Do I Need to Do a Pre-Shift Forklift Inspection Every Day?

Pre-shift inspections can identify problems when they’re still relatively minor. © lovelyday12 – stock.adobe.com

By: Russell Niedzwiecki, Contributor

Have you ever had a forklift or MEWP operator ask this question? We’ll bet you have.

In the rush of a workday, taking five to fifteen minutes to do an equipment inspection may seem like a distraction. One reason to perform these inspections is that OSHA “requires that all forklifts be examined at least daily before being placed in service. Forklifts used on a round-the-clock basis must be examined after each shift. [29 CFR 1910.178(q)(7)]” However, pre-shift inspections are crucial for two more critical reasons: safety and productivity. This article will review why these inspections are important and list things every inspection should include.

SAFETY

OSHA requires that all forklifts be inspected before beginning work each day (or before each shift—see above) to ensure everything is working properly and to identify potential problem areas. A pre-shift inspection should identify safety issues from malfunctioning or damaged equipment, like hydraulic failures, stability issues, and other problems that could increase the risk of a tip-over or other safety incident.

Identifying potential problems before a vehicle is out on the floor protects the operator, other workers in the facility, and visitors. Forklifts are heavy and difficult to stop quickly. Accidents can mean serious injury or even death. Anything, like pre-shift inspections, that can prevent accidents is worth doing.

PRODUCTIVITY

Pre-shift inspections can identify problems when they’re still relatively minor. Often, a small adjustment by the operator is all that’s needed to get the truck back to optimal operating condition. And a vehicle that’s in optimal condition will be more efficient and productive.

If the problem needs more attention, repairs may cost less. Often when an issue is identified early, fixing it costs less and takes less time, so the truck is back to work quickly.

Bottom line? Pre-shift inspections can improve forklift productivity and reduce maintenance costs by finding problems early.

A “TYPICAL” PRE-SHIFT INSPECTION CHECKLIST

There are two important points to make here. The first is that having a checklist will make the inspection process easier and standardized. The second is that “typical” may not be an appropriate word to use here since pre-shift checklists vary based on the manufacturer and model. (OSHA provides some sample, generic checklists; however, we highly recommend you consult the owner’s manual for each model in your fleet.)

Key items to check include:

• Forks for bending or signs of damage
• Chains for proper tension and greasing
• Carriage and load backrest for signs of damage
• Tires for chunking, tearing, or damage
• Signs of leaks or drips from the engine or hydraulics
• Seatbelt for proper tension and performance
• Battery charge
• Fluid levels
• Mast for signs of damage
• Lights, horn
• Brakes, steering

Visual inspections allow operators to catch problems before they happen, problems that could turn into costly OSHA violations or equipment repairs. However, in order to utilize daily inspections effectively, there are a few things you will need to implement in addition to just walking around the machine.

STAYING CONSISTENT

The only way daily walk around inspections are effective over time is if they are performed consistently. Looking at each critical aspect of the machine daily can help you keep track of when machines will require maintenance, helping you become more efficient regarding when you schedule those machines to be serviced. Catching problems before they become an even bigger problem will likely save you money, as it is less expensive to fix a machine with a small issue rather than a larger issue. Therefore, in order to reap the benefits of daily inspections, be sure you are consistent by actually performing them daily.

CREATING A SYSTEM OF ACCOUNTABILITY

Accountability is important in remaining consistent and avoiding accidents as it keeps everyone on the same page about the condition of a machine. Being accountable for your inspection can be as simple as initialing a daily log that tracks the machine’s condition. If there is an issue with a machine, do not ignore it. Report the unsatisfactory condition immediately and if it is unsafe to proceed, do not use the machine. Using good judgement and staying accountable for your daily walk around inspection is another important factor in ensuring your inspection is effective in keeping yourself and those around you safe from unnecessary accidents.

IF YOUR FORKLIFT TRUCKS HAVE BEEN IDLE FOR AN EXTENDED PERIOD OF TIME

There may be extended periods of time in which your machinery sits idle or unused. In these cases, in addition to performing your daily check sheets for each unit prior to employees coming back to work, we recommend that you add the following extra steps to your routine to ensure your machine is ready for operation:

• Place electric truck batteries on the charger and check battery water levels.
• Start I.C. trucks to verify batteries are charged and ready.
• Perform a short test drive to check all systems are operational after setting
• Look under units that have been setting for signs of leaks

Another thing to ask yourself if your machines will go unused for an extended period of time is when was the last service completed? Is it close to needing service? If you are experiencing a temporary closure, now is a good time to perform occasional services such as:

• Coolant flushes
• Transmission flushes
• Hydraulic fluid and filter changes
• Differential fluid changes
• Ignition tune ups

Using this time to service and repair machines will save you time whenever you are ready to reopen. Operating equipment that is in good condition is not only to protect yourself, but also those who work around you. Remember, conducting thorough inspections could prevent costly and dangerous accidents, saving yourself and those around you from the consequences of a workplace injury. WMHS

Russell Niedzwiecki is Corporate Trainer for TrainMOR, a company dedicated to the safety of operators and their co-workers. He has provided powered industrial truck operator, mobile elevating work platform (MEWP) and Train the Trainer courses for more than 10,000 people for more than 800 companies throughout Michigan and Indiana. Visit: https://www.trainmor.com/ Morrison Industrial Equipment offers a mobile industrial tire service. Call 833-633-0256 for a free, no obligation tire survey.