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OSHA reports that every year, thousands of forklift truck injuries and
property damage accidents occur in the U.S. workplace. Many of the injuries
are due to lift truck rollovers, trucks inadvertently driven off loading
docks, lifts falling between docks and an unsecured trailer, pedestrians
struck by a lift truck, and employees falling from elevated pallets or
forks. Many incidents also involve property damage. All of these injuries
and property damage events are costly and preventable.
It's not possible to discuss all the incidents summarized above or go
into detail about the failures attributed to the events, but simply bringing
them to your attention may prompt you to take a critical look at your
overall lift truck program and make some adjustments.
OSHA identified training as one of the key factors responsible for these
accidents. If you're experiencing any forklift truck injuries or property
damage accidents, you need to ask yourself: Is my forklift truck training
sufficient and adequate, and does it meet the OSHA requirements? Let's
take a look at the requirements.
Training & Evaluation
1910.178(l) - Employees who operate a forklift must be properly trained
and evaluated before they operate any forklift. The training must consist
of a combination of formal instruction (classroom work) and practical
training (demonstrations) and conclude with an evaluation of the driver's
performance in the workplace. The trainers must have knowledge, training
and experience to train drivers and evaluate their competence.
Training Program Content
1910.178(l)(3) - The regulation is very specific as to the content of
the initial training, unless it can be shown that they do not apply to
your workplace. The training content requirements can be found in your
GAWDA OSHA Manual, Section 21, page 3.
Three-Year Evaluation and Refresher Training
1910.178(l)(4) - Evaluate the performance of each forklift operator's
performance once every three years to ensure that the employee has retained
and continues to use the knowledge and skills necessary to operate the
vehicle safely. The evaluation of performance cannot be met by a written
exam alone. The evaluation must include observing the operator during
normal operation to determine if the operator is performing safely, and
asking pertinent questions to ensure the operator has the knowledge or
experience needed to operate a truck safely. The evaluation must be documented;
a form for this purpose is in your GAWDA OSHA Manual, Section 21.
The standard requires that refresher training be conducted and documented
when:
- The operator has been observed operating the forklift in an unsafe
manner.
- The operator has been involved in an accident or near miss.
- The operator has received an evaluation that indicates unsafe operation.
- The operator is assigned a different type of truck.
- A workplace condition changes in a manner which could affect safe
operation.
The final rule provides a performance-oriented and cost-effective approach
to refresher training. The type, amount and timing of refresher training
depend on several factors, such as the equipment and terrain characteristics,
nature of the unsafe act, and the potential for an accident.
Avoid Duplication of Training
1910.178(l)(5) - You may avoid duplication of training for new hires if
your evaluation of the driver and prior training was adequate. You should
refer to the standard for more specific details.
Certification
1910.178(l)(6) - You are required to certify that each operator has been
trained and evaluated and has proven to be competent to operate the truck
safely. The operator would need additional training in those elements
where his or her performance indicates the need for further training and
for new types of equipment and areas of operations. The certification
must include the name of the operator, the date of the training, the date
of the evaluation, and the identity of the person(s) performing the training
or evaluation. A form for this purpose is included in your GAWDA OSHA
Manual, Section 21.
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