OSHA regs alter operator training

Strict rules now in force have led to changes in the programs companies use to instruct those who drive powered industrial trucks

By -- Modern Materials Handling, 4/1/2000

Late in 1998, the Occupational Safety and Health Administration set in motion new, detailed regulations on instructing operators of powered industrial trucks. Employers throughout the U.S. had until December 1999 to gear up their training programs to comply.

Modern Materials Handling surveyed readers who specify and buy lift trucks to determine the impacts of compliance. We e-mailed a series of questions to 3,000 readers.

Overwhelmingly, readers say their companies and organizations have changed training programs to meet the agency' s rules. Eighty-seven percent say they have modified or adapted their instruction efforts compared to what they did before.

Even among those who replied "no" to this question, more readers (58%) anticipate a need to make changes in the future, than those who are satisfied (42%) with the status quo.

We asked readers to check all of the resources they use to train.

A surprisingly high percentage of readers (79%) use in-house programs to train their operators. Responses checking off private training firms and dealer programs both drew 20% scores. Only 6% of respondents turn to manufacturer training.

Before the survey, we would have guessed that those using in-house programs would be lower, and dealer programs higher, in percentage terms.

Here are several possible explanations for the high response rate for in-house programs: OSHA' s rules require that some part of the training be site specific. Moreover, employers are required to take final responsibility that their employees are trained.

Classroom instruction (88%) and hands-on practice (90%) are the most popular methods of operator training, the survey finds. Videos are shown to train operators, say 71% of our respondents.

Far less commonly used methods are slide presentations (21%) and CD-ROM instruction (5%).

One question sought to discover whether experienced operators receive training, and, if so, how much. Sixty-nine percent of respondents say they give these more skilled operators some degree of training; 31% say they have received no added training.

Much of that added instruction is minimal, however. That's how 58% of MMH readers described instruction given the older hands. Moderate training was necessary for 37%, while only 5% required extensive instruction.

Spending this year on operator training will be $10,000 or less, say 82% of responding readers. An additional 5% reply that there will be no expenses for instruction. But for 11% the expense will range as high as $50,000.

Among some readers the costs will be even higher. Two readers (1% of responses in our sample) say costs will be between $50,001 and $100,000. And two others (1%) say spending will be more than $100,000. Presumably, these four responses come from execs in charge of large fleets of forklifts or those who manage multiple plant and warehouse sites.

Finally, readers were asked about the record-keeping aspect of the agency's rules. Three-quarters of responses gave OSHA high marks: 76% say record-keeping is "fair, easy to comply with." Meanwhile, 24% say it is "too detailed, complicated."