SAFE OPERATION OF FORKLIFT

A TRAINING FOR THE

METALWORKING INDUSTRIES

Updated on June 2015

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

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

Forklift Fatalities in Singapore

1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Total
Forklift

31

Motor
vehicles NEC

15

Others

Lorries

Trucks

Mechanical
Conveyors

`0

`4

Source: Ministry of Manpower

Potential Forklift Accidents

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

Potential Forklift Accidents

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

Forklift Accidents

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

Forklift Accidents

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

Forklift Accidents

Picture source: European Industrial Gases Association

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

Risk Management on Operation of

Forklift

Step 1: Identification of hazard

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

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

Common 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

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

Common Forklift Hazards

Pedestrians and forklift moving in

same place

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

Common Forklift Hazards

Forklift traveling on slope

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

Common Forklift Hazards

Poor ground conditions

Picture source: http://eternitycaptured.com/blog/wpcontent/uploads/2007/04/bigstockphoto_Road_Cracks_And_Potholes_606173.jpg

Common Forklift Hazards

Worn out tyres

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

Common Forklift Hazards

Unsecured load

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

Common Forklift Hazards

Picture source: http://www.ubuyme.com/img_prod/679/pic1.jpg

Electric shock
from battery

Common Forklift Hazards

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

Risk Management on Operation of

Forklift

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

Risk Management on Operation of

Forklift
Rare
(1)

Remote
(2)

Occasion Frequen
al
t
(3)
(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

Risk Management on Operation of

Forklift

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)

Risk Management on Operation of

Forklift
HIERARCHY OF HAZARDS CONTROL

1st Remove the Hazards

Forklift Route Planning

Picture source: http://maaw.info/images/Figure8-10.gif

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

areas

Designated maintenance, parking and battery charging

Forklift Operation Separated from

Worker Area

Forklift
operation area

Picture source: Hi Tech Coatings, Inc

Allocated Goods Area

Goods sitting
area

Picture source: Hi Tech Coatings, Inc

Designated Battery and Parking Area

Forklift battery
charging and
parking area

Picture source: Hi Tech Coatings, Inc

2nd Guard the Remaining Hazards:

Protective Barriers

Brightly
coloured
barriers

Picture source: Hi Tech Coatings, Inc

Risk Management on Operation of

Forklift
3rd Mitigate impact of hazard (E.g. Operator to wear an
seat belt)

Source: Ministry of Manpower

Risk Management on Operation of

Forklift

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: Ministry of Manpower

Risk Management on Operation of

Forklift
Forklift Safe Work Procedures (SWP)

Forklift Training

Pre-Operation Check

Load Assessment

Common Safe Practice

Traffic Control
Source: Ministry of Manpower

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

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

Why Conduct Pre-operation Checks?

Ensure efficient and safe operation of forklifts

Prevent workplace injuries

To remove inefficient forklift practices

Under WSHAC Forklift Checklist, Preoperation 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

Pre-operation Checks 1

Source : http://www.thefabricator.com/Images/96/forklift-truck-diagram.jpg

Pre-operation Checks 2 Propane

Forklift

Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif

Pre-operation Checks 3 Electric

Forklift

Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif

Pre-operation Checks 4 Yard

Forklift

Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif

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

Forklift 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.au

Forklift Load Assessments 1

Dont increase the capacity of the forklift using personnel
as additional counterweights

Picture source : http://www.staugustinelighthouse.com/blog/forklift.jpg

Forklift Load Assessments 2

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

Load Assessments Weighing the

Load

Picture source: http://www.weighing-systems.com/TechnologyCentre/forkliftweigh.html

Load Assessments Weight at Centre

of Gravity

Forklift

Picture source: http://www.morsemfgco.com/images/forklift_sm.gif

Load Assessments Weight at Centre

of Gravity

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

Load Assessments Weight at Centre

of Gravity

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

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

Load Assessments Shape

Odd shape load

may hit
pedestrians
causing injuries
Picture source: http://www.nepowder.com/images/FORKLIFT%20II.JPG

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

Common Safe Practices

Dont drive a forklift unless you are trained and authorized
Use seatbelts

Wearing
seatbelts

Common Safe Practices

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

Common Safe Practices

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

Common Safe Practices

where

Slow down and sound the horn at crossings and locations

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

Common 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: http://www.safety-mirrors.co.uk/cabfront.jpg

Common Safe Practices

Source: Ministry of Manpower

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

Traffic Controls

Follow the forklift route plan and pedestrian path

Obey the speed limits, pedestrian crossings and one way signs
etc.

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

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

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

All accidents are preventable

Be proactive: it is up to US to
prevent it

Thank You

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)

Appendix 1

Appendix 1

Appendix 1

Appendix 2

Appendix