CHECKLIST FOR POWERED INDUSTRIAL TRUCK (FORKLIFT)

OPERATOR TRAINING

Step 1 Who will be responsible for training and evaluation of operators ?

OUTSOURCE OUR TRAINING TO: _____________________________________________________________________ For the following aspects of training/evaluation:_______________________________ _____________________________________________________________________ _____________________________________________________________________

IN-HOUSE (name)____________________________________________________ Briefly describe the person(s)

Knowledge __________________________________________________________ ______________________________________________________________________

Training_____________________________________________________________ ______________________________________________________________________

Experience___________________________________________________________ ______________________________________________________________________ 1910.178 (2)(iii) Requires that all training and evaluation "shall be conducted by persons who have the knowledge, training, and experience to train . . .and evaluate. . ."

Step 2 What type(s) of Powered Industrial Trucks do we operate?

Using tables 1 & 2, write down the descriptions of all powered industrial trucks used:

Examples:

Our Designation Area (s) Used Class (See Table 1) High Lift? OSHA Designation (table 2) Comments

FK-1 Warehouse 5 No LP Also used in plant

Hi-Lift Job Sites 7 Yes D Load brick pallets onto scaffold

G-17 Paint Storage Whse 1 No EE Has hydraulic 55-gal drum handler

Shipping Dept West Docks 4 No LPS 5 identical forklifts in shipping department

Paint Dept. Spray Booth Area 1 No EX "Explosion-Proof"

Powered Industrial Trucks Used in our Facility Include the Following:

Our Designation Area (s) Used Class (See

Table 1)

High Lift? OSHA

Designation (table 2)

Comments

1910.178 (l)(3) Requires that operators be given specific instruction and training in each type of truck s/he is to operate, and the particular hazards of each type of truck. (For

instance, hazards of handling a high-lifted load, operating a rough-terrain vehicle on rutted roads, etc.)

Table 1

CLASS VEHICLE High Lift?

1 Electric Motor, sit-down rider, counter-balanced. (Solid and pneumatic tires)

2 Electric Motor, narrow aisle (solid tires)

3 Electric Motor hand trucks or hand/rider trucks (solid tires)

4 Internal combustion engine trucks (solid tires)

5 Internal combustion engine trucks (pneumatic tires)

6 Electric and internal combustion engine tractors (solid and pneumatic tires)

7 Rough terrain forklift trucks (pneumatic tires)

Table 2 OSHA (Fire Safety) DESIGNATIONS (see manufacturer’s nameplate on truck)

DESIGNATION DESCRIPTION OF INDUSTRIAL TRUCK

G Gasoline powered units having minimal acceptable safeguards against fire hazards

D Diesel powered units with same minimal fire hazard safeguards as G units.

GS Gasoline units with additional safeguards to the exhaust, fuel and electrical systems. May be used in some locations where G units are not suitable.

DS Diesel powered units, with similar safeguards to GS units. May be used in some locations where D units are not suitable.

DY Diesel units having all the safeguards of DS units, additionally do not have any electrical equipment, including ignition, and are equipped with temperature limiting features.

LP Liquefied Petroleum Gas (Propane, butane, mixtures) powered units with equivalent minimal safeguards as G units.

LPS Liquefied Petroleum powered units having additional safeguards to the exhaust, fuel, and electrical systems. May be used in some locations where use of an LP unit is not suitable.

E Electrically powered units having minimum acceptable safeguards against fire hazards.

ES Electrically powered units with all the safeguards of E units, plus additions to the electrical system to prevent the emission of hazardous electrical sparks, and to limit surface temperatures. May be used in some locations where use of an E unit is not suitable.

EE Electrical units with all safeguards of E and ES units, plus all electrical equipment and motors are fully enclosed. May be used where E and ES units

are not suitable.

EX Electrical units having all safeguards of E, ES, and EE units, plus all electrical fittings, equipment, and motors are designed, constructed, and assembled so that the EX unit may be used in certain atmospheres containing flammable vapors or dusts.

Step 3 Obtain & assemble training materials for General Workplace Hazards, and General Hazards pertaining to operation of all or most Powered Industrial Trucks. a. Solicit the input of your most experienced, most knowledgeable employees. b. Contact your forklift (Powered Industrial Truck) vendor, parts supplier, or manufacturer for

existing programs, video tapes, literature, hand-outs, etc. for this purpose. c. Be sure to evaluate previous accidents, problems, etc. that have occurred at your facility, and

identify what hazards operators have faced in your operations. Include these hazards in your training program.

d. Actual training sessions should include a combination of teaching methods, for instance, a classroom lecture, followed by actual tour of the facility, to point out, in the field, the actual point of hazard, operating practice, etc. being taught.

e. Seriously consider including "Appendix A-4—A-7, (of the 1910.178(l) standard) as part of your operators’ general training; it is the only specific training information OSHA included in the standard, therefore it is reasonable to expect that OSHA will want to see operators trained in it.

Step 4 Obtain & assemble training materials for Hazards Particular to Our Workplace, and Hazards Pertaining to Operation of Our Particular Powered Industrial Trucks. a. "Hazards Particular to Our Workplace" must be identified on-site, and cannot be a "canned"

program approach. Use previous accident records, known hazards, input from experienced operators, and other on-site resources.

Types of workplace hazards under this section would include items such as: Hazard—"Blind corner at the SW corner of the warehouse, next to rack row 12." Controls—"Slow down as you approach corner, tapping the horn, checking the convex mirror placed in the corner for oncoming traffic or pedestrians." Hazard—"Pedestrian crossing from shipping office to main office area." Controls—"Slow, tap horn, pedestrians to observe stripe-painted walkway." Hazard—"Severe ruts and wash-outs occur in yard between buildings 1 and 2, after severe rainstorms." Controls—"After severe rainstorms, check area for ruts and wash-outs. Do not operate in this area until gravel can be spread to re-level the area."

b. Use information from STEP 2 to help identify "Hazards Pertaining to Our Particular Powered

Industrial Trucks." Also, operator manuals, technical manuals, tapes booklets, and other

information available from manufacturers and vendors of Powered Industrial Trucks can be used to train on the hazards of particular industrial trucks. Finally, use information from experienced operators at your site, to help fill in "tips" and information pertaining to operation of your particular forklifts at your site.

Step 5 Ensure that each of the following OSHA-mandated topics is adequately covered, and note how each is to be presented (Video tape, vendor’s trainer, our trainer, written checklist, operator’s manual, field demonstrations etc.) Truck-Related Topics:

_____Operating instructions, warnings, and precautions for each of the types of trucks the operator will be authorized to operate.

_____Differences between the truck and automobile. _____Truck controls and instruments; where they are located, what they do, how they work. _____Engine or motor operation. _____Steering and maneuvering. _____Visibility (including restrictions due to loading). _____Fork and attachment adaptation, operation, and use limitations. _____Vehicle capacity. _____Vehicle stability. (see Appendix A4-A7 of standard) _____Any vehicle inspection and maintenance the operator will be required to perform. _____Refueling and/or recharging of batteries. _____Operating limitations. _____Any other operating instructions, warning, or precautions listed in the operator’s manual

for the types of vehicle(s) that the employee is being trained to operate. Workplace-Related Topics

_____Surface conditions where the vehicle will be operated. _____Composition of loads to be carried and load stability. _____Load manipulation, stacking, and unstacking. _____Pedestrian traffic in areas where the vehicle well be operated. _____Narrow aisles and other restricted places where the vehicles will be operated. _____Hazardous (classified) locations where the vehicle will be operated. (i.e. explosive

atmosphere in paint booth). _____Ramps and other sloped surfaces that could affect the vehicles’ stability. _____Closed environments and other areas where insufficient ventilation or poor vehicle

maintenance could cause a buildup of carbon monoxide or diesel exhaust. _____Other unique or potentially hazardous environmental conditions in the workplace that

could affect safe operation. Miscellaneous Topics:

_____Employees must be given a copy of this standard (1910.178 (l)) and trained in its requirements.

Step 6 Conduct training, using varied training methods. a. Operator training should include some "behind the wheel" practice and instruction, but only

under the direct supervision of the trainer, and under conditions where this will not endanger other employees or property.

b. In addition to lecture, reading, video, and other presentation methods, be sure to include as much "hands-on" instruction as possible. Let employees manipulate controls, observe instruments in their normal position, let them check oil dipsticks, etc. This keeps them involved, motivated and interested.

c. Information repeated is better learned. Don’t expect employees to learn after one brief mention of a topic during a lecture. Reinforce learning by hands-on exercises, asking frequent questions of the learner, ask for feedback. Emphasize key points by review and repetition. Present the same information using different presentation methods.

Step 7 Test and evaluate operator’s training. a. Formulate and administer a good summary examination that goes over the topics covered in

the training program. Remember that a specific test and skills evaluation must per performed for each type of forklift truck an employee is to operate. Establish a minimum score a trainee should earn before s/he is allowed to operate a powered industrial truck.

b. Also require each operator-trainee to demonstrate critical procedures, tasks, maneuvers, and other hands-on skills. Allow the trainee to operate the industrial truck on a limited, supervised basis. Observe the operator’s proficiency in the necessary aspects of safe operation. Develop a short form to document this observation / evaluation, and establish a written record of this test, recording the trainee’s score and proficiency in these areas.

c. Ensure trainees who do not earn a satisfactory written or hands-on score are adequately re-trained, or are placed in non-driving positions. Do not place an operator trainee in service on a powered industrial truck until he passes your minimum requirements for safe operation.

Step 8 Certify that training and evaluation has been completed. a. For each operator, the employer must certify that the required training and evaluation have been conducted, and that the employee is competent to operate the powered industrial truck(s) on which he is trained, in a safe manner. The certification must contain:

• The name of the trainee. • The dates of training. • The name of the person performing the training or evaluation. • A statement that the employee is competent to operate a powered industrial truck.

AVOIDING DUPLICATE TRAINING

For employees who already have been trained, have received adequate training on previous jobs, and otherwise can demonstrate they have adequate knowledge, skill, and competence to be safe operators, you only need to evaluate (to verify the operator’s competence) and certify.

Step 9 Establish a follow-up and re-evaluation schedule. a. Schedule all operators for re-evaluation every 3 years (required by OSHA). Develop a simple

form for observation, and to record a simple verbal quiz results, given to the operator. b. Establish an evaluation form for use any time there is an indication an operator’s competence

is in question, or that re-training is needed, (an accident, improper operation, failure to observe established procedures, etc.). In these cases, remove the operator from service until retraining can be satisfactorily completed, and certified.

c. Establish a simple form to record random observations between "formal" (3-year) re-evaluations, to use as a basis for the extent of the 3-year evaluations, and to document on-going competence of operators, or the need to modify the training program to improve results.

"FEEDBACK LOOP" OSHA intends for your forklift training program to be an ongoing process. Any changes in your operation, such as different types of forklifts, new buildings, facilities, new processes, and so forth will probably mean you’ll have to change your training program to reflect these changes. Also, whenever information comes to your attention that might indicate your training program needs changes (repeat incidents by different operators of improper operation, failure to observe established procedures, accidents, etc.) you should evaluate and implement these changes as soon as possible. Solicit input and suggestions from operators and other personnel. They work with these machines and in your facility continuously, and should be in the best position to see what does and doesn’t work.

Congratulations! You’ve completed your Powered Industrial Truck Operator Training Program

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