Whether you’re an operator, warehouse manager or part of the maintenance crew, forklift safety is a team effort. And while one day a year is dedicated to the cause, we know it takes a daily commitment to really make a difference.

Why National Forklift Safety Day Matters

This day is a reminder that safe forklift operation requires constant attention, education and action. According to OSHA, forklifts are involved in tens of thousands of workplace accidents each year—many of which are preventable with the right training, equipment and policies.

It’s also a great opportunity to step back and ask:

• Are we doing everything we can to protect our team?
• Is our equipment in good shape?
• Do our operators feel confident and prepared?

As a material handling dealer and warehouse solutions provider, we see firsthand how safety lapses—large or small—can result in injury, damage and costly downtime. That’s why we’re committed to helping our customers maintain the safest working environment possible.

7 Common Forklift Accidents—And How to Prevent Them

We’ve teamed up with our partners at Hyster^® to provide to highlight seven of the most common forklift accidents, and practical ways to help reduce the risk:

1. Falling Loads

Loads that aren’t properly secured or balanced can fall and cause injury or product damage. To help prevent this:

• Use wide, well-marked travel lanes
• Avoid sharp turns or sudden mast movements
• Center the load and spread forks as wide as the load allows
• Inspect forks for damage or bending
• Use a load backrest, and always travel with the load uphill on inclines
• Consider using operator assistance systems for added control

2. Physical Injuries

In a warehouse, forklifts, operators and pedestrians must share space safely. Key tips include:

• Maintain at least three feet of clearance between pedestrians and stopped forklifts (more if the truck is moving)
• Use barriers or marked walkways to separate foot traffic
• Keep arms and legs inside the cab while driving
• Always face the forklift and use three points of contact when entering or exiting
• Prohibit mobile phone or walkie-talkie use while operating

3. Technical Malfunctions

Equipment failures can often be avoided with routine care. Be sure to:

• Conduct pre-shift inspections before every use
• Follow the manufacturer’s maintenance schedule
• Use only parts approved by the original equipment manufacturer (OEM)
• Never modify a forklift in ways that affect its capacity, stability, or safety without written OEM approval

4. Collisions

Forklift impacts with people, equipment, or infrastructure can be costly and dangerous. To minimize this risk:

• Utilize Hyster Reaction with the innovative Hyster® Pedestrian Awareness Camera
  feature
• Separate forklifts and pedestrians where possible
• Use high-visibility vests, pedestrian lights, and floor markings
• Add protective barriers like bollards and safety rails in high-risk areas
• Establish speed limits or install speed-limiting features
• Design your warehouse layout with safety in mind

5. Tipping Over

Forklift tipovers can lead to serious injury. Prevent them by:

• Never exceeding the rated load capacity
• Keeping loads low and stable while traveling
• Avoiding uneven surfaces, steep slopes, or sharp turns
• Making use of speed limiters or operator assistance systems
• Ensuring the capacity plate reflects any attachments in use

6. Falls from Height

Operators should never be lifted on a forklift unless it’s with purpose-built equipment. Instead:

• Use ladders, scaffolding, or aerial work platforms where appropriate
• Monitor for proper use of fall protection gear and lift attachments designed for personnel

7. Emissions Hazards

Gas-powered forklifts used indoors can create dangerous fumes. To stay safe:

• Ensure proper ventilation in enclosed spaces
• Avoid unnecessary idling
• Shut off the engine if operating inside confined areas like trailers
• Use carbon monoxide monitors
• Where ventilation is limited, switch to electric forklifts
• Charge lead-acid batteries only in designated, well-ventilated areas

Our Commitment to Your Team’s Safety

At the end of the day, safety is about protecting your team—and we’re here to support you in doing just that. Whether you need help scheduling operator training, updating your safety procedures, or checking your fleet’s condition, we’ve got your back.

Let’s work together to reduce accidents, protect your people, and keep operations running smoothly—on National Forklift Safety Day and every day.

Need help with forklift or your warehouse’s safety? Contact LiftOne today for expert guidance and support.

The post Prioritizing Safety Every Day: Why National Forklift Safety Day Matters appeared first on LiftOne.

Safety is critical in the materials handling industry. Industry statistics estimate that approximately one out of every 10 forklifts is involved in an accident in the United States each year. However, OSHA also estimates that approximately 70 percent of these accidents could be avoided through better adherence to standardized training and safety procedures. That significant reduction in accidents can, in turn, help decrease occupational injuries and associated costs. But how do you know if your operation is doing enough to support lift truck operating best practices?

The truth is, there’s no single, silver bullet – forklift safety requires a comprehensive, multi-faceted approach, including training, real-time support and monitoring, and reactive evaluation after-the-fact.

In addition, you need to partner with a material handling supplier that can help support your lift truck operating best practices. Here are three layers of forklift safety practices that LiftOne can help support so you can build a comprehensive forklift safety strategy for your operations.

1. Forklift training: build a strong foundation.
2. Telemetry: monitor operator performance in real time with a telemetry tool like Hyster Tracker and Yale Vision
3. Enhanced stability system: help reinforce best practices with forklift technologies like operator assist systems (OAS) with Hyster Reaction and Yale Reliant, and dynamic stability system.

Contact LiftOne for More Information

LiftOne is your source for the warehouse equipment and aftermarket solutions you need to get the job done safely and efficiently. Contact us today for more information on how we can help you operate a safe and effective warehouse.

The post Making sense of the “Safety Triangle” – Three layers of forklift safety best practices appeared first on LiftOne.

While many of the safety concerns presented in a warehouse environment involve the use of forklifts or other heavy machinery, there are also a number of safety issues associated with the way in which materials are stored. Whether stacked incorrectly, in a less than ideal location, or without regard to OSHA guidelines, there are a number of factors that can compromise the safety of your warehouse environment.

Jump to Sections:

• Potential Stacking Hazards & Solutions
• Guidance From OSHA
• Pallet-Specific Safety

As one of the leading suppliers of storage rack systems and shelving in the industry, LiftOne has a depth of knowledge and experience when it comes to pallet racking and warehouse safety. Below you’ll find a variety of tips and best practices for safe storage and pallet stacking in and around the warehouse.

Potential Warehouse Stacking Hazards & Solutions

When materials are stacked too high or placed in unstable configurations, removing pallets or items from the stack, or even accidentally bumping it, can result in an unpredictable and potentially dangerous tumble. The warehouse stacking methods below can be used to ensure stability and reduce the risk of falling objects in your warehouse:

• Irregular Stacking – For improved stability, add sheets of plywood between each layer of irregularly shaped items.
• Brick Stacking – Turn each level of a stack 90 degrees to increase stability.
• Block Stacking – Stack square items in a cube and make sure to secure them with wire or plastic shrink wrap.
• Pinwheel Stacking – Turn each quadrant of items 90 degrees. This helps to “lock” everything in place.

Guidance From OSHA

Thanks to OSHA guidelines, warehouse managers everywhere have an accessible and detailed manual to help increase warehouse safety and improve safe storage in very concrete and deliverable ways. A few of the key elements that comprise OSHA safe stacking guidelines include the following material handling safety precautions:

1. Stack loads as straight and evenly a possible.
2. Place heavier loads on lower shelves.
3. Keep storage areas free from accumulation of materials that could lead to tripping, fire, explosion, or pest infestations.
4. Ensure that personnel use proper lifting techniques.
5. Store bags, containers, bundles, etc. in tiers that are stacked, blocked, interlocked, and limited in height. This helps keep materials stable and secure, while preventing them from sliding or collapsing.
6. Maintain appropriately marked and sufficiently safe clearances for aisles and at loading docks or passageways where mechanical handling equipment is used.

Pallet-Specific Safety

With pallets an integral part of warehouses everywhere, staying on top of pallet-specific safety measures and best pallet racking practices is key to continued warehouse safety. A general guideline to pallet safety includes remembering to systematically inspect pallet conditions, specifically looking for damaged stringers, broken pieces, or protruding nails. Pallets that show signs of damage or wear should be removed from use. You’ll also want to remember not to exceed load capacities, as well as ensure the size of your pallets is compatible with the safety standards of your material handling equipment.

For more tips on safe storage or information about how to improve warehouse safety, get in contact with the experts at LiftOne today.

The post Safe Storage and Stacking in the Warehouse appeared first on LiftOne.

 

Download Printable Poster

Your forklift operators are an essential part of your business, and their job comes with some risks. Without the right safety practices, your workers may suffer accidents that lead to expensive repairs and workers' compensation claims. Proper forklift safety is key to running an efficient and safe operation.

As a warehouse or distribution leader, your job is to know how to improve forklift safety for the benefit of all your workers. We've compiled a list of the 15 most important safety tips for operating forklifts. Use them to create a safer workplace where your forklift operators can feel confident around their equipment.

For your convenience, you can also download our printable version of these safety tips to share around your facility.

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15 of the Top Forklift Safety Tips

Following forklift safety best practices helps maintain operational efficiency and keeps your team safe. Consider the following forklift safety tips for the workplace to foster a healthier work environment:

1. Receive Proper Training

The Occupational Safety and Health Administration (OSHA) requires your forklift operators to receive proper training via their employer to legally and safely operate a forklift. Hold or attend operator training classes to certify operators as soon as possible after they are hired. You can trust certified forklift operators to get their work done while keeping themselves, their associates and your company's product safe. Learn more about LiftOne's training programs.

2. Inspect Forklifts Each Shift

Forklift inspections should happen at the start of each shift. Using the included operator’s manual, test controls including lights, breaks, horns and steering wheels should be conducted before each shift. Look over the entire forklift for signs of damage that could signal the need for repairs. Check brake, fuel, engine, hydraulic and coolant levels. Inspect the floor and engine bay for leaks. Make sure the forks are in good condition without any signs of damage or wear. Only then can you deem a forklift safe for work.

3. Wear the Proper Attire When Operating Forklifts

You must be sure that every forklift operator is wearing the appropriate clothing and personal protective equipment (PPE) for the job. Long, loose garments or clothes with tassels or strings can get caught in the mechanics of the forklift, potentially leading to injury. If your warehouse has a uniform, be sure every employee is following it. Instruct each of your forklift operators to follow any dress code rules as these are in place for their safety.

4. Understand the Forklift Classes

There are seven classifications of forklifts, each with unique characteristics. Differences can include turning radius, capacity, power source and many other factors. An operator should only get into the operator's seat if they have been trained appropriately.

5. Review Traffic Patterns

Warehouses can be busy places with people and forklifts always traveling in different directions. Take measures to increase forklift traffic safety by applying bright, visible floor markings to the ground of your warehouse. These markings can provide specific areas for forklift and foot traffic. They can also guide forklifts in safe directions when the flow of traffic goes two ways.

6. Use Signals to Alert Others in the Area

In a busy facility, sounds can blend together. Workers may move their forklift around a corner or up or down an incline without knowing what is beyond their eyesight or earshot. People walking may also be unaware of the forklift action happening around the corner. Have operators use their horn at intersections or blind spots. If horns are not effective, consider alternatives, like blue travel lights or red zone curtains to provide a visual tool to recognize oncoming traffic.

7. Move at Appropriate Speeds

Your forklift operators can avoid countless accidents by moving at safer speeds. Chances of accidents are higher if your forklift operators are ripping around turns or moving freight at a rapid rate. Make sure your forklift operators stay below the maximum speed and put safety before quickness. Additional safety tools, like telemetry, can help assist operators in maintaining safe speeds.

8. Ensure Forklift Stability

Every forklift has a maximum load rating. Exceeding this load limit can impact the forklift's stability. Picking up packages in a haphazard or uneven way can also reduce the forward stability of a forklift. Make sure your forklift operators understand how to keep their forklifts stable as they manipulate loads through your facility.

9. Maintain Visibility in the Direction of Travel

Forklift operators should make their operating decisions with full awareness of what is going on around them. For this to be possible, each operator must maintain visibility in the direction of travel. This OSHA requirement can protect your operators from accidents, and ensure your pedestrians are able to flow safely through your facility.

10. Avoid Using Forklifts to Transport People

Under no circumstances should a forklift operator transport another person on the forklift or the forks themselves. The only acceptable time for two people to be on a forklift is if two seats are present on the equipment. If personnel must be raised in the air, an acceptable personnel basket should be used, with the operator only raising and lowering the basket.

11. Stay Clear of Hazardous Areas

Forklift safety extends beyond the forklift operators themselves and includes employees on the ground as well. Your workers should never walk under lifted loads or in the blind spots of a forklift. Likewise, workers should also avoid walking in front of forklifts that are on the move to their next destination. Encourage pedestrians to familiarize themselves with the limited views and operating characteristics of the forklifts used in your facility.

12. Make Sure Each Load Is Secure

Your forklift operators should engage the entirety of their forks beneath every load. An object that is not completely on the forks, with the forks spread wide, is at risk of falling off and injuring someone. If loads are unstable, consider securements like straps or plastic wrap to ensure stability.

13. Maintain a Safe Operating Distance from Other Forklift Operators

Each forklift operator should do their work at a safe distance from other operators. Operators traveling should maintain a distance of three truck lengths while following other forklifts. When lifting the forks, consider a “drop zone” to accommodate for potential accident scenarios. This can help reduce the number of collisions in your warehouse and aid in forklift traffic safety.

14. Park Each Forklift at the End of Shifts

Forklift operators must park their forklifts in designated locations at the end of their shifts. Not only can this rule keep forklifts organized and make them easier to inspect, it will also help clear the travel lanes in your warehouse for other affected personnel or emergency scenarios.

15. Use Safe Practices When Refueling or Recharging Forklifts

Safety should be the number one consideration when preparing a forklift’s power for another shift. If refueling, park the forklift in a well-ventilated space and wear proper PPE before exchanging a tank. If charging a forklift battery, be sure to use the proper PPE to check water levels, keep the battery compartments open to dissipate heat, and keep the forklift parked in a safe configuration.

Contact LiftOne for More Information

Warehouse safety starts with you and your employees, but it also depends on using the right material handling equipment. LiftOne is your source for the warehouse equipment and aftermarket solutions you need to get the job done safely and efficiently.

Contact us today for more information on how we can help you operate a safe and effective warehouse.

 

 

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