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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
Forklift AccidentsForklift Accidents
Picture source: Picture source: http://www.jicosh.gr.jp/english/cases/cases/case105.gifhttp://www.jicosh.gr.jp/english/cases/cases/case105.gif
Forklift AccidentsForklift Accidents
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
Risk Management on Risk Management on Operation of ForkliftOperation of Forklift
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
Common Forklift HazardsCommon Forklift Hazards
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
Common Forklift HazardsCommon Forklift Hazards
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
Common Forklift HazardsCommon Forklift Hazards
Pedestrians and forklift moving in same place
Picture source: http://www.safetyworld.com/images/67.gifPicture source: http://www.safetyworld.com/images/67.gif
Common Forklift HazardsCommon Forklift Hazards
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
Common Forklift HazardsCommon Forklift Hazards
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
Common Forklift HazardsCommon Forklift Hazards
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
Common Forklift HazardsCommon Forklift Hazards
Unsecured load
Picture source: http://www.locknpop.com/images/img_fork.gifPicture source: http://www.locknpop.com/images/img_fork.gif
Common Forklift HazardsCommon Forklift Hazards
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
Common Forklift HazardsCommon Forklift Hazards
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
Risk Management on Risk Management on Operation of ForkliftOperation of Forklift
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
Risk Management on Risk Management on Operation of ForkliftOperation of Forklift
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
Risk Management on Risk Management on Operation of ForkliftOperation of Forklift
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)
Risk Management on Risk Management on Operation of ForkliftOperation of Forklift
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
Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc
Designated Battery and Designated Battery and Parking AreaParking Area
Forklift battery charging and parking area
Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc
22ndnd Guard the Remaining Guard the Remaining Hazards: Protective BarriersHazards: Protective Barriers
Brightly coloured barriers
Picture source: Hi Tech Coatings, IncPicture source: Hi Tech Coatings, Inc
Risk Management on Risk Management on Operation of ForkliftOperation of Forklift
3rd – Mitigate impact of hazard (E.g. Operator to wear an seat belt)
Source: Source: Ministry of Manpower
Risk Management on Risk Management on Operation of ForkliftOperation of Forklift
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
Source: Source: Ministry of Manpower
Risk Management on Risk Management on Operation of ForkliftOperation of Forklift
Forklift Safe Work Procedures (SWP)
Forklift TrainingForklift Training
Pre-Operation CheckPre-Operation Check
Load AssessmentLoad Assessment
Common Safe PracticeCommon Safe Practice
Traffic ControlTraffic Control
Source: Source: Ministry of Manpower
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
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 4 – Yard Pre-operation Checks 4 – Yard ForkliftForklift
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
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
Forklift Load Assessments 1Forklift Load Assessments 1
• 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
Forklift Load Assessments 1Forklift Load Assessments 1
• 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
Forklift Load Assessments 2Forklift Load Assessments 2
• 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
Load Assessments – Weight at Load Assessments – Weight at Centre of GravityCentre of Gravity
Picture source: Picture source: http://www.rentrain.com/resources/fork_21.gif
Load Assessments – Weight at Load Assessments – Weight at Centre of GravityCentre of Gravity
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
Common Safe PracticesCommon Safe Practices
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
Common Safe PracticesCommon Safe Practices
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
Common Safe PracticesCommon Safe Practices
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
Common Safe PracticesCommon Safe Practices
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
Common Safe PracticesCommon Safe Practices
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
Source: Source: Ministry of Manpower
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.
Traffic ControlsTraffic Controls
• 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
Traffic ControlsTraffic Controls
• 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 1Appendix 1
Appendix 1Appendix 1
Appendix 2Appendix 2
Appendix Appendix