Forklifts are material handling tools that help keep manufacturing facilities running. They can also be very dangerous equipment if the operator does not pay attention or take unnecessary risks. Forklifts are essential equipment in most manufacturing facilities. They can effectively transport raw materials, in-process products and finished products to the places where they need to, so as to ensure that the workflow remains stable and the goods are delivered as planned.
Forklifts can also be dangerous, even deadly equipment.
Since 2011, more than 50 people have died in forklift related accidents every year in all industry sectors in the United States. During the same period, more than 6000 people suffered non fatal injuries due to forklifts. When a 10,000 pound vehicle hits a 180 pound person, the person's situation will not be very good.
This is bad news. The good news is that training, smart work procedures, and involved employees can really make a difference. Think about this. According to the Bureau of Labor Statistics, the number of warehouse workers in the United States has more than doubled in the past 10 years, from 707100 in January 2013 to 179100 in June 2022. But the number of injuries and deaths did not surge with the increase in the number of workers.
However, there are too many deaths in the working environment. Any accident involving forklift may require more things than bandages or some ice blocks to enable the injured party to resume work quickly. This is why forklift safety is so important, especially in the manufacturing environment. More than a quarter of all non fatal forklift related injuries in the United States occur in the manufacturing industry.
In order to emphasize the importance of forklift safety, The FABRICATOR interviewed Holly Pups, an editor responsible for environmental, health and safety issues. The company is a supplier of safety related products and services. Since Pups was an official of the Occupational Safety and Health Administration (OSHA) of the United States, and has more than ten years of industrial safety experience in the private sector, Manufacturer magazine also showed her some real death scenes in the OSHA archives, and asked her how to avoid these situations.
Maker: What do you think are the main factors of forklift accidents?
Holly Pups: According to my experience, the two major events I have seen are that there is a big difference between the direct cause and the root cause of the accident. The direct cause of any type of forklift accident, whether it is property loss, danger, or personal injury, is often the operator's distraction. They didn't notice. But the root cause is related to why they are distracted. Is it because the driver is tired? Does the driver work too much overtime? If the driver missed the rest time, did he not arrange the rest later?
Therefore, the schedule and workload of forklift operators are really important. However, the management is aware of what is reasonable for forklift drivers and what is safe for employees. This is your biggest opportunity to improve forklift safety.
Manufacturer: Are the training requirements for forklift drivers the same in all industries?
It usually depends on good communication to ensure that the semi-trailer and trailer will not start when the forklift is still in the trailer. However, the safest tool to ensure the safety of cargo and forklift operators may be the automatic dock lock system, which keeps the trailer in place until the forklift operator presses the button to release the trailer from the dock. (Figure 1)
Holly Pups: OSHA's general industrial standards cover forklifts, basically anything that does not belong to construction, maritime or agriculture. All of this is covered in 29 CFR 1910.178, which includes powered industrial vehicles. Therefore, it also covers forklifts, forward moving trucks and various vehicles used to move materials.
Manufacturer: What are the requirements of OSHA on driver training or certification?
Holly Pups: Similarly, this is reflected in 1910.178. The training requirement for operators is that they have a classroom training section, and you can combine teaching, video, truck demonstration or anything that is meaningful to your facility. Then there should be a practical demonstration. Therefore, you will have a qualified forklift operator to show them the control, and then let the same qualified forklift operator supervise them, so that they can get used to the specific truck. They must be assessed by the trainer to ensure that their operation is good enough not to pose a hazard to the facility. This is required for every type of industrial vehicle.
Manufacturer: Are these training programs generally good at providing forklift operators with effective information and maintaining a safe working environment?
Holly Pups: It depends on the facilities and the way of thinking. According to my personal experience and what I saw and heard when I was an OSHA compliance officer, forklift training is indeed a pencil writing activity. I have seen some companies do one hour training, and complete classroom practice and evaluation within this hour.
Early in my career, I was placed in a similar situation. But it doesn't feel right.
The last thing I did was create a strong training program. I have a class section where I can talk about regulations and safety tips, such as how the weight on a forklift may be transferred. Then, I put the responsibility of demonstration and evaluation on the manager or supervisor of the department where the employee will work. These regulators need to be reassured that this person is handling our products.
Manufacturer: When it comes to OSHA requirements, what changes do you want to see?
Holly Pups: In terms of training, the biggest change I want to see is that OSHA outlines the requirements for trainers. Now, it just says that anyone with enough knowledge can become a trainer. Therefore, this is experience and knowledge, but it is a very large gray area for companies to explain in a meaningful way. This may not be beneficial to employees because they have not received the detailed training they may need.
Maker: You mentioned that the excessive work of employees may lead to the lack of attention of forklift drivers. When it comes to forklift safety, do you think it is the biggest challenge, or are there other factors that people should pay attention to?
The load on the forklift blocks the view and cannot see the situation ahead. The only safe direction for the forklift driver is to move backward. (Figure 2)
Holly Pups: It's always a comprehensive struggle to find enough employees. This involves what I think is the biggest challenge to keep employees safe. This is not limited to powered industrial vehicles. The company has the expectation that when other roles are not filled, employees will bear the burden. As a result, people work more.
The company hopes to continue because they are making money, but the employees cannot work for 6 16 hours continuously. This will increase your chances of accidents and serious injuries to others.
There are other challenges, which are a bit like returning to these staffing issues. Therefore, when these understaffed companies find people, new employees with little experience may start to work. Training costs, so we tend to rush through things like forklift training or lock/tag training.
In the manufacturing industry, people spend a lot of time talking about "doing things right the first time", and avoid mistakes by spending time doing things right the first time. This also needs to apply to training. If we take the time to properly conduct the training, it is thorough, and we have a really good feeling for the employee, then we can let the employee relax. However, if you rush to train and expect them to go on duty, in the long run, it will cost the employer because these people tear down the shelves and drop thousands of dollars worth of products. Or, God bless, they nailed someone to the shelf.
Manufacturer: Sometimes, the best way to understand the importance of topics like forklift safety is to talk about real world examples. With this in mind, we would like to talk about some forklift accidents mentioned on the OSHA website, and let you comment on how these unfortunate events were avoided.
The first example involved a forklift overturning when the operator was apparently making a sharp turn at too fast a speed. The safety belt was not installed. When the employee fell off his seat, he was pressed by the roll over bar. What do you think of this accident?
Holly Pups: Obviously, the direct cause of this accident is that the person was driving too fast. But it is also important that the root cause is that the operator did not fasten the safety belt properly.
Although OSHA does not require a forklift to have a seat belt, it does require that if a forklift is equipped with a seat belt, the operator must use it.
However, according to the general liability clause, that is, all the contents of such topics, OSHA did explain in a letter of explanation that forklifts should be modified into safety belts, because this is a known danger. If the forklift overturns and you wear a seat belt, it will kill you, but it will not kill you.
It is understood that you will modify these. I believe that the latest updates of ANSI or ASME standards require that current forklifts must be equipped with them. However, some forklift trucks of previous versions are not required.
Back to the fact that the operator walked too fast, there is an self-evident rule that the forklift inside should not exceed the walking speed. However, it may be difficult for drivers in a huge facility, especially if you have a forklift powered by propane, which has a little extra power.
In training, speed is a problem that should be solved. OSHA does not give you an accurate mileage per hour, and most of these forklifts are not equipped with speedometers. But you must drive according to the conditions.
Manufacturer: In the following incident, when an operator drove a standing forklift into the tractor to unload, the truck driver pulled away from the dock. The forklift fell on the driver, hit his head and broke his neck. What can be done to prevent this deadly situation?
Holly Pups: In this case, the hierarchy of control may have an impact. In this case, a truck is driving away, and you may let the forklift fall; The level of control indicates that you should take appropriate measures to eliminate this potential danger.
You can't remove the forklift from the truck, so the next step is engineering control. These measures do not depend on people, as they are more about systems that help prevent injury or death.
Then there is administrative control, which is the ultimate goal of most companies (see Figure 1). They tell truck drivers to close the truck or sit in the lounge when loading or unloading. This type of administrative control has a lot of room for error. For example, the driver received a phone call saying that he had to go. He took a look at the trailer, but there was no one in it. But he pulled the door open. He didn't know that the man had not finished it. As a result, an accident occurred.
When I am on site, I try to stay away from the administrative control relying on communication. Because there are different companies and personnel, everyone's schedule and training will be a little different. Therefore, my preference for these situations is something like automatic dock lock, which can basically fix the trailer on the building. The forklift operator can control this and when the truck can leave. Just press a button to unlock the truck. Of course, this is not a 100% guarantee that truck drivers will not pull away, but if they pull away when they are locked on the dock, they will be in trouble.
The Maker: This incident involves the driver's line of sight being blocked. As the operator was driving the forklift, he could not see the front situation correctly. The forklift hit a passing employee, causing him to die. What is the first thing you jump out of here?
Pupu. According to the requirements of OSHA, if your goods block your sight, you must drive back (see Figure 2), or there must be some alternative methods to make the operator's sight unhindered.
This can be tricky because some people don't understand what accessibility really means. I remember when I worked in a company, there was an employee who was 6 feet 7 inches tall. He thought that his vision on the forklift was unobstructed, even if the pallet was loaded to a height of 6 feet. He can see it, but it's like putting your hand on your nose. You can't see anything under your hand. He can only see things in the distance, not in front of him. This is not a good situation.
This is where training can work. One of my favorite ways of training is to sit at a desk, talk and play with a truck. This is a good way to talk about the situation, and then provide a practical exercise to make the discussion lively. What problems do you see here? If you have a cargo blocking your view, which side do you need to drive? This is an ongoing dialogue.
Many companies forget that they should constantly remind people to pay attention to their training. If you only receive training once every three years, or when you have an accident, it is too late.
Manufacturer: There is also a fatal accident related to bad forklift operation. Two employees rode on the goods, which were tied to the fork of the forklift. The goods were lifted with the help of a crane. When the cargo is lifted to a height of about 23 feet, these people stand on the cargo. The goods shifted and slipped off the fork, pushing the two men away from the goods. One man was seriously injured and the other man died of his injuries.
Holly Pups: There are many problems here. First of all, no one is allowed to ride the goods, especially two people. The only exception is that they have man cages that can be installed on forklifts, but even so, it is still not recommended.
Operators, riders and crane operators all have shares here, which indicates that there is a systematic problem, which may be attributed to insufficient training.
Manufacturer: Do you have any final ideas for manufacturers who want to minimize the risk of injury caused by forklift accidents?
Holly Pups: Actually, I have three points, two of which we have already covered. First of all, you need a thorough training plan. When it comes to training employees, you need to focus on doing it right the first time. Take some extra time. Make sure employees feel particularly comfortable.
The next question is related to the company's setting reasonable expectations for employees. They are in a hurry to please others. Sometimes employees set unrealistic expectations for themselves. At this time, communication from the command system is really important. The manager should not be afraid to say, "I see you are in a hurry. You are walking a little fast. Then why do you do this?" If the employee is in a hurry to avoid missing the rest time, the manager should ensure that the rest time can be held in 5 minutes. This communication circle is the key.
There is also one of the biggest issues we haven't really talked about, which is also one of my controversial beliefs in running an effective safety project. That is, when an incident or accident does occur, don't blame employees. The mentality of many enterprises is that if someone messes up, he will be suspended, so that they know they will not do it again. This will do more harm than good. It makes it impossible for people to report things. This makes them feel that if they mess up, they will lose their jobs.
When an accident or incident occurs, these are opportunities to understand the actual situation in the workshop. It gives managers an opportunity to identify the suffering of employees who may affect the accident and take measures to avoid similar accidents in the future.
In my previous job, we had a series of collisions with forklifts and roller shutter doors. After such an event, it is easy to send a forklift operator home without pay for four days. Then, other people will have to take over the work of the employee, and their pressure is growing. They are more likely to have accidents. In addition, the suspended employees feel bad about themselves and their work.
But if you find the root cause, you will find the real truth. I investigated these rolling doors because they are incredibly fast. The company actually had to spend nearly $100000 to add effective security controls around these doors. It is not the employee who tries to rush to the door, but the door rushes to the employee.
Therefore, when you see these accidents, it is an opportunity to see what happened. At any time, when employees are involved in the near impact or miss of forklifts or other powered industrial vehicles, they need to receive some training. At that time, you can solve what you did wrong and use it as a learning opportunity.
