Powered Industrial Truck Safety Program

Forklift & Motorized Pallet Jack Safety

Purpose

Material handling is a significant safety concern. During the movement of products and materials there are numerous opportunities for personal injury and property damage if proper procedures and caution are not used. This chapter applies to all powered industrial tucks, hoists & lifting gear. The information in this chapter shall be used to train prospective industrial truck operators and provide the basis for refresher and annual retraining. OSHA reference for Powered Industrial Trucks is 1910.178.

Responsibilities

Management

• Provide adequate training in safe operation of all equipment used to move or access materials
• Provide equipment that is safe to operate
• Implement an "Out of Service" program for damaged equipment
• Not allow modification to equipment except those authorized in writing by the equipment manufacturer
• Establish safe operating rules and procedures

Supervisors

• Monitor safe operations of material handling equipment
• Ensure all equipment is safety checked daily
• Tag "Out of Service" any damaged equipment

Employees

• Operate only that equipment for which they have been specifically trained and authorized
• Conduct required daily pre-use inspections
• Report any equipment damage of missing safety gear
• Follow all safety rules and operating procedures

Hazard Controls

• Control of equipment keys
• Authorized fueling & recharge areas
• Proper palletizing of material
• Marked travel lanes
• Equipment warning lights
• Seat belts
• Mounted fire extinguishers

Pre-Qualification

All candidates for Powered Industrial Truck (Powered Industrial Trucks (Forklifts)) operators must meet the following basic requirements prior to starting initial or annual refresher training:
• Must have no adverse vision problems that cannot be corrected by glasses or contacts
• No adverse hearing loss that cannot be corrected with hearing aids
• No physical impairments that would impair safe operation of the Powered Industrial Trucks (Forklifts)
• No neurological disorders that affect balance or consciousness
• Not taking any medication that affects perception, vision, or physical abilities

Training

Training for Powered Industrial Truck Operators shall be conducted by an experienced operator, selected by Management. All operational training shall be conducted under close supervision. All training and evaluation must be completed before an operator is permitted to use a Powered Industrial Truck (forklift, etc) without continual & close supervision. Training consists of:.

Trainees may operate a powered industrial truck only:
• Under the direct supervision of persons, selected by management, who have the knowledge, training, and experience to train operators and evaluate their competence; and
• Where such operation does not endanger the trainee or other employees.

Training Content

Training consists of a combination of formal instruction, practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator's performance in the workplace.

Initial Training: Powered industrial truck operators shall receive initial training in the following topics:

Truck-related training topics:
1. Operating instructions, warnings, and precautions for the types of truck the operator will be authorized to operate
2. Differences between the truck and the automobile
3. Truck controls and instrumentation: where they are located, what they do, and how they work
4. Engine or motor operation
5. Steering and maneuvering
6. Visibility (including restrictions due to loading)
7. Fork and attachment adaptation, operation, and use limitations
8. Vehicle capacity
9. Vehicle stability
10. Any vehicle inspection and maintenance that the operator will be required to perform
11. Refueling and/or charging and recharging of batteries
12. Operating limitations
13. Any other operating instructions, warnings, or precautions listed in the operator's manual for the types of vehicle that the employee is being trained to operate.

Workplace-related topics:
1. Surface conditions where the vehicle will be operated
2. Composition of loads to be carried and load stability
3. Load manipulation, stacking, and unstacking
4. Pedestrian traffic in areas where the vehicle will be operated
5. Narrow aisles and other restricted places where the vehicle will be operated
6. Hazardous (classified) locations where the vehicle will be operated
7. Ramps and other sloped surfaces that could affect the vehicle's stability
8. Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust
9. Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation

Refresher training and evaluation. Refresher training, including an evaluation of the effectiveness of that training, shall be conducted to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely. Refresher training in relevant topics shall be provided to the operator when:
1. The operator has been observed to operate the vehicle in an unsafe manner
2. The operator has been involved in an accident or near-miss incident
3. The operator has received an evaluation that reveals that the operator is not operating the truck safely
4. The operator is assigned to drive a different type of truck
5. A condition in the workplace changes in a manner that could affect safe operation of the truck
6. Once every 3 years an evaluation will be conducted of each powered industrial truck operator's performance.

Safe Operating Procedures (SOP) & Rules

• Only authorized and trained personnel will operate Powered Industrial Trucks (Forklifts).
• All Powered Industrial Trucks (Forklifts) will be equipped with a headache rack, fire extinguisher, rotating beacon, back-up alarm and seat belts. Seat belts will be worn at all times by the Operator.
• The operator will perform daily pre- and post-trip inspections.
• Any safety defects (such as hydraulic fluid leaks; defective brakes, steering, lights, or horn; and/or missing fire extinguisher, lights, seat belt, or back-up alarm) will be reported for immediate repair or have the Powered Industrial Truck (Forklift) taken "Out of Service".
• Operators will follow the proper recharging or refueling safety procedures.
• Loads will be tilted back and carried no more than 6 inches from the ground. Loads that restrict the operator's vision will be transported backwards.
• Powered Industrial Trucks (Forklifts) will travel no faster than 5 mph or faster than a normal walk.
• Hard hats will be worn by Powered Industrial Truck (Forklift) Operators in high lift areas. .
• Operator will sound horn and use extreme caution when meeting pedestrians, making turns and cornering.
• Passengers may not ride on any portion of a Powered Industrial Truck (Forklift). Only the operator will ride Powered Industrial Trucks (Forklifts). "NO PASSENGERS" decals will be affixed on all Powered Industrial Trucks (Forklifts).
• If a Powered Industrial Truck (Forklift) are used as a man lift, an appropriate man lift platform (cage with standard rails and toe-boards) will be used.
• Aisle will be maintained free from obstructions, marked and wide enough (six foot minimum) for vehicle operation.
• Lift capacity will be marked on all Powered Industrial Trucks (Forklifts). Operator will assure load does not exceed rated weight limits.
• When un-attended, Powered Industrial Trucks (Forklifts) will be turned off, forks lowered to the ground and parking brake applied.
• All Powered Industrial Trucks (Forklifts) (with exception of pallet jacks) will be equipped with a multi-purpose dry chemical fire extinguisher. (Minimum rating; 2A:10B:C)
• Operators are instructed to report all accidents, regardless of fault and severity, to Management. Management will conduct an accident investigation.
• When loading rail cars and trailers, dock plates will be used. Operators will assure dock plates are in good condition and will store on edge when not in use.
• Rail cars and trailers will be parked squarely to the loading area and have wheels chocked in place. Operators will follow established Docking/Un-Docking Procedures.

Changing and Charging Storage Batteries

• Battery charging installations shall be located in areas designated for that purpose.
• Facilities shall be provided for flushing and neutralizing spilled electrolyte, for fire protection, for protecting charging apparatus from damage by trucks, and for adequate ventilation for

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