2. INTRODUCTION
A forklift is a powered truck used to
carry, lift, stack, or tier materials. They
include pallet trucks, rider operated
forklifts, fork trucks, or lift trucks. They
can be powered by electric battery or
combustion engines. It has a
counterweight to balance the load on
its fork arms. The fork arms and load
project out from the front of the
machine. Loads can be raised or
lowered vertically, and the mast may be
tilted forwards or backwards. Forklifts
are extremely useful workplace vehicles,
if they are used safely and appropriately
by trained and competent operators.
3. Legal Requirement
As per Rule 60(8) of Gujarat Factories Rules, 1963
Proper selection and training of operators for any lifting
equipment's and power trucks are the most essential.
The operators should be more than 18 years of age., medically
fit with regard to eyesight, hearing, reflexes and driving
requirement and should have experience and attitude to
operate the equipment safely.
They should be fully trained to drive and operate the
equipment with better judgement of distance, height, depth,
clearance and turning knowledge of working of the equipment,
routine checks and maintenance methods, signal codes, colour
code, hazards of materials and their handling should also be
given.
Initial & refresher training should be given to truck operators.
4. Forklift operation can be very dangerous as they account for 25% of injuries
at work worldwide.
When employees/ operators become accustomed of using forklifts, they
tend to ignore it as a safety hazard and forget or neglect to follow critical
operating and maintenance procedures leading to serious injuries/
accidents.
At Adani during last few years, there have been around 32 High Potential
Near Misses and 9 serious injuries mainly due to people or objects being hit
or run over by forklift trucks (typically when the forklift is reversing),
Overturning/ toppling, Forklift malfunction including breaking down of forks
while loading or unloading operations.
7. Forklift related Near Miss Summary-32
(As on 1st July 2021)
Majority of Vehicle related Near Misses are due to :
•Toppling/ overturning
•Collision/ struck with object
•Malfunction
•Broken/ damaged fork
12. SAFETY ASPECTS OF FORKLIFT
OPERATIONS
Selection & Procurement of Forklift Forklift Working Environment
Safe Operation of Forklift Forklift Operator Selection, Training & Authorization
Requirements
13. SELECTION AND PROCUREMENT
OF FORKLIFTS
PRUDENT
PRACTICE
OPTIONAL
ATTRIBUTES
MANDATORY
ATTRIBUTES
• Fall on protection
• Safety Seat & Seat Belt
• Contrasting mast and
Counterweight
• Reverse motion alarm
• Reflective Tape & Flashing
light
• Clear view mast & Rear
vision mirror
• Non-skid steps
• Roll over protection
• Rotating & Working light
• Working Lights & Safety Lights
• Protective Bumpers Around
Wheels and Additional Side
Guards
• Operating procedure
• Dual Driving Position
Vehicle
• Forward motion alarm
• Grab handles
• Semi suspension seat
15. FORKLIFT SAFETY LIGHT
Safety lights fitted in front and rear to improve
operator’s visibility & alertpedestrians from
moving forklifts
Forklift Safety Light
(120 – 180 Lumen with Spot Beam
16. FORKLIFT WORKING ENVIRONMENT
MANDATORY ATTRIBUTES PRUDENT PRACTICE
• High Visibility clothing for
operators and nearby
workers
• Forklift designated
walkways & roadways
• Safe maneuvering area
• Parking & Charging area
• Signage & Lighting
• Gentle gradient
• Non-skid steps
• Barriers
• Designated crossing
18. HANDLING BULKY AND UNSTABLE
LOADS
For Bulk bags/ Jumbo bags/ Chemical drums or loads which are bulky
and not stable, Site supervisor must ensure the usage of appropriate
pallets wherein fork can be inserted into the pallet slot prior to loading
such that the fork is all the way under load and length of fork is greater
than 2/3rd of load length
19. FORKLIFT OPERATOR SELECTION AND
TRAINING
The driver/operator of a forklift vehicle should be selected to perform the task of
driving the truck basis following attributes:
Reliable and mature approach to work.
Ability to perform the job in a responsible manner.
Physically and mentally fit.
Experience in operating Forklift > 6 months
All forklift vehicle operators must be medically fit to drive/ operate and shall have
their eye- sight tested on a regular basis as a minimum that shall meet the local
government vehicle driver requirements.
Documented Maintenance Procedures to ensure that the Forklift Vehicle Remain
Fit for Duty.
This is in addition to the daily tests performed prior to and after the forklift vehicle
has been used.
20.
21. SEAT BELT
I. Always use a seat belt
II. If seat belt is damaged or not functioning:
I. Don't use the forklift
III. Apply Lockout / Tagout Procedure
22. SPEED LIMIT FOR FORKLIFT
Under 5 km/hr is most ideal speed for forklift.
Rule of thumb = speed of a walking person.
Reduce forklift speeds when encountering turns,
blind spots, congested areas, inclines/declines,
uneven ground, slippery surfaces, pedestrian
crossing, critical lifts etc.
BRAINNSTORM ??
•What situation requires us to
have better control of forklift
speed?
23. CORRECT HAND POSITION
– While operating or driving
forklift, always keep:
• Left hand on the steering wheel
spinner knob
• Right hand on the control stick
-- Never drive or operate forklift with one
hand
-- Remain at the controls whenever
forklift is in use
24. STEERING & CONTROL
•Always consider the following:
–Always apply even & smooth pressure when operating the controls to
avoid jerky movements
–Avoid sudden start & sudden stop
–Don’t use gloves when operating or driving forklift to have better control
25. SPACE & VISIBILITY
•360° Visibility
•Maintain clear field
of vision
•Use Banksman/
Signalman
•Use Mirrors
•If in doubt, STOP!
26. REAR END SWING
•Always consider the following:
1- Be aware of rear end swing as it will be
approximately 3 times higher than the normal
speed of the forklift.
2- When turning at 90° corners while driving
forward or backward, consider the following
to avoid rear end swing collisions:
•Driving parallel & close to the turning side
•Centering the front wheel of the forklift at the
corner edge before turning
27. DIRECTION OF TRAVEL
•Always consider the following:
1- Use forklift defined path in the facility
2- Consider forward movement if:
•Field of vision is clear
•When driving through inclines
–Consider backward movement if:
•Field of vision is obstructed
•When driving through declines
•When turning is not possible
especially in congested areas
28. GROUND SURFACE
Practice extreme care while driving a forklift on different ground surfaces to
avoid losing stability especially when carrying a load
•Avoid driving/parking over:
–Underground Piping
–Electrical Installation
–Soft Ground Surface
–Water Drainage Points
–Uneven Ground Surface
–Wet / Slippery Surfaces
29. FORKLIFT PARKING
•Always consider the following:
–When not in service, forklifts shall be
properly parked with ignition key removed.
This includes any time a forklift is out of
sight from its driver
–Use designated forklift parking area only
and avoid leaving it in restricted areas
–Ensure the front part of the forks are in
contact with the ground
–Ensure the hydraulic system is free of
stored energy to prevent injury
30. FORKLIFT STABILITY
•Consider the following points:
–Operate forklift within its capacity
–Do not exceed SWL
–Load Centre should not exceed the
middle of the forks
–Loads must be always centre over
the forks and close to the carriage
–Conduct trial lift prior to lifting loads
to ensure the load is stable and is
within the forklift capacity
31. •Trial Lift Considerations:
When conducting trial lift, leave about 6
inches between the load and the forklift
carriage first
1- Ensure parking brake is applied
2- Conduct trial lift and notice the rear
wheels & the load stability
3- If rear wheals start to go off ground or
the load is not stable, STOP! The load
weight in this case is certainly the forklift
capacity
If the rear wheals are still in contact with ground & the load is stable, lower
the load to run the forks fully to start the actual lifting
FORKLIFT STABILITY
32. CRITICAL LIFT
Critical Lift Definition
–A critical lift is any lift that has
the potential to cause impact on
health, safety, environment,
facilities, equipment, operations
if not handled safely
•Special considerations
–Load size, shape, weight
–Load sensitivity & material type
–Movement Space &
Congestion
–Hazards / Activities in the area
33. CRITICAL LIFT WITH PERSONNEL
1. Make sure a HIRA/ Risk
Assessment is there in
place.
2. Lift personnel in approved
cage basket only.
3. Ensure personnel being lifted
in the approved basket have
certified fall protection
harness & lanyard attached
to a proper anchor point
4. If in doubt, STOP!
34. FORKLIFT WORTHINESS
IF YOU FIND ANY FAULT WITH
YOUR MACHINE:
1- REMOVE THE KEY FROM
IGNITION
2- FIT A WARNING TAG
3- NOTIFY YOUR
SUPERVISOR/MAINTENANCE
GROUP
POST OPERATING (UPON SHIFT
COMPLETION
1- PARK ON CLEAR LEVEL AREA
2- LOWER ATTACHEMENTS AS
CLOSE AS POSSIBLE TO THE
GROUND
3- SELECT LOW GEAR
4- APPLY PARK BRAKE
5- TURN ENGINE OFF
6- REMOVE KEY
