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					   FORKLIFT SAFETY
                  OSHA TRAINING




                   OSHA 29CFR 1910.178
NWACC Business & Industry
                                         N-1
Workforce Development Institute
           REGULATORY STANDARD
           POWERED INDUSTRIAL TRUCKS

29CFR - 1910 - 178

29CFR - SAFETY AND HEALTH STANDARDS

              1910 - GENERAL INDUSTRY

                            178 - POWERED INDUSTRIAL TRUCKS


   NWACC Business & Industry
                                                  N-2
   Workforce Development Institute
    FORKLIFT INJURY STATISTICS

APPROXIMATELY 34,000 RELATED INJURIES A YEAR:

  INATTENTION                      REAL
                                    HEAVY
                                    PARTS
  DISTRACTION                          6500lbs




  EXCESSIVE SPEED
  POOR DRIVING HABITS
                                                      LOAD CAPACITY




  LACK OF TRAINING
                                                      6000 lbs



                                                       PROPANE ONLY

                                                  ACME FORKLIFTS




  NWACC Business & Industry
                                                  N-3
  Workforce Development Institute
       CIRCUMSTANCES OF INJURY
                    HOW MOST INJURIES OCCUR

 OVERLOADING CAUSING THE VEHICLE TO TURNOVER
 LOAD INSTABILITY CAUSING TURNOVER
 OBSTRUCTIONS IN THE PATH OF TRAVEL OR LIFT
 USING FORKLIFT OUTSIDE OF DESIGN LIMITATIONS
 STRIKING A PEDESTRIAN



  NWACC Business & Industry
                                              N-4
  Workforce Development Institute
                             CASE STUDY #1
               CRUSHED AGAINST A STEEL POLE

NARRATIVE: AN EMPLOYEE WAS SPOTTING A FORKLIFT BACKING
           UP IN A CONGESTED FLOOR AREA. THE OPERATOR
           ATTEMPTED TO EASE THE VEHICLE SLOWLY BACK
           TO GAIN CLEARANCE TO TURN. THE GAS PEDAL
           STUCK SLIGHTLY CAUSING THE VEHICLE TO LURCH,
           PINNING AND CRUSHING THE SPOTTER BETWEEN THE
           FORKLIFT AND A POLE RESULTING IN FATAL INJURIES.

CITATION: FAILURE TO MAINTAIN CLEARANCE BETWEEN A FIXED
          OBJECT AND THE VEHICLE.


    NWACC Business & Industry
                                               N-5
    Workforce Development Institute
                             CASE STUDY #2
                  KILLED BY TOPPLED FORKLIFT

NARRATIVE: AN EMPLOYEE WAS TRANSFERRING MATERIAL FROM
           A LOADING DOCK TRAILER TO A WAREHOUSE
           LOCATION WHEN THE VEHICLE WAS DRIVEN OFF OF
           THE SIDE OF THE DOCK RESULTING IN A LATERAL
           TIPOVER OF THE VEHICLE AND FATAL OPERATOR
           INJURIES.

CITATION: FAILURE TO MAINTAIN CLEARANCE BETWEEN THE EDGE
          OF THE DOCK AND THE VEHICLE.




    NWACC Business & Industry
                                               N-6
    Workforce Development Institute
                            CASE STUDY #3
                 KILLED BY TOPPLED FORKLIFT

NARRATIVE: AN EMPLOYEE WAS TRANSFERRING MATERIAL FROM
           A STACKED PALLET STORAGE LOCATION TO THE
           WAREHOUSE FLOOR. THE OPERATOR BEGAN
           MOVING THE VEHICLE WITH THE LOAD EXTENDED
           BEFORE LOWERING THE LOAD, RESULTING IN A
           CENTRIFUGAL OVERLOAD AND TOPPLING. THE
           OPERATOR WAS CRUSHED BY THE VEHICLE.

CITATION: FAILURE TO MAINTAIN VEHICULAR CONTROL



    NWACC Business & Industry
                                              N-7
    Workforce Development Institute
         TRAINING REQUIREMENTS

OPERATORS MUST RECEIVE:

 CLASSROOM TRAINING COVERING SAFETY RULES
 BASIC MATERIAL-HANDLING TECHNIQUES
 BASIC OPERATING TECHNIQUES
 DRIVER’S PERFORMANCE TEST
                                            LOAD CAPACITY
                                            6000 lbs



                                             PROPANE ONLY


                                        ACME FORKLIFTS




 NWACC Business & Industry
                                       N-8
 Workforce Development Institute
    RETRAINING REQUIREMENTS

REQUIRED WHEN THERE IS A:
 CHANGE IN VEHICLES AND HANDLING EQUIPMENT
 CLOSE-CALL EVENT
 FAILURE IN THE SAFETY PROCEDURES
 REASON TO DOUBT EMPLOYEE PROFICIENCY

                                                  LOAD CAPACITY
                                                  6000 lbs



                                                   PROPANE ONLY


                                              ACME FORKLIFTS




NWACC Business & Industry
                                         N-9
Workforce Development Institute
     FORKLIFT SAFETY PROGRAM

THREE ELEMENTS TO THE PROGRAM:

1. WRITTEN COMPANY SAFETY PROCEDURES

2. EMPLOYEE TRAINING

3. DRIVING PROFICIENCY                 LOAD CAPACITY
                                       6000 lbs



                                        PROPANE ONLY


                                   ACME FORKLIFTS




 NWACC Business & Industry
                                             N - 10
 Workforce Development Institute
       FORKLIFT SAFETY PROGRAM

WRITTEN COMPANY SAFETY PROCEDURES

1. COMPANY FORKLIFT POLICY REVIEWED ANNUALLY

2. DAILY OPERATOR INSPECTIONS DOCUMENTED

3. DRIVING TRAINING AND PROFICIENCY DOCUMENTED



                                         LOAD CAPACITY
                                         6000 lbs



                                          PROPANE ONLY




   NWACC Business & Industry
                                     ACME FORKLIFTS
                                                         N - 11
   Workforce Development Institute
       BASIC FORKLIFT PRINCIPLES

FORKLIFT MANUFACTURER:

 DICTATES SPECIFIC OPERATION OF VEHICLE
 SPECIFIES MAINTENANCE REQUIREMENTS
 CONSULTED CONCERNING “ADD-ON’s”
 FIRST CHOICE FOR SAFETY QUESTIONS




   NWACC Business & Industry
                                           N - 12
   Workforce Development Institute
        BASIC FORKLIFT PRINCIPLES

 OVERHEAD GUARD

 MAST

 CARRIAGE

 BACKREST
                                          LOAD CAPACITY
                                          6000 lbs

 LIFT CYLINDER
                                           PROPANE ONLY


 TILT CYLINDERS                      ACME FORKLIFTS


 FORKS


    NWACC Business & Industry
                                         N - 13
    Workforce Development Institute
        BASIC FORKLIFT PRINCIPLES

                          THE RATED CAPACITY

THE RATED CAPACITY:

 THE MAXIMUM AMOUNT OF WEIGHT THAT CAN BE SAFELY LIFTED
 HOW THE LOAD RESTS ON THE FORKS IS CRITICAL
 THE CLOSER THE LOAD IS TO THE BACKREST THE BETTER
 CAN BE FOUND ON THE NOMENCLATURE PLATE OF THE VEHICLE




   NWACC Business & Industry
                                                N - 14
   Workforce Development Institute
      BASIC FORKLIFT PRINCIPLES
                              LIFTING PRINCIPLE




COUNTER       PIVOT POINT                 PIVOT POINT    COUNTER WEIGHT
 WEIGHT
                    CONSULT YOUR VEHICLE OWNERS MANUAL

  NWACC Business & Industry
                                                           N - 15
  Workforce Development Institute
       BASIC FORKLIFT PRINCIPLES

                            LIFTING PRINCIPLE

                                                   MOVING THE LOAD AWAY FROM
REAL HEAVY PARTS                                   THE BACKREST CAN LOWER
                                                   THE RATED CAPACITY OF THE
                                   LOAD CAPACITY



        6500lbs
                                   6000 lbs
                                                   FORKLIFT BY HUNDREDS OF
                                    PROPANE ONLY


                             ACME FORKLIFTS
                                                   POUNDS!



           INCORRECT

                   CONSULT YOUR VEHICLE OWNERS MANUAL

 NWACC Business & Industry
                                                                    N - 16
 Workforce Development Institute
     BASIC FORKLIFT PRINCIPLES

                             LIFTING PRINCIPLE


REAL HEAVY PARTS                                  REAL HEAVY PARTS



                                  LOAD CAPACITY
                                  6000 lbs                               LOAD CAPACITY
                                                                         6000 lbs

        6500lbs                    PROPANE ONLY           6500lbs
                                                                          PROPANE ONLY

                              ACME FORKLIFTS
                                                                     ACME FORKLIFTS




           INCORRECT                                      CORRECT

               CONSULT YOUR VEHICLE OWNERS MANUAL

NWACC Business & Industry
                                                                               N - 17
Workforce Development Institute
         BASIC FORKLIFT PRINCIPLES

                                         CENTRIFUGAL FORCES

REAL HEAVY PARTS




        6500lbs                                 MOVING OR TURNING THE VEHICLE
                                                WHEN THE LOAD IS EXTENDED CAN
                                                RESULT IN TURNOVER BECAUSE OF
                                                CENTRIFUGAL FORCES APPLIED AT
                                                THE TOP OF THE LOAD!

                         LOAD CAPACITY
                         6000 lbs



                          PROPANE ONLY

                     ACME FORKLIFTS




   NWACC Business & Industry
                                                                     N - 18
   Workforce Development Institute
    FORKLIFT OPERATING PRINCIPLES

                           PRE-USE INSPECTION
 MAST                                CYLINDER MOUNTING HARDWARE
 ROLLER TRACKS AND CHAINS            TIRES
 FORKS AND ADJUSTMENT                LIGHTS AND WARNING DEVICES
 FLUID LEVELS                        HANDBRAKE
 HYDRAULIC LINES                     STEERING AND BRAKES
 LIFT AND TILT CYLINDERS             DRIVING CONTROLS
 OVERHEAD GUARD MOUNTING             LIFT CONTROLS
 FIRE EXTINGUISHER                   SEAT ADJUSTMENT AND BELTS

   NWACC Business & Industry
                                                       N - 19
   Workforce Development Institute
  FORKLIFT OPERATING PRINCIPLES

                   TYPES OF POWER SOURCES

                      BATTERY POWERED
                      PROPANE POWERED
                      DIESEL POWERED
                      GASOLINE POWERED

                 CONSULT YOUR VEHICLE OWNERS MANUAL


NWACC Business & Industry
                                                      N - 20
Workforce Development Institute
 FORKLIFT OPERATING PRINCIPLES

             INSPECTION OF POWER SOURCES

 BATTERY POWERED
      - REQUIRES CONSTANT CHARGING
      - NO IGNITION SOURCES IN CHARGING AREA
      - FOLLOW LOCAL CHARGING PROCEDURES

                CONSULT YOUR VEHICLE OWNERS MANUAL


NWACC Business & Industry
                                                     N - 21
Workforce Development Institute
 FORKLIFT OPERATING PRINCIPLES

            INSPECTION OF POWER SOURCES

 PROPANE POWER
     - INSPECT TANK FOR SERVICEABILITY
     - INSPECT PROPANE TRANSFER SYSTEM
     - INSPECT TANK RESTRAINT SYSTEM
     - FOLLOW LOCAL REPLACEMENT PROCEDURES
                  CONSULT YOUR VEHICLE OWNERS MANUAL

NWACC Business & Industry
                                                       N - 22
Workforce Development Institute
 DANGEROUS DRIVING CONDITIONS

       LOADED FORKLIFT RAMP OPERATIONS

ALWAYS APPROACH RAMP LOAD FIRST!

                                  REAL HEAVY PARTS



                                                         LOAD CAPACITY
                                                         6000 lbs


                                          6500lbs         PROPANE ONLY


                                                     ACME FORKLIFTS




NWACC Business & Industry
                                                                         N - 23
Workforce Development Institute
  DANGEROUS DRIVING CONDITIONS

       LOADED FORKLIFT RAMP OPERATIONS

     ALWAYS LEAVE RAMP LOAD LAST!


                                  REAL HEAVY PARTS



                                                         LOAD CAPACITY
                                                         6000 lbs


                                          6500lbs         PROPANE ONLY


                                                     ACME FORKLIFTS




NWACC Business & Industry
                                                                         N - 24
Workforce Development Institute
 DANGEROUS DRIVING CONDITIONS

    UNLOADED FORKLIFT RAMP OPERATIONS

ALWAYS APPROACH A RAMP FORKS LAST!



                        LOAD CAPACITY
                        6000 lbs



                         PROPANE ONLY


                    ACME FORKLIFTS




NWACC Business & Industry
                                        N - 25
Workforce Development Institute
  DANGEROUS DRIVING CONDITIONS

   UNLOADED FORKLIFT RAMP OPERATIONS

 ALWAYS LEAVE A RAMP FORKS FIRST!



                        LOAD CAPACITY
                        6000 lbs



                         PROPANE ONLY


                    ACME FORKLIFTS




NWACC Business & Industry
                                        N - 26
Workforce Development Institute
  KEY ELEMENTS TO AN EFFECTIVE PROGRAM


1. DEVELOP AND STRICTLY ADHERE TO SAFETY PROCEDURES.

2. ESTABLISH AND ENFORCE SAFE WORK PRACTICES.

3. ENSURE PROPER TRAINING AND SUPERVISION.

4. STRENGTHEN AND MODIFY PRESENT POLICIES.

5. UNDERSTAND THE RELATIONSHIP BETWEEN 29 CFR 1910.178
   AND THE BUSINESS OR INDUSTRY INVOLVED.




NWACC Business & Industry
                                                N - 27
Workforce Development Institute
          OSHA'S PERCEPTION
      OF A SUCCESSFUL PROGRAM

1. DETAILED FORKLIFT SAFETY PROCEDURES

2. EXTENSIVE EMPLOYEE TRAINING PROGRAMS

3. PERIODIC REINFORCEMENT OF TRAINING

4. SUFFICIENT DISCIPLINE REGARDING IMPLEMENTATION



   NWACC Business & Industry
                                         N - 28
   Workforce Development Institute

				
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