Train the Trainer Things Everyone Should Know About Forklift Safety

Train the TrainerTrain the Trainer

ThingsEveryone Should Know About Forklift Safety


Things Everyone Should Know About Forklift Safety

1. You're Only as Strong as Your Weakest Link

2. Anyone Can Be A Target.

3. Once Your Forklift Safety Plan is Done, it Stays Done.

4. How Protected Is Your Company.

5. There is Help.

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You are Only as Strong as your Weakest LinkThe challenge in establishing a work place forklift

safety plan is finding the time to do the research and

figure out what's right for your company, your

operators and your budget. The problem quickly

becomes obvious: you may be doing everything right

but what about Federal OSHA, Department of Labor

standards and State requirements?

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Anyone Can be a TargetOSHA is back in the enforcement business. Labor Secretary Hilda L. Solis has said: • "There's a new sheriff in town" and "Workplace

safety is more than a slogan. It's the law"

The Department of Labor which oversees OSHA has made it crystal clear that • "The Bush administration days of lax

enforcement are over." • Inspections will become more frequent.• OSHA proposed fines of $87 million - 4 times

greater than any previous sanction against an employer.

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Once your Safety Plan is Done, it Stays DoneA company forklift safety policy is a plan that once it's done it lays out a road map for you to follow any time:

• You hire someone new

• There are safety concerns at your facility

• Remain in compliance with updates

It simply lays a foundation for ongoing forklift safety policies and procedures. It's much easier than you might think.

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How Protected Is Your CompanyLike most of small businesses in America the

chances are that some of your employees are either

family, or get treated like family. Who is going to

play short stop at the next company picnic? If there

is an accident that could have easily been avoided

by simple training and a solid forklift safety plan.

These days who can afford to lose an employee to

an injury or worse?

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There is Help

CertifyMe, the leader in forklift operator safety

training and certification helps you establish your

complete forklift safety plan - even if your budgets

are stretched to the breaking point.

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More Things

All employers should know about forklift certification and training

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Why Should You Take This Course?This course is designed to help you, the Employer,

implement a forklift safety operations program.

After taking our course, you will have the tools

necessary to create an efficient, OSHA-compliant

code of operations for your operators and

employees.

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Who is This Course Designed For?This course is created to address the needs and

benefits of a Powered Industrial Truck training

certification course.

As the employer, you are responsible for

administering a course to your employees that meets

the specific needs of your equipment and situation.

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Who is the Trainer?It is best to plan for classroom training as well as hands-on, on-the-job training.

You may also want to hire an outside person to train your employees. Third-party training consultants may include:

• Forklift suppliers

• Third-party, independent compliance consultants

• Trade organizations or specialized training

schools

• NSC (National Safety Council)

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Employee Certification

Here are some rules of thumb:

• Be able to present a contract of the training process (for outsource training), as well as certificates for each operator.

• Have your trainer work with the operators using his current work routines to ensure proper safety guidelines are followed.

• REMEMBER TO EVALUATE AND CERTIFY!For a Union has trained an operator, have your evaluator observe the operator, issue training on any issues he sees fit, and…

document everything before certifying him.

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Where to Evaluate Employees?Employees must be evaluated within their everyday

workplace.

Since your employees are operating your machinery

each day on your grounds, and according to your

safety training, it makes sense that they're evaluated

in a normal working environment.

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You have A LOT to do!

Your training program will require just as much administrative work as it does planning and actual training.

• Record where and when all training takes place,

including who provided the training

• Be thorough about evaluation and certification

• Ensure all documentation

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What is my Safety Duty to my Employees?According to OSHA, the General Duty Clause of an Employer is as follows:

(GENERAL DUTY CLAUSE)Each employer shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious harm to his employees.

Each employee shall comply with occupational safety and health standards and all rules, regulations and orders issued pursuant to this article which are applicable to his own actions and conduct.

Good administrative policy and regular evaluation, you will ensure that your employees are safe, and your business is OSHA-compliant.

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What is a Good Safety Program?A good safety program has:

• Employer that addresses accidents or safety issues

• Employer commitment and employee involvement

• Possible hazards and prevention are addressed

• Someone "qualified" oversees safety regulations for your operators

• Consequences for employees who don't follow safety procedure

• Safety meetings where employee concerns are addressed.

• Continual program evaluation to ensure the best possible safety program is being implemented

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Forklifts (Powered Industrial Trucks)OSHA defines a Powered Industrial Truck:

Powered industrial trucks, commonly called forklifts

or lift trucks, are used in many industries, primarily to

move materials. They can be used to move, raise,

lower, or remove large objects or a number of

smaller objects on pallets or in boxes, crates, or

other containers. Commonly known as forklifts, pallet

trucks, lifttrucks, or forktrucks

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PIT Training ProceduresThe latest OSHA standard (1999) requires that employees undergo both formal training, as well as hands-on training.

• The Formal Training should cover the new standard, and how it applies to your individual workplace and equipment.

• The Practical Training, or Hands-on Training, is conducted in your employees' work environment by your trainer. This training ensures that your employees control and maneuver forklifts using safe operating procedures.

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Safe OperationAccording to regulation (L)(1):• (L)(1)(i) The employer shall ensure that each powered

industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph (L).

(L)(2) Training program implementation.• (L)(2)(i) Trainees may operate a powered industrial

truck only:(A)Under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence; and

• (B)Where such operation does not endanger the trainee or other employees

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Safe Operation (cont'd)• (L)(2)(iii) All operator training and evaluation

shall be conducted by persons who have the knowledge, training, and experience to train powered industrial truck operators and evaluate their competence.

(L)(3) Training program content. Powered industrial truck operators shall receive initial training in the following topics, except in topics which the employer can demonstrate are not applicable to safe operation of the truck in the employers workplace.

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Safe Operation (cont'd)(L)(3)(i) Truck-related topics • (D)Engine or motor operation;• (E)Steering and maneuvering;• (F)Visibility (including restrictions due to loading)• (G)Fork and attachment adaptation, operation, and use

limitations;• (H)Vehicle capacity;• (I)Vehicle stability;• (J)Any vehicle inspection and maintenance that the operator

will be required to perform;• (K)Refueling and/or charging and recharging of batteries;• (L)Operating limitations;• (M) Any other operation instructions, warnings, or

precautions listed in the operators manual for the types of vehicles that the employee is being trained to operate.

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Related Topics

In addition to operation of the truck, the employee will also need to be trained in workplace environmental factors that involve the space around the truck, and how external factors affect the truck. These include:

(L)(3)(ii) Workplace-related topics:• (A)Surface conditions where the vehicle will be

operated;• (B)Composition of loads to be carried and load

stability;• (C)Load manipulation, stacking, and unstacking;

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Related Topics (cont’d)• (D)Pedestrian traffic in areas where the vehicle will be

operated;• (E)Narrow aisles and other restricted places where the

vehicle will be operated;• (F)Hazardous (classified) locations where the vehicle

will be operated;• (G)Ramps and other sloped surfaces that could affect

the vehicle's stability;• (H)Closed environments and other areas where

insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust;

• (I)Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.

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Refresher Training and EvaluationWhen the Refresher Training and Evaluation comes in handy:

(L)(4) Refresher Training and Evaluation. • (L)(4)(i) Refresher training, including an

evaluation of the effectiveness of that training, shall be conducted as required by paragraph

• (L)(4)(ii), to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely.

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Refresher Training and Evaluation (cont’d)• (L)(4)(ii) Refresher training in relevant topics shall be

provided to the operator when:• (A) The operator has been observed to operate the

vehicle in an unsafe manner• (B)The operator has been involved in an accident or

near-miss incident• (C)The operator has received an evaluation that reveals

that the operator is not operating the truck safely• (D)The operator is assigned to drive a different type of

truck; or • (E)A condition in the workplace changes in a manner

that could affect safe operation of the truck.If any of the above conditions are met by the operator, Refresher Training may be provided. REMEMBER TO RECORD THAT THIS TRAINING HAS OCCURRED!

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Evaluations/Duplicate TrainingFortunately, OSHA gives us specific guidelines on how often we should evaluate employee performance:• (L)(4)(iii) An evaluation of each powered industrial

truck operators performance shall be conducted at least once every three years.

• (L)(5) Avoidance of duplicative training. If an operator has previously received training in a topic specified in paragraph (L)(3) of this section, and such training is appropriate to the truck and working conditions encountered, additional training in that topic is not required if the operator has been evaluated and found competent to operate the truck safely.

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Evaluations/Duplicate Training (cont’d)Also, as we covered before, you do not need to retrain if the operator is found competent. Keep records of any instance where such an evaluation takes place in lieu of duplicate training.

• (L)(5) Avoidance of duplicative training. If an operator has previously received training in a topic specified in paragraph (L)(3) of this section, and such training is appropriate to the truck and working conditions encountered, additional training in that topic is not required if the operator has been evaluated and found competent to operate the truck safely.

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With Regards to Certification(L)(6) Certification. The employer shall certify that each operator has been trained and evaluated as required by this paragraph • (L). The certification shall include:

• Name of the operator • Date of the training • Date of the evaluation • Identity of the person(s) performing the

training or evaluation.

Ensure that all points mentioned on this list are recorded as part of your certification process.

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With Regards to Certification (cont’d)(L)(7) Dates. The employer shall ensure that the operator of a powered industrial truck was trained, as appropriate.

This means that anyone who operates a truck within your workplace should not only be trained, but should have documentation available that the training took place. THIS IS IMPORTANT. Don't skip this valuable step.

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Developing a Training ProgramFortunately, OSHA doesn't leave you in the dark

when it comes to developing your program.

• 1910.178 (L)(8) Appendix A to this section

provides non-mandatory guidance to assist

employers in implementing this paragraph (L).

This appendix does not add to, alter, or reduce

the requirements of this section.

Understanding this section will be very valuable to

you in developing your program.

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What's Going On?

One of your most powerful resources for developing

a great safety program is yourself!

Keep a log of your equipment and the specs, as well

as which operators use that equipment.

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Understanding the EquipmentYou should be prepared to research more about the following basic concepts:

• Stability Triangle: This is an imaginary triangle on the truck representing the force of balance available at any time.

• Center of Gravity: The point which is at the center of the stability triangle - i.e., will stop the truck from tipping.

• Load Center: The truck will tip forward when it is loaded, which adjusts the center of gravity. Shifting the front load up will tip back the mass.

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Understanding the Equipment (cont’d)Your operators should also understand these hazards:• Power Lines and other obstruction hazards could

seriously injure or kill an operator• DO NOT run over power lines. • Stay at least 10 feet away from any live power

lines• Stay over 35 feet away from high-energy lines

• Ramp or slope driving. • Never reverse or speed the truck on a slope• procedures for backing up with a load, • recognizing "blind spots" on the truck

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Operating ManualsOperating manuals are an extremely important part of both your operator's work experience, AND your training program. • OSHA 1910.178.(L)(3)(i)(m) states there must be a

record of: " any other operation instructions, warnings or precautions listed in the operators manual for the types of vehicles that the employee is being trained to operate".

You should make this part of your training materials, as well as readily available within the truck. OSHA inspectors will check for these materials during an inspection.

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ID Plates and InspectionsALL lift trucks are required to display manufacturer ID plates, and inspectors must be able to read them

• Replace damaged plates, contact the

manufacturer for replacement

• Keep records of communication with the

manufacturer, include those in your files as part

of your safety compliance process

• Inspect your equipment daily, note its operating

condition and check the status of your plates

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Evaluating Your OperatorsThough there is no formal process OSHA dictates for evaluating an employee, you MUST have your own process, and you MUST document it thoroughly.

• Written test

• On-site evaluation

• Oral evaluation

• Training documentation

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Training and Evaluation CertificationAccount that every employee who operates the machinery has been trained, evaluated, and certified.

• Include the operator's name

• Date and type of training

• Evaluation date

• Identity of Trainer/Evaluator

Keep your records for three years.

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Special Needs and RequirementsOSHA does not require the employer to have machine operators undergo physical examinations.

If you feel that an operator is a risk to himself or fellow operators, or to your equipment, you do have the right to take appropriate action to ensure the safety of your workers.

Federal law makes it illegal to hire an operator under the age of 18. After confirming age, you do not need to require special licensure for operators to drive your forklifts.

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OSHA Construction Safety Course OSHA 10-Hour Construction Safety Course Now Mandatory In Seven States• Conneticut • Massachusetts• Missouri• Nevada• New Hampshire• New York • Rhode Island

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Train the Trainer Things Everyone Should Know About Forklift Safety