Cheryl Bikowski

Cheryl Bikowski is Marketing Communications Supervisor of Gamber-Johnson. Cheryl supervises all website activity and has a key role in strategic planning. Gamber-Johnson is a supplier of rugged computer mounting systems and vehicle mounting components.

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While accidents will happen, knowing the key causes and taking steps to avoid them will help keep your facility from experiencing a costly disaster.

Lack of Training
A forklift is a vehicle and a piece of heavy equipment. This means that operating a forklift requires training. Federal law prohibits forklift operation by anyone who is not trained and certified.
A well-trained operator will make it look easy, but that does not mean anyone can just hop on and move loads. Complete training includes operating at safe speeds, using proper braking techniques, and never driving with the load in a raised position.
Extra attention to training is needed to ensure that operators know how to set up and lift loads. A tip-over can trap the driver or an unsuspecting bystander. Operators must also be alert to loading dock edges - driving off a dock or falling into a gap are common causes of accidents.

Poor Facility Layout
Collisions with shelving or pedestrians are major disasters and these situations can be avoided. Your warehouse must be set up to allow for safe vehicle operation.
* Make sure the vehicle aisles are wide enough and there is adequate room for the forklift to back up or turn.
* Provide strong lighting in all areas where vehicles operate.
* Large facilities should use lane markings to keep vehicles and pedestrians separated.
* Keep both vehicle and pedestrian pathways clear of debris.
* Mark obstacles and dock edges with bright yellow tape or paint.
* Place mirrors on any blind corners.
In addition, all the shelving in your facility should be securely anchored. If a forklift accidentally bumps into a shelf, it should not fall. Items loaded on the shelves also need to be secure.

Inattention or Carelessness
Your employees should be trained to pay attention while operating a forklift, and any other workers in the forklift area need to be alert to vehicle operation. Everyone in your warehouse must also recognise that a forklift is a vehicle and not a toy. For example, having forklift races at lunchtime is an invitation for disaster. No-one should ever be allowed to hitch a ride on a lift truck.
Operators need to think of the forklift like any motorised vehicle; the driver should not be impaired by medications or overly tired. Being tired or using certain prescription or non-prescription substances can lead to carelessness.

Preventing Fatigue
Warehouses are often noisy and forklift operators cannot always hear well. Using a cellphone or radio while working may not produce the best results. Consider a hands-free tablet or computer to stay in contact and make your employees' jobs easier. Your workers will not have to return to a particular area for instructions, which prevents unnecessary trips.
You can also make use of a facility map to route drivers with the least amount of backtracking to reduce fatigue and save operating costs. Just remind your operators to use the devices while parked.

Lack of Maintenance
No matter how well you train your workers or how perfectly your warehouse is organised, if your forklifts are in poor condition, you have a problem. Braking systems and hydraulics are key areas that require inspection and maintenance. OSHA provides daily checklists for all types of forklifts to ensure vehicle safety.
When a defect is noticed, the lift must be removed from service immediately. Moving one more load can be the difference between a repairable forklift and a major disaster.
You do not need to rebuild your warehouse to prevent forklift disasters. Ensure your operators are trained properly, check the facility layout for safety, and enforce safe operating procedures and routine maintenance.