Hi Dan et al
It's interesting that the experiences of safety professionals around the world are similar. I was engaged by a large paper and cardboard manufacturer to undertake three forklift refresher training courses - these were to include hazard identification and risk assessments with the forklift drivers during a walk around their work area and an inspection of their forklifts. The equipment included 7000 kg forklifts with large roll paper grabs lifting 2850 kg paper rolls. I observed the stacks of paper rolls were too high for the forklift lift height and that operators were in fact lifting two paper rolls at once with a total of 3400 kg. In addition none of the forklifts were plated for paper roll grab use. My quick calculation showed the forklifts were in fact being overloaded. I reported this to the company. They contacted me next day to say I was wrong about the forklift capacity "because the company who leased the units said so." I rang the forklift manufacturer, gave them the grab make and model, and they confirmed the forklifts were being overloaded - maximum capacity = 3090 kg. I advised the company and they accepted that information and at the same time told me they did not need me to do the second and third courses!
However that does not stop me being upfront and honest about forklift safety issues. I have found the best process is to say that I cannot tell them what to do as they are the ones who have to manage company risks including safety risks and commercial risks et cetera. As a result in identifying hazards all I can do is alert them to the same - they are the ones that must decide what to do about them. I then detail my observations and if requested give advice about what they could do.