1. SAFE OPERATION OF FORKLIFT METALWORKING INDUSTRIES
A TRAINING FOR THE
METALWORKING INDUSTRIES

2. Table of Contents Introduction Risk management on forklift
Common forklift hazards
Route plan
Training for forklift operators
Pre-operation checks
Load assessments
Common safe practices
Forklift traffic control

3. Introduction Forklift can be hazardous if not handled properly
Forklift accidents can cause serious injury, death, property and product damage
This poses a serious problem
for everyone
Accidents can be prevented if risk assessment and safe work procedures (SWP) are followed.
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4. Forklift Fatalities in Singapore
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
Total
Forklift 5 2 1 6 3 9 31
Motor vehicles NEC 4 15
Others
Lorries
Trucks
Mechanical Conveyors `0 `4
Source: Ministry of Manpower

5. Potential Forklift Accidents
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6. Potential Forklift Accidents
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7. Forklift Accidents
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8. Forklift Accidents
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9. Forklift Accidents
Picture source: European Industrial Gases Association

10. Risk Management on Operation of Forklift
Required to manage risks under WSH (risk management) regulations
Assess the risk
Take all reasonably practical steps
Eliminate any risks

11. Risk Management on Operation of Forklift
Step 1: Identification of hazard
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12. Common Forklift Hazards
Overloading
Unsafe stacking
Speeding
Raised forks
Unauthorized operation of forklift
Untrained forklift operators
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13. Common Forklift Hazards
Lifting of persons on forks
Pedestrians and forklifts moving in the same place
Travelling on slope
Obstruction in the path e.g. overhead, blind corners
Poor ground conditions e.g. slippery, uneven, potholes

14. Common Forklift Hazards
Source: Ministry of Manpower
Body/limbs caught in moving parts of the forklift
Falling loads
Poor condition tyres e.g. without thread markings
Electric Shock (Battery operated forklift)
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15. Common Forklift Hazards
Pedestrians and forklift moving in same place
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16. Common Forklift Hazards
Forklift traveling on slope
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17. Common Forklift Hazards
Poor ground conditions
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18. Common Forklift Hazards
Worn out tyres
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19. Common Forklift Hazards
Unsecured load
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20. Common Forklift Hazards
Electric shock from battery
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21. Common Forklift Hazards
Lifting Persons on Forks
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22. Risk Management on Operation of Forklift
Step 2: Assess the risk
Dependent on severity of risk and likelihood of hazards occurring
severity X likelihood = risk level
Risk Level = Low, Moderate or High

23. Risk Management on Operation of Forklift
Severity
Minor
Moderate
Major
Likelihood
Remote
Low
Low
Medium
Occasional
Low
Medium
High
Frequent
Medium
High
High

24. Risk Management on Operation of Forklift
Step 3: Select Measures to Control and Reduce Risk
Based on hierarchy of hazards control
1st – Remove the hazard (E.g. Forklift operations route separated from workers)
2nd – Guard the remaining hazards (E.g. Erect physical protective barriers)

25. Risk Management on Operation of Forklift
HIERARCHY OF HAZARDS CONTROL

26. 1st Remove the Hazards – Forklift Route Planning
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27. Route Plan Floors and surfaces in good condition
Efficient workplace layout/plan
Floors and surfaces in good condition
Fixtures which are clearly visible
Forklift operating and pedestrian paths identified and clearly marked
Designated maintenance, parking and battery charging areas

28. Forklift Operation Separated from Worker Area
Forklift operation area
Picture source: Hi Tech Coatings, Inc

29. Allocated Goods Area Goods sitting area
Picture source: Hi Tech Coatings, Inc

30. Designated Battery and Parking Area
Forklift battery charging and parking area
Picture source: Hi Tech Coatings, Inc

31. 2nd Guard the Remaining Hazards: Protective Barriers
Brightly coloured barriers
Picture source: Hi Tech Coatings, Inc

32. Risk Management on Operation of Forklift
3rd – Mitigate impact of hazard (E.g. Operator to wear an seat belt)
Source: Ministry of Manpower

33. Risk Management on Operation of Forklift
Risk assessment to be done for every forklift tasks
To identify the risk and control measures
Establish safe work procedures (SWP)
Inform staff of SWP
Staff to follow SWP
Source: Ministry of Manpower

34. Risk Management on Operation of Forklift
Forklift Safe Work Procedures (SWP)
Forklift Training
Pre-Operation Check
Load Assessment
Common Safe Practice
Traffic Control
Source: Ministry of Manpower

35. Forklift Training Conducted by a MOM Accredited Training Provider
Under Factories (Safety Training Courses) Order, all forklift operators shall undergo a Forklift Drivers’ Training Course
Conducted by a MOM Accredited Training Provider
Consists of 1-day theory course
And 4 or 2 days practical course

36. Why Conduct Forklift Training
Ensure forklift drivers are competent
To train driver in basic forklift operation
To provide knowledge of safe operating practices for forklift
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37. Why Conduct Pre-operation Checks?
Ensure efficient and safe operation of forklifts
Prevent workplace injuries
To remove inefficient forklift practices

38. Under WSHAC Forklift Checklist, Pre-operation Checks Includes:
Tyres and wheels
Forks/attachments
Chains, cables and hoses
Safety devices (e.g. seat belts, warning devices, rear mirror and etc.)
Leaks
Hour meter
Battery/LPG system
Battery connector
Guards
Structural damage

39. Pre-operation Checks 1
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40. Pre-operation Checks 2 – Propane Forklift
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41. Pre-operation Checks 3 – Electric Forklift
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42. Pre-operation Checks 4 – Yard Forklift
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43. Forklift Load Assessments 1
Forklift can only handle loads within rated capacity
Follow forklift manufacturer’s load chart
Forklift Model
Length of fork
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44. Forklift Load Assessments 1
When attachments are used, the total weight of the load and attachment must not exceed the lifting capacity
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45. Forklift Load Assessments 1
Don’t increase the capacity of the forklift using personnel as additional counterweights
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46. Forklift Load Assessments 2
Only handle stable or safely arranged loads
Care to be taken when handling extra long or high load
When loads can’t be centered, the forklift should be operated with caution
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Source: CP 101: Code of practice for safe use of powered counterbalanced forklifts

47. Load Assessments – Weighing the Load
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48. Load Assessments – Weight at Centre of Gravity
Forklift
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49. Load Assessments – Weight at Centre of Gravity
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50. Load Assessments – Weight at Centre of Gravity
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51. Load Assessments – Characteristics
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Unstable load
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52. Load Assessments – Shape
Odd shape load may hit pedestrians causing injuries
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53. Load Assessments – Shape
View blocked, the forklift may hit another container or somebody
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54. Common Safe Practices
Don’t drive a forklift unless you are trained and authorized
Use seatbelts
Wearing seatbelts

55. Common Safe Practices
Report to your supervisor on any forklift damage or problems
Don’t use a forklift to lift worker
Use caution on slopes or ramps
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56. Common Safe Practices
While on slopes, tilt the load back and raise it above road surface
Don’t raise or lower the forks while the forklift is moving
Don’t handle loads that are above the weight capacity of the forklift
Follow the speed limit

57. Common Safe Practices
Slow down and sound the horn at crossings and locations where view is blocked
Focus on the travelling path and keep a clear view of it
When leaving a forklift, pull the parking brake, lower the forks and neutralize the controls
Source: NIOSH Publication No
Hand brake not engaged
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58. Common Safe Practices Attend briefing on forklift operations
Follow traffic management
Carry out daily forklift pre-operation checks using checklist
Ensure that the forklifts are well maintained
Use rear view mirrors while reversing
Give way to pedestrians
Park forklift at approved locations.
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59. Common Safe Practices
Source: Ministry of Manpower
Operate forklifts with forks at low position at all times
Don’t drive and raise load at the same time
Don’t make sudden sharp turns
Don’t brake suddenly when the forklift is
loaded
Watch out for overhead structures (e.g. pipes & beams)
Travel in reverse when front view is blocked
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60. Traffic Controls Follow the forklift route plan and pedestrian path
Obey the speed limits, pedestrian crossings and one way signs etc.

61. Traffic Controls Follow site rules and inform all staff and visitors
Operate forklift only in clearly marked areas
Lookout for people opening doors
Check back when reversing
Give way to pedestrians
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62. Traffic Controls Wear high visibility clothing
Be cautious on road slopes
Park on flat surfaces
Avoid driving over objects on the road surface
When making turns, reduce speed to safe level
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63. Summary of Key Points Training for forklift operators
Pre-operation checks
Load assessments
Route plan
Common forklift hazards
Forklift common safe practices
Forklift traffic control
Risk management on operation of forklift

64. All accidents are preventable
Be proactive: it is up to US to prevent it

65. Thank You

66. References:
WSHAC Occupational Safety & Health Technical Advisory – Safe Operation of Forklift Truck
WSHAC Forklift Safety Checklist
CP: 101: 2004 Code of Practice for Safe Use of Powered Counterbalanced Forklifts
MOM Case Studies on Forklift Accidents
NIOSH Publication No NIOSH Alert: Preventing Injuries and Deaths of Workers Who Operate or Work Near Forklifts
Chisholm Institute (Warehouse Task – Drive a forklift) (

67. Appendix 1

68. Appendix 1

69. Appendix 1

70. Appendix 2

71. Appendix