Address these common violations to reduce forklift accidents
The most common accidents involve rollovers, collisions with pedestrians, and loads falling from the tines. Since these incidents often result from operator violations, we’ll review the most common violations that cause them.
Since lack of training can increase accidents, check the related article Considerations when designing practical training for PITs. |
Failing to conduct the pre-shift inspection. If the operator skips (or rushes through) the inspection, safety concerns won’t get identified. Problems with critical systems like hydraulics, brakes, or steering can obviously contribute to accidents. But even things like a non-functioning horn or lights could increase the risk of collisions.
Related to this, operators must report any problems that arise during the shift. If a pre-shift inspection identifies failures, the problem likely occurred during the previous shift and should have been reported. Equipment failures may occur during operation, not during idle time between shifts. If something goes wrong, the operator must remove the truck from service. Make sure operators know how to report problems, send the truck for service, and obtain an alternate vehicle for the shift.
Carrying loads too high. Operators should carry loads as low as possible. During OSHA inspections, compliance officers commonly see loads carried too high. This limits both visibility and stability. When the load size restricts visibility and no other options are feasible, the operator should use a spotter.
Related, operators should never raise or lower a load while moving or turning. Doing so increases the risk of accidents from falling loads, and limited visibility can increase the risk of striking pedestrians or objects.
Driving too fast for conditions. Employers might communicate “speed limits” but forklifts don’t usually have speedometers. Still, operators should understand what constitutes a safe (and unsafe) speed under various conditions. In some locations, this might be a walking speed, which can seem painfully slow. Certain areas like intersections or locations with limited visibility require slowing down even further.
OSHA compliance officers commonly issue citations for excessive speed. Excessive speed increases the risk of spilling a load, striking a pedestrian, and rollover potential.
Operator not certified. Forklift operators must receive training that covers the types of vehicles used. An operator trained on a sit-down counterbalanced forklift needs additional training to operate a stand-up model, or even a powered pallet jack. A supervisor might be able to explain the operating controls for a different vehicle type, but that does not constitute “training.” OSHA commonly issues citations for lacking operator certification.
In addition, employers must evaluate each operator’s performance at least once every three years. Typically, this involves questioning the operator on safety rules and observing the operator performing typical duties. If the evaluation identifies problems, the employer must provide refresher training. Skipping this evaluation could result in a failure to identify violations that contribute to accidents. Remember that OSHA also requires additional training when physical changes to the workplace introduce new hazards.
If the operator is not certified for the particular vehicle used, the lack of understanding regarding handling characteristics (or different safety precautions) can contribute to accidents such as falling loads or collisions.
Watch for unsafe behaviors. While spills and collisions threaten workers around the forklift, unsafe operator behaviors such as failing to wear the seatbelt, attempting to operate the controls while standing beside the truck, and leaning or reaching outside the running lines all put the operator (and others) at risk.
Key to remember: Forklift operator behaviors can cause serious injuries — or help avoid them if the operator uses appropriate caution.