2008

Instructor : Seth A. Brown

Forklift Safety Training Class

Contents

• Forklift safety

• Introduction

• Training and Standards

• CD# One –

Forklift Fundamentals

• Review Quiz# One

• CD# Two –

Forklift Operations

• Review Quiz# Two

• Types of Forklifts

• Maintenance

• Day-to-Day Considerations• Daily Checklist• Refuel procedures Do’s & Don’ts• Conclusion

Forklift Safety

Learning the safeway to operate a forklift …

…may save your life

A forklift is a powerful tool that allowsone person to precisely lift and placelarge heavy loads with little effort.Using a tool such as a forklift, cart orhand truck instead of lifting andcarrying items by hand can reduce therisk that you will suffer a back injury.

However, there is great risk of injury ordeath when a forklift operator:

· has not been trained in the principles of physics that allows it to lift heavy loads,

· is not familiar with how a particular forklift operates,

· operates the forklift carelessly, or

· uses a forklift that is not safe due to malfunctioning or missing parts.

Introduction

Introduction Every year nearly 100 workers are killed and 20,000 are seriously injured inforklift mishaps. According to the National Traumatic Occupational Fatalities(NTOF) Surveillance System 1530 workers field from forklift related accidentsbetween 1980 and 2001. At least 22% of these deaths were caused by forkliftoverturns and another 20% to workers on foot being struck by the forklift. Withwell over one million forklifts in operation today, emphasis must be placed onboth worker and pedestrian safety.

Forklift Fatalities, 1992-1996

86 89

120

95

114

1992 1993 1994 1995 1996

Source: Bureau of Labor Statistics, Job Related Fatalities Involving Forklifts

Forklift Fatalities by Age Group1992 -1996

3%

10%

22%

21%

12%

5%

27%

Under 20

20 - 24

25 - 34

35 - 44

45 - 54

56 - 64

65 & over

Source: Bureau of Labor Statistics

Industries Where Powered Industrial Truck Accidents Occurred

Source: OSHA Fatality/Catastrophe Reports, complied by OSHA Office of Electrical/Electronic andMechanical Engineering Safety Standards.

Nonfatal Occupational Injuries and Illnesses by Source, 1996

Source: Bureau of Labor Statistics, Job Related Fatalities by Selected Characteristics, 1996.

An effective material safety program is required to limit accidents. An important part of this programIs operator selection and training. There are federal and Industry standards which cover both operator selection and training.

OSHA Standards require that the employer ensure that a :

1. Forklift operator is competent to operate the forklift he or she is assigned to use.

2. The employer must document operator training and an evaluation of the operator’s performance while using the forklift.

A copy of the Osha Standards – Subpart N-Materials Handling and Storage.

Section 1910.178, Powered industrial trucks Will be on hand in the Shipping and Receiving department.

Training and Standards

Operator Training pt1• Safe operations

– The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by successful completion of the training and evaluation specified in the OSHA standard.

– Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the required training (or previously received appropriate training).

A copy of the Osha Standards – Subpart N-Materials Handling and Storage.Section 1910.178, Powered industrial trucks will be on hand in the Shipping and Receiving department.

Training Program Implementation

• Trainees may operate a powered industrial truck only:– Under direct supervision of a person who

has the knowledge, training, and experience to train operators and evaluate their competence; and,

– Where such operation does not endanger the trainee or other employees.

Training Program Implementation (continued)

• Training shall consist of a combination of:Training shall consist of a combination of:– Formal instruction (e.g., lecture, discussion, Formal instruction (e.g., lecture, discussion,

interactive computer learning, written interactive computer learning, written material), material),

– Practical training (demonstrations and Practical training (demonstrations and exercises performed by the trainee), and exercises performed by the trainee), and

– Evaluation of the operator’s performance in Evaluation of the operator’s performance in the workplacethe workplace

Training Program Implementation (continued)

• Training and evaluation shall be conducted by a person with the knowledge, training and experience to train powered industrial truck operators and evaluate their competence.

Refresher Training and Evaluation

• Refresher training, including an evaluation of the effectiveness of that training, shall be conducted to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely.

• Refresher training required when:– Unsafe operation – Accident or near-miss– Evaluation indicates need– Different type of equipment introduced – Workplace condition changes

Powered Industrial Trucks -Operator Training

1910.178 (l)1910.178 (l)1915.120 (a)1915.120 (a)1917.1 (a)(2)(xiv)1917.1 (a)(2)(xiv)1918.1 (b)(10)1918.1 (b)(10)1926.602 (d)1926.602 (d)

Powered IndustrialTruck - Definition

• A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier materials. [American Society of Mechanical Engineers (ASME) definition]

• Excluded are vehicles used for earth moving and over-the-road hauling.

• Commonly known as forklifts, pallet trucks, rider trucks, fork trucks, or lift trucks.

• Can be powered through electric or combustion engines.

Performance-Oriented Requirements

• The powered industrial truck operator training requirements are performance-oriented to permit employers to tailor a training program to the characteristics of their workplaces and the particular types of powered industrial trucks operated.

Refresher Training and Evaluation (continued)

• An evaluation of each powered industrial truck operator’s performance must be conducted:– After initial training,– After refresher training, and– At least once every three years

Forklift FundamentalsCD# 1

17 minutes

1.) each forklift is designed to perform specific tasks in set situations and should never be used in any other way.

True or False

2.) OSHA requires that you be qualified for each type of forklift and each kind of work Situation you encounter.

True or False

Review Quiz

Forklift OperationsCD# 218 Minutes

1.) Using good judgment on every load and carry is the mark of a professional forklift operator.

True or False

2.) In the traveling position, the forks are about one foot above the floor.

True or False

Review Quiz

A forklift is a type of “powered industrial truck” covered by OSHA standards. Likeother powered industrial trucks, its purpose is to move carry, push, pull, and lift amaterial load then stack it or place it in a storage rack (tier). Forklifts come inmany sizes and capacities. They can be powered by batteries, propane, gasolineor diesel fuel. Some are designed to be used in a hazardous location oratmosphere where an ordinary forklift might cause a fire or explosion.Powered industrial trucks are classified into seven types based on theircharacteristics.

• Class 1 - Electric Motor, Rider, Counter-Balanced Trucks (Solid Pneumatic Tires)• Class 2 - Electric Motor Narrow Aisle Trucks (Solid Tires)• Class 3 - Electric Motor Hand Trucks or Hand/Rider Trucks• Class 4 - Internal Combustion Engine Trucks (Solid Tires)• Class 5 - Internal Combustion Engine Trucks (Pneumatic Tires)• Class 6 - Electric and Internal Combustion Engine Tractors Pneumatic Tires). There are no forklifts in this class.• Class 7 - Rough Terrain Forklift Trucks (Pneumatic Tires)

Types of Forklifts

Good maintenance practices are essential to keep trucks safe and productive. Maintenance procedures must also be safe for those who perform the maintenance

Trained Mechanics

Mechanics must be trained in safe maintenance and repair practices, such as 1. securing moveable parts, 2. proper use of tools,3. wearing of protective clothing, 4. use of protective equipment.5. And safe operating procedures of the forklift trucks and their attachments.

Maintenance

Day-to-Day ConsiderationsOnsite Considerations

• Pedestrians • Daily Checks• Lifting & Transporting

Loads• Charging• Do’s & Don’ts

• Forklifts capacities – Diesel 3000 lbs, Gas (old yellow) 6000 lbs- Electric 2000 lbs

• Rough Terrain – Extended-reach FLT –

Additional attachments include lift cage, a fabricated attachment for forks to lift extra long pallets, a small fabricated attachment to tow trailers,and a attachment /w chains to lift shelters and generators.

Daily Checklist

• Tires

• fluid levels

• Chains

• Horn

• Lights

• Water

• Steering

• Mast

• Battery

• Hydraulic leaks

REFUELLING and BATTERY MAINTENANCE

• Diesel

• Gas

• Electric

DIESEL & GAS FUEL

• Use refuelling area –Our Refuelling area is behind shipping and receiving, across from the warehouse #2. Fire Extinguisher, Gloves, and Dry Sweep are available .

• Turn off engine and

use parking brake• Avoid overfilling the fuel tank• Refuel forklifts when gage reads ½ and below

* Always strap equipment before movement

* Always use Ground Guides

BATTERY CHARGING

• Change in a well ventilated area - Motor pool

• Use eye protection when making connections

• Have eye wash facilities available

• Have an acid neutralizing agent available

• Don’t over fill the batteries with water

“DON'T”

• DO NOT– Consume alcohol while at work– Pick up a load if someone is standing close– Allow people to walk underneath the load– Try to pick up an unsuitable load– Leave a lift truck unattended with the engine running– Carry passengers– Drive over cables or piping– Operate with the load raised except at creep speed– Drive forward if visibility is impaired by a load– Make sharp turns, only turn at creep speed– Alter, remove or disconnect any mechanical or safety devices

on any forklift. ONLY AUTHORIZE PERSONNEL CAN .

“DO’S”• DO…..

– Only issue keys to authorized drivers– On completion of work, park lift truck in designated area– Be careful with pedestrians / obey site rules / speed limits– Sound horn at potential danger spots– Stop before entering building, sound horn then proceed– Avoid violent breaking– Travel slowly down slopes with the fork facing uphill– Always use the hand brake when necessary– Never travel across an incline– Before you raise a load check over head for obstructions– Always check for traffic when dismounting– Avoid driving over wet, grease and oil spilled areas– Report all accidents and safety violations to your supervisors

immediately.

Certification

• The employer shall certify that each operator has been trained and evaluated as required by the standard.

• Certification shall include:– Name of operator– Date of training– Date of evaluation– Identity of person performing the training or

evaluation

Any Questions?

We have a two part test before Certification

A Written and a Driving test

Good Luck

Conclusion

The End