Forklift safety

A forklift is the most useful machine in a warehouse and also the most dangerous. It lifts heavy loads, turns on the spot, and a driver behind the load in front of them may not see the way ahead. Most serious incidents are of three kinds: hitting a pedestrian, tipping over and a load falling. The good news is that the rules for preventing them are simple; the hard part is following them every day, including during a rush to load. For exact official requirements (driver authorisation, inspection) consult a qualified specialist.

Who drives and who holds the key

Only a trained and authorised person drives a forklift. In practice, hopping on "just for a minute" happens often, especially on the night shift and when a truck is waiting. The easiest way to prevent it: the key is kept by the shift supervisor, issued at the start of the shift, returned at the end and entered in a log. Do not let a tired or unwell person drive either: a forklift demands quick reactions.

The pre-shift check

Before every shift the driver carries out a five-minute check:

• do the brakes, steering and horn work;
• do the lights and the flashing beacon come on;
• are the forks free of cracks and bends, are the chains tight;
• is there any oil leaking from the hydraulics, are the tyres intact;
• is there a seat belt, and is the capacity plate legible.

If a fault is found the truck is not used, a "Do not use" tag is hung on it and it is entered for repair. The result of the check stays in a short log. We covered regular maintenance of equipment in a separate article.

Rules of movement

• Speed. In the warehouse speed does not exceed walking pace, and is lower still at corners, doors and places with poor visibility. Decide an internal limit and show it with signs.
• Forks. While travelling the forks are low above the floor and the mast tilted slightly back. Driving with a raised load leads to tipping.
• Turning. Do not turn with a raised load or at speed; this is one of the main causes of tipping.
• Visibility. If the load blocks the view, drive in reverse. On a slope the load always faces uphill.
• Load. Never exceed the capacity on the plate: the higher the load is lifted, the lower the permitted weight.
• People. Nobody rides on the forks or on the load, no passengers are carried and nobody stands under a raised load.

When stopping, lower the forks to the floor, apply the parking brake and take out the key. Do not leave the truck in a thoroughfare or where people walk.

Separating trucks from pedestrians

Most incidents happen where trucks and pedestrians meet, so separating them is the most effective measure. Mark a separate walkway for pedestrians or fence it off, reduce the number of crossings and mark the ones that remain. Fit convex mirrors at corners, and at doors provide a stopping place and a window.

Visibility matters a great deal too: reflective clothing for everyone, a flashing beacon on the truck or a blue beam projected on the floor ahead of it. Pedestrians need rules as well: do not cross a truck's path until you are sure the driver has seen you, and raise a hand. Neither the driver nor the pedestrian should look at a phone while moving.

Surroundings and near misses

Even with a sound machine the place can be dangerous. An uneven floor, an oil patch, narrow aisles, poorly lit corners and an empty pallet forgotten in an aisle all lead to incidents. On a dock a chock goes under the truck's wheels. The battery charging area should be separate and ventilated; an internal-combustion truck must not run in a closed, unventilated room.

A particularly useful tool is a near-miss log. Every case where there was no damage but it came down to "a second" is recorded: date, place, what happened. Do not punish the person who reports, or nobody will write anything down. At the end of the month find the recurring spot in the log: usually it is one junction or one corner, and you fix it with a mirror, a speed limit or a barrier.

Conclusion

Forklift safety rests on three things: an authorised driver, a sound machine and pedestrians kept apart from traffic. During a warehouse audit, SkladKontrol helps map the places where equipment routes and walkways cross; official requirements for driver training and equipment inspection remain under the control of a qualified specialist.