Although lift trucks are safe machines, every day workers are injuring themselves due to unsafe operating. Even those who have had the highest level of forklift training find themselves in crucial accidents as a result of getting too comfortable and loosing concentration.
As an RTITB accredited training company, safety is our number 1 priority and we hope that after completing a course with us it will be yours too. At Key Performance Training, we believe that the first step in avoiding mistakes is to be aware and educated on the possible mistakes you can make, especially the most common ones.
Here are the 4 most deadly mistakes you can make when operating a forklift truck. However, all it takes is one mistake; so don’t let it be you.
1. Driving with an elevated load
Many experienced operators believe they can get away with driving the truck with an elevated load and so do not bother to lower the forks. This is a huge mistake to make and is one of the most common causes of fatal injuries and deaths in forklift operating.
When the truck has a higher centre of gravity, it becomes much less stable meaning one fast turn can cause the truck to tip over and potentially crush the driver on its way down.
Reminder- if you do find yourself in a situation where your forklift has overturned you should always lean in the opposite direction to the way the truck is tipping rather than attempting to escape before the truck overturns.
2. Not inspecting the forklift truck
Inspections need to be a thorough procedure that is carried out each time the forklift is used. It only takes a matter of minutes but could potentially save lives. Some of the areas that should be a part of your daily inspection include; the tyres, brake and transmission fluids, loose parts or leaks, instrument and pedals.
Check out our other blogs for more in detail information about the importance of carrying out pre-op checks and the ones that are often forgotten.
3. Operating with a non- secured load
Non- secured loads are just an accident waiting to happen. Many operators are aware of the consequences but carry on risking it and don’t secure loads before operating. Yes, at times you could get away with it and yes your friend may have gotten away with it but when it goes wrong it won’t be you suffering but someone else in your workplace who has been struck by this load due to your negligence.
4. Blind spots
Blind spots in busy warehouses are something that is impossible to avoid, the actual mistake here is a miscommunication between workers. Not only are forklifts dangerous for the operator, they also cause great danger to other works and pedestrians. The best way to avoid this is by maintaining good communication at all times.
As workers in a warehouse, you need to be sure to follow the correct safety procedures, signs , signals. As operators, you need to enable the workers to follow these procedures by making sure your sound and light signals are working before moving and also that you are staying within the zones.
According to the UK health and safety executive almost one in five lift truck accidents occur as a result of mechanical failure, which could be avoided through correct pre-inspection completion. Inspecting a forklift before operating will only take a short amount of time but could save you from severe injuries and accidents. With all heavy equipment or vehicles, a complete inspection is the best way to make sure equipment is ready for use and all systems are working efficiently. Warehouse managers and employers should always get damaged or broken equipment immediate repair to ensure the safety of workers.
At Key Performance Training, we ensure all of the delegates who complete a course with us know and understand the importance of inspecting the lift truck before operating and that going forward into employment they carry out all safety procedures to the RTITB standard.
Below are 5 of the most important pre-checks to conduct before operating, however the list doesn’t stop there!
1. Tyre inspection/check over
Tyres provide grip for movement, friction for braking and suspension for safety and comfort. Before operating any forklift you must check that the tyres are in perfect condition as the wrong tyres or excessively worn ones can be a dangerous and expensive risk.
When inspecting the tyres there are two crucial aspects to ask yourself:
Is there any visible damage to the tyres such as cracks, tears or bulges?
Do they have a sufficient thread depth? (You can check this with a simple gauge whilst referring to manufacturer’s handbook for specific thread depth required for the truck you are operating.)
2. Checking the breaks before moving the forklift.
Insufficient or worn-out breaks are the cause of many serious forklift accidents. As an operator, you need to be sure that if a hazard gets in your way not only are you ready to break but the breaks are also ready to break!
To carry out an inspection\test of the brake you first need to press the footbrake checking for downward pressure whilst ensuring the handbrake is applied. Then, repeat with the handbrake released to compare the level of pressure in the brake pedal. If the pedal goes to the floor, this could mean there is an issue with the brakes that could cause a risk for you as the operator.
3. Checking how the truck moves.
Before attempting to carry any load, the operator should be sure that the truck is moving as it should. To carry out this check the operator will need to engage the reverse gear (whilst carrying out safety checks by looking over both shoulders), release the parking brake and slowly move off; checking that the lift truck moves off with ease and as normal.
The operator can also use this as another opportunity to check the brakes by accelerating and then pressing the foot brake to ensure that the lift truck comes to a complete stop.
4. Checking for leaks after having removed the lift truck.
After moving off, operators should check that there is no signs of leakage where the truck was previously parked. If you do find any leakage it could be engine oil, water , electrolyte or hydraulic oil. In an incident where you find any evidence of leaks it’s best to immediately dismount the vehicle and stop operating.
We would also advise you to report any leaks to the management so they can solve the issue so no other operators are at risk.
5. Clutch and gearshift check.
Like a car, many issues can arise from a worn-out forklift clutch or gearbox; doing a quick check of both will maximise your safety.
Any signs of jumps or jerks when changing gear should not be ignored and instead means you should stop operating and report instantly. A safe to operate truck will shift gear smoothly and with ease.
Did you know that there are on average 35,000 serious injuries and 85 deaths each year as a result of poor safety whilst operating a Forklift Truck? This frightening statistic shows just how dangerous these 4,000kg machines are, especially when those operating do not have adequate training.
However, the majority of these accidents are preventable when both operators and supervisors become aware of the potential hazards and know what they can do to reduce the risks. This is where we come in! Below, are the top 4 major FLT hazards and what you can to do avoid them.
1. Forklift overturning
Overturning is the leading cause of serious fatalities and deaths when operating a forklift. In fact, overturning is responsible for 25% of accidents.
Turning or stopping too quickly, an unbalanced load, loads that are too heavy or high along with uneven and wet surfaces are all possible causes of a forklift overturning.
The best way to prevent these accidents is adequate training that includes; which surfaces trucks are designed for, at what point the truck becomes ‘overloaded’, speed limits, securing a load and more. However, if an accident does occur where the forklift overturns the operator should NEVER try to jump out of the vehicle and instead brace themselves against the back of the seat and hold on firmly.
2. Obstacles
Obstacles obstructing the operators view is a hazard that may seem obvious but way too many accidents happen as a result of an untidy warehouse. Some possible obstacles in a warehouse include; pallets, stocks, pipes, poles and barriers.
To significantly reduce the chances of an accident, operators and supervisors need to ensure they are checking for any obstacles that could impede the forklift before and whilst operating. Either by moving these potential obstructions or simply being aware of them, the chances that they will cause an accident, massively decreases.
3. Attachments
Attachments can be a hazard for several reasons as a change in maintenance, capacity and adjusting to different types of attachments can all cause potential hazards. The main hazard occurs when attachments are subject to poor maintenance. Stretched chains, worn out forks and other run-down areas all increase your risk of injuries.
To reduce the risks, the operator and supervisors should have a full understanding of the capacity limits and safety protocols on each individual attachment used. Also, before starting a job, the truck should be thoroughly checked to ensure everything is safe and not worn out.
4. Blind spots
A blind spot is when the operator cannot see past something that is blocking their view. Some common situations when this is likely to occur are; when weather conditions are poor, the lighting of the warehouse is insufficient or the forklift has a full load.
To reduce the risks, employees should direct pedestrians or other employees away from potential blind spots or, if possible, block off the whole area. If this cannot be done, drivers should have a ‘spotter’ when maneuvering around blind spots.
A dangerous hazard that could arise from blind spots is workers being struck or crushed. Having a traffic management plan where for example workers follow a one-way system or barriers are put in place is as good way to avoid this issue. In the instance that this does happen however, then immediately call 111.
Did you know that on average, 25% of workplace transport accidents are to do with lift trucks? Immediately, after seeing this statistic you would blame the operator, however one of the top causes of these accidents is down to poor/lack of supervision. “To reduce these accidents and comply with the law, those in these senior roles must be correctly trained too” states Laura Nelson, managing director of RTITB. www.rtitb.com
To help reduce these risks, our accredited training partner, RTITB have launched a new eLearning course for anyone who is ‘Managing or Supervising’ lift truck operators. The eLearning course, which can be accessed via mobile, PC, tablet or MAC includes sections on: Health and safety at work, Operational Experience and Qualification guidance, administrative responsibilities and much more. As an overview, the course is designed to enhance Manager and Supervisors understanding of material handling equipment operation whilst also expanding their knowledge.
By the end of the interactive training course, Managers and Supervisors will be able to promote safe working principles, challenge poor standards or issues, carry out effective observation, communicate effectively with operators and line managers. They will also feel confident in what their responsibilities are, as well as understand which parts of their role are required in order to comply with the industry legislation.
Here is why you should invest in the course:
It is a legal requirement under The Provision and Use of Work Equipment Regulations 1998 that managers and supervisors are adequately trained.
Minimise operations risk.
Ensure managers and supervisors are fully aware of their role and what it entails.
Simple and cost-effective way to ensure your team is armed with the necessary knowledge.
We have partnered with RTITB, the UK’s leading accrediting body for forklift and plant operator training, to offer you new, secure, environmentally friendly electronic ID cards (the RTITB eCard), instead of the plastic ID cards offered by so many other accrediting bodies.
The brand new eCard – which launched on Monday 12th July 2021 – will see materials handling equipment (MHE) operators successfully completing our RTITB courses receive a digital ID card detailing their RTITB qualifications. The new eCards can be downloaded and stored in Apple Wallet (Apple smartphones) or Google Pay (Android smartphones) providing you supply your email address when training with us.
Information on your eCard will include:
Your photo (passport style)
Your name
Your RTITB registration number
RTITB logo
Accrediting Bodies Association for Workplace Transport (ABA) logo
ABA truck code (where applicable)
Our company name and website address
Course title and QR code to easily verify you as the operator
With the new RTITB eCard, you will receive your proof of training quicker than ever before, thanks to an average four-hour delivery time (from RTITB to us). To ensure data security and give you assurance a unique verification code is sent to your designated email address so that only you can download your eCard from the web link we will provide you with.
If you have any questions or queries about eCard, the team at RTITB would be more than happy to answer your questions – simply email NORS_team@rtitb.com or learn more about eCard by clicking here.
If you’re ready to get started on an operator course with us, and receive a brand RTITB eCard following completion, contact us on david.gearon@keyperformancetraining.co.uk
Almost 1,000 workers in the UK are seriously injured every year in forklift accidents, according to the Forklift Truck Association. From load falls to tip-overs to pedestrian casualties, winter weather can make operating a forklift truck highly dangerous for even the most experienced drivers, not to mention extremely challenging. Even with modern technology and advanced machinery, snowy and icy conditions pose risks for all forklift truck operators. Here at Key Performance Training, we are a leading provider of training in the forklift industry, so we know how important it is to be fully equipped with the right knowledge and skills. Read our guide on improving forklift truck safety in cold weather, so you and your employees can drive safely at work in the winter months.
Wear the right clothing
Employees operating forklifts in the winter months are likely to be working in very cold or even freezing temperatures. Too much exposure to the cold can cause health problems as serious as hypothermia and frostbite, which is why drivers need to wear the right clothing during their workday.
Thermal workwear including body warmers, fleece jackets, insulated hats and warm gloves are vital for employees operating in winter. A high-quality pair of work boots is also essential to keep your feet warm and dry while minimising the chance of slipping over on icy paths. Don’t forget to put on a high-visibility vest as well, to ensure you can be seen in all conditions. Most of the clothing required to improve forklift safety in winter can be found at Zoro. Install tyre chains.
All forklift drivers will know that having the right tyres is essential. As well as choosing strong, thick tyres which are durable and long-lasting, it is also recommended to have tyres with a deep, robust tread area. That’s not just the case for cold weather, though: well-maintained tyres are vital for forklift trucks, no matter what the weather conditions are.
But to make tyres even safer in winter, think about installing tyre chains to your forklift truck. These are designed to provide better traction in snow, which reduces the chances of drivers losing control on icy surfaces. Snow Chains offer a variety of tyre chains in different sizes, which can be easily fitted to most forklift trucks and then removed when the weather’s warmer.
Consistent maintenance is key
It is especially important to maintain a forklift truck in winter to avoid any accidents. Checks such as examining fluid levels, warning lights and the battery are some things operators should do every day. There are also obvious issues which should be looked for, including leaks and bodywork problems. But there are further tests drivers should be carrying out in winter to make sure their forklift is completely safe to operate. For example, you need to take extra care with trucks fuelled by liquid propane, as their coolant system can freeze in cold weather. It’s worth taking additional safety measures and purchasing a winter forklift service.
Provide full forklift training
If your employees have not been fully trained on operating a forklift in winter, they should not be driving it. Driving a car is simply not the same as handling a forklift truck and there are many more skills you need to have. Plus, when it comes to winter, supplementary knowledge is required to make sure you are completely prepared for harsh weather conditions.
Key Performance Training provides expert training on operating forklifts, including refresher training for those who need a reminder of how to work safely in winter. You can find out more about our forklift training courses here.
Staying safe in winter can be difficult for even the most experienced forklift truck drivers. But if you wear the right clothing, install additional protective gear, maintain your truck correctly and have it comprehensively serviced, you can greatly reduce the risk of danger. It’s also recommended to take forklift truck training courses, so you know the proper procedures for operating in cold weather.
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