6 Ways to Improve Forklift Safety in the Warehouse

Forklifts are invaluable pieces of equipment in a warehouse that are critical to daily operations. Unfortunately, forklifts pose a serious safety risk for injury and in extreme cases, even death. According to the Canadian Centre for Occupational Health and Safety, common factors that lead to forklift-related injuries include:

• Excessive speed
• Mismanagement of production stress
• Improper type of forklift used 
• Lack of forklift safety training
• Poor forklift maintenance
• Age of the forklift

Fortunately, most forklift accidents can be prevented. Warehouse safety is the top priority to protect operators, workers and anyone who enters the facility. Here’s how to keep forklift operations safe in the warehouse:

1. Provide the right forklift

One of the biggest mistakes that a warehouse manager can make is assigning a type of forklift without careful consideration for the job. For example, a forklift that is not designed to maneuver through tight spaces is more likely to knock over warehouse racks. A forklift that carries loads that exceed its capacity can result in a tip over. Using the wrong type of forklift truck is a significant safety risk, it is crucial to choose the right equipment for your application. Considerations that will determine the type of forklift you need include:

• The weight of the products transported
• The required lifting capacity
• The height of the warehouse shelves and racks
• Whether the forklift truck will be used indoors, outdoors, or both

Additionally, if the forklift truck is showing visible signs of wear, it may be time to replace it with a newer model. All equipment has a lifespan, it is best to proactively replace a worn forklift before a malfunction results in a workplace injury. A modern forklift improves warehouse productivity, efficiency and overall safety. 

2. Be strict about speed and corrective action

Most tip overs and pedestrian accidents are caused by excessive speed. Setting a strict forklift speed limit in the warehouse safety policy can prevent tip overs and pedestrian accidents. Place speed limit reminders around the warehouse and take corrective actions when they are not followed. Forklift speed limit depends on factors including: 

• The type of the forklift
• The size and weight of the forklift
• Obstacles on the path
• The layout of the warehouse
• The visibility and lighting of the warehouse

When the warehouse manager takes disciplinary measures, the importance of safety is emphasized and expectations about adherence to policies are set. Taking corrective action is preferable to filing a serious workplace injury report under your supervision.

3. Set up clear protection barriers and pedestrian aisles

Forklift safety is the responsibility of everyone, not just trained operators. All warehouse safety procedures should include identifying hazardous areas and applying clear barriers. We recommend a warehouse walkthrough and safety audit to determine the strategic placement of impact barriers and pedestrian aisles. Observe areas of constraint and where workers need to walk to access equipment or products. Make note of and address common concerns to identify where improvements can be made. 

4. Offer refresher forklift training for operators

First and foremost, no untrained personnel should ever use a forklift. It should be mandatory that the only people who can operate the forklift are trained and certified workers. We recommend placing a sign to reinforce this rule. Even though a worker may be trained in forklift safety, it can be easy to forget the information over time. Investing in refresher forklift training for operators limits accidents. 

5. Include safety awareness training for all staff

Generally, trained personnel feel safe and confident operating a forklift. However, there are instances out of their control, staff may suddenly cross into the forklift’s path and pedestrians may walk underneath a lifted load. Untrained employees may not be aware of the precautions needed when a forklift is being used. The following precautions should also be posted around the warehouse: 

• Stop and look at all intersections in the warehouse
• Never walk under a lifted load
• Walk only in pedestrian aisles
• Make eye contact with the operator to make sure they see you

Offering forklift safety training for staff reduces accidents. This training focuses on warehouse safety awareness rather than on the logistics of forklift operation. 

6. Create a consistent maintenance schedule

Like all equipment, forklifts need to be maintained to ensure they are in good working condition. Electrical and tire issues can go unnoticed until they become a larger, more dangerous problem. As part of the maintenance plan, be sure to:

• Follow the manufacturer’s recommended maintenance guidelines
• Inspect the machine daily before operating
• Clean the forklift weekly
• Inspect the tires regularly
• Repair and replace components as soon as issues arise

The above steps will help extend the life of your forklift and contribute to safe warehouse operations. 

Wrapping up

Forklift safety is also dependent on the overall warehouse environment. A pre-inspection should be completed prior to the work shift to minimize clutter, clear debris in the forklift’s path, remove safety hazards and ensure proper storage of equipment. Everyone has a part to play in keeping the work environment safe, clean and compliant with health and safety regulations. 

Accident prevention is key to a safe work environment. Make sure the proper safety precautions are in place to avoid hazardous conditions. Only a serviced, inspected and regularly maintained forklift suited to the working conditions should be used. Speed limits and designated walking aisles should be followed and protection barriers placed. Proper training such as refresher courses for the operator and safety training for all staff should be given. Forklift safety is paramount to the creation of safe working conditions. 

Our team of Materials Handling professionals can assist you with selecting a forklift safety training course, creating a maintenance plan for routine checks, servicing your forklift and showing you upgrades to newer forklift models. Contact your local Brandt Material Handling dealership today to enhance safety and efficiency in your warehouse.