Top 5 Forklift Safety Procedures – Preventing Accidents Now Means Less Trouble Later

By Alex Johns, VP of sales, ELOKON

Forklifts should always be operated according to the manufacturer’s instructions

In material handling, ensuring safety and efficiency is essential for smooth operations in warehouses and other facilities. Unfortunately, accidents caused by lapses in forklift safety are all too common in the workplace. In fact, according to the Occupational Safety & Health Administration (OSHA), forklifts accidents resulting in serious injuries average a total of 34,900 annually, with 95 people on average seriously injured every day and one person killed every four days in the US alone.

These accidents, along with costly warehouse and inventory damage and downtime, could be greatly reduced, if not prevented entirely, if facilities established and implemented important safety rules – and employees followed them. But where do you start? And how do companies implement advanced safety features to ensure a safe and efficient warehouse?

Forklift manuals and OSHA regulations provide forklift safety measures, and refresher safety courses are often required. Consider these five essential forklift safety rules with expert guidance for improving the safety of the warehouse, pedestrian workers, and forklift drivers.

1. Stay Current on Forklift Training and Certification

In the U.S., following OSHA forklift standards such as the “1910 Subpart N – Materials Handling and Storage” is critical. This includes finding and completing forklift training to be licensed to operate forklifts (OSHA Forklift Certification & Online Training). Employees need to be current in their forklift training and certifications, so they know the latest forklift system safety rules and procedures for operating forklifts, with operators specifically needing to be trained, tested and certified every three years on rules such as:

• Operate the forklift according to the manufacturer’s instructions
• Always wear a seatbelt if the forklift has one
• Watch for pedestrians and maintain a safe speed limit
• If provided, use proper footing and handholds when entering the vehicle
• Never exceed the rated load
• Do not attempt to raise or lower the load while the forklift is traveling
• Keep a safe distance from the platform and ramp edges
• Maintain clear visibility of the work area when operating the forklift
• Use horns at cross aisles and obstructed areas to alert other drivers and pedestrians
• Be aware of other vehicles in the area

2. Follow Pre-Operational Checklists

Pre-operational inspections ensure that all equipment is ready to be used before the driver operates them. Inspections differ among different types of equipment, but OSHA requires that all forklifts be examined at least daily before being placed in service, and “any vehicle in need of repair, defective or in any way unsafe, should not be driven and should be taken out of service immediately.” Operators should use checklists like those offered by OSHA that are specific to forklifts for maximal forklift safety.

Critical aspects to inspect:

• Fluid levels — oil, water, and hydraulic fluid.

• Leaks, cracks or any other visible defect including hydraulic hoses and mast chains. NOTE: Operators should not place their hands inside the mast. Use a stick or other device to check chain tension.

• Tire condition and pressure including cuts and gouges

• Condition of the forks, including the top clip retaining pin and heel.

• Load backrest extension

• Finger guards

• Safety decals and nameplates. Ensure all warning decals and plates are in place and legible. Check that information on the nameplate matches the model and serial numbers and attachments

• Operator manual on truck and legible

• Operator compartment. Check for grease and debris

• All safety devices are working properly including the seat belt

3. Implement Safe Operation Procedures

Updating forklift fleet management systems can help ensure safe operational procedures and keep warehouse workers safe. Updated forklift fleet management systems can accurately alert forklift operators and supervisors if certain forklifts need maintenance. This adds another layer of safety in the warehouse.

4. Keep Your Forklift Technology Up to Date

Technology advancements such as artificial intelligence-driven vision detection and ultra-wideband (UWB) sensors proximity detection systems have made it easier than ever to prolong the life of your equipment while ensuring safety and fleet management. If you aren’t ready to replace older forklifts that lack the latest safety capabilities, examine third-party automated safety solutions that enhance workplace awareness for your operators. These enable safer forklift operations, better efficiency and less risk of human error.

5. Improve Pedestrian Safety

Although the forklift operator is primarily responsible for forklift safety, warehouse workers anywhere within the proximity of a forklift should be trained to be aware of oncoming forklift traffic. They should be focused on their surroundings, never walk or stand under a load or ride on forklifts unless a seat is provided. For warehouses especially concerned about pedestrian safety, proximity detection systems exist that enable both forklift operators and pedestrians of possible collisions. Advanced systems include tags pedestrians wear that alert them of an upcoming forklift – and alert the operator of an upcoming pedestrian. Improving pedestrian safety with training and state-of-the-art technology makes the warehouse function more smoothly and safely.

Following government safety regulations, company policies, and other safety tips keeps employees safe and warehouses running smoothly. Prioritizing worker safety and reviewing critical safety information regularly can prevent these serious, and often fatal, accidents that also disrupt the warehouse workflow.

Alex Johns is the vice president of sales for ELOKON, an international provider of forklift telematics and safety solutions that enhance safety, efficiency, and productivity in intralogistics operations. The company will exhibit at ASSP Safety 2025 booth 2728 in Orlando July 22-24. For more information, visit http://www.elokon.com