Forklift Safety Fundamentals

Mar 11, 2021

Did you know that there are an estimated one million forklifts currently in use in the US? That leaves plenty of potential for accidents — in fact, OSHA reports that forklift accidents cause roughly 35,000 serious injuries and 85 fatal accidents every year. It’s also reported that nearly 25% of these accidents happen because of inadequate training. By revisiting forklift safety fundamentals and relaying this information through training and continuing education, managers can build and maintain a thriving culture of safety. 

Require Certification

Since a good portion of forklift accidents happen because of poor training, it’s a good idea for warehouse managers to allow only those who are trained based on OSHA regulations, experienced and certified to operate a forklift. These employees need to have performance evaluated regularly (every few years or so) and organizations need to provide continuing education and training materials to keep the knowledge fresh in the minds of forklift operators.

Inspect Equipment

Checking the forklift before every use needs to be a requirement, and any issues should be reported immediately and repaired before the equipment goes back out on the floor. Brakes, lights, the horn, and the steering wheel should be tested, tire and fluid levels need to be examined, and the forks should be inspected for damage. 

Maintain Visibility

Having a good view of what’s around the forklift makes it much easier to assess potential hazards and avoid accidents. Keep the forks low to the ground to avoid obstructing the view and make eye contact with pedestrians around the equipment. Tools like rear-view mirrors and headlights in darker work conditions also work to help keep operators (and other employees) safe while operating the forklift.

Invest In Floor Marking

Your facility should already have safety markings on the floors, but if that’s not the case, this process needs to be prioritized. The pedestrian flow of traffic needs to be separated from the areas where pedestrians can safely travel, and hazards along each path need to be clearly marked.

Maintain Capacity

Whether it’s inventory or passengers, don’t carry more than the maximum on the forklift. Overloading a forklift can impact the counterweight and cause the equipment to fall forward, leading to loss or damage of inventory or even injury. The same is true for carrying passengers. Unless the forklift has an extra seat and is designed to hold another operator, nobody should be hitching rides. It’s also common sense, but bears repeating: Don’t lift anyone with the forks; there are safety platforms and cages designed for this specific purpose.

Watch Stability

Every forklift has a center of gravity and is designed and built to have a suspension system that’s referred to as the stability triangle. The heavier the load, the further forward the center of gravity, and the bigger risk of tip over. When traveling with loads, keep them tilted backward and keep the forks low to the ground. Use bindings or tethers to secure the loads, and don’t overweight the forks.

Optimize Operation

Operate your equipment at recommended speeds, don’t stop or change direction when traveling at higher speeds, and watch for other equipment while operating the forklift. Just like driving on the road, there needs to be an appropriate distance between your equipment and others to ensure safe stopping. If a forklift starts to tip over, experts advise NOT to jump out — instead, you should stay in the vehicle and grip the steering wheel.

Designate Parking, Refueling, and Recharging Areas

There needs to be a designated space in your warehouse for equipment to be refueled, recharged, and parked between shifts. This helps to keep your forklifts off the floor and prevent hazards. Forklifts should also be refueled and recharged between each use; losing power or running out of fuel during operation or while a load is attached can quickly become a serious safety hazard.

Invest In Your Equipment

Forklifts that need repair or replacement need to be out of operation until they’re functioning properly. That means you need an equipment partner who will perform routine preventative maintenance and inspections of material handling equipment to minimize breakdowns. Better yet, that partner should be able to provide rental equipment to reduce downtime. 

When it comes to the operational safety of the forklifts in your facility, don’t leave things to chance. Our technicians are OSHA trained, and Factory Certified in Hyundai and PowerBoss equipment — get in touch today, let’s create a culture of safety together. 

Common Hazards in Your Warehouse (And How to Avoid Them)

08 Apr, 2024
Warehouses are the backbone of many industries, storing and distributing goods to keep the economy moving. However, behind the scenes of this logistical hub lurk various hazards that can pose severe risks to employees and property. Let's investigate some of the most common warehouse hazards and explore proactive mitigation strategies. Slips/Trips/Falls Slips, trips, and falls are among the most prevalent hazards in warehouse spaces. Spills, cluttered aisles, and uneven surfaces can easily lead to accidents if not adequately addressed. To prevent such incidents, warehouses should prioritize proper housekeeping, including regular cleaning and maintenance of floors. Additionally, using signage to highlight potential hazards and ensuring adequate lighting throughout the facility can significantly reduce the risk of slips, trips, and falls. Fires Flammable materials and electrical equipment in warehouses make them susceptible to fires. Faulty wiring, improper storage of combustible materials, and lack of fire suppression systems can all contribute to the risk of fire outbreaks. Implementing preventive measures such as regular equipment maintenance, proper storage protocols for flammable materials, and employee training on fire safety procedures are crucial in mitigating this hazard. Harmful Substances Warehouses often house various chemicals and hazardous substances, which can pose risks to employees' health if not handled properly. Exposure to harmful substances can lead to respiratory issues, skin irritation, and other serious health problems. To mitigate this hazard, warehouses should properly store and label hazardous materials, provide employees with appropriate personal protective equipment (PPE), ensure adequate ventilation systems, and conduct regular training on safe handling procedures. Falling Objects With shelves stacked high with merchandise, falling objects present a significant hazard in warehouses. Poorly secured storage systems, improper stacking of items, and inadequate safety measures can all increase the risk of objects falling and causing injury. Warehouses can minimize this risk by adequately securing shelves and storage systems, using barriers or guardrails to prevent objects from falling, and conducting regular inspections of overhead storage areas. Overexertion The physical demands of warehouse work can lead to overexertion injuries if employees lack adequate training or don't perform tasks ergonomically. Lifting heavy objects, repetitive motions, and working in awkward positions can all contribute to overexertion injuries such as strains and sprains. To prevent such injuries, warehouses should provide comprehensive training on proper lifting techniques, encourage the use of mechanical aids such as forklifts and pallet jacks, and implement ergonomic workstations to reduce strain on employees' bodies.

Common Inventory Management Mistakes

08 Mar, 2024
Effective inventory management practices influence the success of each warehouse, the supply chain, and the business at large. Inventory management involves many moving parts and elements – everything from the product catalog to the warehouse space to tracked KPIs. Experienced warehouse managers know that no matter how fool-proof your inventory management systems are, there’s always room to improve and prepare for unexpected circumstances. Let’s discuss common inventory management mistakes (and what to do instead). Overstocking or Understocking One of the most prevalent inventory management mistakes is maintaining too much or too little inventory. Overstocking ties up valuable capital and warehouse space, leading to increased carrying costs and a higher risk of obsolescence. On the other hand, understocking can result in stockouts, backorders, and dissatisfied customers. Businesses should leverage historical sales data, market trends, and advanced forecasting techniques to accurately predict demand and optimize inventory levels. Inaccurate Demand Forecasting Businesses are prone to making costly inventory planning errors without precise demand forecasting. Relying on outdated data or flawed forecasting methods can lead to inefficiencies and missed opportunities. By utilizing advanced analytics and predictive modeling, businesses can better anticipate shifts in demand, seasonal fluctuations, and emerging trends, allowing for more informed inventory decisions and improved responsiveness to customer needs. Lack of Inventory Visibility Poor visibility into inventory levels across multiple locations or channels can result in operational inefficiencies and errors. Without real-time data on stock levels and movement, businesses may struggle to fulfill orders on time, leading to customer dissatisfaction and lost sales. Implementing integrated inventory management systems that provide comprehensive visibility into inventory across the supply chain can help businesses optimize inventory allocation, reduce stockouts, and improve overall operational performance.

A Beginner’s Guide to Electric Forklifts

By Denis Benden • 08 Feb, 2024
Efficient material handling is crucial for businesses of all sizes and industries. It directly impacts productivity, cost-effectiveness, and overall operational success. Effective material handling ensures that goods are moved, stored, and transported in a streamlined and organized manner, minimizing delays, damages, and errors. Electric forklifts play a significant role in effective material handling, transforming the […] The post A Beginner’s Guide to Electric Forklifts appeared first on Benco Industrial Equipment.
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