ULTIMATE GUIDE TO

ORGANIZING OUR
OWN
FORKLIFT TRAINING
TABLE OF CONTENTS
 Importance of forklift operator safety training

 Organization of forklift operator training

 Forklift operator performance evaluation

 OSHA’s training requirements

 Providers of forklift operator training

 Developing our own in-house forklift training program

IMPORTANCE OF FORKLIFT OPERATOR TRAINING
Time and money is saved by the company whenever we indulge in safety trainings
to keep our operators safe. Accidents and the after-math on the company,
personnel and tools are more expensive to deal with than actually going through
the proper safety trainings to prevent them from happening in the first place.
In 1984, a study was conducted by the National Institute for Occupational Safety
and Health (NIOSH) to determine the effectiveness of a lift truck safety training
program. The results indicate that better training reduces operators’ errors.

With a proper safety training program, NIOSH found

that forklift operators can achieve a 61%
improvement in their performance.

According to OSHA as well as many other experts, when errors are reduced,
accidents are reduced as well. Thus, proper safety training is vitally important to
our employees’ safety and the trick is to provide the best possible safety training
to our forklift operators and pedestrians in order cover all lose ends.
ORGANIZATION OF FORKLIFT OPERATOR TRAINING
Formal Instruction Requirement
The formal instruction component of forklift operator training is simply classroom
education.
The instructor is to give a comprehensive lecture, show a PowerPoint slideshow,
play videos, or host a question-and-answer exercise to discuss training topics.
Overall, what’s taught in the classroom includes:
 Instructions, precautions, and limitations for different types of forklifts
 How to calculate forklift capacities
 How to load, transport, and unload materials safely
 How to perform forklift inspections before operating
 The different types of forklift fuel and how to safely work with them
 How to handle different driving surfaces
 Pedestrian safety principles
Forklift Practical Training
Once the classroom instruction portion is complete, the next step is the practical
training component. OSHA states that:

Prior to operating the truck in the workplace, the

employer must evaluate the operator's performance
and determine the operator to be competent to
operate a powered industrial truck safely.

This is to ensure that operator trainees have some hands-on experience actually
operating a lift truck according to proper safety procedures. The practical training
should be conducted according to the:

 Specific type of forklift the operator will use in the workplace

 Same conditions it’ll be used under
  Same types of tasks that the operator will be performing at work

Certification Requirements
On completion of the formal and practical training is complete, forklift operators
can then be certified to operate a forklift in the workplace. According to OSHA
regulations, it's the employer's responsibility to certify that their operators have
been trained and evaluated according to the OSHA standard. The certification
must include the:

1. Operator's name
2. Training date
3. Evaluation date
4. Name of the person(s) performing the training or evaluation

An example of a forklift certification card

Hiring an outside consultant to perform our operator safety training raises a
shared responsibility for ensuring that our operators complete both classroom
and practical training before using any industrial equipment. That means
providing proper documentation and evidence that our personnel completed
their forklift operator training.

If years of experience have taught us one thing it's that the type and quality of
documentation our employees receive can make all the difference during an
audit. After training, the employer still has a shared responsibility to certify that
their operators are both competent and safe. Determining this takes place in the
form of a hands-on evaluation.
FORKLIFT OPERATOR PERFORMANCE EVALUATION
During an evaluation, the training instructor will evaluate trainees on different
forklift operating procedures. Evaluation typically consists of obstacle courses,
picking up sample loads, and in general, seeing how the operator trainee handles
driving, turning, and reversing. Specifically, operators should be evaluated on
each of the following items:
INSPECTION
 Did the operator complete a pre-operational inspection?
TRAVELING WITHOUT A LOAD
 Is the operator’s seat belt on?
 Did the operator put the forks in the correct travel position (4-6 inches
above the ground) before moving the lift truck?
 Did the operator perform a 360-degree check before moving?
 Did the operator sound the horn before moving?
 Is the operator facing the direction of travel?
 Does the operator’s body remain inside the operator’s compartment?
 Does the operator demonstrate the correct procedure for a blind
intersection?
 Did the operator check their end swing when turning?
 Did the operator maintain a consistent distance from the corner/obstacle
when turning?
PICKING UP A LOAD
 Did the operator square up to the load/is the load centered?
 Is the truck the correct distance away from the racking/stack?
  Did the operator elevate the forks to the correct height?
 Are the forks leveled for entry into the pallet?
 Did the operator drive the forks fully into the pallet?
 Did the operator apply the brake while using the hydraulic controls?
 Did the operator apply the correct amount of tilt to the load?
 Did the operator use the hydraulic controls in a smooth manner?
 Does the operator’s body remain inside the operator’s compartment?
 Did the operator perform a 360-degree check before reversing the load?
 Did the operator sound the horn before reversing the load?
 Did the operator lower the load to travel height (4-6 inches above the
ground) before turning/traveling?
TRAVELING WITH A LOAD
 Are the forks placed in the correct travel position (4-6 inches above the
ground)?
 Did the operator sound the horn before moving?
 Is the operator facing the direction of travel?
 Does the operator’s body remain inside the operator’s compartment?
 Does the operator travel with an unobstructed view? (Or if the load
restricts their view, did they drive in reverse?)
 Did the operator maintain a consistent distance from the corner/obstacle
when turning?
DEPOSITING A LOAD
 Did the operator square up to the racking/stack before elevating the load?
(No turning after they approached the location and elevated)
 Did the operator apply the brake while using the hydraulic controls?
 Did the operator level the load correctly for the deposit?
  Did the operator lower the load gently on the racking/stack?
 Is the pallet in the correct position on the racking/stack?
 Did the operator perform a 360-degree check before reversing?
 Did the operator sound the horn before reversing?
 Did the operator lower the forks to travel height (4-6 inches above the
ground) before traveling?
PARKING THE LIFT TRUCK
 Did the operator park the truck away from any doors, exists, or emergency
routes?
 Did the operator lower the forks to the ground?
 Did the operator put the lift truck into neutral?
 Did the operator apply the parking brake?
 Did the operator shut off the lift truck?
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) TRAINING REQUIREMENTS
Powered Industrial Trucks training requirements are governed by OSHA's
standard 1910.178(l), which states:
Training shall consist of a combination of formal instruction (e.g., lecture,
discussion, interactive computer learning, video tape, written material),
practical training (demonstrations performed by the trainer and practical
exercises performed by the trainee), and evaluation of the operator's
performance in the workplace.
Generally, forklift operator training containing formal and practical instruction
should cover the:
 Types of lift trucks used in a specific work environment
 Hazards created by the use of those vehicles
 General safety requirements (such as pre-shift inspections)
 General principles of safe forklift operation
Question: Do forklift operators need to be trained specifically on every forklift
they operate?
Operators need to be trained on each type of lift truck they'll be expected to
operate. That said, once trained on a specific type of lift truck, they don't
require additional training if operating the same type of fork truck from
different manufacturers. That's unless the truck or the work-related
applications are different from what's required in standard 1910.178(l)(3).

OSHA’s Forklift Refresher Training Requirements

Forklift certification isn’t a one-and-done thing, like getting a regular driver’s
license. Instead, forklift operators must be re-evaluated periodically to ensure
they maintain the necessary knowledge to operate safely. Overall, reevaluations
must be completed every three years. However, certain circumstances can arise
that require operators to be reevaluated before that three-year mark. In
standard 1910.178(l)(4), OSHA lists the scenarios that will require forklift operator
refresher training:

 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 lift truck
 A condition in the workplace changes in a manner that could affect the safe
operation of the fork truck
These evaluations can be a discussion with the employee, written documentation
of previous training, performance testing, or simply observing the employee.
PROVIDERS OF FORKLIFT OPERATOR TRAINING
Overall, there are three different options for getting forklift operator training:
1. Employer-provided training
2. Online courses
3. In-person courses
Employer-Provided Training
As a company making efficient use of forklifts, providing in-house operator
training to our employees is highly necessary. The company provides the training
to the employee and the employee is not responsible for the costs.
Some companies offer on-the-job forklift training to their new hires. In the outline
for their employee full job description, it is stated that “The Company will provide
individualized training with a qualified trainer during the first two weeks. Previous
forklift experience and basic computer knowledge are helpful, but not necessary.”
The downside of employer-provided training is that not many companies offer
this option.

Online Courses
Online forklift certification courses have become extremely popular in recent
years. A quick Google search reveals dozens of companies offering these services
for a low cost, often between $50 and $200. These courses generally consist of
slideshows and videos, with quizzes after each section, and a final exam. At the
end of the course, a certificate of completion can be downloaded from the
platform.
The downside of these courses is that, while they can fulfill OSHA's requirement
for formal instruction, they cannot fulfill the practical requirement. Thus, online
courses only get operators partially qualified. Operators will still need to be
evaluated operating a forklift in actual workplace conditions.
In-Person Courses
In-person courses are generally provided by forklift dealerships and technical
colleges. Operator-trainees will sit through classroom-style instruction, then be
taught how to operate an actual forklift by the instructor. These courses usually
last anywhere from 8 hours to 2 full days.
Overall, in-person classes are an excellent way to get certified by an authoritative
trainer. The downside is that they’re generally more expensive than online
courses.
DEVELOPING OUR OWN FORKLIFT SAFETY TRAINING
PROGRAM
Since our business requires the use of enough certified forklift operators, it may
make sense to handle all safety procedures and training in-house rather than hire
an outside contractor.
Some of the benefits of doing so include:
 The convenience of working around our schedule and needs
 Saving money on training costs
 Develop a curriculum that’s specific to our equipment and operation
That said, we need to make sure our in-house trainers are knowledgeable and
skilled, along with complying with OSHA which is not necessarily a walk in the
park. A successful forklift safety training program will do both.
So here’s how you can craft a training program that hits all those targets.
1. Enroll in a Train-The-Trainer Program
To ensure their training programs meet OSHA’s recommended practices, many
companies send their training personnel to specialized Train-The-Trainer classes.
These classes help trainers develop the skills to teach safety guidelines and
protocols.
Enrolling staffs in a train-the-trainer program is an excellent first step to
developing our own in-house training program. However, having this alone won’t
make our safety training program a success. We’ll also need to carefully evaluate
our facility, equipment, and employees – both operators and pedestrians – to
create a comprehensive forklift equipment safety awareness program that
protects both our employees and assets.

2. Identifying the Equipment in our Workplace

Our operators will need to be trained on the specific equipment they’ll be
expected to operate so identifying what types of equipment our operators
currently use will help refine our training curriculum.
3. Evaluate Your Facility's Hazards
If one new to safety training they may not realize just how many hazards are
present in the workplace. Many hazards differ depending on the type of forklift
and your application.
For example, a sit-down rider lifts loads much higher than a walkie pallet jack.
Therefore the sit-down rider is more likely to be involved in an accident with a
falling load.

An effective forklift safety program takes into account all potential workplace
hazards
Likewise, pedestrians can be at greater risk in retail applications due to the high
frequency of pedestrians working near forklift operations. Regardless of our
forklift type, forklift operators and pedestrians should be aware of the hazards
associated with your worksite and application.
To get us started, just a few of the hazards that may apply are listed below:
 Obstructed view - Often carrying a load results in an obstructed view for
the operator. But an obstructed view can also be caused by cross aisles and
blind corners. Operators should drive backward if their load is causing
visibility issues.

 Grades, ramps, or inclines - Overturns can happen more easily when the lift
truck is not on a flat surface. Operators should travel slowly on an incline
and pedestrians should not approach the forklift when it’s on an incline.

 Special attachments - Many applications utilize special attachments.

However, these attachments often change the capacity, stability, and load
center of the forklift. They can also reduce the operating clearance of the
forklift (height or width). Operators should be aware of the changes these
attachments may make to the forklift’s capabilities and respond
appropriately.

 Unstable loads - Unstable loads can fall on pedestrians and operators. They
can be caused by a load that is too heavy, too high, or uneven.

 Loading docks - Loading docks are a universal hazard that affects virtually
every application. If the trailer in the loading dock is not properly secured,
both lift trucks and pedestrians could fall through. Proper loading dock
 procedure should be reviewed with every employee that works around
them.

A walk through around the facility will be required in order to identify hazards
that both operators and pedestrians will encounter during their daily activities.
Any hazards that may affect our worksite and application must be covered in our
operator safety training as work site-specific instruction. Training employees on
safety protocols for navigating these areas is very essential.

4. Establish our Training Methods

The need to determine when and how our operators and pedestrians will be
trained and what type of training they’ll receive is important. Recall that training
can include videos, slideshows, lectures, discussions, and the like. We need to be
sure to include both in-class and practical components for operators.

5. Create Training Program Content

Our training program should be comprehensive enough to cover everything an
operator needs to know to safely operate a forklift.
Here’s a forklift training checklist to ensure we don’t miss a topic that should be
covered:
WORKPLACE SAFETY
 What is the employer responsible for?
 What is the supervisor or manager responsible for?
 What is the forklift operator responsible for?
 What are the rights of the forklift operator?
  What are the penalties for forklift-related violations and accidents?
 What are the best practices for pedestrian safety for forklift operators?

FORKLIFT INSPECTIONS

 When are forklift inspections required?

 What are the two parts of a forklift inspection?
 What items should be checked during each part of a forklift inspection?

FUEL SOURCES

 What are the different fuel sources for forklifts?

 What are the steps involved with inspecting, watering, and charging forklift
batteries?
 How can you detect a propane leak?
 How do you change a forklift propane tank?
 How do you inspect a forklift propane tank’s integrity?

CAPACITY

 How can you tell how much weight your truck can lift?
 How can you tell how high you can lift the load
 What does “de-rate” mean and how can you calculate it?
 How do you read a data plate?
 What does capacity mean?
 What is the rated capacity?
 What does load center mean?
 What is the rated load center?
 What does the center of gravity mean?
  What is rated lifting height?

STABILITY

 How can you avoid forklift tip-overs?

 What are the most common causes of lift truck tip-overs?
 What should you do if your lift truck tips over?
 What are the principles of stability?
 What affects the stability of a lift truck?
 What are the different types of momentum?

MATERIAL HANDLING BASICS

 What are the main elements of basic forklift driving safety?

 What is the proper way to pick up loads?
 How do you properly transport loads?
 How do you transport barrels, drums, and kegs?
 How do you deposit a load?
 How do you properly secure your load?
 When should you use a spotter?
 What is the procedure for entering and exiting a semi-trailer?
 What is the procedure for parking and securing a lift truck?
 What are the different lift truck classifications?

Also, we need to make sure pedestrians know safety procedures concerning

forklift operation.
6. Determine a Valid Employee Evaluation
Evaluations should include a written test combined with a visual evaluation of the
operator’s skills using the equipment.

7. Developing a Documentation System

Remember: As the employer, we’re responsible for certifying that our operators
have been trained and evaluated. Therefore, we are to make sure that detailed
records of the training should be kept properly, in case of an audit.

8. Prepare Refresher Training

In the case where one of our operators is involved in an incident, conditions

change in our facility so it would need to be reviewed after a specific period of
time. It may have simply been 3 years since the last one and requires a renewal.
Therefore, refresher trainings inevitable.

Review the section titled “OSHA’s Forklift Refresher Training Requirements?” to

ensure we understand when it’s required and how to perform one.