Forklift accidents result in roughly 85 workplace deaths and thousands of injuries per year. For the most part, these incidents could have been prevented with adequate training and equipment upgrades.
To protect your workforce, reduce liability, and maintain your operations, you need to understand some common forklift safety mistakes and how to avoid them. With this helpful guide, you’ll discover how modern safety technologies and proven operational practices work together to create better work environments.
No matter the circumstances, you cannot allow untrained operators to use forklifts. Since many accidents are the result of improperly trained operators, OSHA mandates that all forklift operators complete formal training and evaluation before driving the equipment alone.
Comprehensive training should cover load capacity limits, stability principles, preoperational inspections, and emergency procedures. Your operators must also understand how load weight distribution affects vehicle stability and how environmental factors impact safe operation.
Establish a certification renewal schedule that includes refresher training every three years or after any accident. To comply with OSHA requirements, document all training activities and maintain certification records diligently. Additionally, consider partnering with certified training providers who offer hands-on instruction tailored to your specific equipment models and operational requirements.
Exceeding manufacturer-specified load capacities ranks among the most dangerous forklift mistakes. You risk catastrophic tip-overs when operators attempt to lift loads beyond equipment limits or ignore proper load positioning requirements.
Every forklift displays a data plate that specifies its maximum load capacity at specific load centers. Train your operators to calculate actual load weights and verify capacity before attempting lifts. Keep in mind that loads positioned beyond the standard 24-inch load center dramatically reduce safe lifting capacity.
Using floor scales or load moment indicators, implement load weight verification procedures. Establish clear protocols for handling oversized or irregularly shaped loads that affect vehicle stability. Ensure all operators understand that rushing to move heavy loads without proper assessment creates unnecessary risks.
Skipping daily preoperational inspections can lead to equipment failures that cause accidents and costly downtime. Before each shift, operators must complete thorough inspections of critical safety systems and mechanical components.
Preoperational checklists should account for the following:
After the inspection, document all results and remove defective equipment from service immediately. Plus, establish clear reporting procedures for maintenance issues and ensure repairs meet manufacturer specifications. With regular inspections, you can prevent minor problems from becoming major safety hazards.
Excessive speed contributes to numerous forklift accidents, particularly in congested work areas or when navigating turns. You must establish and enforce speed limits appropriate for your facility layout and operational conditions.
The primary factors affecting safe operating speeds include floor conditions, visibility, pedestrian traffic, and load characteristics. For instance, operators should reduce speed when carrying loads, approaching intersections, or working in confined spaces. Wet or uneven surfaces require additional speed reductions to maintain control.
To alert operators when they exceed safe limits, install speed monitoring systems and consider implementing speed governors on equipment used in high-traffic areas. Also, your facility layout should include clearly marked speed zones with appropriate signage to remind operators of speed requirements.
Poor visibility can easily cause collisions with pedestrians, equipment, and structures. You must address sight line obstructions through proper load handling techniques and facility design improvements.
Large or tall loads can block operator vision, requiring reverse travel or spotter assistance. Train operators to position loads at appropriate heights during transport and use mirrors or camera systems when direct vision is limited. Plus, establish clear protocols for navigating blind corners and intersections.
Installing forklift proximity warning systems provides advanced warning when pedestrians or objects enter dangerous zones around moving equipment. These sensors detect movement and alert operators to potential collision risks before accidents occur. These systems work particularly well in busy warehouse environments where visual confirmation alone may not provide adequate safety margins.
By separating pedestrian and forklift traffic, you can reduce the risk of accidents significantly. You need clearly defined walkways, barriers, and warning systems to protect workers in mixed-traffic environments.
To maintain pedestrian safety, take the following precautions:
Additionally, ensure your pedestrian safety program includes regular training sessions that emphasize awareness and safe practices around moving equipment.
Improper load handling creates instability that leads to tip-overs and dropped loads, so train all operators to position loads correctly and secure items before transport.
For example, operators should tilt masts slightly backward during travel to improve stability and prevent loads from sliding forward. Forks must fully support loads with weight distributed evenly across both fork arms. Before lifting, always secure loose items with strapping or wrapping.
Furthermore, establish maximum stacking heights based on load characteristics and stability requirements. Your operators need clear guidelines for handling different product types, including hazardous materials that require special precautions. With regular load handling assessments, you can identify technique problems before they cause accidents.
Deferred maintenance creates safety hazards and reduces equipment reliability. You must implement preventive maintenance programs that address manufacturer recommendations and operational demands.
Based on operating hours and usage intensity rather than calendar intervals alone, establish a clear maintenance schedule. Critical components like brakes, hydraulics, and electrical systems require professional attention from qualified technicians. However, operators should report unusual noises, vibrations, or performance changes immediately.
You should also keep meticulous maintenance records. These documents track repairs, component replacements, and inspection results. To reduce costs, budget adequately for maintenance expenses and avoid extending service intervals. Well-maintained equipment operates safely and provides better long-term value through reduced downtime and repair expenses.
Now that you’re aware of some common forklift safety mistakes, you can avoid them with proper training, modern equipment, and strong management support for safety initiatives.
Investing in forklift safety protects your most valuable assets—your employees—while reducing operational costs and regulatory compliance risks. To make the move toward comprehensive forklift safety, reach out to the experts at Logimate today. No matter your needs, we have the solution for you.