Fork truck training

1. Powered Industrial Equipment
Awareness
By: David Pastore
Distribution Department
630-529-5787 davidpastore@yahoo.com

2. Managers and Supervisors have the responsibility to ensure the safety
of their employees and co-workers at all times.
It is also the responsibility that our employees follow the rules for
operating powered industrial equipment safely.
EVERYONE needs to be aware of the working environment especially
when in close contact with powered industrial equipment.
The National Safety Council recommends that all managers take a
“Powered Industrial Equipment” training class. I put together this
presentation to educate ALL EMPLOYEES, so there is an complete
understanding of what to look for when around powered industrial
equipment.
By adhering to these rules, it will provide a safe work environment. It
is everyone’s responsibility to ensure that individuals are operating
powered industrial equipment safely at all times.
Please take the time to look at the following presentation and review
whenever you would like to refresh your understanding of the do’s and
don’ts of operating powered industrial equipment.

3. Powered Industrial Equipment
Accidents
 OSHA estimates that there are 680,400
accidents each year
 Approximately 90,000 employees suffer
some type of injury

4. Breakdown of the 680,400 accidents
 90,000 employees injured
 100 deaths
Source: Powered industrial truck accidents report through OSHA’s
“First report of serious accidents” 1985-1990

5. Causes of P.I.E. accidents in
percentages
7
Ran off loading dock
12.2 Elevated employee on lift
Struck by falling load 14.4
Struck by PIT 18.8
25.3
Tip over of PIT
0 5 10 15 20 25 30

6. Causes of P.I.E. accidents in
percentages
Faulty powered lift 3.1
Employees overcome by fumes 4.4
P.I.E. struck material 4.4
4.4
Lost control of the P.I.E.
Improper maintenance procedures 6.1
0 1 2 3 4 5 6 7

7. Causes of P.I.E. accidents in
percentages
1 Electrocutions
Improper use of P.I.E. 2.6
Employee fell from P.I.E. 3.1
Unloading unchocked trailer 3.1
0 0.5 1 1.5 2 2.5 3 3.5

8. Powered Industrial Equipment
Accidents
 Losses affect employers
 damage to equipment
 loss productivity

9. Powered Industrial Equipment
Accidents
Losses affect employees
 physical suffering
 mental suffering
 DEATH

10. Benefits of Powered Industrial
Equipment
 Assist in the movement of materials
 Reduce employee injuries

11. Powered Industrial Equipment
operating abilities and environments
 Pedestrians area
 Blind spots
 Indoors/Outdoors
 Narrow aisles
 Building columns
 Operate 24 hours per day
 Turning radius

12. Powered Industrial Equipment
and Pedestrians
 Pedestrians contribute to accidents
 Pedestrians do not understand stopping distances
 Pedestrians try to “beat” P.I.E.
 Pedestrians can DIE

13. Methods used to reduce Powered
Industrial Equipment Accidents
 Training of drivers
 Maintenance of equipment
 Managed daily operations

14. Pre Safety Check
 A pre-safety check must be performed at the beginning of each shift.
 Checklist will be filled out and displayed on all operating vehicles at
all times.
 Defects must be reported to supervisor
 A “Do Not Operate” tag is placed on vehicle and is taken out of service
until repairs can be made.
 All safety check off tags are to be turned in at the end of each shift and
kept for a year .

15. Pre Safety Inspection Tags
Tags must be displayed on vehicle while operating P.I.E.
“Green for go , Red for lock out”.

16. Always wear a Seatbelt! It’s the law!
 Always look to see if an operator is wearing a seat belt. If operator is not
wearing a seat belt ask them to please put one on and then report the incident
to their supervisor. Wearing a seat belt is not up to the operator
 it’s the law!

17. The rules for unattended vehicles
 Never get off vehicle and leave running if your more then 15 feet away or if the vehicle is out of sight.
 Never park on an incline.
 Never park in front of a door way or exit.
 Never park truck on a dock.
 Never park in a trailer.
 Always park truck in a designated area with attachments at
ground level, shut down controls and set emergency brake.
No! Never leave unattended Yes! Proper placement of No! Never park across dock
vehicle’s parked in aisles. vehicle when not in use. plate or on an incline.

18. 1.Operating P.I.E. in a working environment
 Operators must be aware of their working environments. Complacency by
the operator who assumes no one is around can be disastrous.
This picture was taken while the work area was fully staffed!

19. 2.Operating P.I.E. in a working environment
 Operators must be aware of their working environments. Complacency by
the operator who assumes no one is around can be disastrous.
This picture was taken a few seconds later than the last slide but at a different angle.

20. 3.Operating vehicle in a working environment
 Most accidents take place at shift change and or break time. Operators must
be extremely cautious when operating P.I.E. during these times.
As you can see from the pictures our loading dock is in close proximity
to our employee exit area. Operators should be extremely cautious at
shift time and /or break time.

21. 4. Operating P.I.E. in a working environment
 Drive slow.
 Avoid spinning vehicle.
 Slow down at cross sections , sound horn and proceed with caution.
 Make sure pedestrians know you are there and make eye contact.
Slow down at cross sections and then proceed with caution. Make eye
contact letting workers know that you are in their work area.

22. 5.Operating P.I.E. in a working environment
 Never drive up to a fixed object to retrieve something.
 Never drive up to someone or walk up to P.I.E.
 Never let someone walk up to you.
Never drive up to Keep your Never drive up to a
someone or walk distance. fixed object to
up to an operating retrieve something
truck!

23. Driving with or without a load
 Drive in reverse when transporting a load that is unstable or blocks view.
 Proceed with caution when load is unstable.
 Empty attachments should be 4 inches from the floor.
 Always go up and down an incline with the load trailing.
Drive in reverse when view is Attachments 4 inches from floor
blocked. when traveling empty

24. Operating P.I.E. in a warehouse environment
 Are operators approaching loads correctly?
 Are operators raising and lowering loads while stationary?
 Are operators aware of their overhead environment?
 Are operators performing housekeeping?
 Are operators stacking pallets correctly?
 Are operators moving in and out of racking environments
cautiously?
 Are operators trying to lift more than vehicle can support?
 Are operators following all the rules for operating in a storage
environment? no passing, no horse play, no riders and no reaching
out of vehicle.

25. Stacking and unstacking
 Always approach head on and square, never
stack or unstack while turning.
Approaching head on Never stack or unstack while
turning P.I.E.

26. Storing or retrieving a pallet from a
rack position
Right way is to line up squarely Wrong way is turning
with rack before lifting or while lifting or lowering.
lowering pallet.

27. Rules of the road
 Always follow another P.I.E. by three lengths.
 Never pass another moving vehicle.
 Avoid wide turns.
 Slow down at intersection and blind spots, sound horn, and proceed with
caution.
Keep three truck lengths when
Don’t pass while traveling.
following another operator.

28. Operating P.I.E. on a dock and in and out of trucks
 Are operators inspecting trucks before loading or unloading?
 Are wheel chocks being used correctly?
 Are drivers proceeding with caution when entering and exiting trailers or rail
cars?
Wheels must Locking
mechanism Trailer must Proceed with
be chocked be inspected caution when
must be
engaged for defects loading or
unloading
trailers.

29. Types of Power Walkers at Berlin
 We have three types of power walkers at Berlin Industries:
 1) Power rider walkers - this is the only walker hat can be ridden.
 2) Power walker only.
 3) Blue Giant with stabilizer bars which should only be used to remove half
size pallets from press delivery system.
Powered Walker Power Walker Specialized Power
Rider Only Walker

30. Operating powered walkers
correctly
Proper way of Proper way to operate
operating powered powered rider walker.
walker.

31. Oversized pallets
 Use extended forks.
 Buddy system when loading, unloading and
stacking.
Oversized Use fork Buddy system
pallets extensions

32. The following slides are examples
of major safety violations

33. Never drive up to someone or walk
up to someone operating a P.I.E.!

34. Never drive up to a fixed object to
retrieve something!

35. Always operate a P.I.E. in
designated aisles!
Operators should be following the arrows and not
cutting across the staging area.

36. Never operate with body parts out of
the protected confines of P.I.E.
Keep feet and arms in confines of P.I.E.
at all times.

37. Never transport elevated loads

38. This person is to close to the P.I.E.
operator
Losing control
of this roll at
this level could
result in the
death of this
individual
sweeping the
floor.
Note: This picture was
staged in a controlled
situation, the clamp is
not attached to the roll.

39. Never transport another individual
on a P.I.E., they are for transporting
goods not people

40. Never raise someone up on a P.I.E. to
retrieve something

41. Never reach through the uprights of a
P.I.E.

42. The End
 . The next time you are around
powered industrial equipment keep
and eye open and put “Safety First”.
Thank you for taking the time to view
this presentation.