What are the most effective ways to train employees on forklift safety?
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Forklifts are essential tools for many industries, but they also pose serious risks for workers and property if not used properly. According to the Occupational Safety and Health Administration (OSHA), forklift accidents cause about 85 fatalities and 34,900 serious injuries each year in the US. That's why training employees on forklift safety is crucial to prevent accidents, comply with regulations, and create a culture of safety in the workplace. In this article, we'll explore some of the most effective ways to train employees on forklift safety, based on the latest standards and best practices.
Before designing and implementing a forklift safety training program, you need to know the legal and industry requirements that apply to your business. OSHA has specific standards for forklift operators, such as 29 CFR 1910.178, which covers the general requirements for powered industrial trucks. This standard requires employers to ensure that forklift operators are competent, certified, and evaluated at least every three years. It also specifies the topics that must be covered in the training, such as operating instructions, warnings, precautions, load handling, vehicle capacity, stability, inspection, maintenance, refueling, and battery charging. Additionally, you may need to follow other regulations or guidelines from your state, industry association, or insurance provider.
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Christian Harris
Slipologist: reduce slips by 57%+ with science | Host: Safety And Risk Success Podcast | Advocate for proactive safety risk management
Enhance training by incorporating real-life scenarios specific to your workplace. Simulated situations can mirror the challenges employees might encounter, providing practical insights into handling complex real-world scenarios. Integrating these situations into the training not only prepares operators for varied challenges but also ensures they understand the relevance of the training in their daily tasks. This approach fosters a deeper understanding of safety protocols and encourages critical thinking, enabling employees to adapt their knowledge effectively in different operational contexts.
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Mohammad Sami GradIOSH
Environment, Health and Safety Manager at Saudi Consulting Services - SAUD CONSULT
Pictorial and visual Trainings The training methods should be practical but not dramatic. Audio-visual methods and in-house trainings are most effective but professional and practical experts are super trainers to share their live experiences to train an operator. Industrial code of conduct should be included within the training material to improve the cultural ethics.
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Forklift safety training should not be a one-time event, but a continuous process that combines different methods and formats. A blended approach can help you deliver more engaging, effective, and relevant training for your employees. For example, you can use a mix of online courses, videos, quizzes, simulations, manuals, posters, and checklists to cover the theoretical aspects of forklift safety. Then, you can supplement the online training with hands-on practice, demonstrations, coaching, feedback, and assessments to reinforce the practical skills and behaviors. You can also use refresher courses, toolbox talks, newsletters, and reminders to keep the forklift safety knowledge fresh and updated.
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Randy Milliron, SMS, EMR
Safety Manager at City of Gillette
If they are a seasoned operator, you won't have to spend as much time on the lecture portion of the training. Even a good refresher video might be a good thing to have them watch. But more time can be spent out watching them during the hands-on training. But then also, anyone who knows how to operate the forklift can observe an operator for poor operating behavior and report them. Driving too fast, not using the horn, reckless driving while transporting items, and load securement are just a few things that a person can observe.
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KLIFTINDO PERKASA
FORKLIFT Sale, Rent, Service & Parts
Forklift operator training must be carried out before and after someone becomes a forklift operator 1. before becoming an operator; so that they understand all the indicators on the forklift dashboard, their functions and warnings and know how to safely operate a forklift, starting from how to get on the forklift to drive it to knowing how to handle materials safely and correctly. 2. after becoming an operator; This serves as a reminder to operators not to adopt bad habits in operating forklifts and to prioritize safety, not speed, because many work accidents are caused by advanced forklift operators compared to new forklift operators.
Forklift safety training should be tailored to the specific needs, characteristics, and goals of your employees and your workplace. You should consider factors such as the type and model of forklifts you use, the environment and layout of your work site, the materials and loads you handle, the hazards and risks you face, and the level of experience and skill of your operators. You should also involve your employees in the design and delivery of the training, by asking for their input, feedback, and suggestions. By customizing the training, you can make it more relevant, realistic, and applicable to your employees' daily tasks and challenges.
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Randy Milliron, SMS, EMR
Safety Manager at City of Gillette
Operators need to be trained on the types of forklifts they will be using. In our warehouse, we have two forklifts. One is the smaller, more maneuverable forklift and the other one is the bigger one to be able to lift heavier items.
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Forklift safety training should not end with a certificate or a test score, but with a measurable improvement in performance and safety. You should monitor and evaluate the impact of the training on your employees' skills, behaviors, and attitudes, as well as on your workplace's accident rates, productivity, and costs. You can use various tools and methods to measure and track the results of the training, such as observation, feedback, surveys, audits, reports, and analytics. You should also use the data and insights you gather to identify gaps, strengths, and opportunities for improvement, and to adjust and update the training accordingly.
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Randy Milliron, SMS, EMR
Safety Manager at City of Gillette
Our Warehouse employees, who are our qualified forklift training instructors, get to observe every employee who operates the two forklifts. If they recognize unsafe operation behavior, they can stop and work with those employees at the moment.
Forklift safety training should not be seen as a standalone activity, but as part of a broader strategy to foster a safety culture in your workplace. A safety culture is a shared set of values, beliefs, and norms that influence how your employees think and act regarding safety. To build and sustain a safety culture, you need to involve and empower your employees, communicate and enforce clear and consistent safety policies and procedures, provide adequate resources and incentives, recognize and reward good practices, and address and correct bad ones. You should also promote a learning culture, where your employees are encouraged to seek, share, and apply new knowledge and skills to improve their safety and performance.
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Randy Milliron, SMS, EMR
Safety Manager at City of Gillette
So many Americans are killed each year due to forklift accidents. The sad thing about these injuries is some lead to fatalities. This should not be happening because forklift accidents are 100% preventable.
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