FORKLIFT SAFETY IN THE WORKPLACE

Forklifts are essential tools in many industries, significantly enhancing productivity by allowing for the efficient movement of heavy materials. However, their operation comes with significant risks. Ensuring forklift safety in the workplace is crucial to prevent accidents, injuries, and even fatalities. 

 

To help you implement and maintain a safe working environment, we have complied our top tips for maintaining forklift safety in your workplace.  

 

Proper Training and Certification 

One of the most critical aspects of forklift safety is ensuring that all operators are properly trained and certified. Various types of training and certification programs are available to meet different needs and regulations. 

In the UK, the training and certification requirements for forklifts follow the Provision and Use of Work Equipment Regulations 1998 (PUWER) and the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER). 

All employees should be trained by authoritative bodies, such as training providers recognised by relevant industry bodies. 

• Operator Training and Certification: All forklift operators must undergo comprehensive training programs that cover the fundamentals of forklift operation, including safety protocols, operating procedures, and basic maintenance. For experienced operators, focusing on advanced techniques, there are a range of courses tailored to handling complex loads, working in challenging environments and many more. 

• Machine Specific Training: Operators must be specifically trained on the equipment that they are using as each type has its own unique operation characteristics. Where equipment has similar operating requirements, conversion courses may be available.  

• Refresher Training: All operators should undertake refresher training regularly, doing so will ensure that they remain up-to-date on safety protocols and reinforces safe operating habits.  It also helps with knowledge retention that will boost confidence and morale along with their productivity and efficiency.  Refresher training should always be undertaken after any incidents or near misses. 

• Recertification: Many certifications require periodic renewal, often every three years, to ensure operators stay up-to-date with the latest safety practices and regulations. 

 

Conduct Regular Inspections 

Regular inspections are crucial to ensuring the safe operation of forklifts in the workplace. They help identify potential issues before they lead to malfunctions and accidents, protecting both the operators and other employees. 

• Pre- Operational Inspections: Pre-operational inspections should be carried out before each shift to ensure that the forklift is in proper working condition.  You should check for any visual damage or leaks, look for cracks, rust or any other signs of wear and tear. Verify that all fluid levels, including fuel, oil, hydraulic fluid, and coolant, are within the proper range. Inspect tires for proper inflation, cuts, and wear. Ensure the tires are suitable for the operating environment. Check the condition of the forks for cracks, bends, or any other damage and ensure they are properly aligned and secure. Test the horn, lights, alarms, and other safety devices to ensure they are functioning correctly.  

• Operational Inspections: Operational inspections focus on the functional aspects of the forklift and should be performed during the initial use of the equipment. Test the brakes for proper operation. Ensure both the service brakes and parking brake are working effectively. Check the steering for responsiveness and smooth operation. There should be no excessive play or unusual noises. Ensure that all operational controls (lifting, lowering, tilting) are functioning smoothly and correctly. Check for any leaks or unusual noises in the hydraulic system. Ensure the mast and tilt cylinders are operating smoothly. Verify that all gauges and indicators (fuel level, battery charge, oil pressure) are functioning correctly. 

• Report and Repair: Encourage operators to report any issues immediately and ensure that repairs are made promptly. Workplace safety is a shared responsibility, everyone must be committed to maintaining high safety standards to prevent accidents and injuries. 

• Scheduled Maintenance:   Adhere to a strict maintenance schedule from daily inspections to Thorough Examinations and LOLER Inspections as recommended by the manufacturer and Workplace Safety Acts and Legislation. 

This proactive approach not only enhances safety but also extends the lifespan of the forklift and maintains productivity. Always ensure that inspections are documented, and any identified issues are addressed promptly to uphold the highest safety standards. 

 

Maintain a Safe Operating Environment 

A safe operating environment is crucial for preventing accidents. 

• Clear signage: Use clear, visible signs to indicate forklift operating areas, pedestrian walkways, loading zones, and hazardous areas. 

• Clear pathways: Keep aisles and pathways clear of obstructions to allow for safe pedestrian and forklift movement. 

• Proper lighting: Ensure that all areas where forklifts operate are well-lit. 

• Marking zones: Clearly mark forklift operating zones and pedestrian walkways with floor tape or paint. 

 

Implement Safe Driving Practices 

Safe driving practices significantly reduce the risk of forklift accidents. 

• Dedicated Areas: Create clearly marked areas for pedestrians and moving forklifts, within the workshop and yard area.  You could also use guard rails to help with this.  

• Safe Speed: Enforce strict speed limits for forklift operators, within the workshop or warehouse and within the yard.  

• Load Handling: Ensure loads are stable and secure before moving. Never exceed the forklift’s load capacity. 

• Visibility:  Always drive with the load low to the ground and ensure clear visibility. 

• No Riders: Never allow passengers on the forklift unless it is specifically designed for multiple people. 

• Avoid hazards: Ensure forklift operators know they area they are working in so that they can avoid bumpy or bumpy or slippery surfaces, as well as items that could be knocked loose, etc. 

 

Use the Correct and Proper Equipment 

Using the right equipment for specific tasks is essential for safety. 

• Personal Protective Equipment (PPE):  Ensure operators wear suitable PPE, such as hard hats, safety shoes, and high-visibility vests. Appropriate PPE must always be worn when operating a forklift to prevent injury and to comply with employee safety standards. 

• Technology Aids: Implement technology aids like rear-view cameras, sensors, and alarms to enhance safety. 

• Attachments: Use appropriate attachments for the load being carried.  

 

Communicate Effectively 

Effective communication between forklift operators and other employees is an easy way to prevent accidents. 

• Hand Signals: Establish a set of standard hand signals for communication between operators and ground workers. 

• Two-Way Radios: Equip operators with two-way radios for better communication in noisy environments. 

• Signs and Warnings: Post clear signs and warnings in areas where forklifts operate. 

 

Encourage a Safety-First Culture  

Promoting a safety-first culture can significantly reduce workplace accidents. It involves a combination of leadership commitment, employee engagement, effective communication, training, and continuous improvement.  

• Leadership Commitment: Leadership should demonstrate a genuine commitment to safety by prioritising it in all decisions and actions, through allocating resources, setting safety goals, and leading by example. Along with establishing clear safety policies and procedures that are aligned with industry standards and regulations. 

• Employee Engagement: Encourage employees at all levels to participate in safety committees, risk assessments and the development of safety procedures. Empower employees by giving them the authority to stop work if they identify unsafe conditions or behaviours.  Implement programmes to recognise and reward employees for safe behaviours and proactive safety initiatives.  

• Effective Communication: Hold regular safety meetings to discuss safety performance, share lessons learned and to address any concerns. Foster a no-blame culture where reporting hazards is encouraged and valued.  Use multiple communications channels to regularly convey safety messages, updates, and reminders. Ensure that safety incidents and near-misses are reported transparently and that investigations are conducted to understand root causes and prevent recurrences.  

• Continuous Improvement: Conduct regular safety audits and workplace inspections to identify and address potential hazards. Establish ways for employees to provide feedback to enhance safety measures. Use data from safety reports, audits and incident investigations to identify trends and areas for improvements. 

• Build a Supportive Environment: Ensure that workstations and tools are ergonomically designed to reduce strain and prevent injuries. Create an environment where employees feel comfortable speaking up about safety concerns without fear of retribution.  
   

Ensuring forklift safety in the workplace requires a thorough approach that includes proper training, regular inspections, a safe operating environment, and a strong safety culture. By following our top tips, you can significantly reduce the risk of accidents and create a safer workplace for everyone. Remember, safety is a shared responsibility, everyone must be committed to maintaining high safety standards to prevent accidents and injuries. 

 

Let Rushlift take the hassle out of owning your own Forklift with our comprehensive range of service packages. Maintenance packages are tailored to suit your specific requirements, whether it is a single item of equipment or a large and complex fleet. You can choose from Routine Maintenance, Inclusive Maintenance or Bespoke Packages.  All packages are designed to assist you in meeting their Health and Safety obligations, in particular, those arising out of the Provision and Use of Work Equipment Regulations. Contact the Service Team Today!