Forklift Operation Procedure
Preface
The purpose of this procedure is to ensure that only trained personnel operate forklifts in a safe manner.
Operation
The following rules must be followed at all times while operating a forklift:
- Trucks shall not be driven up to anyone standing in front of a bench or other fixed object.
- No person shall be allowed to stand or pass under the elevated portion of any truck, whether loaded or empty.
- Unauthorized personnel shall not be permitted to ride on or operate powered industrial trucks.
- It is prohibited to extend arms or legs outside the past the width or height of the truck.
- Riders, other than the operator, are prohibited from getting onto the forklift.
- When a powered industrial truck is left unattended, load engaging means shall be fully lowered, controls shall be neutralized, power shall be shut off, and brakes set. Wheels shall be blocked if the truck is parked on an incline.
- A powered industrial truck is unattended when the operator is 25 ft. or more away from the vehicle which remains in his view, or whenever the operator leaves the vehicle and it is not in his view.
- When the operator of an industrial truck is dismounted and within 25 ft. of the truck still in his view, the load engaging means shall be fully lowered, controls neutralized, and the brakes set to prevent movement.
- A safe distance shall be maintained from the edge of ramps or platforms while on any elevated dock, or platform or freight car. Trucks shall not be used for opening or closing freight doors.
- Brakes shall be set and wheel blocks shall be in place to prevent movement of trucks, trailers, or railroad cars while loading or unloading.
- Fixed jacks may be necessary to support a semi-trailer during loading or unloading when the trailer is not coupled to a tractor.
- The flooring of trucks, trailers, and railroad cars shall be checked for breaks and weakness before they are driven onto.
- There shall be sufficient headroom under overhead installations, lights, pipes, sprinkler system, etc.
- An overhead guard shall be used as protection against falling objects.
- It should be noted that an overhead guard is intended to offer protection from the impact of small packages, boxes, bagged material, etc., representative of the job application, but not to withstand the impact of a falling capacity load.
- A load backrest extension shall be used whenever necessary to minimize the possibility of the load or part of it from falling rearward.
Traveling
Other trucks traveling in the same direction at intersections, blind spots, or other dangerous locations shall not be passed.
The driver shall be required to slow down and sound the horn at cross aisles and other locations where vision is obstructed. If the load being carried obstructs forward view, the driver shall be required to travel with the load trailing.
The driver shall be required to look in the direction of, and keep a clear view of the path of travel.
When ascending or descending grades in excess of 10 percent, loaded trucks shall be driven with the load upgrade.
On all grades the load and load engaging means shall be tilted back if applicable, and raised only as far as necessary to clear the road surface.
Stunt driving and horseplay shall not be permitted.
Running over loose objects on the roadway surface shall be avoided.
While negotiating turns, speed shall be reduced to a safe level by means of turning the hand steering wheel in a smooth, sweeping motion. Except when maneuvering at a very low speed, the hand steering wheel shall be turned at a moderate, even rate.
Loading
Only stable or safely arranged loads shall be handled. Caution shall be exercised when handling off-center loads which cannot be centered.
Only loads within the rated capacity of the truck shall be handled.
The long or high (including multiple-tiered) loads which may affect capacity shall be adjusted.
Trucks equipped with attachments shall be operated as partially loaded trucks when not handling a load.
A load engaging means shall be placed under the load as far as possible; the mast shall be carefully tilted backward to stabilize the load.
Extreme care shall be used when tilting the load forward or backward, particularly when high tiering. Tilting forward with load engaging means elevated shall be prohibited except to pick up a load. An elevated load shall not be tilted forward except when the load is in a deposit position over a rack or stack. When stacking or tiering, only enough backward tilt to stabilize the load shall be used.
Forklift Inspections
Prior to use, forklifts must be inspected to ensure safe operation. Inspections should include:
- Operational controls.
- Warning lights and horn.
- Mast and fork operation.
- Wheel condition.
- Steering controls.
- Speed control.
- Brakes.
Inspections will be documented using Appendix A.
Forklift Training
Bodine shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph.
Prior to permitting an employee to operate a powered industrial truck (except for training purposes), Bodine shall ensure that each operator has successfully completed the training required by this policy.
Trainees may operate a powered industrial truck only:
- Under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence.
- Where such operation does not endanger the trainee or other employees.
Training shall consist of a combination of formal instruction, practical training and evaluation of the operator's performance in the workplace.
Training Program Content
Powered industrial truck operators shall receive initial training in the following topics:
- Truck-related topics:
- Operating instructions, warnings, and pre cautions for the types of truck the operator will be authorized to operate;
- Differences between the truck and the auto mobile;
- Truck controls and instrumentation: where they are located, what they do, and how they work;
- Engine or motor operation;
- Steering and maneuvering;
- Visibility
- Vehicle capacity;
- Vehicle stability;
- Any vehicle inspection and maintenance that the operator will be required to perform;
- Refueling and/or charging and recharging of batteries;
- Operating limitations;
- Any other operating instructions, warnings, or precautions listed in the operator's manual for the types of vehicle 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 will be operated;
- Narrow aisles and other restricted places where the vehicle will be operated;
- Hazardous (classified) locations where the vehicle will be operated;
- Ramps and other sloped surfaces that could affect the vehicle's 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.
Refresher training, including an evaluation of the effectiveness of that training, shall be conducted to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely.
Refresher training in relevant topics shall be provided to the operator when:
- The operator has been observed to operate the vehicle in an unsafe manner.
- The operator has been involved in an accident or near-miss incident.
- The operator has received an evaluation that reveals that the operator is not operating the truck safely.
- The operator is assigned to drive a different type of truck.
- A condition in the workplace changes in a manner that could affect safe operation of the truck.
An evaluation of each powered industrial truck operator's performance shall be conducted at least once every three years.
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