Safe Operation of Forklift

1. SAFE OPERATION OF FORKLIFTSAFE OPERATION OF FORKLIFT
A TRAINING FOR THE
METALWORKING INDUSTRIES
 Updated on June 2015

2. Table of ContentsTable of Contents
 Introduction
 Risk management on forklift
 Common forklift hazards
 Route plan
 Training for forklift operators
 Pre-operation checks
 Load assessments
 Common safe practices

3. IntroductionIntroduction
 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.jpgPicture source: http://www.thompsonandjohnson.com/images/accident1.jpg

4. Forklift Fatalities in SingaporeForklift Fatalities in Singapore
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
Tota
l
Forklift 5 2 2 1 1 1 1 6 0 3 9 31
Motor
vehicles NEC
0 0 4 0 3 1 1 1 3 0 2 15
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 ManpowerSource: Ministry of Manpower

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

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

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

8. Forklift AccidentsForklift Accidents
Picture source: http://www.jicosh.gr.jp/english/cases/cases/case105.gifPicture source: http://www.jicosh.gr.jp/english/cases/cases/case105.gif

9. Forklift AccidentsForklift Accidents
Picture source: European Industrial Gases AssociationPicture source: European Industrial Gases Association

10. Risk Management on Operation ofRisk Management on Operation of
ForkliftForklift
 Required to manage risks under WSH (risk management)
regulations
 Assess the risk
 Take all reasonably practical steps
 Eliminate any risks

11. Risk Management on Operation ofRisk Management on Operation of
ForkliftForklift
 Step 1: Identification of hazard
Picture source: http://www.safetyworld.com/images/101.gifPicture source: http://www.safetyworld.com/images/101.gif

12. Common Forklift HazardsCommon 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.jpgPicture source: http://www.iqsdirectory.com/info/fork-lift-trucks/images/fork2.jpg

13. Common Forklift HazardsCommon 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

14. Common Forklift HazardsCommon Forklift Hazards
 Body/limbs caught in moving parts of the forklift
 Falling loads
 Poor condition tyres e.g. without thread markings
 Electric Shock (Battery operated forklift)
Source: Ministry of ManpowerSource: Ministry of Manpower
Picture source: http://www.cdc.gov/niosh/face/images/96nj062.jpgPicture source: http://www.cdc.gov/niosh/face/images/96nj062.jpg

15. Common Forklift HazardsCommon Forklift Hazards
Pedestrians and forklift moving in
same place
Picture source: http://www.safetyworld.com/images/67.gifPicture source: http://www.safetyworld.com/images/67.gif

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

17. Common Forklift HazardsCommon Forklift Hazards
Poor ground conditions
Picture source: http://eternitycaptured.com/blog/wp-Picture source: http://eternitycaptured.com/blog/wp-
content/uploads/2007/04/bigstockphoto_Road_Cracks_And_Potholes_606173.jpgcontent/uploads/2007/04/bigstockphoto_Road_Cracks_And_Potholes_606173.jpg

18. Common Forklift HazardsCommon Forklift Hazards
Worn out tyres
Picture source: http://www.riverina.coop/depts/Realestate/Other/forsale_auctions/whybro/RIMG2040.JPGPicture source: http://www.riverina.coop/depts/Realestate/Other/forsale_auctions/whybro/RIMG2040.JPG

19. Common Forklift HazardsCommon Forklift Hazards
Unsecured load
Picture source: http://www.locknpop.com/images/img_fork.gifPicture source: http://www.locknpop.com/images/img_fork.gif

20. Common Forklift HazardsCommon Forklift Hazards
Electric shock
from battery
Picture source: http://www.ubuyme.com/img_prod/679/pic1.jpgPicture source: http://www.ubuyme.com/img_prod/679/pic1.jpg

21. Common Forklift HazardsCommon Forklift Hazards
Lifting Persons
on Forks
Picture source: http://www.ttt-services.co.uk/Healthandsaftey/forklift_web.jpgcPicture source: http://www.ttt-services.co.uk/Healthandsaftey/forklift_web.jpgc

22. Risk Management on Operation ofRisk Management on Operation of
ForkliftForklift
 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

23. Risk Management on Operation ofRisk Management on Operation of
ForkliftForklift
Rare
(1)
Remote
(2)
Occasional
(3)
Frequent
(4)
Almost
Certain
(5)
Catastrophic (A) Medium Medium High High High
Major (B) Medium Medium Medium High High
Moderate (C) Low Medium Medium Medium High
Minor (D) Low Medium Medium Medium Medium
Negligible (E) Low Low Low Medium Medium

24. Risk Management on Operation ofRisk Management on Operation of
ForkliftForklift
 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)

25. Risk Management on Operation ofRisk Management on Operation of
ForkliftForklift
HIERARCHY OF HAZARDS CONTROL

26. 11stst
Remove the Hazards –Remove the Hazards –
Forklift Route PlanningForklift Route Planning
Picture source: http://maaw.info/images/Figure8-10.gifPicture source: http://maaw.info/images/Figure8-10.gif

27. Route PlanRoute 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

28. Forklift Operation Separated fromForklift Operation Separated from
Worker AreaWorker Area
Forklift
operation area
Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc

29. Allocated Goods AreaAllocated Goods Area
Goods sitting
area
Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc

30. Designated Battery and Parking AreaDesignated Battery and Parking Area
Forklift battery
charging and
parking area
Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc

31. 22ndnd
Guard the Remaining Hazards:Guard the Remaining Hazards:
Protective BarriersProtective Barriers
Brightly
coloured
barriers
Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc

32. Risk Management on Operation ofRisk Management on Operation of
ForkliftForklift
 3rd
– Mitigate impact of hazard (E.g. Operator to wear an
seat belt)
Source:Source: Ministry of Manpower

33. Risk Management on Operation ofRisk Management on Operation of
ForkliftForklift
 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:Source: Ministry of Manpower

34. Risk Management on Operation ofRisk Management on Operation of
ForkliftForklift
 Forklift Safe Work Procedures (SWP)
 Forklift TrainingForklift Training
 Pre-Operation CheckPre-Operation Check
 Load AssessmentLoad Assessment
 Common Safe PracticeCommon Safe Practice
 Traffic ControlTraffic Control
Source:Source: Ministry of Manpower

35. Forklift TrainingForklift 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

36. Why Conduct Forklift TrainingWhy 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.htmlPicture source: http://www.crowndfw.com/training.html

37. Why Conduct Pre-operation Checks?Why Conduct Pre-operation Checks?
 Ensure efficient and safe operation of forklifts
 Prevent workplace injuries
 To remove inefficient forklift practices

38. Under WSHAC Forklift Checklist, Pre-Under WSHAC Forklift Checklist, Pre-
operation Checks Includes: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

39. Pre-operation Checks 1Pre-operation Checks 1
Source : http://www.thefabricator.com/Images/96/forklift-truck-diagram.jpgSource : http://www.thefabricator.com/Images/96/forklift-truck-diagram.jpg

40. Pre-operation Checks 2 – PropanePre-operation Checks 2 – Propane
ForkliftForklift
Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gifPicture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif

41. Pre-operation Checks 3 – ElectricPre-operation Checks 3 – Electric
ForkliftForklift
Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gifPicture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif

42. Pre-operation Checks 4 – YardPre-operation Checks 4 – Yard
ForkliftForklift
Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gifPicture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif

43. Forklift Load Assessments 1Forklift Load Assessments 1
• Forklift can only handle loads within rated capacity
• Follow forklift manufacturer’s load chart
Forklift Model
Length of fork
Picture source : http://gmesupply.com/images/product_desc_images/forklifts/load-chart.jpgPicture source : http://gmesupply.com/images/product_desc_images/forklifts/load-chart.jpg

44. Forklift Load Assessments 1Forklift 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.auPicture source : http://www.kinggroup.com.au

45. Forklift Load Assessments 1Forklift Load Assessments 1
• Don’t increase the capacity of the forklift using personnel
as additional counterweights
Picture source : http://www.staugustinelighthouse.com/blog/forklift.jpgPicture source : http://www.staugustinelighthouse.com/blog/forklift.jpg

46. Forklift Load Assessments 2Forklift Load Assessments 2
• Only handle stable or safely
arranged loads
• Care to be taken when handling
extra long or high load
• When loads can’t be centered,
the forklift should be operated
with caution
Picture source: http://www.baileypottery.comPicture source: http://www.baileypottery.com
Source: CP 101: 2004 Code of practice for safe use of powered counterbalanced forkliftsSource: CP 101: 2004 Code of practice for safe use of powered counterbalanced forklifts

47. Load Assessments – Weighing theLoad Assessments – Weighing the
LoadLoad
Picture source: http://www.weighing-systems.com/TechnologyCentre/forkliftweigh.htmlPicture source: http://www.weighing-systems.com/TechnologyCentre/forkliftweigh.html

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

49. Load Assessments – Weight at CentreLoad Assessments – Weight at Centre
of Gravityof Gravity
Picture source:Picture source: http://www.rentrain.com/resources/fork_21.gif

50. Load Assessments – Weight at CentreLoad Assessments – Weight at Centre
of Gravityof Gravity
Picture source: http://www.ccohs.ca/images/J05-2.gifPicture source: http://www.ccohs.ca/images/J05-2.gif

51. Load Assessments – CharacteristicsLoad Assessments – Characteristics
Unstable load
Picture source:Picture source: http://www.thetoyspace.com/images/planforklift.gif
Picture source: http://user1292213.sites.myregisteredsite.com/sitebuildercontent/sitebuilderpictures/forklift.gifPicture source: http://user1292213.sites.myregisteredsite.com/sitebuildercontent/sitebuilderpictures/forklift.gif

52. Load Assessments – ShapeLoad Assessments – Shape
Odd shape load
may hit
pedestrians
causing injuries
Picture source: http://www.nepowder.com/images/FORKLIFT%20II.JPGPicture source: http://www.nepowder.com/images/FORKLIFT%20II.JPG

53. Load Assessments – ShapeLoad Assessments – Shape
View blocked, the
forklift may hit
another container
or somebody
Picture source:Picture source:
http://www.fremantleports.com.au/About/PhotoGallery/North_Quay_forklift_operations_at_night_rdax_772x526.jpghttp://www.fremantleports.com.au/About/PhotoGallery/North_Quay_forklift_operations_at_night_rdax_772x526.jpg

54. Common Safe PracticesCommon Safe Practices
Don’t drive a forklift unless you are trained and authorized
Use seatbelts
Wearing
seatbelts

55. Common Safe PracticesCommon Safe Practices
Report to your supervisor on any forklift damage or problems
Don’t use a forklift to lift worker
Use caution on slopes or ramps
Picture source: http://www.liftomatic.comPicture source: http://www.liftomatic.com

56. Common Safe PracticesCommon Safe Practices
While on slopes, tilt the load back and raise it above road surface
Don’t raise or lower the forks while the forklift is moving
Don’t handle loads that are above the weight capacity of
the forklift
Follow the speed limit

57. Common Safe PracticesCommon 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:Source: NIOSH Publication No. 2001-109
Hand brake not engaged
Picture source:Picture source: http://www2.worksafebc.com/i/posters/2003/ha0313_forklift.htm

58. Common Safe PracticesCommon 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:Picture source: http://www.safety-mirrors.co.uk/cabfront.jpg

59. Common Safe PracticesCommon Safe Practices
Operate forklifts with forks at low position
at all times
Don’t drive and raise load at the same time
Don’t make sudden sharp turns
Don’t brake suddenly when the forklift is
loaded
Watch out for overhead structures (e.g.
pipes & beams)
Travel in reverse when front view is blocked
Source:Source: Ministry of Manpower
Picture source:Picture source: http://www.iqsdirectory.com/info/fork-lift-trucks/images/fork1.jpg

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

61. Traffic ControlsTraffic 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.jpgPicture source: http://www.derrycity.gov.uk/Site_Images/forklift.jpg

62. Traffic ControlsTraffic 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.jpgPicture source: http://www.thompsonandjohnson.com/newsletter/images/tip70509.jpg

63. Summary of Key PointsSummary 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

64. All accidents are preventableAll accidents are preventable
Be proactive: it is up to US toBe proactive: it is up to US to
prevent itprevent it

65. Thank YouThank You

66. References: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)

67. Appendix 1Appendix 1

68. Appendix 1Appendix 1

69. Appendix 1Appendix 1

70. Appendix 2Appendix 2

71. AppendixAppendix