March 2010
Forklift Training

Each year, tens of thousands of injuries related to powered industrial trucks (PIT), or forklifts, occur in US workplaces. Many employees are injured when lift trucks are inadvertently driven off loading docks, lifts fall between docks and an unsecured trailer, they are struck by a lift truck, or when they fall while on elevated pallets and tines. Most incidents also involve property damage, including damage to overhead sprinklers, racking, pipes, walls, and machinery. Unfortunately, most employee injuries and property damage can be attributed to lack of safe operating procedures, lack of safety-rule enforcement, and insufficient or inadequate training.

It is a violation of Federal law for anyone UNDER 18 years of age to operate a forklift or for anyone OVER 18 years of age who is not properly trained and certified to do so.

What does the OSHA 1910.178 standard require?

The standard requires employers to develop and implement a training program based on the general principles of safe truck operation, the types of vehicle(s) being used in the workplace, the hazards of the workplace created by the use of the vehicle(s), and the general safety requirements of the OSHA standard. Trained operators must know how to do the job properly and do it safely as demonstrated by workplace evaluation. Formal (lecture, video, etc.) and practical (demonstration and practical exercises) training must be provided.

• Employers must also certify that each operator has received the training and evaluate each operator at least once every three years.
• 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 known as the performance test. OSHA has a sample form that can be used to document the performance test at this link: http://www.osha.gov/dte/library/pit/test.html
• Refresher training is needed whenever an operator demonstrates a deficiency in the safe operation of the truck.

Who should conduct the training?

All training and evaluation must be conducted by persons with the necessary knowledge, training, and experience to train powered industrial truck operators and evaluate their competence. An example of a qualified trainer would be a person who, by possession of a recognized degree, certificate, or professional standing, or who by extensive knowledge, training, and experience has demonstrated the ability to train and evaluate powered industrial truck operators.

There are many resources available to the employer if he/she chooses not to perform the training himself. Truck manufacturers, local safety and health safety organizations, such as the National Safety Council local chapters, private consultants with expertise in powered industrial trucks, local trade and vocational schools are some available resources.

Various Internet sites are devoted to forklift safety. Private companies, who provide forklift safety training services, including videos and written programs, can be located on various Internet websites. Most videos can be either leased or purchased. One important thing to remember is that simply by showing employees a video or videos on some aspect of forklift safety does not meet the full requirements of the OSHA standard. Site specific information must be conveyed as well as a method to evaluate the employee's acquired knowledge subsequent to the training.

Is testing required?

No. The standard does not specifically require testing; however, some method of evaluation is necessary.

Does OSHA require the employer to issue licenses to employees who have received training?

No. The OSHA standard does not require employees to be licensed. An employer may choose to issue licenses to trained operators.

What type of records or documentation must I keep?

The OSHA standard requires that the employer certify that each operator has received the training and has been evaluated. The written certification record 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.

How long must I keep the certification records?

Employers who evaluate the operator's performance more frequently than every three years may retain the most recent certification record; otherwise, certification records must be maintained for three years.

OSHA has a great frequently asked questions site here: http://www.osha.gov/dte/library/pit/pit_q-a.html

OSHA also has another great site here: http://www.osha.gov/dcsp/products/etools/pit/index.html

As always, if there are questions or items that I can help you with, please don’t hesitate to contact me.

Michael Dodd

GAWDA DOT, Security, OSHA, & EPA Consultant
MLD Safety Associates, LLCP.O. Box 93
Poplar Bluff, MO 63902
(573) 785-5111
Fax: (573) 785-5112
Email: MLDSafety@hotmail.com