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.
At Key Performance Training, our aim is to provide delegates with a pathway to employment and help them find a job, a better job or a career.
In Swindon and the surrounding areas there are many job opportunities and a demand for Forklift Truck operators meaning that employment is easy to find after completing training. We see ourselves as the stepping stone between a delegate and their future in employment.
Below are the 4 steps towards the pathway of employment.
Step 1- Free Taster Session: Our free taster sessions or ‘Forklift Fridays’ are an opportunity for potential delegates to come along to the warehouse and find out more about the courses we offer. The session is up to two hours and includes demonstrations, information sheets, having a go on one or both trucks and also being given a chance to ask questions to our highly experienced trainers.
We want to be sure that all delegates are committed to a course before booking so we will always give feedback to either the delegate, the company or job coaches as to whether they are likely to succeed.
Step 2- Training: The duration of training can be anywhere from 1-5 days depending on the type of course, your level of experience and the delegates:trainer ratio. In all FLT courses there are elements of both theoretical and practical training that need to be completed before test day. At the end of the training you will be given both a theory and practical test that will be completed in a non- pressurised environment. Don?t worry though, as our trainers will make sure you are 100% ready before putting you in for the test and have the skills to put you at ease beforehand.
Step 3- You have your license: Successful learners will be presented with an RTITB approved certificate and photo ID card and will also be registered onto the RTITB National Operators Register Scheme database of approved forklift truck operators (NORS) for 3 years. We will then put you in contact with local employment agencies that can help you find work and also keep you updated on any new job vacancies that come up in the local area.
Step 4: Finding work- There you have it, you have now unlocked your pathway into employment! Often delegates find work 1-2 weeks after completing a course with us and although it is not certain you will find work straight away we always make sure you are the first people to know about any new job vacancies.
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.
About Bob Hayward- The Managing Director and owner of Key Performance Training
Bob has had quite a journey from humble beginnings near Broad-water Farm in Tottenham (yes, he is a Spurs fan) failing his A levels and even the entrance exam for a Postman. Then a bad motor bike accident changed the course of his life forever. The six-week stay in hospital and the one year on crutches it took to recover led him to become a nurse. First a Registered General Nurse, then a spell in Intensive Care before taking a second-degree course in Psychiatric Nursing. After a 12-year career in nursing he took up selling and built a nursing agency from scratch to a 5.6 million turnover in five years. In his business career, Bob has started four businesses from scratch and built each of them to 1M turnover or more.
Bob actually hit the national headlines in 2001, but not for his business or consultancy skills, this was when he ran 33 marathons in only 40 days to get from Lands End to John O’groats in aid of a burns victim called ‘Podge’. He continues to raise money for charities close to his heart through marathon running and completed a further major test of endurance in October 2005 by running 6 marathons over 6 days across one of the hottest places in the world~ Death Valley~ this time in aid of Swindon food bank, tackling issues of poverty and deprivation.
How Key Performance Training started:
In 2017 Bob was involved in one of his many business ventures throughout his life; a recruitment firm recruiting pickers and packers for warehouses. He became aware that there was a huge demand for Forklift Truck Drivers in general but specifically in Swindon and the surrounding areas. As the business minded man he is, he decided to try and meet this demand by setting up a FLT training company to get as many people their license as possible and also to upskill pickers and packers.
The next stage? He needed to find a warehouse. After searching, he found a suitable location in Upper Stratton Headlands Unit trading estate where ‘Mr Shifter’ a local house moving and storage company were located and had enough room to rent out half of the warehouse for KPT. Bob and the 3 owners of Mr Shifter came to an agreement that they would all co-own the business and after months of finalisations on the 19th December 2017 Key Performance Training was born.
Although Bob had expertise and business knowledge behind him, he had no idea how to operate, let alone teach people how to operate Forklift Trucks. This was where the expert came in – David Gearon.
David had years of FLT training experience behind him from working as a trainer at Honda for 5 years, being a subcontractor for a company called Mentor for a further 2 years and then going on to turn around a company with a particularly bad reputation of their safety around FLT and getting them to do things the proper way. Whilst Bob was creating KPT, David was working in a job that he wasn’t enjoying and wanted to get back into training. By chance, as his contract was coming to an end, he saw advertised a job as a FLT trainer for a new company Key Performance Training and applied instantly. The recruiters knew how amazing David was at what he does and was surprised that he was out of training work. He was invited in for an interview at the warehouse which solidified that he would be the perfect man for the job.
Now , 4 years later and with Bob now as the sole owner and David as the head trainer. KPT is still surviving; even through a pandemic where nobody could be trained!
Cross- training employees can be a catalyst to a huge improvement in workforce productivity of any business. Here are the 5 main benefits of cross-training in the warehouse sector, however the advantages do not stop here, they are endless!
What does it mean to cross train an employee?
Cross-training is building the skills of your employees so that they can work in several different roles and carry out tasks even if they aren’t part of their main daily responsibilities. As a result, you, as the employer, can increase productivity in the workplace by making the maximum use out of the latent talents and skillsets of your employees.
For example, when summer is approaching and people are rushing into travel agents to book their last-minute holidays, if employees who usually handle telephone customer service enquiries are also trained to handle walk-in customers, then the travel agency will be more able to handle the increased demand.
Similarly, in the warehouse sector if someone in your team who usually works in production work could also operate forklift trucks you could move them temporarily to the loading team if there is a spike in demand. This prevents orders falling behind and increases the overall efficiency and effectiveness of your team.
Cross-training, specifically in the warehouse sector, is something that gets spoken about more than it is actually implemented. What is the main reason for that? Because people are simply unaware of the multitude of gain generated from this method. Hopefully after reading this blog post, you will be part of the percentage who are aware of the benefits, and will be tempted to use that knowledge to your advantage!
1. Great return on investment
The key to cross-training making a great return on investment is realising that the talent you are trying to outsource is most likely already within your business. Once you’ve had this realisation and act upon it, you are likely to see ways to boost to your bottom line.
2. Improved employee retention
A study conducted at the university of Warwick via Forbes found that on average, happy and engaged employees are 12% more productive than their unhappy counterparts. Cross-training has a significant effect on individual employee happiness because with a broader range of skills employees will feel as though they are being invested in and in return will become more engaged. Continuously focusing on the skillset of your existing employees rather than trying to recruit new employees with prior qualifications, will keep long term employees more committed to stick around.
3. Reduced impacts when employees are absent
This is a fairly straightforward benefit but often people do not realise the extent of a positive impact having cross-trained employees can have when absence occurs. For example, if your business has 10 employees and each of them have a total of 25 holidays per year that would be a total of 250 days a year where at least 1 person’s list of responsibilities are not getting completed. Does that sound efficient to you?
When your work-force is “cross-fit”, you will be able to substitute somebody from a less busy shift or a different sector who has the knowledge to cover for the absent employee. As a result, a significant increase to the number of responsbilities and tasks that are being completed will arise and the productiveness\output of the company will expand.
Ideally, even in a small company, you would have three people or more who could do any single job – even if only to ‘hold the fort’ professionally for a shift or a day. There is a direct link between the competency of your people and the confidence your customers have in you as a supplier.
4. Better employee collaboration
There are two types of employees. Those who have just expertise in one area (not cross-trained) and those who have expertise in one particular aspect but also still have a broad knowledge of other aspects in the company (cross-trained). When you are the non-cross trained type of employee you are hyper-focused to that one particular area and therefore find it difficult to collaborate with those in other sectors of your company.
Good collaboration is crucial within a company as it allows you and a team to solve problems together, speeding up the process of finishing a task and avoiding breakdowns in communication.
5. Makes your company more agile
The actual process of cross-training employees may reveal areas of strengths and weaknesses in employees. Throughout the on-the-job-training hidden talents and strengths may be revealed that means people would work better in another area or field of the business. You can then change people around accordingly. This makes your company more agile and responsive to change as-well as increasing flexibility when needing to fill last minute absences.
Being an agile company has a range of benefits such as more resilience, quicker decision making, more collaborative and also quick mobilization.
How Key Performance Training can help your business with cross-training
Key Performance Training based in Swindon and RTITB Approved, can unlock your potential with novice, refresher, experienced courses in Forklift Training, First Aid, Health and Safety and Fire Marshall Training, amongst others, at regular times throughout the year in a specifically designed training centre or on-site at your own location , amongst others, at regular times throughout the year in a specifically designed training centre or on-site at your own location if you prefer. From individual training to large scale corporate roll outs.
