m a n a g e m e n t

o p e r a t o r

s i t e

t r u c k

safety MOST

Welcome to the Fork LiftTruck Association Safety4MOST campaign.

Its aim is to remind us all of ourbasic responsibilities when it comesto the safe operation of fork lifttrucks. In fact, we almost called it a‘Back to Basics’ campaign – but wewant it to be more than that.

The idea started when an FLTAmember remarked on how manycounterbalance truck operators werestill not wearing seat restraints. A subsequent survey showed that asmany as 90% of operators were guiltyof this.

Seat restraints come into their ownwhen there is a major incident, with atruck turning on its side or falling offthe back of a lorry or loading bay.Thankfully such incidents are rare,but when they do occur, and theoperator is not wearing a belt, youend up with, literally, a bloody mess!Roll-overs are not called mouse-trapping without good reason. Thenthere are the many other, less bloody,incidents that ‘only’ result in a bumpto the head, a broken rib or adislocated shoulder.

Talking to some operators, it’s almostas if this doesn’t matter – just theway it was before the wearing of belts

in cars became compulsory. Well, letus assure you that a bump or a breakor a dislocation does hurt – in fact itcan hurt a lot! And even if thisdoesn’t convince everyone, perhapsthe resulting time off work, loss ofproductivity and increased pressureon work colleagues should persuadepeople that seat belts are to be takenseriously.

Of course, there are occasional taskswhere it may be impractical tooperate a truck whilst wearing a seatbelt. That’s fine, and for such a taskyou should carry out a riskassessment and put adequateprocedures in place to minimise thehazards. However, these tasks don’taccount for anything like 90% of forklift truck operations. Most of thetime seat belts are not being wornbecause operators are lazy andmanagement is turning a blind eye!

The wearing of seat belts is just oneexample, and it may not apply tomany types of lifting equipment, butthere are many similar, basicprinciples that are essential to thesafety of all materials handlingoperations. You will find them

summed up in the Safety 4MOSTpack for easy, regular reference.

The Safety 4MOST campaign isdesigned to support the anticipatedHSE Route Map for the SafeOperation of Workplace Transport.The FLTA fully supports this HSEinitiative and hopes that all involvedin operating fork lift trucks willsupport it too.

Inside the Safety 4MOST pack youwill find four small, double-sidedposters. As you would expect, theycover Management safety, Operatorsafety, Site safety and Truck safety.There is nothing new. This is notrocket science. But there are lots ofsimple reminders – going Back toBasics – that can save lives andlimbs. Find time to read them and –importantly – find space to displaythem in your workplace.

You have the opportunity to preventtragedies, by supporting thiscampaign and by promoting,encouraging and enforcing safepractice at all times. Make theMOST of it.

safety MOST

safety MOST

There’s nothing magic about risk assessment.

creating and maintaining

a safe working environment

managementsafety

is a key function of management

creating and maintaining a safeworking environment is a key function of management1. Management in this context

should cover all levels - fromthe managing director throughto supervisors and shiftleaders.

2. Managers have ultimateresponsibility.

“Next time you blame anoperator for poor performance,remember who employed himor her, remember whodetermines the level of trainingprovided and remember whodecides what equipment topurchase.” Dr Will Murray.

3. Risk assessment is a key toolin the fight for a safe workingenvironment. This includesthe layout and condition ofyour site, the type andspecification of equipmentused, the maintenanceregimes, and the training,monitoring and discipline ofyour operators.

4. A safe manager:

■ Understands the tasks to beperformed and the risksinvolved.

■ Sees to it that regularinspections of the site andequipment take place.

■ Ensures that remedial actionis taken to keep the site andequipment in a safe condition.

■ Makes sure that workpractices are designed tominimise risk.

■ Knows that different types ofmaterials handling equipmenthave different operatingcharacteristics, and that itmay be necessary to usedifferent types of equipmentfor different tasks and/orlocations.

■ Maintains an awareness ofdevelopments in materialshandling equipment so thatbest use can be made of thesafest and most appropriateequipment for the task to beperformed.

■ Insists that maintenance iscarried out in accordance with manufacturers’recommendations and thatThorough Examinations arecarried out as required bycurrent regulations.

■ Acknowledges the requirementfor operator training and themonitoring of skills andattitudes.

■ Appreciates that, if tasks varyand different equipment is tobe used, additional trainingwill probably be required.

■ Is able to identify good andbad practice and has authorityto take remedial action torectify poor performance asquickly as possible.

managementsafety

“Next time you blame anoperator for poor performance,remember who employed him orher, remember who determinesthe level of training providedand remember who decideswhat equipment to purchase.”

Dr Will Murray

operatorsafety

a safe operator respects his/her equipment and looks out for co-workers

See and be seen.

A safe operator respects his/herequipment and looks out for co-workers

1. Safe operators take trainingseriously and maintain highstandards at all times.

2. Safe operators don’t try tooperate types of equipmentthey haven’t been trainedto use – and don’t allowuntrained colleagues tooperate, or mess with, anykind of materials handingequipment.

3. Safe operators check theirtruck properly before everyshift. They report anydefects and won’t use atruck that’s considered tobe unsafe.

4. Safe operators don’t takeshort cuts but observegood practice at all times.In particular they:

■ Don’t speed.

■ Don’t overload their truck(and they check with theirsupervisor if they areunsure).

■ Use the parking brake,correctly, as they havebeen trained.

■ Wear the seat belt (if fitted).

■ Keep well clear ofpedestrians and potentialhazards.

■ Slow down when nearpedestrians, trucks andother hazards.

■ Take particular care inloading bays.

■ Respect their truck.

■ Look out for their co-workers.

5. Safe operators understandthat they and others are atgreat risk if their truckoverturns, and will do allthey can to avoid thishappening.

Some of the mostcommon reasonsfor trucksoverturning are:

■ Travelling on slopes thatare too steep.

■ Going over slipperysurfaces such as oil orgrease patches, ice, oreven just water.

■ Trying to cross soft oruneven ground.

■ Going over kerbs, stepsor other edges.

■ Being overloaded orunevenly loaded.

■ Going too fast,especially aroundcorners.

■ Carrying loads at adangerous height.

operatorsafety

sitesafety

Don’t dodge ’em ...... clear ’em!

a safe site should be clean and tidy!

a safe site should be clean and tidy!

sitesafety

There are three main components of a safe site:

1. DesignA site can be designed tominimise risk. This is easiestto achieve with the design ofa new building or complex.However, reviewing the risksand re-designing wherepossible can improve even anold site. Some of the mainpoints to consider are:

■ Pedestrian segregation, with acomplete ban on non-essential personnel in areaswhere fork lift trucks operate.Provide clear, well-signedcrossing points if needed.

■ Provide one-way routes wherepossible. Movement aislesshould be sufficiently wideand free of obstacles.

■ Consider speed limits andprovide signs. Provide othersigns as needed and considerthe use of wall or rack-mounted mirrors to enhancevisibility.

■ Minimise the need forreversing.

■ Minimise the use of rampsand other gradients.

■ Provide high levels of lighting,and good ventilation if dieselor gas trucks are in use.

■ Pay particular attention tointerfaces such as lorrydocking areas.

■ Provide space for the parkingand maintenance of fork lifttrucks and for the charging ofbattery-operated equipment.

2. MaintenanceMaintenance affects safetyand is everyone’sresponsibility. Debris shouldbe removed and spillagescleared up as they occur –not left for cleaners.

■ Keep the whole area clear ofrubbish and any operatingdebris such as packingmaterial and broken pallets.

■ Keep surfaces clean, free ofoil, grease and othersubstances, and in goodcondition. Repair cracks andpotholes as they occur.

■ Maintain lights, signs, barriersand other safety features.

3. AttitudeDemand a safe attitude tosafety across the site. Never just assume that safepractices will be followed –and don’t get complacent.Schedule routine checks. In particular:

■ Enforce speed limits androutes.

■ Provide site familiarisationtraining for new employeesand agency operators.

■ Discuss site safety issues aspart of regular Health andSafety meetings.

■ Involve everyone in site safety.

A truck doesn’t have to be packedwith gadgets to be safe.

trucksafety

a safe truck is one that’s suited toits task and location and maintained

on a regular basis

1. Make sure the task andlocation are properlyassessed before a fork lifttruck is bought or hired.There are many types offork lift truck available andyou need the correct onefor the job. Seekprofessional advice.

2. If the task and/or locationchanges, consider whetheryou need to change thetruck. Make sure it stillmeets your requirementsand is safe for the job.

3. Remember:

■ Warehouse equipment –such as reach trucks,stackers, order pickers andpallet trucks – is notdesigned for outdoor useor on rough, unstablesurfaces.

■ Counterbalance trucks aredesigned for outdoor use,but still on generallysmooth, sound and levelsurfaces. Diesel and evengas trucks need goodventilation if used indoors.

■ Uneven, rough, potholedand slippery surfaces willrequire an all-terrain truck,and this must be used withskill and caution.

■ You may need differenttrucks to perform differentfunctions safely.

4. A truck doesn’t need everymodern development to besafe, but technology doesmove on – not least in thefork truck industry. Keepup to date withdevelopments. If you havea particular problem, checkand see if there may be apotential new solution. For example:

■ There are different ways inwhich the speed of a forklift truck can be controlled,and this can be zoned fordifferent parts of the site.

■ There are trucks designedto give greater visibility,and these can beenhanced by the use ofcameras.

■ There are trucks withrotating or tilting cabs toreduce the strain of certainmanoeuvres.

5. Attachments can enhancesafety but must be selectedwith professional adviceand the truck must have adifferent rating plate forevery attachment used.

trucksafety

A safe truck is one that’s suitedto its task and location andmaintained on a regular basis

Maintenance and inspectionEven the safest of trucks will not stay safefor long unless it is properly maintained.There needs to be a formal regimeunderstood by all. This should consist of:

Daily Checks Properly recorded andsupervised daily or pre-shift checks arecarried out to ensure that the truck is safeto use. Some additional checks may berequired weekly. Faults that may affectsafety should be rectified before the truck isused. These checks should be carried outby the operator of the truck.

Preventive Maintenance This is routinemaintenance, carried out in accordance withthe manufacturer’s recommendations, toensure the safe and efficient operation ofthe truck. When completed with aninspection, it may identify potential problemsbefore they occur and hence save time andmoney. These checks are usually scheduledby hours or months and are best providedthrough an agreed maintenance contract.

Thorough Examination This is a legalrequirement similar to an MOT. It must becarried out by a Competent Person at leastevery 12 months and is different to, andseparate from, maintenance. Further advice and guidance is available onwww.thoroughexamination.org.

Repairs. There is no point in carrying outany of the above checks and inspections ifremedial action is not taken to rectifyfaults as and when they are identified.