In Part One of my series on OSHA Regulations Concerning Industrial Trucks, I discussed responsibilities warehouse executive have in assure safe forklift operations.
In part Two, I discussed what OSHA expected warehouses to do concerning the training of forklift operators.
In Part Three, I covered OSHA requirements concerning pre-use inspections and operations of a forklift.
In Part Four, I covered what OSHA requires concerning unattended vehicles and maintenance and fueling procedures.
In Part Five, I will discuss the various checklists OSHA requires warehouses use to keep records concerning forklift use and maintenance.
Operator’s Daily Checklist – Electric Vehicles
A checklist to evaluate the condition of electric vehicles should be filled out daily. The checklist should include the following:
· Truck Number
· Date
· Operator’s Name
· Hour Motor Reading
· Supervisor Signature
Under “Visual Checks” there should be nine categories listed:
· Obvious damage and leaks
· Tire/Wheel Condition
· Battery plug connection
· Head and taillights
· Hour meter
· Other gauges and instruments
· Battery discharge indicator
· Fire extinguisher
Under “Operational Checks” there should be seven categories:
· Horn
· Steering
· Brakes
· Parking brake
· Vehicle movement; forward and reverse
· Lift, tilt side shift controls
Three boxes should be beside each category. One box must be checked.
· OK
· Needs Attention or Repair
· Not Applicable
Operator’s Daily Checklist – Gas, LPG and Diesel Vehicles
· Include “OK”, “Needs Attention or Repair” “Not Applicable” check boxes beside each category.
· Truck Number
· Date
· Operator Name
· Hour Meter Reading Start of Day
· Supervisor Signature
Visual Checks has 11 categories:
· Engine oil level
· Radiator water level
· Fuel level
· Battery water level
· Obvious damage and leaks
· Tire condition
· Head and taillights
· Warning lights
· Hour meter
· Other gauges and instruments
· Fire extinguisher
Operational Checks has five categories:
· Horn
· Steering
· Brakes
· Parking brake
· Lift, tilt, side shift controls
Operator’s Daily Checklist – Gas, LPG and Diesel Vehicles
This checklist should be used for field session evaluation of forklift operator proficiency as well as periodic evaluation of operators. Each category should have four boxes beside it with one box to be checked.
· Good
· Fair
· Poor
· N/A
Checklist should also include:
· Operator Name
· Evaluator Name
· Date of Evaluation
· Equipment Operated
Pre-use Inspection
· Follow the operator’s daily checklist
· Look for damage
· Document all findings on appropriate checklist
Pick Up A Load
· Square up on the center of the load
· Stop with the fork tips about 1 foot from the load
· Level the forks; then slowly drive forward until the load contacts the carriage
· Lift the load carefully and smoothly until it is clear
· Tilt the mast back slightly to stabilize the load
· Look over both shoulders
· After out and stopped, lower the load to travel height
Traveling
· Do nut raise or lower the load and fork while traveling
· Maintain a safe speed
· Observe all traffic rules, warning signs, floor load limits and overhead clearances
· Keep arms and legs inside the powered forklift
· Follow other vehicles at a safe distance
· Slow down when cornering
· Use the horn to alert others
· Travel with the load facing uphill while on a ramp or incline
· Stop smoothly
Putting Down A Load
· Make sure there is sufficient clearance for the load
· Clear personnel from the area near the load
· Square up to the location; then stop about 1 foot away
· Raise the load to placement level
· Move slowly forward
· If the load is on a pallet, lower it into position and lower the forks further
· Look over both shoulders before backing out
· Back straight out until the forks have cleared
· Lower the forks to traveling position
Parking
· Fully lower the forks
· Neutralize the controls
· Set the brakes
· Turn off the power
· If parked on an incline, block the wheels
· Park only in authorized areas
Fueling and Battery Recharging
· Engine off
· Fire extinguisher nearby
· Proper personal protective equipment
· Safe fueling and battery recharging procedures followed
· Spills cleaned up immediately
Evaluation
· Check box beside each of following
· Based on my evaluation, the operator has successfully completed the evaluation and is qualified to operate the following equipment
· Based on my evaluation, the operator has not demonstrated competence in operating the following equipment
Provide space to write in equipment type for each evaluation, evaluator’s signature and operator’s signature.
Order Picker Operator Evaluation Form
This checklist should be used to evaluate the field session of a forklift operator’s proficiency and for periodic evaluation that operators are operating order pickers properly.
Check box besides each category:
· Good
· Fair
· Poor
· N/A
Pre-use Inspection
· Follow the operator’s daily checklist
· Look for damage
· Document all findings on the checklist
Fall protection
· Make sure fall protection is in place before beginning work
· Inspect all components of the fall protection system before use
· Make sure fall protection is worn correctly
Traveling with an order picker
· Clear a path in the aisle
· Travel with the operator’s platform as low as possible
· Keep hands, feet and head inside the vehicle at all times
· Go slowly when coming out of aisles and into cross traffic
· Use the horn to alert others
Pick up a pallet
· Back into the pallet at ground level until the forks are completely under it and the pallet contacts the platform
· Lock the pallet on
Raising the platform
· Remain stationary
· Watch for overhead clearance
Pulling materials out of racking
· Use good body mechanics
· Position the machine so materials are at waist level
· Do not force materials into or out of the racks
· Use tubs or bins on the pallet
· Fill the pallet from front to back; putting the heavier parts toward the platform
· Stay on the work surface
· If the operator cannot reach the materials, pull the pallet down, rearrange the materials and return it to the rack
Moving with the platform raised
· Move slowly in a straight line in rack aisles
· Avoid turning
· Go slowly and watch for obstructions
Placing pallets
· Return the load to the pallet staging area
· Lower the pallet to ground level before releasing it
· Look over both shoulders
· Carefully reverse direction
Parking
· Lower the machine to the lowest position
· Turn the key to “off”
· Fire extinguisher nearby
· Proper personal protective equipment
· Safe fueling and battery recharging
· Spills cleaned up immediately
Check box besides each of the following:
· Based on my evaluation, the operator has successfully completed the evaluation and is qualified to operate the following equipment:
· Based on my evaluation, the operator has not demonstrated competence in operating the following equipment:
· Provide space where equipment type can be written in and for evaluator and operator signatures.