Plumb Safety: Best Practices for Forklift Safety

Best Practices for Forklift Safety

Forklift accidents rank consistently among the most common claims we see each year at PLM. While most are small in nature, every now and then, a forklift accident can create serious injuries—even fatalities—and multi-million dollars’ worth of damage. And that doesn’t even include the additional negative impacts that a mishap can have on a business’ reputation.

Here are some best practices for forklift safety that your clients can implement in their operations to better protect themselves, their people, and their business.

1. Institute a formal forklift training program. It should combine classroom and practical training. Document your program so it is repeatable and consistent. Make sure it includes:

• Processes for daily pre-operational forklift inspections. These can include checking the brakes, tires, steering, battery charge level, warning lights and other key items.
• Procedures for near-miss and post-accident investigation. Spell out how you will conduct each type of incident review and how you will take steps to avoid similar incidents in the future.

2. Get your drivers certified. All forklift drivers must be trained and certified on each piece of equipment they operate. If your shop includes both counterbalanced and truck-mounted forklifts, your drivers will need separate certifications for each one. The same is true if you have a mix of propane-powered and gas-powered forklifts.
3. Keep driver certifications up-to-date. Certify forklift operators at hire and then once every three years. Do not take a driver’s word for it if they just joined your company and say they got certified at their prior workplace. Supervisors need to certify that they have personally trained and observed every driver operating in a safe manner at their place of business.
4. Integrate forklift safety into your regular processes. Does your shop have regular toolbox talks or Monday morning meetings? If so, then make forklift safety a regular topic of discussion. Offer refresher training and remind everyone in your yard how dangerous forklifts can be.
5. Provide in-the-moment feedback. If you see any unsafe acts—such as three people riding on a forklift—address them as soon as they happen. This top-of-mind training reinforces the importance of safe behaviors and prevents future incidents.
6. Always use a spotter. Spotters are not just for big box stores or large warehouses. Every yard should use them. They help to keep loading and unloading zones clear of pedestrian and customer traffic. Spotters also allow forklift operators to focus on driving and balancing their load while someone else watches for passersby.
7. Know where truck drivers are at all times. When loading and unloading vehicles, forklift operators should stay aware of the truck drivers’ location. The only safe spaces for a truck driver to stand are far away from the vehicle or next to the wheel of their cab. It is not safe to stand on the opposite side of where you’re loading.
8. Create a designated forklift area. As space permits, set aside a dedicated loading and unloading zone. Keep customers and other unauthorized personnel out of the area to enhance safety.
9. Prohibit forklifts from passing each other. If space permits, implement a one-way traffic pattern—such as forklifts only going clockwise around the yard—to prevent forklifts from crossing paths. Use floor markings to designate traffic lanes and safe pedestrian walkways.
10. Ban headphones and hoodies. Forklift operators wearing headphones won’t hear others urging them to stop in an unsafe situation. Hoodies, meanwhile, can block a driver’s peripheral vision, creating dangerous blind spots.
11. Look over your shoulder—always. Although many forklifts have mirrors today, it remains a best practice for drivers to look over their shoulder while backing up. This will ensure that the area behind you is clear.
12. Empower your operators. Let your drivers know they should stop whenever they feel unsafe. If a customer won’t get out of a loading zone, encourage drivers to ask a manager for help in clearing the area.

Driving a forklift is a repetitive activity, and when one does the same thing over and over, they are bound to make mistakes. By encouraging your clients to institute these best practices in their business, they’ll keep safety top of mind for their employees and reduce their forklift-related risks significantly.