Guidelines for Forklift Operator Safety Training

Importance

Forklift operations are crucial to many industries, from warehouses and manufacturing plants to construction sites. However, the statistics reveal significant risks.

In New South Wales alone, from 2017 to 2022, there were 1,538 forklift-related incidents—a number that highlights the potential dangers. In the United States, data from the US Bureau of Labor Statistics shows that between 2011 and 2017, 614 workers died in forklift incidents, with more than 7,000 nonfatal injuries annually leading to workdays lost.

Forklift injuries can be significantly reduced through comprehensive training programs. Below are more reasons investing in it is essential:

Complying with Legal Requirements

Businesses must comply with various legal requirements regarding forklift operations. The laws related to forklift operator safety training are primarily governed by the Occupational Safety and Health Administration (OSHA) and the Canadian Standards Association (CSA). These standards mandate that operators undergo proper training and certification.

Enhancing Operational Efficiency

Properly trained forklift operators can perform their duties more efficiently. They can handle the equipment better, leading to smoother operations, reduced downtime, and fewer mistakes. This efficiency translates to higher productivity and cost savings for the business.

Reducing Equipment Damage and Maintenance Costs

Training operators on the correct use of forklifts minimizes equipment damage. Operators learn how to handle the machinery properly, reducing wear and tear. This proactive approach lowers maintenance costs and extends the lifespan of the equipment.

Building Operator Confidence

Forklift safety training not only enhances skills but also builds confidence in operators. When they have the necessary knowledge and skills, they feel more comfortable operating the equipment.

Who is Responsible for Forklift Operator Safety Training?

Here are the parties responsible for forklift operator training:

Employers

There is no single, certified body that conducts forklift operator training. Instead, employers are responsible for ensuring that their employees receive proper training and evaluation to operate forklifts safely. They either provide the necessary training internally, hire qualified trainers, or arrange for employees to attend certified training programs.

Supervisors and Safety Managers

Supervisors and safety managers play a crucial role in ensuring forklift operator safety. They are responsible for ongoing monitoring of forklift operations, identifying potential hazards, and taking corrective actions when necessary.

Safety Officers

Safety officers conduct risk assessments to identify potential risks and implement measures to mitigate them. They develop tailored training programs to address specific hazards related to forklift operations.

Components of Effective Forklift Operator Safety Training

Forklift operator safety training should have these key components to be effective:

Formal Learning

This foundational component focuses on teaching the fundamental principles of forklift operation, either online or in-person, covering:

• Anatomy and Mechanics
• Regulations and Standards, such as OSHA guidelines in the US or Work Health and Safety (WHS) standards in Australia.
• Hazard Identification and Prevention
• Emergency Procedures

Workplaces can streamline formal training by leveraging advanced technology and automation, such as implementing digital modules, training management systems, and mobile training applications like Training by SafetyCulture.

Practical Training

The theoretical learning should be complemented by practical training, where operators have hands-on experience with the equipment. The extent of practical training may vary depending on the type of forklifts used and specific workplace hazards.

To make the most of this component, operators should be trained on the actual equipment they will use in their workplaces. Technology solutions such as monitoring sensors can detect vibrations or unsafe movements, providing instantaneous feedback to learners.

Performance Evaluation

Upon completion of theoretical and practical training, operators must undergo a comprehensive evaluation to assess their proficiency. This evaluation should be based on the specific competencies required for the job and include a written test, practical assessment, or both.

Certification and Recertification

Certification, after successful training and evaluation, is a critical component of forklift safety training. It signifies an operator’s competence to operate the equipment safely and legally. Sample certification includes:

• Forklift Safety and Inspector
• Commercial Driver License (CDL)
• OSHA Safety Certificate
• Operator Certification

Recertification is necessary every three years or under specific conditions:

• Operators involved in accidents or near-miss incidents
• Operators assigned to drive different types of forklifts
• Changes in workplace conditions

Documentation

Employers must keep records of each operator’s training, including training dates, contents covered, and the trainer’s name. Documentation serves as proof that operators have received proper training in case of an incident or when OSHA inspectors conduct an inspection.

Laws and Regulations

Forklift operator safety training is governed by various laws and regulations, including:

• Occupational Safety and Health Administration (OSHA) in the United States
• Canadian Standards Association (CSA) in Canada
• Work Health and Safety (WHS) laws in Australia

OSHA Regulations

OSHA’s regulations for forklift operator safety training are detailed in the OSHA standard 1910.178. Here are some key points from the standard:

• Age Restrictions: Operators must be at least 18 years old to operate a forklift.
• Training Requirements:
  • Formal Instruction: Includes lectures, discussions, interactive computer learning, videotapes, and written materials
  • Practical Training: Hands-on demonstrations by the trainer and exercises by the trainee
  • Evaluation: Even if an operator claims to be experienced, they must be evaluated by the employer
  • Certification: Employers are required to ensure that each operator has undergone training and evaluation.
  • Refresher Training: Operators must undergo refresher training and evaluation at least every three years

OSHA Outreach Training Program

OSHA 10-Hour and 30-Hour Training for General Industry programs are not mandatory. However, they might be necessary in specific circumstances. For example, many construction sites require workers to have OSHA 10-hour or 30-hour training before they can access the worksite.

CSA Regulations

Regulations for forklift operator safety training are outlined in the CSA Safety Standard for Lift Trucks (B335-15). It includes four key aspects:

• Theory
• Knowledge verification
• Hands-on training
• Practical evaluation

Other key points include:

1. Operators must undergo comprehensive training that includes:
   • Pre-use inspections
   • Load handling and stability
   • Refueling and battery maintenance
   • Special applications
   • Regular maintenance and record-keeping
2. Operators must be certified and recertified at regular intervals. The frequency of recertification varies, but it is typically every three years.

WHS Regulations

In Australia, forklift operator safety training falls under Work Health and Safety (WHS) laws. These laws are administered by each state or territory’s workplace health and safety authority. Some key points include:

License Requirements:

Forklift operators need a high-risk work forklift license from a Registered Training Organisation (RTO).

Training and Supervision:

1. Operators may operate a forklift at their workplace:
   1. if they are enrolled with an RTO to train as a forklift operator; and
   2. if a person with the right license and suitable experience directly supervises them.
2. Refresher training is required to maintain and enhance skills.

Best Practices for Conducting Training

To ensure effective and comprehensive training for forklift operators, employers and trainers should follow these best practices:

Use a Forklift Training Checklist

Having a detailed training checklist helps employers cover all the necessary topics and assess trainees’ knowledge objectively. It also serves as documentation of the training provided.

Make Training Memorable and Relevant

Encourage active participation by utilizing interactive, live classroom settings with qualified instructors. Ensure content is relevant and meaningful, covering real-world elements such as using seat belts, maintaining proper fork height, traveling in reverse when forward vision is obstructed, and operating at controlled speeds. Moreover, utilize visual aids, such as presentations and videos, to reinforce training.

Tailor Training to Different Learning Styles

Effective forklift operator safety training should accommodate diverse learning styles. Some trainees may learn better by watching demonstrations, while others may prefer hands-on practice. Incorporate various teaching methods to ensure all trainees understand and retain the information provided.

Conduct Regular Refresher Training

Regular refresher training is essential in keeping a forklift operator’s skills and knowledge up-to-date. It also provides an opportunity for operators to ask questions or seek clarification on any topics they find confusing.

Utilize Technology Solutions

Advances in technology have made it easier for employers to provide comprehensive and effective training. Here are some technology solutions that can enhance forklift operator training:

• Virtual Reality (VR) and Augmented Reality (AR)
• Automated Training Systems
• Forklift Monitoring Systems
• Forklift Shock Sensors