Safe Operation of Forklifts

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SAFE OPERATION OF FORKLIFT
A TRAINING FOR THE

METALWORKING INDUSTRIES
2008 All Rights Reserved

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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

1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Total
Forklift 5 2 2 1 1 1 1 6 0 3 9 31
Motor
0 0 4 0 3 1 1 1 3 0 2 15
vehicles NEC
Others 1 0 0 0 0 0 1 2 1 0 4 9
Lorries 0 2 1 0 0 0 0 0 1 0 1 5
Trucks 0 0 2 0 0 0 0 1 0 0 1 4
Mechanical
Conveyors 0 0 0 0 1 1 `0 0 0 2 0 `4
Source: Ministry of Manpower

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Potential Forklift Accidents
Picture source: http://marbella.to/humour/sep00/forklift.jpg

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Potential Forklift Accidents
Picture source: http://www.facelift.co.uk/images/roguesgallery/forklift_no-no1.jpg

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Forklift Accidents
Picture source: http://siri.uvm.edu/graphics/Industrial_Operations/Forklift_accident.gif

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Forklift Accidents
Picture source: http://www.jicosh.gr.jp/english/cases/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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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/fork-lift-trucks/images/fork2.jpg

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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/images/96nj062.jpg

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Pedestrians and forklift moving in

same place
Picture source: http://www.safetyworld.com/images/67.gif

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Forklift traveling on slope
Picture source: http://www.sandhillquilting.com/images/M-16-SYS-8436-L.jpg

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Poor ground conditions
Picture source: http://eternitycaptured.com/blog/wp-

content/uploads/2007/04/bigstockphoto_Road_Cracks_And_Potholes_606173.jpg

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Worn out tyres
Picture source: http://www.riverina.coop/depts/Realestate/Other/forsale_auctions/whybro/RIMG2040.JPG

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Unsecured load
Picture source: http://www.locknpop.com/images/img_fork.gif

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Electric shock
from battery
Picture source: http://www.ubuyme.com/img_prod/679/pic1.jpg

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Lifting Persons
on Forks
Picture source: http://www.ttt-services.co.uk/Healthandsaftey/forklift_web.jpgc

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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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Severity
Minor Moderate Major
Likelihood
Remote Low Low Medium
Occasional Low Medium High
Frequent Medium High High

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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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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

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Designated Battery and Parking Area
Forklift battery
charging and
parking area

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2nd Guard the Remaining Hazards: Protective Barriers
Brightly
coloured
barriers

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3rd Mitigate impact of hazard (E.g. Operator to wear an

seat belt)

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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

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

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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.html

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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/forklift-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

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Pre-operation Checks 4 Yard Forklift

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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/product_desc_images/forklifts/load-chart.jpg

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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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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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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/TechnologyCentre/forkliftweigh.html

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Load Assessments Weight at Centre of Gravity
Forklift
Picture source: http://www.morsemfgco.com/images/forklift_sm.gif

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Picture source: http://www.rentrain.com/resources/fork_21.gif

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Picture source: http://www.ccohs.ca/images/J05-2.gif

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Load Assessments Characteristics
Picture source: http://www.thetoyspace.com/images/planforklift.gif
Unstable load
Picture source: http://user1292213.sites.myregisteredsite.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/FORKLIFT%20II.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/About/PhotoGallery/North_Quay_forklift_operations_at_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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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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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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Slow down and sound the horn at crossings and locationswhere 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/posters/2003/ha0313_forklift.htm

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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/cabfront.jpg

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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/fork-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_Images/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:
1. WSHAC Occupational Safety & Health Technical Advisory Safe

Operation of Forklift Truck
2. WSHAC Forklift Safety Checklist
3. CP: 101: 2004 Code of Practice for Safe Use of Powered
Counterbalanced Forklifts
4. MOM Case Studies on Forklift Accidents
5. NIOSH Publication No. 2001-109 NIOSH Alert: Preventing Injuries
and Deaths of Workers Who Operate or Work Near Forklifts
6. Chisholm Institute (Warehouse Task Drive a forklift)
(http://olvc.chisholm.vic.edu.au/warehouse/D10/Virtualwa
rehouse/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

Safe Operation of Forklifts

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1

SAFE OPERATION OF FORKLIFT

A TRAINING FOR THE

2008 All Rights Reserved

Risk management on forklift

Common forklift hazards

Training for forklift operators

Common safe practices

Forklift traffic control

2008 All Rights Reserved

Forklift can be hazardous if not handled properly

Forklift accidents can cause serious injury, death,

This poses a serious problem

Accidents can be prevented if risk assessment and safe

Picture source: http://www.thompsonandjohnson.com/images/accident1.jpg

2008 All Rights Reserved

Forklift Fatalities in Singapore

Source: Ministry of Manpower

2008 All Rights Reserved

Potential Forklift Accidents

Picture source: http://marbella.to/humour/sep00/forklift.jpg

2008 All Rights Reserved

Potential Forklift Accidents

Picture source: http://www.facelift.co.uk/images/roguesgallery/forklift_no-no1.jpg

2008 All Rights Reserved

Picture source: http://siri.uvm.edu/graphics/Industrial_Operations/Forklift_accident.gif

2008 All Rights Reserved

Picture source: http://www.jicosh.gr.jp/english/cases/cases/case105.gif

2008 All Rights Reserved

Picture source: European Industrial Gases Association

2008 All Rights Reserved

Risk Management on Operation of Forklift

Required to manage risks under WSH (risk management)

Assess the risk

Take all reasonably practical steps

Eliminate any risks

2008 All Rights Reserved

Risk Management on Operation of Forklift

Step 1: Identification of hazard

Picture source: http://www.safetyworld.com/images/101.gif

2008 All Rights Reserved

Common Forklift Hazards

Unauthorized operation of forklift

Untrained forklift operators

Picture source: http://www.iqsdirectory.com/info/fork-lift-trucks/images/fork2.jpg

2008 All Rights Reserved

Common Forklift Hazards

Pedestrians and forklifts moving in the same place

Obstruction in the path e.g. overhead, blind corners

Poor ground conditions e.g. slippery, uneven, potholes

2008 All Rights Reserved

Common Forklift Hazards Source: Ministry of Manpower

Body/limbs caught in moving parts of the forklift

Poor condition tyres e.g. without thread markings

Electric Shock (Battery operated forklift)

Picture source: http://www.cdc.gov/niosh/face/images/96nj062.jpg

2008 All Rights Reserved

Common Forklift Hazards

Pedestrians and forklift moving in

Picture source: http://www.safetyworld.com/images/67.gif

2008 All Rights Reserved

Common Forklift Hazards

Forklift traveling on slope

Picture source: http://www.sandhillquilting.com/images/M-16-SYS-8436-L.jpg