Where would our modern-day supply chain be without the humble forklift truck? This warehouse workhorse is used worldwide to carry heavy loads safely and securely, boasting lifting power, speed, and durability that human strength simply can’t match. However, operating a forklift isn’t always simple. Without the right safety measures in place, even the most skilled forklift operator can be at risk of serious injury or death.
Thousands of driver and pedestrian accidents related to forklifts are reported by the Occupational Safety and Health Administration (OSHA) every year, leading to employee harm, lost productivity, and significant fines for non-compliant businesses. But by taking the right precautions, most common forklift accidents can be prevented before they occur. Here’s what you need to know about how to prevent forklift accidents at your warehouse or other material handling facility!
Establish a Safe Warehouse Environment
The number one way to prevent forklift accidents is to establish a strong safety culture among forklift operators and non-operators. Every warehouse worker — whether or not they plan to undergo forklift operator training — must understand and adhere to basic forklift safety protocols, which may also include reach trucks, order pickers, electric pallet jacks, and other mechanical equipment.
Essential accident prevention practices include, but are not limited to:
Clear Communication
Use hand signals, warning horns, or other standardized methods to communicate while operating a forklift or traveling near one. Workers should also understand the locations of forklift blind spots and avoid walking under a raised load under any circumstances.
Designated Pathways
All workers should observe and follow barriers, signage, speed limits, and floor markings that regulate the flow of foot and vehicle traffic in the warehouse.
Zero Tolerance for Horseplay
Horseplay is a leading cause of forklift fatalities, and it has no place in the warehouse environment. Establish and enforce a zero-tolerance policy for reckless behavior, such as distracted driving, exceeding speed limit signs, climbing equipment, or other horseplay on or near your forklift fleet.
Continuous Education
Provide ongoing safety tips and training to reinforce best practices and address emerging risks. These tips should be available to both forklift drivers and all warehouse employees who work near forklifts.
Maintain a Well-Marked & Orderly Warehouse
Another way to prevent common forklift accidents is to limit who can access your warehouse in the first place. Restrict access to equipment and secure areas to trained and authorized individuals only. Keep locations such as pedestrian walkways and loading areas clearly marked with floor tape or vivid signage, and use safety measures such as physical barriers to prevent accidental entry into hazardous zones.
The organization of your warehouse can also play a significant role in preventing the most common forklift accidents. Avoid leaving pallets, pallet jacks, forklift attachments, or other items scattered across the warehouse floor. Keep all aisles, lanes, loading docks, and other pathways clear so machines — and humans — have space to move. At Diversified Rack & Shelving, our pallet rack installers can help you plan an optimized layout for your warehouse to minimize the possibility of forklift accidents.
Provide Thorough Forklift Operator Training
While there’s no such thing as a universal “forklift license,” all forklift operators should be required to complete OSHA-approved forklift safety certification programs before handling equipment. OSHA-approved forklift operator training covers a variety of essential topics, including:
Forklift Parts and Operation
Operators should be able to identify the different parts of a forklift truck and understand how they work together. They should understand how to properly operate the forklift, including how to start and stop it, how to use the controls, and how to maneuver it with extreme caution. Finally, they should always utilize all available protective equipment in or on the forklift, including seat belts, harnesses, and other gear.
Load Capacity and Stability
According to forklift accident statistics, uneven weight distribution is a leading cause of forklift accidents. Operators should receive proper training regarding a forklift’s weight capacity and how to safely carry loads (the “stability triangle”).
Workplace Hazards
Forklift drivers should be aware of the hazards present in their workplace, such as pedestrians, other vehicles, and obstacles. They should also know how to identify and avoid potentially dangerous situations, such as slippery floors, uneven surfaces, and overhead obstructions.
Emergency Procedures
Along with knowing how to prevent accidents, forklift operators should know what to do in case accidents occur, such as forklift rollovers, collisions, and falling loads. Your facility should also have an emergency plan in place to handle forklift injuries.
Require Refresher Training
Current safety laws mandate that operators receive evaluations and forklift safety training at least every three years, but OSHA regulations encourage drivers to refresh their skills even more often. In addition, refresher training should be mandatory in several situations, including:
Involvement in an Accident or Near-Miss
Drivers who have caused (or nearly caused) an injury to people or property should review safety protocols and improve their skills to prevent forklift accidents in the future.
Changes in Workplace Conditions
Updates to warehouse layouts, new equipment, or revised safety procedures may require forklift drivers to undergo additional training.
Demonstration of Unsafe Practices
If a forklift operator’s performance appears unsafe — such as moving with elevated forks or traveling too quickly over uneven surfaces — they should undergo corrective training to address gaps in their knowledge.
Regularly Inspect & Maintain Equipment
Equipment failure is one of the most common causes of forklift accidents. Implement daily pre-operation equipment inspections to identify issues such as tire pressure problems, malfunctioning brakes, failing proximity sensors, or low hydraulic fluid levels. Address any problems immediately to avoid accidents caused by mechanical failures.
Along with regular safety checks, it’s essential to invest in regular forklift maintenance by professionals. Certified technicians can perform thorough inspections, replace worn parts, and ensure compliance with forklift manufacturer guidelines. Prioritizing regular maintenance not only extends the lifespan of your equipment but also safeguards your employees against forklift injuries and other costly accidents.
Contact Diversified Rack for Superior Warehouse Organization Solutions!
Forklift accidents can be dangerous or even deadly, but with the right precautions, you can minimize the likelihood that they will occur. By following these essential steps at your facility, you can provide a safer working environment for everyone.
If you’re looking for new or used industrial shelving or pallet racking for your NJ, PA, or NY warehouse, Diversified Rack & Shelving is the team to call. With decades of experience in material handling solutions, CAD warehouse design, and other related specialties, we are here for all of your warehouse organization needs. Contact us today to request a quote or to speak with our pallet racking pros!