Forklift Safety

OBJECTIVE

The purpose of this procedure is to describe the actions and responsibilities involved in the operation, maintenance and inspection of forklifts.

SCOPE 

This procedure is applicable to all forklift operators in the company. Contractors shall not be permitted to operate forklift trucks in the plant.

RESPONSIBILITY

Management is responsible in ensuring adequate resources are allocated to maintaining competency levels of forklift operators, such as training, etc.  

HODs and Supervisors shall be responsible for ensuring that only competent persons in their departments operate forklifts in the company.

DEFINITIONS

Competent Persons – refers to persons who have completed and passed the training course for operators of forklift trucks in an Accredited Training Institute.

PROCEDURE

The following procedures must be followed by forklift operators:

1) Battery charging procedures

• Sweep away dusts accumulated on the floor around battery charging area.
• Wipe off dusts accumulated on the battery chargers.
• Eye or face protection must be worn when connecting a charger to a battery.
• Chargers must be turned off when leads are being connected or disconnected.
• All leads and cables must be checked and in good condition.
• When charging batteries and when moving batteries, vent caps must be kept firmly in place to avoid electrolyte splashing. Care must be taken to assure vent caps are functioning.
• If charging is to be conducted on a battery in a mobile piece of equipment, the battery compartment cover must be left open to dissipate heat and explosive gases.
• Any additional safety requirements or operating procedures specified by the manufacturer of the forklift, battery or charging system must be followed.
• No smoking near charging areas.

2) Housekeeping in battery charging area

There are fire and explosion risks associated with battery charging of forklift trucks. Hydrogen gas is released when the batteries are being re-charged. The following MUST be strictly adhered to. 

• No Hot work is allowed within 11 meters of where the batteries of lift trucks are being recharged.
• No flame, burning cigarette is allowed in the area.
• No storage of combustibles, such as cardboard, paper wood pallets, around the battery charging area is allowed.
• No storage of cleaning agents such as WD-40 is allowed. This includes spray cans with the ‘flammable’ hazard symbol located on the can.
• Excessive dust must not be allowed to accumulate on the floor in the vicinity of the battery charging areas as well as the battery chargers itself.

3) Pre operating procedures

• Start and warm up the engine for 3-5 minutes.
• Check the forklift based on Appendix A – Daily Forklift Inspection Form, and fill them up before starting to operate forklift.
• If there are defects discovered, inform his/her Supervisor immediately and not operate the forklift unless it is safe to do so.

4) Moving Procedures

• Check that the forward-reverse lever is in the neutral position.
• Raise all lowered attachments just clear of ground (200 – 300 mm).
• Release park brake and select forward or reverse.
• Check that the direction of travel is clear.
• On entering or leaving a confined space, sound the warning device to warn any personnel of the machine movement.
• Test brakes and steering for correct operation before moving off.

5) After operation procedures

• Park the forklift properly
• Lower the fork to let it rest on the floor.
• Switch off the engine and return the key

6) Safety

• Put on head protection (e.g., bumpcaps, hard hats, etc)
• Ensure seatbelt is worn
• No speeding.
• No stacked load is allowed.
• No more than one operator is allowed on the forklift.
• Always look at blind spots when reversing.
• Always lower the fork before moving off with a load.
• Always tilt the fork with a load towards the driver.
• Always switch on the headlights when the visibility is limited.

7) General maintenance

• Lubricate forklift’s chains with grease.
• Lubricate all moveable parts with grease.
• Always keep the forklift clean after use.
• Inspect the forklift periodically.

8) Guidelines for safe operation

• Always be conscious about stability while operating forklift.
• Look out for overhead obstruction, side clearance and on-coming people and traffic.
• When forward vision is a problem, drive in reverse.
• Slow down at blind corners and horn.
• Slow down on wet and slippery surfaces.
• When negotiating sharp bends, keep close to inner side.
• Keep hands and feet away from mast assembly.
• Park safely with forks centred on ground level.
• Report to Supervisor/ EHS officer in case of any incidents/accidents.
• Don’t drive with wet or oily hands.
• Don’t operate the control levels haphazardly.
• Don’t use the forks as pokes.
• Don’t run over objects or holes.
• Don’t indulge in stunts or horseplay.
• Don’t drive in parallel along with others.
• Don’t follow too closely.
• Don’t use forklift for transporting personnel.
• Don’t stop suddenly and don’t park in front of emergency equipment.
• Don’t leave the forklift unattended with engine running. 

9) Guidelines for loading /unloading

• Inspect the size, shape and weight of the cargo before loading.
• When working with long length cargo, use forklift with wide carriage and ensure that the forks are centralised to give equal balance. Space the forks apart for securing maximum stability.
• Keep forks low to whilst moving with load to avoid side tipping.
• Use the load backrest extension and overhead guard for high stacking.
• Keep load on uphill side.
• Ensure chassis brakes are set and wheels locked prior to loading and unloading.  
• Ensure that the floor is capable of carrying the combined weight of load and forklift.
• Ensure that the load has been set and balanced before withdrawing forks.
• Don’t overload beyond the load indicator/ rated capacity marked on the forklift.
• Don’t carry unstable loads or loose loads.
• Don’t allow anyone to stand or walk under the forks.
• Don’t try to steady loads while the forklift is moving.
• Don’t carry defective pallets.
• Don’t unload in front of fire-fighting equipment or alarms.

10)Refresher Training

Forklift operator to attend refresher training once in every 3 years as recommended by the Singapore Ministry of Manpower.

Forklift operators shall ensure they complete Appendix A Daily Forklift Inspection Checklist

Department Supervisors shall ensure forklifts under their charge are serviced and maintained on a periodic basis.  This can be through achieved through means such as service contract arrangements with external parties.

11) Training 

All in-house forklift operators must have completed and passed the training course for operators of forklift trucks conducted by an Accredited Training Institute

Annex A Forklift Inspection Checklist