Forklift/powered Industrial Truck Safety Training

Introduction

The scope of this training program is to establish a procedure for the operation of all powered industrial trucks (P.I.T.) utilized at Aero Fulfillment Services. These P.I.T.s include, but are not limited to, forklifts, walkie riders, order pickers, turret trucks, scissor lifts, and reach trucks.

Forklift/Powered Industrial Truck Safety Training

Employers are required by OH Rev. 4167-3-03 Amending of existing standards for Power Industrial Truck Safety to ensure that all employees, both permanent and temporary, adhere to the laws set forth by this code. This training additionally supports compliance with the Occupational Safety and Health Administration Powered Industrial Truck Standard, as found in 29 CFR 1910.178. This training applies to all Aero Fulfillment employees, permanent or temporary, who are required to operate material-handling equipment, including forklifts, reach trucks, order pickers, and powered pallet jacks.

Responsibilities

Powered Industrial Truck Operators:

Operators are responsible for the following:

• Operating all powered industrial trucks in a safe manner consistent with safe rules of operation.
• Inspecting powered industrial trucks at the beginning of each work shift and completing the appropriate inspection forms.
• Reporting all equipment malfunctions and/or maintenance needs to their supervisors immediately. Park lift in a safe place, remove key, tag, or note problem.

Who Requires Training

All personnel who operate forklifts, scissor lifts, powered hand trucks, order pickers, turret, and any other P.I.T. are required to have the following training. Training shall consist of a combination of formal instruction, practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), a written test, and evaluation of the operator's performance in the workplace. Someone who is authorized, qualified, and determined to be competent shall conduct all training.

Training Overview

This training class will encompass the following:

• Operating instructions, warnings, and precautions for the types of truck the operator will be authorized to operate;
• Truck controls and instrumentation: where they are located, what they do, and how they work;
• Steering and maneuvering;
• Visibility (including restrictions due to loading);
• Fork operation and use limitations;
• Vehicle capacity and stability;
• Any vehicle inspection and maintenance that the operator will be required to perform;
• Charging and recharging of batteries;
• Operating limitations;
• Any other operating instructions, warnings, or precautions listed in the operator's manual for the types of vehicle that the employee is being trained to operate.
• Surface conditions where the vehicle will be operated;
• Composition of loads to be carried and load stability;
• Load manipulation, stacking, and unstacking;
• Pedestrian traffic in areas where the vehicle will be operated;
• Narrow aisles and other restricted places where the vehicle will be operated;
• Hazardous (classified) locations where the vehicle will be operated;
• Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.

The Need for Refresher Training

Refresher training will be conducted on an as-needed basis. The need for a refresher training course shall result from any circumstance listed below:

• The operator has been observed to operate the vehicle in an unsafe manner;
• The operator has been involved in an accident or near-miss incident;
• The operator has received an evaluation that reveals that the operator is not operating the truck safely;
• The operator is assigned to drive a different type of truck;
• A condition in the workplace changes in a manner that could affect the safe operation of the truck.

An evaluation of each powered industrial truck operator's performance shall be conducted at least once every three years. Employee training records shall be maintained for five years.

Program Activities

Equipment Inspection and Maintenance

• Each powered industrial truck will be inspected before each shift.
• A file will be maintained that lists the shift inspections of equipment. This file will be kept on the equipment being inspected.
• A maintenance log will be kept that identifies repair needs and corrective actions taken for each powered industrial truck. This log will be kept at the Maintenance Administration Offices.
• If repairs are needed on a powered industrial truck such that it cannot be safely operated, it will be tagged out and taken out of service until the repairs have been made.
• After repairs have been completed, the powered industrial truck will be given a performance test to ensure that the equipment is safe to operate.
• Powered industrial trucks will be kept in clean condition, free of dirt, excess oil, and grease.

Changing and Charging Batteries

• Equipment will be provided to safely flush and neutralize spilled battery acid and electrolyte.
• Eyewash equipment will be maintained in all charging areas.
• Precautions will be taken to prevent open flames, sparks, and electric arcs in charging areas.

Safe Work Practices

• Only authorized, trained personnel shall operate lift trucks.
• Before the start of the shift, a visual inspection must be conducted. Employees shall not operate an unsafe forklift at any time.
• Operators shall drive with both hands on the steering wheel. Horseplay is prohibited. Do not drive with wet or greasy hands.
• No person shall ride as a passenger on any P.I.T. or on the load being carried.
• A forklift will not be used to elevate a platform or pallet with persons on it, except work platforms especially designed for this purpose. Work platforms must have standard guard rails and must be securely fastened to the forks.
• No person shall stand or walk under elevated forks.
• Operators should avoid making jerky starts, quick turns, or sudden stops. The operator will not use reverse as a brake.
• Operators nearing a blind corner shall make their approach at reduced speed. Sound horn and proceed carefully.
• Operators shall give pedestrians the right-of-way at all times.
• Operators shall not drive toward any person who is in front of a fixed object or wall.
• Operators shall not overtake and pass another forklift traveling in the same direction, at intersections, blind spots, or hazardous locations.
• Operators should not put their fingers, arms, or legs between the uprights of the mast or beyond the contour of the forklift.
• Forks should always be placed under the load as far as possible. Do not lift a load with one fork.
• No load should be moved unless it is absolutely safe and secure.
• Avoid sharp or fast end-swing.
• Forklifts must be safely parked when not in use. The controls shall be neutralized, power shut off, brakes set, key removed, and the forks left in a down position flat on the surface, and not obstructing walkways or aisles.
• A forklift shall not be left on an incline unless it is safely parked and the wheels blocked.
• Only stable and safely arranged loads will be handled.
• Only loads within the rated capacity of the powered industrial truck will be handled.

Traveling

• A powered industrial truck will be operated at speeds that will permit it to be brought to a stop in a safe manner.
• Three truck lengths (or two seconds) will be maintained between powered industrial trucks in operation.
• The powered industrial truck will be kept under control at all times.
• When vision is obscured, the operator will slow down and sound the horn.
• If the load blocks the operator’s view, the powered industrial truck will be driven in the direction that provides the best visibility.
• The operator will keep a clear view of the path of travel.
• When the forklift is not carrying a load, the operator shall travel with the forks as low as possible (maximum of 3 inches off the floor). When carrying a load, it should be carried as low as possible (consistent with safe operation, 2 to 6 inches above the surface).
• The forks should not be operated while the forklift is traveling.

References

• Occupational Safety and Health Administration. (n.d.). Powered Industrial Trucks - Forklifts. Retrieved from https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.178
• Ohio Administrative Code. (n.d.). 4167-3-03 Amending of existing standards for Power Industrial Truck Safety. Retrieved from http://codes.ohio.gov/oac/4167-3-03