Operator training is widely recognised as essential for anyone using material handling equipment (MHE). But basic training alone is not enough to maintain a safe workforce in the long term. Unless employers continuously meet training requirements in full, sites can face a higher risk of accidents.

Closing these gaps is vital for protecting people and maintaining compliance, so businesses must understand how to identify potential dangers.

In many cases, evidence already exists in reporting data, training records or equipment damage, if you can spot the warning signs. 

The following overlooked areas provide a useful starting point for reviewing your MHE training program and strengthening site safety.

Initial training – going beyond the basics

Firstly, though basic operator training is an essential foundation, the standard to which it is completed can leave you open to risk if requirements are not met. 

In the UK, checking for accreditation from a member of the Accrediting Bodies Association can help provide assurance.

Once standards have been confirmed and individuals complete basic operator training, there are still important steps to take before they start operating MHE.

UK forklift operators must complete three essential stages of training, in line with the industry’s Approved Code of Practice, L117: Basic, Specific Job and Familiarisation. 

Though often overlooked, the final two elements ensure operators are comfortable using their truck in their normal working environment.

Only when all three stages are complete should employees be authorised to operate and, as L117 states: “You should not allow anyone to operate lift trucks on any premises without authorisation”.

Check your training records to see whether individuals have completed all of the necessary training to be authorised to operate MHE.

Day-to-day compliance

Training is essential to make operators aware of best practice, but businesses must also ensure that what is learned continues to be applied day-to-day. This is where regular monitoring comes in.

Direct supervision, CCTV and forklift truck tracking data, among other methods, can all help to build a clearer picture of onsite behaviour.

Look at the site itself too. Is there an area where problems occur, or racking shows repeated damage? This could point to an issue with operating practice, or perhaps systems of work or site layout need adjusting.

Site audits, alongside reviews of past accidents, can help build a clearer picture of site safety and the measures needed to improve it.

And don’t forget to include near misses or informal feedback from operators. While accident records are valuable, near misses often highlight unsafe behaviours or environmental issues before a serious incident occurs. Encouraging employees to report concerns can reveal trends that might otherwise go unnoticed.

Periodic refreshers and awareness training

Even experienced operators can develop bad habits or become complacent, particularly in fast-paced or repetitive environments. 

Regular refresher training will help reinforce best practice – complete a risk assessment of your specific operations to help determine a suitable frequency. Beyond this, additional training may be needed to ensure operating standards are maintained should anything change. 

When considering further training, it’s also important not to overlook those working around your operators. 

Managers and supervisors must know what to look for to be able to challenge bad practice, while colleagues on foot need to be made aware of the risks and how to play their part in site safety.

Ultimately, basic operator training is essential, but it is not the end of the process. Businesses must ensure all training requirements are met to prepare employees to work safely, then continually monitor operations and identify areas for improvement for long-term safety and compliance.