Power Industrial Lift Truck

Purpose and Objective 

To establish requirements for the use and maintenance of powered industrial trucks. 

Definitions 

Approved powered industrial lift truck – An industrial lift truck that is listed or approved for fire safety purposes for the intended use by a nationally recognized testing laboratory, using nationally recognized testing standards. 

Attachment: A device, other than conventional forks or load backrest extension, mounted permanently or removable on the elevating mechanism of the truck for handling the load. 

Cantilever truck: A self-loading, counterbalanced or non-counterbalanced truck equipped with cantilever load engaging means. 

Carriage: The support structure for forks or attachment, generally roller mounted, traveling vertically within the mast of a cantilever truck. 

Counterweight:  The weight that is a part of the basic structure of a truck that is used to offset the weight of a load and to maximize the resistance of the vehicle to tipping over. 

Forks: Horizontal tine-like projections, normally suspended from the carriage, for engaging or supporting the load. 

Forklift: A high-lift, self-loading industrial truck equipped with load carriage and forks for transporting and tiering loads. 

Grade: The slope of a surface, which is usually measured as the number of feet of rise or fall over a 100-foot horizontal distance (the slope is expressed as a percent). 

Lateral Stability: A truck’s resistance to overturning sideways. 

Load Engaging: A load-handling device attached to a powered industrial truck for the purpose of handling a load. 

Longitudinal Stability: The truck’s resistance to overturning forward or rearward. 

Mast: A support member providing the guide ways permitting vertical movement of the carriage.  It is usually constructed in the form of channels or similar sections providing the supporting pathway for the carriage rollers. 

Self-Loading: The capability of a truck to pick up, carry, set down and stack or tier its load without the aid of external means. 

Tiering: A process of placing a load on or above another load. 

Responsibilities 

Management  

• Implement and administer the Powered Industrial Truck program. 
• Review the Powered Industrial Truck program annually for compliance and effectiveness. 
• Verify that all employees who operate or work near powered industrial trucks are trained. 
• Maintain written records of operator training on each model of a powered industrial truck and the name of the trainer. 
• Annually review and update the program, as necessary. 
• Provide orientation and initial training. 
• Provide the general safety training requirements for the program. 

Supervisors 

• Coordinate employee training and refresher training. 
• Ensure that only trained and qualified individuals use powered industrial trucks. 
• Verify employee compliance with the principles and practices outlined in the program. 
• Provide specific operational training for each powered industrial truck in their department. 
• Observe the operation of powered industrial trucks in your department and correct unsafe practices. 
• Removing license of operator who is involved in an incident until refresher training is completed. 
• Remove powered industrial trucks from service if they do not pass inspection. 
• Coordinate repairing powered industrial trucks. 

Operators 

• Complete the training program. 
• Complete an inspection prior to operating any powered industrial truck. 
• Attend refresher training every three years. 
• Observe the operation of powered industrial trucks in your department and report unsafe practices to your supervisor. 

Hazard Identification 

The company will implement an ongoing process to identify and assess hazards at all levels of the organization. Being able to recognize hazards is an extremely important element of a proactive approach so that hazards can be mitigated prior to work taking place. A failure to identify hazards is often cited as a root cause of workplace accident and injuries. An effective hazard identification program is a critical element to continuously improve safety performance. 

Collect Information 

The first step in hazard identification is to collect existing information about workplace hazards. This collection of information happens in a variety of ways including collecting SDS’s (safety data sheets), audit and inspection reports, previous injury logs, and input from workers. It is also important to gather information from the company’s written safety and health programs, OSHA or NIOSH websites, and trade associations. 

Inspect the Workplace 

The next step in hazard identification is to inspect the workplace for hazards that have been introduced over time or as the workflow or work processes change. This inspection will be conducted in the form of an audit, which should be conducted regularly and should involve employees. Setting aside time to inspect the workplace on a regular basis identifies problems so they can be addressed before an incident occurs. It is also a good time to confirm that hazardous conditions that were previously recognized have been corrected. Use checklists to highlight items that should be part of the inspection such as: 

• Chemical agents 
• Biological agents 
• Physical agents 
• General housekeeping 
• Equipment operation 
• Equipment maintenance 
• Fire protection 
• Fall protection 
• Work process flow 
• Work practices 
• Emergency procedures 

Not only is hazard identification a good process for existing equipment, but it should also be utilized prior to changing workflow or introducing new equipment. Even conflicting work schedules should be evaluated as a potential hazard that can be mitigated. Hazard assessments will be considered whenever the following take place: 

• Facility modifications 
• New chemicals are introduced 
• New equipment is installed 
• Work practices change 
• Equipment maintenance changes 
• New safety and health information is received 

Hazards Associated with Emergency or Non-Routine Situations

Although all preventative actions are to be taken in order to reduce the likelihood of emergencies, it is important to plan for the unexpected and be prepared in case an emergency does occur in the workplace. This should involve identifying possible emergency scenarios including employee health situations, fires, or non-routine shut down of equipment and procedures to respond safely should be developed.. 

Some situations to consider may include: 

• Fires and explosions 
• Chemical releases 
• Hazardous material spills 
• Startups or unplanned shutdowns 
• Non-routine tasks 
• Natural disasters 
• Weather emergencies 
• Medical emergencies 

Conducting emergency planning exercises such as drills or “tabletop” exercises should be done on a regular basis by each department. 

Determine and Prioritize Hazard Controls 

After hazards have been identified, the information collected must be used to determine which controls to implement and to set priorities for the timely implementation of them. This prioritization must be conducted by evaluating each hazard and considering the possible severity of the outcomes, likelihood of the event, and number of workers exposed. 

Once the severity is determined, the greatest risks should be addressed first. However, it is important not to stop at the greatest risk but to continue mitigating hazards so that continuous improvement can be achieved. For those controls that need a more extensive timeline to sustainably control (equipment modifications, engineering designs), control measures must be implemented in the interim to protect workers. 

Hazard Prevention and Control 

Hazard prevention and control must be implemented when hazards are recognized in the workplace. Hazard prevention is a process and often may involve several steps, including: 

• Identifying potential options for controlling hazards 
• Using a hazard control plan to guide selection and implementation of controls 
• Developing plans to protect workers during emergencies 
• Evaluating the effectiveness once implemented to determine if additional controls are necessary 

Identifying control measures for a recognized hazard can involve a variety of methods such as using manufacturer’s suggestions, training, substituting one chemical for another, getting input from workers, etc. Hazard control options will fall into one of the following categories: elimination, substitution, engineering, administrative, or PPE. 

Elimination 

Elimination is the most effective means of hazard control and involves physically removing the hazard such as moving equipment to a different location so that work at heights is not required. 

Substitution 

The next most effective means of control is substitution. This involves substituting one method or substance for another thereby reducing the hazard. An example may include finding alternative paints and substituting a paint that is less toxic than a hazardous paint. 

Engineering 

Engineering controls are the third most effective means of control. Although they do not eliminate the hazard, these controls isolate people from hazards. For example, building a working platform to access equipment rather than wearing fall protection would be an appropriate engineering control.

Administrative 

Administrative controls only work when employees behave in a way which avoids hazards or reduces their interaction with them. For example, employee training may state that tanks are only to be changed when empty in order to avoid moving hazardous chemicals. Administrative controls are common on work as well as on an employee’s adherence. 

Personal Protective Equipment 

Personal protective equipment (PPE) is the least effective means of control and should only be used when other methods are not available. It is the least effective because there is a high potential for damage to PPE and it must be maintained and worn properly at all times to be effective. An example of proper PPE selection is to provide gloves with a high cut resistance rating when working with razor knives. 

Selecting the best controls should focus on using the hierarchy above and eliminating hazards first where possible, then substitution, engineering, administrative controls, and continuing to personal protective equipment (PPE). PPE is the least effective control and should only be used as a last resort. If implementing the proper hazard control is a timely process, interim controls must be implemented until the hazard is adequately controlled. In many cases, a combination of controls may be necessary to fully protect workers. 

Incident Investigations 

The purpose of investigations is to identify the root cause(s) and prevent future occurrence. This will be done by developing a clear plan for investigation which covers who will be involved, evidence collection, interviewing, root cause identification, corrective actions, and reporting. 

In order for investigation teams to be effective they must involve both management and employees. All members of the team need to remain open-minded throughout the process and treat the investigation as a learning event. As root causes are determined, they will help to pinpoint what corrective actions will be the most effective in preventing similar incidents from occurring. Corrective actions must be conducted with a sense of urgency and be sustainable to prevent further incidents. 

Coordination on Multiemployer Worksites 

There are cases in which employees will be required to coordinate with employees of other companies. These outside employees may be contractors, vendors, or specialized service workers. When this occurs, coordination between company employees and outside employees is critical for safe work. This section describes how to communicate and coordinate the necessary safety information between groups to prevents accidents and injuries. 

The efforts to coordinate in a multiemployer work environment must be led by management. Before any work is to start onsite, the host employer and guest employer must establish their safety and health responsibilities and obligations, as well as procedures for coordinating and communicating this information. This information may include task coordination, hazard controls in place, hazardous work to be aware of, PPE requirements, and procedures that are implemented for the safe flow of work. 

Employees are an important component of this coordination. They must be able to effectively recognize and control hazards and communicate them to their peers both inside and outside the company. Because of this, employees must always have the opportunity to participate in the program, be provided with health and safety information, and be encouraged to raise concerns when hazards are recognized. 

Multiemployer worksites can be complicated to manage due to the number of individuals and activities. Additional measures in order to ensure hazard identification and control need to be in place. The host employer is responsible for performing a worksite hazard assessment before work is assigned and must share the results with the other employers onsite. Any contractors, subcontractors, vendors, etc., must also perform a pre-job hazard assessment and share relevant information with the host employer. Both parties are required to share information and coordinate hazardous activities and controls. 

When injuries, illnesses or incidents occur onsite, the host employer and guest employer must establish procedures for reporting injuries and identifying responsibilities for recording and investigating incidents. In the case of incident investigations, both groups must work together to accomplish an effective investigation, report, and corrective actions that will prevent similar occurrences in the future. 

Occasionally, the safety and health program as well as coordination efforts must be evaluated. Evaluation is intended to identify improvement opportunities. Both employees and management should participate in evaluation to ensure it is effective. This evaluation may include: 

• Exchanging data and metrics on the program’s effectiveness for controlling hazards 
• Discussing the effectiveness of communication and coordination and identifying opportunities for improvement 
• Sharing the results of periodic evaluations and corrective actions with all involved 

Training Requirements 

Quality training is a key element of any health and safety program. Workers who understand workplace hazards and how to mitigate them are safer and more productive. Employees of this company come from a variety of backgrounds and experience levels. It is extremely important that a consistent training program is in place to ensure that knowledge and skills are developed and maintained. 

The objective of education and training is to provide employees, managers and supervisors with: 

• Knowledge and skills needed to work safely and mitigate hazards 
• Awareness and understanding of hazards including identification, reporting, and controlling them 
• Specialized training involving employee’s work tasks 

Meeting this objective requires several different approaches to training including awareness training, job specific training, and hazard identification and control. Training must take place both initially at the beginning of employment and periodically thereafter. 

Awareness Training 

Awareness training is training that is intended to provide employees with a basic understanding of a program’s structure and procedures. This general training allows everyone to participate in recognition and control. When awareness training is deemed necessary, it should be made available to relevant employees, supervisors, managers, and contractors on subjects including: 

• Safety and health program goals 
• Safety program functions 
• How to respond in an emergency 
• Employer responsibilities in the program 
• Worker’s rights under the OSHA Act 

Awareness training will be provided in a language that is understood by the workforce. In this training, it must be stated that all workers have the right to report accidents, injuries, and hazard observations without fear of retaliation. 

Job-Specific Training 

When employees have specific job tasks that require additional safety measures, job-specific training will be provided. This training should focus on instructing workers in those roles on how to safely carry out their responsibilities. Training will provide an environment where workers are able to ask questions and seek feedback during and after the training. Depending on the type of training provided, a demonstration of skills may be required in order to pass the training to ensure that the skills needed to conduct work safely are adequately in place. 

Hazard Identification and Control Training 

The step of actively involving employees in hazard identification and control is extremely important in an effective safety and health program. Often, employees have firsthand knowledge of hazards they may encounter on a daily basis and it is important to empower them to recognize and mitigate those hazards for their own safety and for the safety of those around them. In this way, a proactive approach is adopted to eliminate hazards before an incident occurs. 

In order to eliminate hazards, managers and employees alike will be trained on hazard identification and analysis. In hazard analysis, employees will be instructed on how to estimate the severity of a hazard and prioritize controls. This training will also have workers demonstrate that they can recognize hazards they may encounter and that they understand the controls that mitigate them. 

In cases where specific hazards exist, specialized training will be provided to affected employees for subjects such as lockout/tagout, confined space, hazard communication, and bloodborne pathogens, as examples. 

In order to ensure training is effective, periodic evaluations will take place to verify that it has been implemented as intended. Employee knowledge will be verified through conversations and workplace actions. When opportunities for improvement are identified, adjustments will be made and the progress of the program will be monitored. 

Recordkeeping 

Records will be maintained for: 

• Training 
• Injuries 
• Incident investigations 

An annual program review and document updates must be maintained indefinitely.