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Introduction

Approximately 34,000 Forklift related injury happened every year:

Immediate causes:

INATTENTION
DISTRACTION
EXCESSIVE SPEED
POOR DRIVING HABITS
LACK OF TRAINING

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Circumstances of Injury

HOW MOST INJURIES OCCUR:

Overloading Causing the Vehicle to Turn Over.
Load Instability Causing Turnover.
Obstructions in the Path of Travel or Lift.
Using Forklift Outside of Design Limitations.
Striking a Pedestrian.

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Case Study # 1 �

NARRATIVE: AN EMPLOYEE WAS SPOTTING A FORKLIFT BACKING UP IN A CONGESTED FLOOR AREA. THE OPERATOR ATTEMPTED TO EASE THE VEHICLE SLOWLY BACK TO GAIN CLEARANCE TO TURN. THE GAS PEDAL STUCK SLIGHTLY, CAUSING THE VEHICLE TO LURCH, PINNING AND CRUSHING THE SPOTTER BETWEEN THE FORKLIFT AND A POLE AND RESULTING IN FATAL INJURIES.

CITATION: FAILURE TO MAINTAIN CLEARANCE BETWEEN A FIXED OBJECT AND THE VEHICLE.

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Case Study # 2

NARRATIVE: AN EMPLOYEE WAS TRANSFERRING MATERIAL FROM A LOADING DOCK TRAILER TO A WAREHOUSE LOCATION WHEN THE VEHICLE WAS DRIVEN OFF THE SIDE OF THE DOCK, RESULTING IN A LATERAL TIPOVER OF THE VEHICLE AND FATAL OPERATOR INJURIES.

CITATION: FAILURE TO MAINTAIN CLEARANCE BETWEEN THE EDGE OF THE DOCK AND THE VEHICLE.

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Case Study # 3

NARRATIVE: AN EMPLOYEE WAS TRANSFERRING MATERIAL FROM A STACKED PALLET STORAGE LOCATION TO THE WAREHOUSE FLOOR. THE OPERATOR BEGAN MOVING THE VEHICLE WITH THE LOAD EXTENDED BEFORE LOWERING THE LOAD, RESULTING IN A CENTRIFUGAL OVERLOAD AND THE VEHICLE TOPPLING. THE OPERATOR WAS CRUSHED BY THE VEHICLE.

CITATION: FAILURE TO MAINTAIN VEHICULAR CONTROL

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Forklift Safety Program

ELEMENTS OF THE PROGRAM:
Written Company Safety Procedures
Employee Training
Measurement of Training Effectiveness
Measurement of Driving Proficiency
Pre-employment and regular medical examination

DW-HSE-TM045

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Forklift Safety Program

WRITTEN COMPANY SAFETY PROCEDURES:

Forklift Safety Procedure Reviewed Annually
Daily Operator Inspections Documented
Driving Training and Proficiency Documented

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Forklift Access Way

Aisles must be well-lighted and free from obstruction
Aisles must be clearly marked and of ample width
Driving surfaces must be in good condition
Pedestrian must be must be informed about the forklift access way
Regulatory signs must be prominent and enforced
Guardrails, door warning, mirrors and other obstacles
Standard precautions must be considered and installed

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Forklift Type and Designation

Forklift type to be use must be compatible with the type of environments and working conditions the vehicle will be exposed to.
Some types of Forklift configuration:

D – Diesel
E – Electrically powered
G – Gasoline
LP - Propane

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Basic Principles

Forklift Manufacturer:
Dictates specific operation of vehicle
Maintains operation and maintenance manual
Specifies maintenance requirements
Consulted concerning “attachments”
To be consulted for safety questions

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Basic Principles

OVERHEAD GUARD

MAST

CARRIAGE

BACKREST

LIFT CYLINDER

TILT CYLINDERS

FORKS

LOAD CAPACITY

6,000 lb

PROPANE ONLY

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Basic Principles

HALF-TAPERED FORKS

- USED WITH HEAVIER LOADS

FULL-TAPERED FORKS

- USED WITH LIGHTER LOADS

- USED WITH NARROW PALLETS

TYPES OF FORKS

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Basic Principles

PNEUMATIC AIR-FILLED TIRES

- USED WITH HEAVIER LOADS

- OUTDOORS OR UNEVEN SURFACES

PNEUMATIC SOLID TIRES

- PUNCTURE PROOF

- INTERCHANGED WITH AIR FILLED

AIR

SOLID RUBBER

CONSULT YOUR VEHICLE OWNERS MANUAL

TYPES OF TIRES

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Basic Principles

AUTO STEERING VS. FORKLIFT STEERING:

AUTO

FORKLIFT

TRAVEL

Front side

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Basic Principles

Swing Out

Forklift steer with rear wheels
Swing out can occur when back end of the lift truck juts out during turning and it is attributed to the unique rear-wheel steering of lift trucks

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Basic Principles

AUTO STEERING VS. FORKLIFT STEERING:

AUTO

TRAVEL

THERE IS NO “SWING OUT” WITH AN AUTOMOBILE. IN OTHER WORDS, THE VEHICLE FOLLOWS THE TURNING RADIUS OF THE FRONT WHEELS.

TURNING PRINCIPLE

PIVOT POINT

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Basic Principles

AUTO STEERING VS. FORKLIFT STEERING:

FORKLIFT

TRAVEL

THERE IS CONSIDERABLE ”SWING OUT” WITH A FORKLIFT. IN OTHER WORDS, THE VEHICLE FOLLOWS THE TURNING RADIUS OF THE REAR WHEELS.

TURNING PRINCIPLE

PIVOT POINT

SWING RADIUS

DANGER ZONE

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Basic Principles

Rated Capacity

The maximum amount of weight that can be safely lifted
How the load rests on the fork is critical
The closer the load to the backrest, the better
Can be found on the nomenclature plate of the vehicle

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Basic Principles

Operating near Pedestrians

Speed limit of 3mph
Establish eye contact when possible
Acknowledged their presence with a nod
Avoid congested pedestrian areas if possible
Panic stop distance for typical loaded truck;
1mph = 1~3 feet
10mph = 22 feet
18mph = 55 feet

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Basic Principles

PIVOT POINT

COUNTER WEIGHT

PIVOT POINT

COUNTER

WEIGHT

LIFTING PRINCIPLE

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Basic Principles

LIFTING PRINCIPLE

6,500 lb

REAL HEAVY PARTS

INCORRECT

MOVING THE LOAD AWAY FROM

THE BACKREST CAN LOWER

THE RATED CAPACITY OF THE

FORKLIFT BY HUNDREDS OF

POUNDS!

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Basic Principles

LIFTING PRINCIPLE

6,500 lb

REAL HEAVY PARTS

INCORRECT

CORRECT

6,500 lb

REAL HEAVY PARTS

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Basic Principles

CENTRIFUGAL FORCES

MOVING OR TURNING THE VEHICLE

WHEN THE LOAD IS EXTENDED CAN

RESULT IN TURNOVER BECAUSE OF

CENTRIFUGAL FORCES APPLIED AT

THE TOP OF THE LOAD!

6,500 lb

REAL HEAVY PARTS

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Basic Principles

FORK ADJUSTMENT

FORKS SHOULD BE SPREAD AS

WIDE AS POSSIBLE TO ALLOW FOR

MAXIMUM STABILITY OF THE LOAD!

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Basic Principles

Mast
Tires
Fluid levels
Hydraulic lines
Handbrake
Lift controls
Driving controls
Fire extinguishers

Roller tracks and Chains
Forks and adjustments
Cylinder mounting hardware
Lights and warning devices
Seat adjustment and belts
Lift and tilt cylinders
Overhead Guard mounting
Steering and brakes

Pre-use Inspection

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Handling and Moving Loads

Visibility during Forklift Operations

Approach the load slowly and do not “Bump”
Know where all the bystanders are located

6,500 lb

REAL HEAVY PARTS

ACME

FORKLIFTS

TRAVEL

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Handling and Moving Loads

Visibility during Forklift Operations

Never allow bystanders between you and fixed object
Know where all spotters are located
If you lose sight of a spotter, stop and find them
Assume lost spotter are in your path

ACME

FORKLIFTS

6,500lb

REAL HEAVY

PARTS

STOP

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Handling and Moving Loads

Pick-up a Load

Approach the load slowly and straight on (Load centered)
Stop when the tips of the forks are about a foot away
Level forks and adjust fork height
Move forward slowly until load is fully against backrest
Lift the load high enough to clear floor obstructions
Back the load out slightly from the storage location
Carefully tilt mast back to stabilize the load
Ensure rear is clear; move backwards

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Handling and Moving Loads

Put down a Load

Approach the unloading point straight on
Stop when the tips of the forks or side of the load are about a foot away
Lower load, carefully level forks
Move forward slowly until load is in desired location
Lower the load to floor or storage location
Ensure forks are clear of pallet
Ensure rear is clear; move backwards

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Handling and Moving Loads

Unstacking Loads

Approach the load slowly and straight on (Load centered)
Stop when the tips of the forks are about a foot away
Raise forks to desired height
Level forks and drive forward
Move forward slowly until load is fully against backrest
Lift the load high enough to clear obstructions
Ensure rear is clear; move backwards
Once the stack is cleared, lower to desired height
Carefully tilt mast back to stabilize the load

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Handling and Moving Loads

Stacking Loads

Approach the location slowly and straight on
Stop about a foot away and raise load to desired height
Drive forward until load is square over stack
Level forks and lower load until load is supported
Ensure forks are clear of pallet
Ensure rear is clear; move backwards

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Handling and Moving Loads

Stacking and racking of materials:
Setting height limits for stacks to prevent them collapsing under their own weight.

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Handling and Moving Loads

Lifting Object using pallet:

Placing goods on the pallet correctly and ensuring nothing can roll off or fall through between the slats..

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Handling and Moving Loads

Driving with a Load

Travel with the load tilted slightly back for stability
If you can’t see over the load, drive in reverse
Drive with load approximately 6 inches above surface
Pedestrians always have the Right of Way
Remember that the driving wheels are your pivot point
Obey traffic rules and local policies
Always slow down whenever attempting a turn

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Dangerous Driving Condition

Site specific problem contributes to the hazards of Forklift operations such as;

Classified Hazardous operation area (working in petrochemical, gas processing plant)
Closed environment / poorly ventilated areas
Handling hazardous substances
Potentially hazardous road and environment condition

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Dangerous Driving Condition

Unstable floor surface

Traction problems, skidding, and sliding can occur
Drive cautiously at slow speed
Be aware of debris and spills
Be aware of the other personnel working nearby
Avoid making tight turns
Ensure brakes are applied carefully

Slippery

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Dangerous Driving Condition

Overhead Clearances

Plan your route in advance
Drive cautiously at low speed
Know the mast height and facility overhead clearances
Be careful around electrical lines or any live system around the area

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Dangerous Driving Condition

Spatially Restricted areas

Consider getting out before getting in
Try moving empty forks to one side of the carriage
Use maximum turning angles
Be careful when making tight turns

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Dangerous Driving Condition

High Traffic Areas

Pedestrian consideration:
Never allow pedestrian between you and a fixed object
Pedestrians always have the Right of Way
Maintain a safe distance when loading and unloading
Be careful when making tight turns
Never assume pedestrians knows your position (get their attention)

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Dangerous Driving Condition

High Traffic Areas

Multiple Forklift consideration:
Obey all local traffic rules and signs
Know where all mirrors are positioned
Use horns when approaching corners, doorways & aisles
Never exceed the safe working speed of 5mph
Keep a safe distance from other Forklifts (3 lengths)
Pass only in authorized areas

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Dangerous Driving Condition

Uneven Driving Surfaces

Understand the type of tires installed in the vehicle
Understand the limitation of the tires
Approach railroad tracks at a 45-degree angle
Take alternate route rather than unnecessary risks
Determine if different types of vehicles are available

Uneven surface

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Dangerous Driving Condition

Loading Dock Operations

Ensure Bridge or Dock Plates are secured
Ensure Bridge or Dock Plates are rated for the vehicle
Ensure trailer, truck or railcar wheels are secured
Never accelerate on Bridge or Dock Plates
Always maintain a safe distance from edges
Never compete with pedestrians

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Dangerous Driving Condition

Trailer Operations

Ensure trailer floor is rated for the vehicle weight
Verify that the trailer floor is in serviceable condition
Ensure that the Forklift will not unbalance the trailer
Use additional trailer supports if unbalancing is a risk
Consider the interior trailer height
Ensure the trailer cannot roll away or move away from the dock
Consider lighting and inclement weather

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Dangerous Driving Condition

ALWAYS APPROACH RAMP LOAD FIRST!

LOADED FORKLIFT RAMP OPERATIONS

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Dangerous Driving Condition

ALWAYS LEAVE RAMP LOAD LAST!

LOADED FORKLIFT RAMP OPERATIONS

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Dangerous Driving Condition

ALWAYS APPROACH RAMP FORKS LAST!

UNLOADED FORKLIFT RAMP OPERATIONS

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Dangerous Driving Condition

ALWAYS LEAVE RAMP FORKS FIRST!

UNLOADED FORKLIFT RAMP OPERATIONS

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Dangerous Driving Condition

TURNOVERS

LONGITUDINAL TURNOVER

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Dangerous Driving Condition

TURNOVERS

LATERAL TURNOVER

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Dangerous Driving Condition

Spotters

Never under estimate the value of a spotter

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Summary

Forklift Operation can be done safely without endangering any personnel or causing damage to property; through the following;

Detailed Forklift Safety Procedure
Extensive Employee Training program
Periodic Reinforcement Training
Sufficient Discipline Regarding Implementation