Kevin k and tcmgirl -

Yes we do have risk assessment procedures and requirements here. Legally every piece of plant has to be provided with a comprehensive risk assessment. I'm yet to see a forklift risk assessment that is "honest". For example these statements from a large forklift supplier in respect of a newspaper roll grab forklift to place 1500 kg rolls at 6500 mm (unit supplied was 7000 lb at 600 mm base forklift which would have passed ISO 1074 or AS 2359, though all other suppliers tendered 10000 lb at 600 mm base forklift). At rated capacity and full height normal reversal away from a stack resulted in rear/ steer wheel lift off!. I risk assessment under crushing from "the plant tipping or rolling" the statement was "Yes - if the plant is travelling very fast with a load high and the plant turns."
Should have said "Yes - if the plant is loaded beyond 40% full braking will cause the unit to tipover; if the plant empty and forks down and turns tightly plant will rollover; if plant is placing /picking up loads at full height braking or reversing will cause tipover...."
The supplier did the right thing in he end and replaced the unit with a 10000 lb unit at no cost.

And tcmgirl's statement reflects the underlying issues with forklifts - the extra safety features of the TCM unit are described along with "outside turning radius is 70.5 in." This repesents a productivity featue allowing racks to be placed closer together - but it is also a danger as it means forklift could rollover at very low speed.

Similarly Toyota introduced there 7 series with excellent safety featues including roll resistance based on four wheel design. In end were "forced" to release a 7 series 3 wheel unit which could not have that feature.

As an excellent OH&S colleague would say: "Are we running a race (maximising productivity) or working safely?"

My view would be that in respect of forklifts we are still "running a race."