When safety consultant Garland Hanson, CSP, was called in to investigate a fatal forklift incident last year, he wasn’t surprised by his findings.  It was a virtual list of everything a driver isn’t supposed to do when operating a powered industrial truck.  “It was a classic and very ugly,” says Hanson in listing some of the contributing causes:

• Operator’s first week on the job.

• No training provided.

• Driver was not authorized to operate the forklift.

• A bulky load was carried 15 feet in the air.

• The driver was speeding and not wearing a seat belt.

• The driver made a sharp turn.

• As the forklift tipped over, the driver unsuccessfully attempted to jump out.

“You know the rest,” says Hanson, resignedly. Hanson, of the Arizona Safety Center hopes that perhaps others can learn from these tragic mistakes.  His main concern is that some employers are just not providing training for powered industrial truck operators or they are depending  on informal instruction to get by.

Formalized training

That was the conclusion of OSHA regulators as well, who rewrote the powered industrial truck standard to beef up and formalize training requirements for operators.  The standard now requires employers to:

• Train operators on the general principles of safe truck operations, the types of vehicles used in the workplace, the hazards involved in such operations, and the requirements of the OSHA standard.

• Provide formal training (lecture, video, etc.), practical exercises, and demonstrations on the equipment.

• Certify that each operator has received the training.

• Evaluate each operator every three years.

• Provide refresher training whenever an operator is observed using the truck in an unsafe manner.

• Provide additional training as new types of powered industrial trucks are introduced into the workplace.

OSHA even provides a list of training topics to cover, although it is up to the employer to decide which subjects are relevant.

Sound simple?

Just follow the preceding steps and you’re in good shape, right?  Wrong, says Joe Monaco of the Monaco Group in New Jersey, that runs a customized training and certification system called National LIFTOR (Lift Truck Operator Registry) for supervisors and operators.

Monaco feels the certification requirements of the OSHA standard are too weak and fail to emphasize the hands-on side of the training.  “Don’t make operators suffer through classroom instruction beyond the five minutes it takes to explain that their training and practice will be done on the truck,” says Monaco, who believes that on-truck training can “literally make the difference between life and death.”

Cautionary advice

One of the most difficult aspects of training operators is to get the instruction to “transfer” to everyday use, says Monaco.  “‘Training transfer’ simply means that an operator would acquire some new skill or method for maneuvering the truck while in training and then be seen actually using the newly acquired skill on the job during a normal routine,” he explains.  “Direct observations and your safety record will tell you whether transfer has occurred.”

Monaco also believes that many operators are just not prepared for all of the hazards they may encounter, and they don’t decide in advance how to respond to each hazard.  He says that his training system ensures that such preparation is practiced enough until it becomes “second nature.”

Getting down to details

Garland Hanson emphasizes that employers must provide training that is specific to the type of vehicles used and the kind of worksite. He also subscribes to the view that “operators need to spend more time behind the wheel during training.”

OSHA is also concerned about customized training.  The agency warns employers that they can’t just rely on canned programs or videos for their training, but must supplement them with specific information about their equipment and worksite. Also, if you employ drivers from temporary agencies or workers who have been trained by a union, you still need to ensure that they are adequately briefed on the particulars of your workplace.

Maintenance trade-offs

Inextricably linked to safety training is making sure that employees know how to properly maintain their vehicles, advises Hanson.  Cutting corners on preventive maintenance will only cost you more in the end. An incident from OSHA’s files provides a vivid illustration of this maxim:

A forklift was parked on the decline of a loading ramp and the operator was repositioning the load in front of it.  The brakes failed and the operator was struck in the lower back by the forks, causing severe injuries.  Total cost of incident: $8,260 plus insurance rate increase.  Cost of repairing/replacing brakes:  $800 to $3000.

Incorporating truck maintenance into your safety training will improve the effectiveness of your powered industrial truck safety program.

Yeehaw, it’s rodeo time!

One method used by some employers to generate interest in proper driving and maneuvering techniques is known as a “forklift rodeo.”  A company will set up a forklift tournament where the best operators compete in various challenges with prizes awarded for those who complete the tasks in a timely and efficient manner.  “It can be an interesting and fun event,” says Hanson.  “But, it should not be used as a training tool. Only the most experienced drivers should compete in such an event.”

Monaco thinks they are a good idea “only if they are organized around a rigorous set of on-truck maneuvering criteria that operators have a chance to practice in advance of the event.”  He doesn’t like the term “rodeo” however, because he says it conjures up an image of “risk-taking and irresponsible behavior.”

It’s your choice

Whether you use rodeos or not, there are plenty of resources out there, from OSHA to private companies, to assist you in your training efforts.  Just don’t wait until an incident happens or an OSHA inspector shows up before you decide to do something about it.

Protecting Pedestrians

The safety of forklift operators isn’t the only thing you need to worry about. Employees who work around powered industrial trucks are at risk for injury or death if they happen to collide with one. Here are some safety tips to pass on to your working pedestrians:

 • Make eye contact with the operators, and make sure they acknowledge you before you cross their path.

• Stay within walkways and crosswalks at all times.

• Yield the right-of-way to powered industrial trucks.

• Both look and listen for lift trucks. Be aware that you may not always hear them.

• Never approach a powered industrial truck from the rear because the back end can swing around suddenly.

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