Forklift Safety: Osha Training

NWACC Business & Industry
Workforce Development Institute

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OSHA 29CFR 1910.178
FORKLIFT SAFETY
OSHA TRAINING
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29CFR - SAFETY AND HEALTH STANDARDS

1910 - GENERAL INDUSTRY

178 - POWERED INDUSTRIAL TRUCKS
REGULATORY STANDARD
POWERED INDUSTRIAL TRUCKS
29CFR - 1910 - 178
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FORKLIFT INJURY STATISTICS
INATTENTION

DISTRACTION

EXCESSIVE SPEED

POOR DRIVING HABITS

LACK OF TRAINING
APPROXIMATELY 34,000 RELATED INJ URIES A YEAR:
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
6500lbs
REAL
HEAVY
PARTS
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CIRCUMSTANCES OF INJURY
OVERLOADING CAUSING THE VEHICLE TO TURNOVER

LOAD INSTABILITY CAUSING TURNOVER

OBSTRUCTIONS IN THE PATH OF TRAVEL OR LIFT

USING FORKLIFT OUTSIDE OF DESIGN LIMITATIONS

STRIKING A PEDESTRIAN
HOW MOST INJ URIES OCCUR
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CASE STUDY #1
CRUSHED AGAINST A STEEL POLE
CITATION: FAILURE TO MAINTAIN CLEARANCE BETWEEN A FIXED
OBJECT AND THE VEHICLE.
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 RESULTING IN FATAL INJURIES.
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CASE STUDY #2
KILLED BY TOPPLED FORKLIFT
CITATION: FAILURE TO MAINTAIN CLEARANCE BETWEEN THE EDGE
OF THE DOCK AND THE VEHICLE.
NARRATIVE: AN EMPLOYEE WAS TRANSFERRING MATERIAL FROM
A LOADING DOCK TRAILER TO A WAREHOUSE
LOCATION WHEN THE VEHICLE WAS DRIVEN OFF OF
THE SIDE OF THE DOCK RESULTING IN A LATERAL
TIPOVER OF THE VEHICLE AND FATAL OPERATOR
INJURIES.
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CASE STUDY #3
KILLED BY TOPPLED FORKLIFT
CITATION: FAILURE TO MAINTAIN VEHICULAR CONTROL
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 TOPPLING. THE
OPERATOR WAS CRUSHED BY THE VEHICLE.
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TRAINING REQUIREMENTS
CLASSROOM TRAINING COVERING SAFETY RULES

BASIC MATERIAL-HANDLING TECHNIQUES

BASIC OPERATING TECHNIQUES

DRIVERS PERFORMANCE TEST
OPERATORS MUST RECEIVE:
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
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REQUIRED WHEN THERE IS A:

CHANGE IN VEHICLES AND HANDLING EQUIPMENT

CLOSE-CALL EVENT

FAILURE IN THE SAFETY PROCEDURES

REASON TO DOUBT EMPLOYEE PROFICIENCY
RETRAINING REQUIREMENTS
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
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FORKLIFT SAFETY PROGRAM
1. WRITTEN COMPANY SAFETY PROCEDURES

2. EMPLOYEE TRAINING

3. DRIVING PROFICIENCY
THREE ELEMENTS TO THE PROGRAM:
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
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FORKLIFT SAFETY PROGRAM
1. COMPANY FORKLIFT POLICY REVIEWED ANNUALLY

2. DAILY OPERATOR INSPECTIONS DOCUMENTED

3. DRIVING TRAINING AND PROFICIENCY DOCUMENTED
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
WRITTEN COMPANY SAFETY PROCEDURES
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BASIC FORKLIFT PRINCIPLES
FORKLIFT MANUFACTURER:

DICTATES SPECIFIC OPERATION OF VEHICLE

SPECIFIES MAINTENANCE REQUIREMENTS

CONSULTED CONCERNING ADD-ONs

FIRST CHOICE FOR SAFETY QUESTIONS
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OVERHEAD GUARD

MAST

CARRIAGE

BACKREST

LIFT CYLINDER

TILT CYLINDERS

FORKS
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
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THE RATED CAPACITY:

THE MAXIMUM AMOUNT OF WEIGHT THAT CAN BE SAFELY LIFTED

HOW THE LOAD RESTS ON THE FORKS IS CRITICAL

THE CLOSER THE LOAD IS TO THE BACKREST THE BETTER

CAN BE FOUND ON THE NOMENCLATURE PLATE OF THE VEHICLE
THE RATED CAPACITY
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PIVOT POINT
COUNTER WEIGHT
PIVOT POINT
COUNTER
WEIGHT
LIFTING PRINCIPLE
CONSULT YOUR VEHICLE OWNERS MANUAL
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LIFTING PRINCIPLE
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
6500lbs
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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LIFTING PRINCIPLE
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
6500lbs
REAL HEAVY PARTS
INCORRECT
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
CORRECT
6500lbs
REAL HEAVY PARTS
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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!
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
6500lbs
REAL HEAVY PARTS
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FORKLIFT OPERATING PRINCIPLES
PRE-USE INSPECTION

MAST

ROLLER TRACKS AND CHAINS

FORKS AND ADJUSTMENT

FLUID LEVELS

HYDRAULIC LINES

LIFT AND TILT CYLINDERS

OVERHEAD GUARD MOUNTING

FIRE EXTINGUISHER

CYLINDER MOUNTING HARDWARE

TIRES

LIGHTS AND WARNING DEVICES

HANDBRAKE

STEERING AND BRAKES

DRIVING CONTROLS

LIFT CONTROLS

SEAT ADJUSTMENT AND BELTS
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TYPES OF POWER SOURCES

BATTERY POWERED

PROPANE POWERED

DIESEL POWERED

GASOLINE POWERED
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INSPECTION OF POWER SOURCES

BATTERY POWERED

- REQUIRES CONSTANT CHARGING

- NO IGNITION SOURCES IN CHARGING AREA

- FOLLOW LOCAL CHARGING PROCEDURES
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PROPANE POWER

- INSPECT TANK FOR SERVICEABILITY

- INSPECT PROPANE TRANSFER SYSTEM

- INSPECT TANK RESTRAINT SYSTEM

- FOLLOW LOCAL REPLACEMENT PROCEDURES
INSPECTION OF POWER SOURCES
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DANGEROUS DRIVING CONDITIONS
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
6500lbs
REAL HEAVY PARTS
ALWAYS APPROACH RAMP LOAD FIRST!
LOADED FORKLIFT RAMP OPERATIONS
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LOADED FORKLIFT RAMP OPERATIONS
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
6500lbs
REAL HEAVY PARTS
ALWAYS LEAVE RAMP LOAD LAST!
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UNLOADED FORKLIFT RAMP OPERATIONS
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
ALWAYS APPROACH A RAMP FORKS LAST!
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UNLOADED FORKLIFT RAMP OPERATIONS
ACME FORKLIFTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
ALWAYS LEAVE A RAMP FORKS FIRST!
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1. DEVELOP AND STRICTLY ADHERE TO SAFETY PROCEDURES.

2. ESTABLISH AND ENFORCE SAFE WORK PRACTICES.

3. ENSURE PROPER TRAINING AND SUPERVISION.

4. STRENGTHEN AND MODIFY PRESENT POLICIES.

5. UNDERSTAND THE RELATIONSHIP BETWEEN 29 CFR 1910.178
AND THE BUSINESS OR INDUSTRY INVOLVED.
KEY ELEMENTS TO AN EFFECTIVE PROGRAM
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OSHA'S PERCEPTION
OF A SUCCESSFUL PROGRAM
1. DETAILED FORKLIFT SAFETY PROCEDURES

2. EXTENSIVE EMPLOYEE TRAINING PROGRAMS

3. PERIODIC REINFORCEMENT OF TRAINING

4. SUFFICIENT DISCIPLINE REGARDING IMPLEMENTATION

Forklift Safety: Osha Training

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Workforce Development Institute

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