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    Forklift Safety: Training, Maintenance, Facility Tips

     

    Every year in the United States, there are more than 100,000 forklift-related accidents. Proper transportation management and warehouse safety protocols are essential to reducing these incidents.

    According to statistics provided by OSHA, 34% of these accidents lead to an injury. Out of that, about 100 workers per year are fatally injured due to a forklift accident.

    While forklifts appear to be straightforward machines to operate, they can be quite tricky to maneuver in tight confines that you may find along aisles in warehouses.

    If you operate a warehouse or distribution center, it might be a good idea to review some of these forklift best practices, to ensure your people stay safe, you reduce the potential of damaging merchandise, and control operational costs associated with these types of tragic accidents. In this blog post, we'll cover three critical areas: maintenance programs, driver training, and facility maintenance.

    Follow Recommended Maintenance Programs

    Like any other mechanical piece of equipment, a forklift has multiple moving parts that need servicing, replacement, and maintenance on a routine basis. There are numerous types of forklifts; all with unique components. As such, there is no universal maintenance program for all forklifts.

    There are a few general rules that all forklift equipment owners and users should follow to ensure the safe and efficient repairs and service for the forklifts they use.

    Contact the forklift manufacturer

    Each forklift sold in the US is required to provide the original customer with a service and user manual. This manual documents when to complete routine services. If you are curious about what and when service is due for your forklift, contact the manufacturer of your forklift directly to request a detailed service and maintenance manual.

    Contact a certified forklift service company

    If you have an older forklift made by a company that is no longer in service, an accredited forklift service company is your next best option. Typically forklifts require a service check-up every 90-days or 100-operating hours.

    Don't wait until something is broke

    While many warehouse and distribution center operators roll their eyes at the thought of another monthly bill – the minimal cost of correctly servicing a forklift much less than the cost of a worker's compensation claim or damaged goods.

    Be Proactive with Driver Training

    Most forklift-related fatalities are due to human error, especially new or poorly trained operators. Therefore, the efficient operation and training of those who operate forklifts is arguably the best way to reduce accidents.

    Noted below are a few of OSHA's recommendations for forklift driver training.

    Driver training

    A detailed training program for any driver should be created – not just for new drivers, but to renew a driver's license every year.

    Ensure all forklifts have functional restraints for drivers

    A forklift must have a set of driver restraints, whether they operate a seated or standing forklift. In the case of a rollover, staying inside the forklift's "cage" can mean the difference between life and death.

    Create a training and vehicle inspection program

    Anyone who operates a forklift needs to know how these heavy pieces of equipment work. OSHA recommends creating an inspection program that an operator should complete before operating one.

    Make sure all drivers are aware of weight and height limitations

    This is typically notated on all forklifts but is not commonly enforced. All forklift operators must be mindful of the weight and height of freight for max load capability of any equipment they operate.

    Facility Maintenance

    Forklift safety is also dependent upon the condition of the facility. Broader warehouse safety issues like cracked concrete or unlevel asphalt are another leading cause of several forklift accidents. To reduce the potential of a forklift accident, make sure to follow these facility best practices.

    Create lanes of operation

    This rule is specifically for foot traffic. If you can avoid the interaction of people with a forklift — whether through physical lanes or AGV systems — you can reduce the potential for disaster.

    Clean up spills or wet spots ASAP

    If a spill happens, make sure to take time to clean up the spill, to maintain traction for heavy forklifts.

    Repair cracks in concrete and asphalt

    Along with keeping the surfaces free of debris, repairing cracks in the road is critical for optimal forklift safety.

    Enforce a Speed Limit

    According to OSHA, a forklift operating with a full load traveling 10 miles per hour will require 40 feet to come to a complete stop. That's the primary reason why most warehouse operators enforce a strict three mph speed limit. Moreover, this typically applies to the operation of any forklift – loaded or unloaded.

    Final Thoughts

    Nobody wants to be that person who must call a family member of an employee after a tragic accident occurs. Following these three best practices for forklifts can significantly reduce the potential of an accident. However, it is highly recommended that you contact OSHA and the forklift manufacturer to receive their official standards for vehicle maintenance, location safety, and driver training.

    Being proactive about forklift service, training, and safety procedures can save a life.

    FAQs

    What are the most important forklift safety practices for a warehouse?

    The most important forklift safety practices are following a maintenance schedule, training operators thoroughly, and keeping the facility in safe condition. Those three areas help reduce injuries, prevent damage to merchandise, and lower the cost of accidents. In practice, that means servicing equipment regularly, making sure drivers know the limits of the machine, and keeping aisles, floors, and traffic patterns safe.

    How often should a forklift be serviced or inspected?

    A forklift should be checked on a routine schedule, and the article notes that many service programs call for a check-up every 90 days or 100 operating hours. The exact interval depends on the manufacturer and the specific model. If the original manufacturer is unavailable, a certified forklift service company is the next best option for maintenance guidance.

    Why is forklift operator training so important?

    Forklift operator training is critical because most forklift fatalities are caused by human error, especially among new or poorly trained operators. A strong training program helps drivers understand how the equipment works, how to inspect it before use, and how to stay within weight and height limits. Annual renewal training is also recommended to keep skills current.

    What should be included in a forklift driver inspection program?

    A forklift driver inspection program should require operators to inspect the vehicle before use and verify that it is safe to operate. It should also cover equipment controls, driver restraints, and basic operating limits such as load weight and lift height. OSHA recommends pairing training with inspection procedures so operators know how the machine should perform before they start work.

    What warehouse conditions create the biggest forklift safety risks?

    The biggest facility-related forklift safety risks are foot traffic near equipment, spilled liquids, cracked concrete, unlevel asphalt, debris, and poor traffic control. Safe warehouses reduce those risks by creating lanes of operation, cleaning spills quickly, repairing damaged surfaces, and keeping people separated from forklift routes whenever possible. Good floor condition and clear travel paths make a major difference.

    Why do warehouses enforce a three mph forklift speed limit?

    Warehouses often enforce a three mph forklift speed limit because stopping distance increases quickly with a loaded machine. The article notes that a forklift carrying a full load at 10 miles per hour needs about 40 feet to come to a complete stop. Slower speeds give operators more control and reduce the chance of collisions in tight warehouse aisles.

    Do forklifts need seat belts or other driver restraints?

    Yes, forklifts should have functional driver restraints whether the operator sits or stands. In a rollover, staying inside the forklift’s protective area can be the difference between life and death. Proper restraints are a basic part of forklift safety because they help protect the operator during sudden incidents or tip-overs.