SAFE OPERATION OF FORKLIFT A TRAINING FOR THE METALWORKING INDUSTRIES Updated on June 2015

SAFE OPERATION OF SAFE OPERATION OF FORKLIFTFORKLIFT

A TRAINING FOR THE METALWORKING INDUSTRIES

Updated on June 2015

Table of ContentsTable of Contents

Introduction

Risk management on forklift

Common forklift hazards

Route plan

Training for forklift operators

Pre-operation checks

Load assessments

Common safe practices

Forklift traffic control

IntroductionIntroduction

Forklift can be hazardous if not handled properly

Forklift accidents can cause serious injury, death,

property and product damage

This poses a serious problem

for everyone

Accidents can be prevented if risk assessment and

safe work procedures (SWP) are followed.

Picture source: Picture source: http://www.thompsonandjohnson.com/images/accident1.jpg http://www.thompsonandjohnson.com/images/accident1.jpg

Forklift Fatalities in SingaporeForklift Fatalities in Singapore

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

Total

Forklift 5 2 2 1 1 1 1 6 0 3 9 31Motor vehicles NEC

0 0 4 0 3 1 1 1 3 0 2 15

Others 1 0 0 0 0 0 1 2 1 0 4 9

Lorries 0 2 1 0 0 0 0 0 1 0 1 5

Trucks 0 0 2 0 0 0 0 1 0 0 1 4

Mechanical Conveyors 0 0 0 0 1 1 `0 0 0 2 0 `4

Source: Ministry of ManpowerSource: Ministry of Manpower

Potential Forklift AccidentsPotential Forklift Accidents

Picture source: Picture source: http://marbella.to/humour/sep00/forklift.jpghttp://marbella.to/humour/sep00/forklift.jpg

Potential Forklift AccidentsPotential Forklift Accidents

Picture source: http://www.facelift.co.uk/images/roguesgallery/forklift_no-Picture source: http://www.facelift.co.uk/images/roguesgallery/forklift_no-no1.jpgno1.jpg

Forklift AccidentsForklift Accidents

Picture source: Picture source: http://siri.uvm.edu/graphics/Industrial_Operations/Forklift_accident.gifhttp://siri.uvm.edu/graphics/Industrial_Operations/Forklift_accident.gif


Picture source: Picture source: http://www.jicosh.gr.jp/english/cases/cases/case105.gifhttp://www.jicosh.gr.jp/english/cases/cases/case105.gif


Picture source: European Industrial Gases AssociationPicture source: European Industrial Gases Association

Risk Management on Risk Management on Operation of ForkliftOperation of Forklift

Required to manage risks under WSH (risk management) regulations

Assess the risk

Take all reasonably practical steps

Eliminate any risks


Step 1: Identification of hazard

Picture source: Picture source: http://www.safetyworld.com/images/101.gifhttp://www.safetyworld.com/images/101.gif

Common Forklift HazardsCommon Forklift Hazards

Overloading

Unsafe stacking

Speeding

Raised forks

Unauthorized operation of forklift

Untrained forklift operators

Picture source: Picture source: http://www.iqsdirectory.com/info/fork-lift-trucks/images/fork2.jpghttp://www.iqsdirectory.com/info/fork-lift-trucks/images/fork2.jpg


Lifting of persons on forks

Pedestrians and forklifts moving in the same place

Travelling on slope

Obstruction in the path e.g. overhead, blind corners

Poor ground conditions e.g. slippery, uneven, potholes


Body/limbs caught in moving parts of the forklift

Falling loads

Poor condition tyres e.g. without thread markings

Electric Shock (Battery operated forklift)

Source: Ministry of Source: Ministry of ManpowerManpower

Picture source: http://www.cdc.gov/niosh/face/images/96nj062.jpgPicture source: http://www.cdc.gov/niosh/face/images/96nj062.jpg


Pedestrians and forklift moving in same place

Picture source: http://www.safetyworld.com/images/67.gifPicture source: http://www.safetyworld.com/images/67.gif


Forklift traveling on slope

Picture source: http://www.sandhillquilting.com/images/M-16-SYS-8436-L.jpgPicture source: http://www.sandhillquilting.com/images/M-16-SYS-8436-L.jpg


Poor ground conditions

Picture source: Picture source: http://eternitycaptured.com/blog/wp-content/uploads/2007/04/bigstockphoto_Road_Cracks_And_Potholes_http://eternitycaptured.com/blog/wp-content/uploads/2007/04/bigstockphoto_Road_Cracks_And_Potholes_606173.jpg606173.jpg


Worn out tyres

Picture source: Picture source: http://www.riverina.coop/depts/Realestate/Other/forsale_auctions/whybro/RIMG2040.JPGhttp://www.riverina.coop/depts/Realestate/Other/forsale_auctions/whybro/RIMG2040.JPG


Unsecured load

Picture source: http://www.locknpop.com/images/img_fork.gifPicture source: http://www.locknpop.com/images/img_fork.gif


Electric shock from battery

Picture source: http://www.ubuyme.com/img_prod/679/pic1.jpgPicture source: http://www.ubuyme.com/img_prod/679/pic1.jpg


Lifting Persons on ForksPicture source: http://www.ttt-services.co.uk/Healthandsaftey/forklift_web.jpgcPicture source: http://www.ttt-services.co.uk/Healthandsaftey/forklift_web.jpgc


Step 2: Assess the risk

Dependent on severity of risk and likelihood of hazards occurring

severity X likelihood = risk level

Risk Level = Low, Moderate or High


Rare(1)

Remote(2)

Occasional(3)

Frequent(4)

Almost Certain

(5)

Catastrophic (A) Medium Medium High High High

Major (B) Medium Medium Medium High High

Moderate (C) Low Medium Medium Medium High

Minor (D) Low Medium Medium Medium Medium

Negligible (E) Low Low Low Medium Medium


Step 3: Select Measures to Control and Reduce Risk

Based on hierarchy of hazards control

1st – Remove the hazard (E.g. Forklift operations route separated from workers)

2nd – Guard the remaining hazards (E.g. Erect physical protective barriers)


HIERARCHY OF HAZARDS CONTROL

11stst Remove the Hazards – Remove the Hazards – Forklift Route PlanningForklift Route Planning

Picture source: http://maaw.info/images/Figure8-Picture source: http://maaw.info/images/Figure8-10.gif10.gif

Route PlanRoute Plan

• Efficient workplace layout/plan

• Floors and surfaces in good condition

• Fixtures which are clearly visible

• Forklift operating and pedestrian paths identified and clearly marked

• Designated maintenance, parking and battery charging areas

Forklift Operation Separated Forklift Operation Separated from Worker Areafrom Worker Area

Forklift operation area

Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc

Allocated Goods AreaAllocated Goods Area

Goods sitting area


Designated Battery and Designated Battery and Parking AreaParking Area

Forklift battery charging and parking area


22ndnd Guard the Remaining Guard the Remaining Hazards: Protective BarriersHazards: Protective Barriers

Brightly coloured barriers



3rd – Mitigate impact of hazard (E.g. Operator to wear an seat belt)

Source: Source: Ministry of Manpower


Risk assessment to be done for every forklift tasks

To identify the risk and control measures

Establish safe work procedures (SWP)

Inform staff of SWP

Staff to follow SWP



Forklift Safe Work Procedures (SWP)

Forklift TrainingForklift Training

Pre-Operation CheckPre-Operation Check

Load AssessmentLoad Assessment

Common Safe PracticeCommon Safe Practice

Traffic ControlTraffic Control


Forklift Training Forklift Training

Under Factories (Safety Training Courses) Order, all forklift operators shall undergo a Forklift Drivers’ Training Course

Conducted by a MOM Accredited Training Provider

Consists of 1-day theory course

And 4 or 2 days practical course

Why Conduct Forklift Training Why Conduct Forklift Training

Ensure forklift drivers are competent

To train driver in basic forklift operation

To provide knowledge of safe operating practices for forklift

Picture source: http://www.crowndfw.com/training.htmlPicture source: http://www.crowndfw.com/training.html

Why Conduct Pre-operation Why Conduct Pre-operation Checks?Checks?

Ensure efficient and safe operation of forklifts

Prevent workplace injuries

To remove inefficient forklift practices

Under WSHAC Forklift Checklist, Pre-Under WSHAC Forklift Checklist, Pre-operation Checks Includes:operation Checks Includes:

Tyres and wheels Forks/attachments Chains, cables and hoses Safety devices (e.g. seat belts, warning devices,

rear mirror and etc.) Leaks Hour meter Battery/LPG system Battery connector Guards Structural damage

Pre-operation Checks 1Pre-operation Checks 1

Source : http://www.thefabricator.com/Images/96/forklift-truck-Source : http://www.thefabricator.com/Images/96/forklift-truck-diagram.jpgdiagram.jpg

Pre-operation Checks 2 – Pre-operation Checks 2 – Propane ForkliftPropane Forklift

Picture source: Picture source: http://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gifhttp://www.osha.gov/dcsp/ote/trng-materials/pit/images/pitchklistimg2.gif

Pre-operation Checks 3 – Pre-operation Checks 3 – Electric ForkliftElectric Forklift


Pre-operation Checks 4 – Yard Pre-operation Checks 4 – Yard ForkliftForklift


Forklift Load Assessments 1Forklift Load Assessments 1

• Forklift can only handle loads within rated capacity

• Follow forklift manufacturer’s load chart

Forklift Model

Length of fork

Picture source : Picture source : http://gmesupply.com/images/product_desc_images/forklifts/load-chart.jpghttp://gmesupply.com/images/product_desc_images/forklifts/load-chart.jpg


• When attachments are used, the total weight of the load and attachment must not exceed the lifting capacity

Picture source : http://www.kinggroup.com.auPicture source : http://www.kinggroup.com.au


• Don’t increase the capacity of the forklift using personnel as additional counterweights

Picture source : http://www.staugustinelighthouse.com/blog/forklift.jpgPicture source : http://www.staugustinelighthouse.com/blog/forklift.jpg


• Only handle stable or safely arranged loads

• Care to be taken when handling extra long or high load

• When loads can’t be centered, the forklift should be operated with caution

Picture source: http://www.baileypottery.comPicture source: http://www.baileypottery.com

Source: CP 101: 2004 Code of practice for safe use of powered counterbalanced forkliftsSource: CP 101: 2004 Code of practice for safe use of powered counterbalanced forklifts

Load Assessments – Weighing Load Assessments – Weighing the Loadthe Load

Picture source: http://www.weighing-systems.com/TechnologyCentre/forkliftweigh.htmlPicture source: http://www.weighing-systems.com/TechnologyCentre/forkliftweigh.html

Load Assessments – Weight at Load Assessments – Weight at Centre of GravityCentre of Gravity

Forklift

Picture source: Picture source: http://www.morsemfgco.com/images/forklift_sm.gif


Picture source: Picture source: http://www.rentrain.com/resources/fork_21.gif


Picture source: http://www.ccohs.ca/images/J05-2.gifPicture source: http://www.ccohs.ca/images/J05-2.gif

Load Assessments – Load Assessments – CharacteristicsCharacteristics

Unstable load

Picture source: Picture source: http://www.thetoyspace.com/images/planforklift.gif

Picture source: Picture source: http://user1292213.sites.myregisteredsite.com/sitebuildercontent/sitebuilderpictures/forklift.gifhttp://user1292213.sites.myregisteredsite.com/sitebuildercontent/sitebuilderpictures/forklift.gif

Load Assessments – ShapeLoad Assessments – Shape

Odd shape load may hit pedestrians causing injuries

Picture source: http://www.nepowder.com/images/FORKLIFT%20II.JPGPicture source: http://www.nepowder.com/images/FORKLIFT%20II.JPG

Load Assessments – ShapeLoad Assessments – Shape

View blocked, the forklift may hit another container or somebody

Picture source: Picture source: http://www.fremantleports.com.au/About/PhotoGallery/North_Quay_forklift_operations_at_night_rdax_77http://www.fremantleports.com.au/About/PhotoGallery/North_Quay_forklift_operations_at_night_rdax_772x526.jpg2x526.jpg

Common Safe PracticesCommon Safe Practices

Don’t drive a forklift unless you are trained and authorized

Use seatbelts

Wearing seatbelts


Report to your supervisor on any forklift damage or problems

Don’t use a forklift to lift worker

Use caution on slopes or ramps

Picture source: http://www.liftomatic.comPicture source: http://www.liftomatic.com


While on slopes, tilt the load back and raise it above road surface

Don’t raise or lower the forks while the forklift is moving

Don’t handle loads that are above the weight capacity of the forklift

Follow the speed limit


Slow down and sound the horn at crossings and locations where view is blocked

Focus on the travelling path and keep a clear view of it

When leaving a forklift, pull the parking brake, lower the forks and neutralize the controls

Source: Source: NIOSH Publication No. 2001-109

Hand brake not engaged

Picture source: Picture source: http://www2.worksafebc.com/i/posters/2003/ha0313_forklift.htm


Attend briefing on forklift operations

Follow traffic management

Carry out daily forklift pre-operation checks using checklist

Ensure that the forklifts are well maintained

Use rear view mirrors while reversing

Give way to pedestrians

Park forklift at approved locations.

Picture source: Picture source: http://www.safety-mirrors.co.uk/cabfront.jpg


Operate forklifts with forks at low position at all times

Don’t drive and raise load at the same time

Don’t make sudden sharp turns

Don’t brake suddenly when the forklift is

loaded

Watch out for overhead structures (e.g. pipes & beams)

Travel in reverse when front view is blocked


Picture source: Picture source: http://www.iqsdirectory.com/info/fork-lift-trucks/images/fork1.jpg

Traffic ControlsTraffic Controls

• Follow the forklift route plan and pedestrian path

• Obey the speed limits, pedestrian crossings and one way signs etc.


• Follow site rules and inform all staff and visitors

• Operate forklift only in clearly marked areas

• Lookout for people opening doors

• Check back when reversing

• Give way to pedestrians

Picture source: http://www.derrycity.gov.uk/Site_Images/forklift.jpgPicture source: http://www.derrycity.gov.uk/Site_Images/forklift.jpg


• Wear high visibility clothing

• Be cautious on road slopes

• Park on flat surfaces

• Avoid driving over objects on the road surface

• When making turns, reduce speed to safe level

Picture source: http://www.thompsonandjohnson.com/newsletter/images/tip70509.jpgPicture source: http://www.thompsonandjohnson.com/newsletter/images/tip70509.jpg

Summary of Key PointsSummary of Key Points

Training for forklift operators

Pre-operation checks

Load assessments

Route plan

Common forklift hazards

Forklift common safe practices

Forklift traffic control

Risk management on operation of forklift

All accidents are All accidents are preventablepreventable

Be proactive: it is up to Be proactive: it is up to US to prevent itUS to prevent it

Thank YouThank You

References:References:

1. WSHAC Occupational Safety & Health Technical Advisory – Safe Operation of Forklift Truck

2. WSHAC Forklift Safety Checklist3. CP: 101: 2004 Code of Practice for Safe Use of Powered

Counterbalanced Forklifts4. MOM Case Studies on Forklift Accidents5. NIOSH Publication No. 2001-109 NIOSH Alert: Preventing

Injuries and Deaths of Workers Who Operate or Work Near Forklifts

6. Chisholm Institute (Warehouse Task – Drive a forklift) (http://olvc.chisholm.vic.edu.au/warehouse/D10/Virtualwarehouse/D10Tasks/D10tasks.htm)

Appendix 1Appendix 1




Appendix Appendix

Documents

SAFE OPERATION OF FORKLIFT A TRAINING FOR THE METALWORKING INDUSTRIES Updated on June 2015