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If you focus on these three key elements, it will have a direct impact on minimising harm to property, people and vital resources.

One of the ways to prevent safety accidents from happening is by training forklift operators on proper ways of lifting and carrying loads in the warehouse or distribution centres (DC).

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Ideally, the warehouse/distribution centre floors should be as flat as possible and free from the obstacles listed above.

🟢 This allows you to separate points of contact between the two and therefore reducing the likelihood of incidents by being nearby.

🟦 They are clear on what actions to take without being paralysed out of fear (amygdala hijack happens in such stressful situations)

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This helps in ensuring safety for all personnel on-site and warehouse property and therefore reducing the likelihood of potential harm to people and property.

🟢 Deliver regular pieces of training using videos, case studies, slides or any other visual format that easily delivers the message.

This is good because when our fear of fight or flight response is activated, we want to get out of the situation as quickly as possible (in this case from Forklift).

This is to ensure they have a clear understanding of the safety guidelines and help reduce workplace accidents that occur in this industry.

Even if the operator has both training and a license, they should have authorisation from management (A team leader, supervisor, or a manager) before operating any of the forklifts.

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🟢 A good option would be to bring experts who specialise in warehouse design and workplace safety. The two goes hand in hand.

🟢 By utilising the knowledge of these people, you ensure you are investing to improve workplace safety and give assurance to your employees to feel safe when on site.

🟥 𝗕𝗹𝗶𝗻𝗱 𝘀𝗽𝗼𝘁𝘀 in areas such as corners, exits, staging area, big loads, narrow aisles etc - all these things affect the vision of the operator

This helps prevent accidents and ensure people go home safely. Also, it saves time, money and helps in building a good safety culture in the team.

🟢 Having proper signage, markings, and safety notices/boards in place throughout the warehouse or a distribution centre, showing clear instructions on what to do and what not to do.

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🔳 When the load is lowered, the tip of the forks should be titled a little backward to prevent the load from falling/slipping forward

Before you lift any worker, an approved work cage (platform) must be attached to the forklift truck, following all the safety instructions.

It will also help you protect valuable resources, assets, reduce incidents, improve the overall operations and warehouse safety.

🗨️ Although doing this way takes a couple more seconds, but it is essential for the safety of your team members and warehouse.

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➖ Machines won't operate when they pass the safety threshold. This could be achieved by using access software that comes with certain forklifts such as Crown

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After you're done with your forklift whether you are going for a break or signing off from the shift, it is important to park the truck correctly.

Managers and Supervisors should not take any unnecessary risks to get the job done, rather wait for appropriate machinery for the job and then proceed.

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Using the above safety guidelines will ensure safe operations and will save valuable time and resources for your business.

A simple way to reduce accidents and harm to your team members is by designing good traffic routes both for pedestrians and machines throughout your warehouse/DC.

When driving in reverse, forklift operators should follow these safety guidelines to protect people, machines, and property around them:

They are very powerful machines and can cause serious damage to people, property, and other types of machinery if treated in the wrong manner.

🟢 Taking employees on a visual walk and explaining different aspects of safety around forklifts. Answering any questions, they may have during these safety walks.

Therefore Managers and Supervisors need to keep tabs on the maintenance and service schedules to ensure they run smoothly and at optimum levels.

🔲 It allows the operator to inform other workers of their presence and communicate through sound where they are operating.

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This not only reduces potential safety incidents but also helps streamline operations, which in turn results in increased productivity.

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Much like driving cars, forklift operators should be trained on defensive driving, allowing them to be safer and better drivers.

To minimise these accidents and incidents, I've shared some practical tips to raise awareness on these issues and to help you improve your warehousing operations.

→ This may seem like a waste of time and money to some, but in the long run, it will do wonder for your warehouse and employee safety.

If you've worked in warehousing operations, you might have seen people taking shortcuts to save themselves a few seconds. They take a risk by either walking under a forklift or standing too close to it while it is in operation.

Understanding this will help us become better drivers. Those who are managers/supervisors will learn what to focus on when training new drivers or giving refresher inductions to their team members.

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This helps in not only making their life easier but also reducing traffic congestion in the warehouse and helping build a safety-focused team culture.

They forget to realise that only the truck is very powerful but also the load they are carrying can crush them in a matter of seconds.

Now that you have a better understanding of the reasons WHY an operator may not be able to see or notice you, it is time to discuss the next part, education, and training.

Forklift operations are an essential part of the Warehousing Operations for a business. Therefore, due diligence and improved safety systems must be in place to protect the following

One of the best ways to keep on top of things is to “Clean as you go”. If you see something pick it up and put it in the nearest rubbish bin.

I remember having worked at a DC where the area for loading and unloading was uneven, inclined and very risky, prone to accidents.

Before the operator turns on the forklift machine, it should be checked for key safety areas, by doing a visual inspection. This can include things such as:

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This not only saves everyone’s time but also helps in making the workplace a lot safer for everyone as there is less congestion.

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The management team needs to put a system in place that helps in educating and training employees around forklift safety.

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You might not know this, but overturning and tipping over is one of the biggest risks for forklift operators. In worst cases, it has led to the death of the warehouse workers.

Once the prestart checks are completed, the operator then should put the key in to start the machine and conduct post-start safety checks.

Testing and tagging is a procedure where items are first tested, usually through a visual check or a physical inspection.

It helps in ensuring the safety of people and property, as faulty forklifts can lead to accidents and incidents, that can be simply avoided by keeping an eye on this.

As with anything else, these training materials should be reviewed, updated, and changed regularly to accommodate the changing needs of a business and to comply with WHS standards.

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Management should put serious efforts to train all of their warehouse floor staff, especially forklift operators on what to do if an emergency occurs.

Team members should do their best to remove unwanted pallets, types of machinery such as sweepers, trolleys etc from the areas where forklift traffic is high.

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→ After the training session, engage all the members of the team through a series of questions and explain any knowledge gap they may have.

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Having the right kind of trucks is essential to productive warehousing operations and making the most out of these machines.

🔳 It should be close to the ground (floor) but a few cms raised so that it does not get caught up with the items on the floor such as plastic, broken pallet pieces etc

𝗡𝗼𝘁𝗲: Managers and Supervisors need to train their team members on how to do the "above activities" correctly to ensure they understand and comply.

⚠️ To reduce the likelihood of accidents and safety incidents, forklift operators should use (beep 🔊) their horns and slow their speed when they are in the following areas:

𝗡𝗼𝘁𝗲: Once a machine or a tool is tagged out, no one should operate it until it is fixed and the tag is removed by the technician.

🢥 https://www.safework.nsw.gov.au/licences-and-registrations/licences/high-risk-work-licences/hrw-accordions/forklift-licences

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Alternatively, if there is a dedicated cleaning team onsite, they should be regularly cleaning the floors and getting rid of these things such as plastics, broken pallets, wooden pieces etc.

🔲 Slowing down at intersections, exit and entry points, rough surfaces, slopes and ramps, and near high pedestrian activities zone

It is, therefore, essential to inform all the people working on a warehouse floor about the power of these trucks, and the damage they can do.

By doing these simple yet effective prestarts and post-start safety checks, you are helping in ensuring a safe workplace for everyone.

Combining these two approaches will ensure they develop a very good understanding of risks and hazards associated with forklift operations.

More often than not, these issues are ignored until they become big or some safety incidents happen - which as the saying goes "It's too late now".

Now we will touch on lightning and cleaning practices and how they can help in improving work health, safety, and productivity.

🔲 Using case studies, simulations, videos, presentation slides and hypothetical situations and then teaching the drivers on how they should handle such situations.

This is essential to maintain a safe workspace for everyone involved in running the floor operations from pickers, packers, store persons, to cleaners and management staff.

I recommend taking the following two approaches to better educate your staff and help make your workplace safe for everyone.