Whitepaper Forklift Protection

Forklifts, also known as Powered Industrial Trucks (PIT), are used in numerous work settings, primarily to move materials. Each year in the United States, nearly 100 workers are killed and another 20,000 are seriously injured in forklift-related incidents.

Forklift overturns are the leading cause of these fatalities representing about 25% of all forklift-related deaths.

In order to reduce the potential for a forklift related accident OSHA requires employers to certify employees in the proper operation of forklifts, properly maintain the lifts and train those who may come into contact with lifts on hazards and best practices.

In terms of certification many believe this is something that has to be completed through private contractors. However, OSHA regulations allow you to certify your own employees through the creation of an OSHA-complaint program.

Independent studies have confirmed forklift training reduces operator errors by 70%. [2]

Forklift Maintenance

OSHA requires you to properly maintain your forklifts. Through this maintenance program your employees are required to examine their truck each day before placing the vehicle in service or, if the trucks are operated around the clock, they need to be inspected prior to the start of each shift. If the truck shows any condition adversely affecting the safety of the vehicle, that vehicle shall immediately be taken out of service and repaired. [29 CFR 1910.178(q)(7)].

A few examples of these conditions can include:

• Defective/unadjusted brakes

• Damaged mast chain

• Play in steering

• Sparks from exhaust/truck

• Inoperable horn

• Defective controls

• Damaged chain anchor pin

• Worn tires/damaged rims

• Inoperable gauges

• Not running well/missing

• Dislodged/defective counterweight

• Damaged overhead guard/LBR

• Wear/defects in the forks/carriage

• Cracks/defects in mast/structure

• Missing/non legible data plate

• Evidence of leaks (i.e. hydraulics, fuel)

Modifications and replacement parts

OSHA regulations strictly forbid the alteration of your forklift without manufacturer's approval and require you to use exact replacement parts.

Common cited modifications include the installation of a taller or heavier mast and adding ballast to the back of the truck to increase its lifting capacity.

Another modification that many operators unknowingly perform with an electric forklift is using a cheaper replacement battery. Stock electric batteries often weigh several thousand pounds and cost thousands of dollars. By installing a smaller battery, you can save hundreds of dollars.

However, these cheaper batteries are lighter and modify the lifting capacity and stability of the lift. This significantly increases the potential for an accident.

Warning Devices

A horn is one of the warning devices you are required to have on all your lifts. Your drivers also must be trained on when to use this horn. The most common usage is when the driver is navigating the lift through areas that may have blind spots. A blind spot is by definition any place in the direction of travel the driver cannot see without special effort. In addition to the horn, the lift is required to have functioning back up buzzers, bell or other audible device. [29 CFR 1910.178 (n)(4)].

Refresher Training

Refresher training must be provided at least every 3 years. In addition to the retraining, OSHA requires your employees to receive regular evaluations. If improper techniques are observed during evaluation then re-training is required.

Here is a list of some things to look for when evaluating:

• loading	• ramps/inclines
• stacking	• ALL traveling
• fueling/charging	• using attachments
• inspecting	• tiering
• pedestrians	• visibility
• parking/shutting down	• lifting/lowering
• maneuvering	• docks
• horn	• floor surfaces
• driving in reverse	• accessing/egressing truck

Safety for non-operators and your workplace

Many of the accidents involving forklifts each year are at no fault of the driver.

In these cases, workplace conditions or actions of employees not utilizing the lift were at fault for the accidents. In cases such as these, the conditions of the workplace or actions of employees not utilizing the lift were at fault for the accidents.

It is because of these extenuating circumstances that OSHA not only requires training for your direct users of lifts, but also requires you to maintain the workplace and train all those who have the potential to come in contact with lifts.

In terms of maintaining the workplace, you must check for cracks in surfaces, pooling of water or any other potential hazard.

Some topics of training for non-lift operators may include:

• Limit some aisles to workers on foot only or forklifts only

• Restrict the use of forklifts near time clocks, break rooms, cafeterias, and main exits, particularly when the flow of workers on foot is at a peak (such as at the end of a shift or during breaks)

• Install physical barriers where practical to ensure that workstations are isolated from aisles traveled by forklifts

• Evaluate intersections and other blind corners to determine whether overhead dome mirrors could improve the visibility of forklift operators or workers on foot

• Make every effort to alert workers when a forklift is nearby. Use horns, audible backup alarms, and flashing lights to warn workers and other forklift operators in the area

• Flashing lights are especially important in areas where the ambient noise level is high

Impact of Training

Training is an important part of eliminating job place injuries. Studies of forklift specific training show a 70% reduction in operator errors. [2]

Through independent studies, OSHA has confirmed employers who have in place a safety and health training program experience a 52 percent lower rate of "injury with days away" than employers without a program. [7]

A second study of private industry employers by OSHA found even more benefits to a safety training program.

Here are a few highlights of those programs:

Company Benefits: [8]5

• Average Sales rose 7.5 percent

• Manufacturing defects and waste dropped from $2.7 million in 2001 to $435,000 in 2005

• Improved decision-making

• Emergency Modification Rate dropped by 45%

Safety and health also make big reductions in indirect costs, due to: [9]

• Increased productivity

• Higher quality products

• Increased morale

• Better labor/management relations

• Reduced turnover

• Better use of human resources

The value of training is further emphasized by a study of 41 workers hospitalized for hand injuries. Through the survey of these employees conducted by members of National Institute for Occupational Safety and Health (NIOSH) it was discovered more than half had no on-the-job training for the equipment that caused their injury.

Workplaces that establish safety and health management systems can reduce their injury and illness costs by 20 to 40 percent, according to OSHA.

Studies not only show the impact safety training has in increasing productivity and preventing injury. It shows the value training has to prevent casualties. [7]

A NIOSH study of 55 confined workplace fatalities found that only three of those losing their lives ever received training on the proper workplace safety procedures.

A study of the California insurance industry also revealed that every dollar invested in safety training resulted in $3 or more dollars in savings,"

Safety training is not a cost, it is an investment.

A Simpler Forklift Safety Solution

By requesting and reading this report, you are no doubt aware of the hazards associated with forklifts and the long list of regulations your company must abide by.

Meeting these regulations is a tedious process that requires you either to develop a training program yourself or to outsource with expensive safety consultants.

There is a better solution.

Here at Safety Services Company we have developed a "Do-It-Yourself" training program that is both simple to administer and fulfills all your OSHA forklift requirements.

Three Steps to Certification

Continuing Commitment

The 12 Industrial Truck Designations

Citations