Safe Operation of Forklifts

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SAFE OPERATION OF FORKLIFT

A TRAINING FOR THE METALWORKING INDUSTRIES
2008 All Rights Reserved
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
Forklift traffic control

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 Motor vehicles NEC Others 5 0 1 0 0 0 2 0 0 2 0 0 2 4 0 1 2 0 1 0 0 0 0 0 1 3 0 0 0 1 1 1 0 0 0 1 1 1 1 0 0 `0 6 1 2 0 1 0 0 3 1 1 0 0 3 0 0 0 0 2 9 2 4 1 1 0
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15 9 5 4 `4
Lorries
Trucks Mechanical Conveyors
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
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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
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Step 1: Identification of hazard
Picture source: http://www.safetyworld.com/images/101.gif
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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
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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
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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
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Pedestrians and forklift moving in same place
Picture source: http://www.safetyworld.com/images/67.gif
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Forklift traveling on slope
Picture source: http://www.sandhillquilting.com/images/M-16-SYS-8436-L.jpg
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Poor ground conditions
Picture source: http://eternitycaptured.com/blog/wpcontent/uploads/2007/04/bigstockphoto_Road_Cracks_And_Potholes_606173.jpg
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Worn out tyres
Picture source: http://www.riverina.coop/depts/Realestate/Other/forsale_auctions/whybro/RIMG2040.JPG 2008 All Rights Reserved
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Unsecured load
Picture source: http://www.locknpop.com/images/img_fork.gif 2008 All Rights Reserved
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Electric shock from battery

Picture source: http://www.ubuyme.com/img_prod/679/pic1.jpg 2008 All Rights Reserved
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Lifting Persons on Forks

Picture source: http://www.ttt-services.co.uk/Healthandsaftey/forklift_web.jpgc 2008 All Rights Reserved
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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
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Severity Minor Moderate Major
Likelihood
Remote Occasional Low Low Low Medium Medium High
Frequent
Medium
High
High
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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)
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HIERARCHY OF HAZARDS CONTROL
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1st Remove the Hazards Forklift Route Planning
Picture source: http://maaw.info/images/Figure810.gif 2008 All Rights Reserved
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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 Designated maintenance, parking and battery charging areas
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Forklift Operation Separated from Worker Area
Forklift operation area
Picture source: Hi Tech Coatings, Inc
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Allocated Goods Area
Goods sitting area
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Designated Battery and Parking Area
Forklift battery charging and parking area
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2nd Guard the Remaining Hazards: Protective Barriers
Brightly coloured barriers
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3rd Mitigate impact of hazard (E.g. Operator to wear an seat belt)
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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
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Forklift Safe Work Procedures (SWP) Forklift Training Pre-Operation Check Load Assessment
Common Safe Practice

Traffic Control
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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
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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
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Why Conduct Pre-operation Checks?
Ensure efficient and safe operation of forklifts
Prevent workplace injuries

To remove inefficient forklift practices
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Under WSHAC Forklift Checklist, Pre-operation 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
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Pre-operation Checks 1
Source : http://www.thefabricator.com/Images/96/forklift-truck-diagram.jpg
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Pre-operation Checks 2 Propane Forklift
Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif
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Pre-operation Checks 3 Electric Forklift
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Pre-operation Checks 4 Yard Forklift
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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
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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
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Dont increase the capacity of the forklift using personnel as additional counterweights
Picture source : http://www.staugustinelighthouse.com/blog/forklift.jpg
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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
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Load Assessments Weighing the Load
Picture source: http://www.weighing-systems.com/TechnologyCentre/forkliftweigh.html
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Load Assessments Weight at Centre of Gravity
Forklift
Picture source: http://www.morsemfgco.com/images/forklift_sm.gif
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Picture source: http://www.rentrain.com/resources/fork_21.gif
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Picture source: http://www.ccohs.ca/images/J05-2.gif
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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
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Load Assessments Shape
Odd shape load may hit pedestrians causing injuries

Picture source: http://www.nepowder.com/images/FORKLIFT%20II.JPG
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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
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Common Safe Practices
Dont drive a forklift unless you are trained and authorized Use seatbelts
Wearing seatbelts
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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
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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
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Slow down and sound the horn at crossings and locations where 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
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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
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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
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Traffic Controls
Follow the forklift route plan and pedestrian path Obey the speed limits, pedestrian crossings and one way signs etc.
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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
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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
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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
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All accidents are preventable Be proactive: it is up to US to prevent it
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Thank You
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References:
1. 2. 3. 4. 5. 6. WSHAC Occupational Safety & Health Technical Advisory Safe Operation of Forklift Truck WSHAC Forklift Safety Checklist CP: 101: 2004 Code of Practice for Safe Use of Powered Counterbalanced Forklifts MOM Case Studies on Forklift Accidents NIOSH Publication No. 2001-109 NIOSH Alert: Preventing Injuries and Deaths of Workers Who Operate or Work Near Forklifts Chisholm Institute (Warehouse Task Drive a forklift) (http://olvc.chisholm.vic.edu.au/warehouse/D10/Virtualwa rehouse/D10Tasks/D10tasks.htm)
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Appendix 1
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Appendix 1
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Appendix 1
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Appendix 2
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Appendix

Safe Operation of Forklifts

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1

SAFE OPERATION OF FORKLIFT

2008 All Rights Reserved

Forklift traffic control

2008 All Rights Reserved

Forklift Fatalities in Singapore

Source: Ministry of Manpower

2008 All Rights Reserved

Potential Forklift Accidents

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

2008 All Rights Reserved

Potential Forklift Accidents

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

2008 All Rights Reserved

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

2008 All Rights Reserved

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

2008 All Rights Reserved

Picture source: European Industrial Gases Association

2008 All Rights Reserved

Risk Management on Operation of Forklift

Take all reasonably practical steps

2008 All Rights Reserved

Risk Management on Operation of Forklift

Step 1: Identification of hazard

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

2008 All Rights Reserved

Common Forklift Hazards

2008 All Rights Reserved

Common Forklift Hazards

Lifting of persons on forks

2008 All Rights Reserved

Common Forklift Hazards

Source: Ministry of Manpower

Picture source: http://www.cdc.gov/niosh/face/images/96nj062.jpg

2008 All Rights Reserved

Common Forklift Hazards

Pedestrians and forklift moving in same place

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

2008 All Rights Reserved

Common Forklift Hazards

Forklift traveling on slope

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

2008 All Rights Reserved

Common Forklift Hazards

Poor ground conditions

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

2008 All Rights Reserved

Common Forklift Hazards

Worn out tyres

Picture source: http://www.riverina.coop/depts/Realestate/Other/forsale_auctions/whybro/RIMG2040.JPG 2008 All Rights Reserved

Common Forklift Hazards

Picture source: http://www.locknpop.com/images/img_fork.gif 2008 All Rights Reserved

Common Forklift Hazards

Electric shock from battery

Common Forklift Hazards

Lifting Persons on Forks

Risk Management on Operation of Forklift

2008 All Rights Reserved

Risk Management on Operation of Forklift

Severity Minor Moderate Major

2008 All Rights Reserved

Risk Management on Operation of Forklift