dcsp/ote/trng-
materials/pit/images/pitchklistimg2.gif
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Forklift Load Assessments 1

• Forklift can only handle loads within rated
  capacity
• Follow forklift manufacturers load chart

Forklift Model
Length of fork
Picture source http//gmesupply.com/images/produ
ct_desc_images/forklifts/load-chart.jpg
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Forklift Load Assessments 1

• When attachments are used, the total weight of
  the load and attachment must not exceed the
  lifting capacity

Picture source http//www.kinggroup.com.au
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Forklift Load Assessments 1

• Dont increase the capacity of the forklift using
  personnel as additional counterweights

Picture source http//www.staugustinelighthouse.
com/blog/forklift.jpg
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Forklift Load Assessments 2

• Only handle stable or safely arranged loads
• Care to be taken when handling extra long or high
  load
• When loads cant be centered, the forklift should
  be operated with caution

Picture source http//www.baileypottery.com
Source CP 101 2004 Code of practice for safe
use of powered counterbalanced forklifts
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Load Assessments Weighing the Load
Picture source http//www.weighing-systems.com/Te
chnologyCentre/forkliftweigh.html
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Load Assessments Weight at Centre of Gravity
Picture source http//www.morsemfgco.com/images/f
orklift_sm.gif
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Load Assessments Weight at Centre of Gravity
Picture source http//www.rentrain.com/resources/
fork_21.gif
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Load Assessments Weight at Centre of Gravity
Picture source http//www.ccohs.ca/images/J05-2.g
if
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Load Assessments Characteristics
Picture source http//www.thetoyspace.com/images/
planforklift.gif
Unstable load
Picture source http//user1292213.sites.myregiste
redsite.com/sitebuildercontent/sitebuilderpictures
/forklift.gif
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Load Assessments Shape
Odd shape load may hit pedestrians causing
injuries
Picture source http//www.nepowder.com/images/FOR
KLIFT20II.JPG
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Load Assessments Shape
View blocked, the forklift may hit another
container or somebody
Picture source http//www.fremantleports.com.au/A
bout/PhotoGallery/North_Quay_forklift_operations_a
t_night_rdax_772x526.jpg
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Common Safe Practices

• Dont drive a forklift unless you are trained
  and authorized
• Use seatbelts

Wearing seatbelts
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Common Safe Practices

• Report to your supervisor on any forklift
  damage or problems
• Dont use a forklift to lift worker
• Use caution on slopes or ramps

Picture source http//www.liftomatic.com
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Common Safe Practices

• While on slopes, tilt the load back and raise
  it above road surface
• Dont raise or lower the forks while the
  forklift is moving
• Dont handle loads that are above the weight
  capacity of the forklift
• Follow the speed limit

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Common Safe Practices

• Slow down and sound the horn at crossings and
  locations where view is blocked
• Focus on the travelling path and keep a clear
  view of it
• When leaving a forklift, pull the parking
  brake, lower the forks and neutralize the
  controls

Source NIOSH Publication No. 2001-109
Hand brake not engaged
Picture source http//www2.worksafebc.com/i/poste
rs/2003/ha0313_forklift.htm
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Common Safe Practices

• Attend briefing on forklift operations
• Follow traffic management
• Carry out daily forklift pre-operation checks
  using checklist
• Ensure that the forklifts are well maintained
• Use rear view mirrors while reversing
• Give way to pedestrians
• Park forklift at approved locations.

Picture source http//www.safety-mirrors.co.uk/ca
bfront.jpg
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Common Safe Practices
Source Ministry of Manpower

• Operate forklifts with forks at low position
  at all times
• Dont drive and raise load at the same time
• Dont make sudden sharp turns
• Dont brake suddenly when the forklift is
• loaded
• Watch out for overhead structures (e.g. pipes
  beams)
• Travel in reverse when front view is blocked

Picture source http//www.iqsdirectory.com/info/f
ork-lift-trucks/images/fork1.jpg
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Traffic Controls

• Follow the forklift route plan and pedestrian
  path
• Obey the speed limits, pedestrian crossings and
  one way signs etc.

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Traffic Controls

• Follow site rules and inform all staff and
  visitors
• Operate forklift only in clearly marked areas
• Lookout for people opening doors
• Check back when reversing
• Give way to pedestrians

Picture source http//www.derrycity.gov.uk/Site_I
mages/forklift.jpg
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Traffic Controls

• Wear high visibility clothing
• Be cautious on road slopes
• Park on flat surfaces
• Avoid driving over objects on the road surface
• When making turns, reduce speed to safe level

Picture source http//www.thompsonandjohnson.com/
newsletter/images/tip70509.jpg
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Summary of Key Points

• Training for forklift operators
• Pre-operation checks
• Load assessments
• Route plan
• Common forklift hazards
• Forklift common safe practices
• Forklift traffic control
• Risk management on operation of forklift

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All accidents are preventable Be proactive it
is up to US to prevent it
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Thank You
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References

• WSHAC Occupational Safety Health Technical
  Advisory Safe Operation of Forklift Truck
• WSHAC Forklift Safety Checklist
• CP 101 2004 Code of Practice for Safe Use of
  Powered Counterbalanced Forklifts
• MOM Case Studies on Forklift Accidents
• NIOSH Publication No. 2001-109 NIOSH Alert
  Preventing Injuries and Deaths of Workers Who
  Operate or Work Near Forklifts
• Chisholm Institute (Warehouse Task Drive a
  forklift) (http//olvc.chisholm.vic.edu.au/warehou
  se/D10/Virtualwarehouse/D10Tasks/D10tasks.htm)

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Appendix 1
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Appendix 1
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Appendix 1
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Appendix 2
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Appendix