Lift truck tips: Top 5 lift truck hazards

Focusing your lift truck operator's efforts on these common situations will result in a safer workplace.

By James P. Kaletta, Guest Columnist -- Modern Materials Handling, 3/1/2009

Remind all operators to look behind the vehicle before and during all backups.

Help your lift truck operators stay sharp with remainders about these common hazards.

1) Pre-use inspection

Correctly done inspections are critical.

Review inspection sheets periodically with operators. Clarify the process and remind them of specific responsibilities. Let operators be held accountable for reporting any problems with the condition of their vehicle.
Conduct random joint inspections of a vehicle with its operator to observe and coach the inspection process.
Review vehicle inspection sheets at least monthly and evaluate them for accuracy and completeness.
Remind your employees to tag out a lift truck whenever a pre-use inspection identifies a problem. Take the truck out of service until the repair is made.

2) Pedestrian safety

Most companies rely on walkways indicated by floor markings where lift trucks and pedestrians co-exist. That’s a good first step.

Keep lift truck operators and pedestrians safe by developing and communicating rules and responsibilities. For example, who has the right of way in your facility?
Provide formal pedestrian safety training to all employees who work on and near lift trucks. Then, hold them accountable by observing, coaching and reinforcing positive behaviors.

3) Backups

A common—and often unconscious—habit for lift truck operators is to look forward during the initial part of the backing up maneuver. Unfortunately, pedestrians often approach trucks from behind, leaving them vulnerable.

Remind all operators to look behind the vehicle before and during all backups.
Develop a targeted observation process to help break this habit.
Develop a safe backing task as part of your initial and refresher training.

4) Speeding

Faster is not always better. Serious injuries and property damage can result from excessive speeds.

Post formal speed limit signs in areas where pedestrians are present. Lift trucks should not go faster than a person’s brisk walking pace, typically about 5 mph.
As part of your observations, walk parallel to operators. If anyone pulls ahead quickly, he needs to slow down.

5) Material storage

Lift truck operators should retain primary responsibility for safely storing and placing materials.

First, the operator must verify each load is stable and stored on pallets of acceptable quality before moving it.
Any load not in good condition must be addressed immediately. This includes replacing the pallet and/or restacking or securing the load.
Hold each operator accountable to a specific area during scheduled walkthroughs. If they see any damaged or unstable stacks, they need to correct the situation.
Limit pallet stacks to no more than 15 high in dock areas. This practice reduces unstable stacks, lessens visual obstructions and reduces the overall fire load. Noncompliant stacks stand out.

Author Information

Jim Kaletta, MS and certified safety professional (CSP), is president of Safety Management Solutions. He can be reached at 773-935-8326 or jkaletta@safeteam.com.

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