In the bustling world of logistics, manufacturing, and warehousing, lift trucks are the workhorses that keep everything moving. These powerful machines are indispensable for a wide range of material handling tasks — from stacking pallets high in cavernous warehouses to carefully maneuvering heavy loads through busy production lines—all the while performing these tasks efficiently and with precision.
Gone are the days of hand-bombing stacks of boxes. Forklifts go beyond simple stacking to handle the heaviest of loads of unique shapes and configurations. But such great power requires a greater sense of responsibility. The safe operation of lift trucks is critical, not just for protecting valuable goods, but, more importantly, for safeguarding the lives of operators and those working around them.
In Ontario and across Canada, workplace safety regulations are stringent, and for good reason. Accidents involving lift trucks can be severe, leading to serious injuries, fatalities, and significant financial losses. This isn't merely about ticking boxes for compliance; it's about fostering a culture of safety where every operator understands the importance of their role in safety and commands good operating practices on a regular basis. This not only necessitates a working knowledge of lifting devices terminology, but also of proper forklift training.
Operators need to acquire the knowledge and skills required to prevent incidents before they occur. This means that safety training must be provided by employers following the relevant regulations of their business. Depending on the industry, this might include O.Reg. 213/91: Construction Projects or R.R.O. 1990, Reg. 851: Industrial Establishments or others. Nonetheless, regardless of jurisdiction, training programs should offer guidance as outlined within the current edition of CSA B335 Safety Standard for Lift Trucks.
In this blog, we will examine the essential components of comprehensive forklift training, focusing on key operator skills, hazard recognition, maintenance best practices, and proper equipment selection—all of which play a critical role in creating a safe and efficient worksite.
The Foundation of Safety: Pre-Operation Checks and Load Capacity
It seems unlikely, but the safety process begins prior to the click of a seatbelt. Even before the wheels of your forklift begin to turn, it is critical to prioritize a thorough pre-operation check. Each element on this checklist is critical, sort of like it is on a pilot’s pre-flight checklist. Just instead of humans that most pilots carry, a forklift operator has to shoulder the responsibility of products worth millions of dollars in value.
Also, just like in commercial flights, maintaining the safety of humans is a critical part of forklift operation. If the brakes fail and a pedestrian is hit, it could lead to fatality. That is why it is imperative to be diligent. Here’s a pre-use checklist that can help you:
- Visual Inspection: Operators must be trained to conduct a thorough visual inspection of the lift truck. This includes checking tires for wear and pressure, forks for cracks or damage, and the mast hydraulics for proper operation and fluid leakage. Most lift trucks today have an overhead guard whose purpose is to protect workers in the event of falling objects, so make sure your model has it. The seatbelt must also be in good working condition, and warning lights and alarms must be checked for functionality. Each of these items requires a full inspection before operation.
- Fluid Levels and Battery Checks: For internal combustion trucks, oil, coolant, and hydraulic fluid levels must be checked in advance as they are critical for the safe operation of the forklift. For electric models, battery charge, water levels, and connector integrity are elements to be included in the pre-use check.
- Controls and Brakes: Before moving, the operator must confirm that all controls – steering, lifting, tilting, and braking – respond smoothly and effectively. A malfunctioning brake system is an accident waiting to happen, placing property and people at peril.
Beyond operating the machine itself, understanding load capacity is arguably the most fundamental skill for any lift truck operator. Exceeding the rated capacity can lead to serious consequences—including equipment instability, tip-overs, and structural damage—putting both the operator and others at risk.
A comprehensive forklift operator training must include the above information along with:
- Reading the Data Plate: Every lift truck has a data plate. The data plate clearly states the maximum load capacity, load center, and lift limitations. Operators not only need to know where to locate the data plate on each piece of equipment, but they are also required to know how to interpret the information on it. This includes the effect on load capacity, especially when using different attachments or handling irregular load configurations are part of the equation.
- Knowing the Load Center: The load center is the horizontal distance from the front face of the forks to the center of gravity of the load. As the load center increases (i.e., the load is positioned further out on the forks), the effective lifting capacity of the truck decreases dramatically. This concept is often misunderstood, making it a critical focus in forklift training.
- Weight Distribution and Stability: Operators must learn how to properly distribute weight on the forks, ensuring the load is stable and secure before attempting to lift or transport it. Unevenly distributed loads are a leading cause of lift truck tip-overs. This type of error is often made by inexperienced operators or those under pressure to rush, highlighting the importance of proper training and a safety-first mindset.
A good training program will cover all the safety and inspection basics to ensure both the workers onsite and the operator can get to work in the most productive and efficient environment.
Navigating the Unseen: Hazard Awareness in Diverse Environments
Constantly on the move, a lift truck operator’s environment is ever-changing. Busy loading docks, narrow warehouse aisles, and tight spaces, sites with poor layouts, outdoor construction sites, and more, present a unique set of challenges and potential hazards. Comprehensive training instills a proactive mindset in operators, teaching them to anticipate and mitigate these risks, no matter the type of environment or situation they are in.
- Pedestrian Traffic: One of the most common and dangerous hazards is the interaction between lift trucks and pedestrians. Training must emphasize safe work practices like horn usage, maintaining safe distances, and making eye contact. In high-traffic areas and those with limited visibility or obstructions, visual and audible warnings are crucial. Likewise, pedestrians need to respect the rules of traffic, understand the limitations of the operator, and use designated walkways at all times with no exceptions.
- Blind Spots and Intersections: Lift trucks have significant blind spots, and navigating corners and intersections requires extreme caution. Operators must be taught to slow down, sound their horn, and proceed with an abundance of caution, assuming that a pedestrian or another vehicle might be out of sight.
- Floor Conditions and Ramps: Uneven surfaces, slippery spills, debris, and damaged flooring are all environmental hazards that can lead to loss of control or tip-overs. Operators must be trained to identify and report such conditions and adjust their driving accordingly. Ramps and inclines pose additional risks, requiring operators to understand how to safely ascend and descend—both with and without a load—to maintain control and stability.
- Overhead Obstructions and Stacking Heights: Awareness of overhead hazards, such as pipes, sprinkler systems, and lighting, is vital, especially when lifting loads to place at a height. Operators must know the maximum stacking heights for different materials and ensure stability when placing or retrieving loads from elevated racks. Oftentimes, high stacking occurs when a business experiences seasonality or demand trends that result in excess inventory, requiring the use of vertical storage to maximize space.
- Confined Spaces and Aisles: Operating in narrow aisles or confined spaces demands precision and constant vigilance. Training should cover safe maneuvering techniques, including understanding the turning radius and avoiding collisions with racks or other equipment. The machine choice for these types of conditions should be adapted accordingly. Appropriate machine selection could include the use of a narrow aisle reach truck or an order picker.
- Loading Docks and Trailers: The interface between lift trucks, loading docks, and trailers is one of the most hazardous zones in material handling operations. Proper safety procedures in this area are critical and should include: securing trailers with wheel chocks or trailer restraints, verifying that dock plates are correctly positioned and locked in place, and understanding the weight limits of both dock plates and trailer floors.
Thorough training in these practices is essential to prevent accidents and ensure safe loading and unloading operations. However, to get this kind of training, you need to choose a program that goes beyond covering all the basics. Act First Safety’s expert forklift training is renowned as the most comprehensive program you can avail of in Ontario.
The Lifespan of Safety: Maintenance Best Practices
Maintaining your lift truck is critical to ensuring its safety. While operators typically perform daily checks, a deeper understanding of maintenance best practices ensures the equipment remains in optimal working condition, preventing breakdowns and potential accidents. Basic maintenance practices include:
- Checking the tires
- Maintaining the battery (if it’s a hybrid or electric lift truck)
- Keeping records of daily checks
- Testing safety equipment
- Regular machine servicing
…and lots more! In a future edition, we will explore more thoroughly the importance of preventative maintenance.
Beyond the Basics: Continuous Learning and a Culture of Safety
Lift truck safety training is not a one-time event. It’s an ongoing process that includes refresher courses, regular performance evaluations, and adapting to new technologies or changes in workplace procedures. Ultimately, the goal is to cultivate a robust safety culture where every individual understands their role in preventing accidents.
Conclusion
For businesses in Toronto, the GTA, and across Ontario, investing in comprehensive, high-quality lift truck safety training is not just a regulatory requirement; it's a way to keep workers safe. A well-trained operator is a valuable asset – someone who is confident, efficient, and most importantly, trained to operate the machine safely.
Training your operators to be competent is an insurance policy in protecting your business while rewarding them with the skills to feel accomplished in a job well done. If you want to enroll your crew in the best forklift training program, turn to Act First Safety. Our comprehensive course will ensure your operators come out wiser and with the skills required to practice onsite safety. Contact us to schedule a session for your team at your worksite.
