Key Risks Associated with Industrial Forklifts and Their Mitigation

Forklifts are an indispensable part for operations in several industries, including manufacturing, construction, warehousing, and logistics. The Industrial Truck Association (IPA) recorded over 850,000 operational forklifts in the United States alone. They are primarily used for material handling since they streamline the industrial processing by boosting productivity and optimising operational efficiency.

With an active adoption of forklift in everyday operations, the industry also witnessed a spike in safety risks, primarily due to mismanagement of the vehicle. According to the Occupational Safety and Health Administration (OSHA), 11% forklifts are involved in some kind of accident every year, accounting for over 85 fatal and thousands of non-fatal injuries annually. These alarming statistics highlight the importance of adopting safety measures to mitigate the safety risks associated with industrial forklifts.

This article identifies the key risks posed by forklifts and recommends a list of measures for the industries to adopt to significantly mitigate the discussed safety hazards.

Common Risks Associated with Industrial ForkliftsOperator Error

Operator error is one the primary risks resulting in forklift accidents. These errors usually stem from inadequate training, fatigue, and distraction of the forklift operator. Lack of comprehensive training often makes the operator incapable of manoeuvring a forklift safety, according to the recommended guidelines. On the other hand, long shifts for the operators can lead to fatigue and distraction, which makes the operator prone to poor judgements and leaves them incapable of immediate responses in case the forklift suddenly encounters a pedestrian or a sharp turn. OSHA claims that workers working in over 12-hour shifts are 37% more at risk of injury or causing accidents. Ensuring proper training and taking steps to mitigate operator’s fatigue can significantly reduce the forklift accidents resulting from operator’s error.

Mechanical Failures

Mechanical failures constitute forklift malfunction due to regular wear and tear, lack of maintenance, and defects in the machinery. Forklifts that are operational for long hours everyday. Thus, it is not unusual to find depreciation in their performance over time. Especially in absence of regular maintenance, the forklift may experience regular breakdowns, malfunctioning of critical parts, and unexpected failing of defective components. Such breakdowns can often result in a serious pile up in the industry, often putting the pedestrians and carried goods at risk. Implementation of rigorous maintenance protocols and investment in quality-checked forklifts by reputed providers helps mitigate mechanical failure risks and ensure safer forklift operations.

Overloading

Forklift operators often deliberately ignore the prescribed weight limit for the forklift to meet their demanding daily targets. Exceeding the forklift’s weight capacity can often lead to tipping and loss of control over the forklift. Unbalanced loads further destabilise the forklift, exacerbating the risk of accidents. Furthermore, improper lifting techniques and incorrect judgement of fork placement for goods on higher racks can cause the goods to fall from a height and cause damage to the operator, forklift, and the load. Adhering to weight limits, understanding of safe loading practices, and investment in better visibility solutions for forks of a forklift is essential for safer forklift operation.

Workplace Environment

With cluttered or uneven surfaces, poor lighting, and tight or confined spaces, the workplace environment poses substantial risks to forklift safety. Where cluttered areas and uneven surfaces can result in forklift tip over or collision with obstacles, inadequate lighting reduces visibility for the operator and increases the likelihood of accidents. Operating in tight or confined spaces further complicates manoeuvrability, leading to potential collisions. Regular maintenance of the workplace along with the forklift as well as avoiding cluttering of the space is necessary to counter these safety hazards.

Pedestrian Interactions

Pedestrian interactions with forklifts pose significant risks due to poor visibility, lack of designated pedestrian paths, and inadequate communication between operators and pedestrians. According to OSHA, 36% of the forklift fatalities involve pedestrians. Poor or limited visibility for the forklift operator can prevent them from seeing an approaching pedestrian or forklift, leading to collisions in busy workspaces. The odds of these collisions are significantly higher for industries without clear pedestrian pathways. Additionally, in the absence of proper communication, pedestrians may unknowingly enter the forklift’s path. Establishing designated walkways and improving communication protocols are essential to enhance forklift safety and in turn, promote a safer work environment.

Mitigation Strategies for Forklift RisksComprehensive Training Programs

70% of the forklift injuries can be avoided with better training policies. Thus, implementing comprehensive training programs is crucial for mitigating forklift risks. Regular training sessions ensure operators stay updated on best practices, while a balance of theoretical knowledge and practical skills enhances their competency. Certification and continuous education keep operators informed about new safety protocols and technologies. This approach not only improves industrial safety but also ensures compliance with regulatory standards, creating a safer and more efficient workplace.

Regular Maintenance and Inspection

Regular maintenance and inspection are vital for mitigating forklift risks. Scheduled maintenance checks help identify potential issues before they become serious problems, ensuring industrial forklifts operate safely. Immediate repair of any identified issues prevents accidents caused by equipment failure. Using high-quality, certified parts during repairs and replacements ensures the longevity and reliability of the forklifts, further enhancing workplace safety and efficiency. Consistent maintenance routines are essential for safe operations.

Load Management

Effective load management is crucial for mitigating forklift risks. Strict adherence to load capacities prevents overloading, which can cause tipping and accidents. Proper load balancing techniques ensure stability and safe handling of materials. Additionally, using appropriate lifting accessories like forklift cameras enhance industrial safety and efficiency in operations by improving the visibility for operators while lifting loads and reduces the risk of accidents due to forklift’s blindspots. These practices collectively reduce the risk of forklift-related incidents, ensuring a safer workplace and protecting both operators and equipment.

Optimising the Workplace Environment

Optimising the workplace environment is essential for mitigating forklift risks. Maintaining clean and organised work areas prevents obstructions and enhances safety. Adequate lighting and clearly marked pathways improve visibility and guidance for both operators and pedestrians. Designing workspaces to accommodate forklift operations ensures sufficient space for manoeuvring, reducing the likelihood of collisions. These measures collectively contribute to a safer and more efficient workplace, minimising the risk of forklift-related accidents.

Enhancing Communication and Awareness

Enhancing communication and awareness is key to mitigating forklift risks. Implementing clear communication protocols ensures effective interaction between operators and pedestrians. The use of visual and auditory signals, such as lights and alarms, increases awareness of forklift movements. Designating separate pathways for industrial forklifts and pedestrians minimises the risk of collisions, creating a safer work environment. These strategies collectively improve safety and reduce accidents in workplaces with forklift operations.

Utilisation of Safety Technology

Leveraging safety technology is crucial for mitigating forklift risks. Installing forklift safety cameras and sensors enhances visibility and detects obstacles, preventing accidents. Proximity warning systems alert operators to nearby personnel or objects, reducing collision risks. Adopting telematics for real-time monitoring allows for tracking forklift performance and operator behaviour, ensuring adherence to safety protocols. Further, forklift lights create a safety parameter around the forklift and reduce the rate of pedestrian accidents. These technologies collectively improve safety and operational efficiency in environments where forklifts are used.

For further reading on industrial safety and best practices, explore NIOSH's Workplace Safety and Health Topics for in-depth articles and research.

Conclusion

As seen above, forklifts play a vital role in forklift operations, but they also pose a significant risk to the safety of the pedestrians, operators, and goods in an industry. While the risks discussed above are commonly found across different industries, it is important to identify the key risks that could contribute to accidents in your workplace. With a better understanding of the core safety challenges in an industry, one can better adopt the safety measures, customised to target the unique problems of your industry.

SharpEagle is an end-to-end safety consultant in the GCC and the UK for all the forklift hazards in your industry. From safety lights to cameras, SharpEagle offers a range of safety solutions for maximising the efficiency and visibility for the operator. Their team of experts also conduct thorough site inspection to recommend customised forklift safety solutions across different industries. Book a consultation call with the SharpEagle experts and get a free quote today!

For all the safety solutions you could invest in or adopt, proactivity is the key. One needs to constantly keep updating their safety measures to incorporate the latest technological trends to optimise forklift operations and meet OSHA’s recommended safety standards. By prioritising safety, organisations can protect their workers, operators, forklifts, and goods, boost the overall productivity, and create a safer work environment.

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