Forklifts are one of the most useful pieces of equipment in any warehouse, manufacturing plant, or distribution center.
They’re also one of the most dangerous.
What’s interesting is that most forklift accidents aren’t caused by equipment failure.They’re caused by operators and managers becoming comfortable. I’ve spent years around forklifts, and the biggest safety risks I see are usually the same ones over and over again.
The scary part?
Most of them are completely preventable.
This is probably the most common issue I see. Operators get comfortable with their truck, warehouse and routes. Over time, speed starts creeping up.
The problem is that a forklift isn’t a car. Forklifts have a higher center of gravity, turn differently, carry shifting loads and need significantly more stopping distance. These are real world dangers with real world consequences like tipping over or running into pedestrians. A few seconds saved aren’t worth the risk
Talk to your local dealer about a governor installation.
This one makes me nervous every time I see it. Operators often think, “It’s only a few feet.” But that’s exactly how accidents happen.
Operators need to understand that even when a load is elevated the center of gravity rise and the stability decreases which raises the tip over risk dramatically.
Your best and safest use is to travel with the load low to the ground and slightly tilted back to help stabilize it against the load back rest. The higher the load while traveling, the more unstable the truck becomes.
Forklift operators aren’t the only people responsible for safety. Pedestrians play a huge role too.
Your workers should not expect the machinery operators to keep them safe. And there are plenty of things they do now that put themselves at risk. Including walking behind forklifts, entering blind intersections, assuming the operator sees them or the king of all culprits these day! Looking at phones while walking!
I tell people, never assume the forklift sees you. Even if your experienced operators have blind spots, obstructed visibility and good old fashioned distractions. Pedestrian awareness saves lives.
This is one of the most misunderstood risks in material handling. Many people believe, “The forklift picked it up, so it must be okay.” That’s not how capacity works.
Operators often forget that capacity changes based on load center, attachment weight, fork length, mast height and more. A truck rated for 5,000 lbs may not actually lift 5,000 lbs in your application.
That’s not hyperbole either. You’re stressing components under conditions they have proven to fail under. I have personally watched an overloaded 30k capacity forklift, who’s rear axle was suspended in the air due to the weight on the front end; and seen the weight snap the forks in half sending one flying 50 feet into the air only to come crashing down around the work force. Had it hit anyone it would have killed them
These machines are not toys.
Ramps change everything. Yet many operators treat them like flat ground.
Driving in reverse when descending. Why? This keeps the load secure and prevents it from sliding or shifting. Improper ramp operation is one of the fastest ways to lose control of a truck.
This may be the biggest risk of all.
Most serious incidents don’t happen on Day one or Week one. They happen after months or years of routine operation.
Why? Because familiarity creates shortcuts and people grow complacent. They start thinking, “I’ve done this a thousand times.” And that’s when mistakes happen.
Almost every forklift related injury I’ve seen has been entirely due to not following proper procedures. People who have gotten comfortable and stop paying attention to the details.
The best forklift operators I’ve worked around all have one thing in common, they respect the machine. Not because they’re afraid of it. Because they understand what can happen when safety becomes an afterthought.
And that’s a lesson worth remembering whether you’ve been operating for one day or twenty years.
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Jasonf@forkliftexchange.com
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Special Note: If you’re still reading, like and share. It’s appreciated. If you’re evaluating safety procedures, consult a safety expert. But if you’re looking for your next forklift, send me a message and I’d be happy to discuss your safety protocols to see if the life you have fits your needs. Send me a message.
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