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<CompanyName>

Powered Industrial Truck (Forklift) Safety Program

Version <Version>

Updated: <Date>

Contents

1.	Program Purpose	3

2.	Responsibilities	3

3.	Definitions	3

4.	Certification Training	4

5.	Refresher Training	5

6.	Certification	5

7.	Rules and Safe Operating Procedures	6

8.	Recordkeeping	8

Appendix I: List of Authorized Personnel	9

Appendix II: Pre-shift Inspection Checklist	10

Employee Acknowledgement	11

Program Purpose

The purpose of this program is to protect the health and safety of Powered Industrial Truck (PIT) operators and pedestrians at <CompanyName>. PITs include forklifts, platform lift trucks, motorized hand trucks, and other specialized industrial trucks powered by electric or internal combustion engines. The Occupational Safety and Health Administration (OSHA) and National Fire Protection Agency (NFPA) have established rules and guidelines for the protection of workers and facilities relating to PITs in 29 CFR 1910.178 Powered Industrial Trucks; and NFPA 505 Fire Safety Standard for Powered Industrial Trucks. This program intends to address the issues of employee training, authorization, safety requirements, fire protection, maintenance, and general operation of PIT.

This program serves to:

Assure the safe operation of PITs

Assure that all employees understand and comply with safety standards related to PITs

Assign responsibilities to personnel to assure successful implementation

Responsibilities

<JobPosition1> is responsible for implementing the PIT Safety program.

<JobPosition2> is responsible for enforcing the program and ensuring compliance within departments.

<JobPosition3> is responsible for monitoring compliance to this procedure and will conduct its annual review. Also responsible for ensuring operators receive certification training when they are first allowed to operate and at least every three years afterwards.

Certified Operators (those listed in Appendix I) are only allowed to operate the PIT model they have been certified with, in addition to adhering to established safety procedures.

Pedestrians (all other employees not operating a PIT) are responsible for keeping at least four feet from a moving PIT and 15 feet from elevated loads.

Definitions

Competent Trainer – an employee who has successfully completed a Train–the–Trainer, or equivalent type of training program, and is familiar with the type of PITs in their company. A contractor or equipment vendor who has experience training PIT safety and operation, and is familiar with the equipment is also permitted to be a Competent Trainer.

Competent Evaluator (Hands-on) – an employee in the department who is experienced and competent with the PIT. An employee must be familiar with the equipment and its safe operation. In order to be considered competent, in regards to conducting the evaluation portion of the PIT training, an employee must have successfully completed the classroom portion of PIT training. This employee could be, but is not limited to, a certified operator, supervisor/manager, or safety officer.

Certified Operator – certification of a PIT operator is a three-step process consisting of classroom instruction and evaluation, hands-on PIT familiarization, and hands-on operation and evaluation. Once the employee has successfully completed all three steps, they are considered to be a certified operator.

Authorized Repair Person – someone with training and experience on the brands/models being serviced. There are specific safety considerations that are unique to forklift trucks, thus the training must be specific to the brands/models being serviced.

Certification Training

Only a competent trainer that is familiar with the company’s equipment, how the equipment will be used, the layout of the facility, and its environmental conditions, can certify employees. <JobPosition4> will be responsible for certifying employees, both initially and every three years.

Initial training shall consist of formal instruction to include in-person lecture, web-based training, videos, and/or written training. The training elements must include, when applicable:

Specific operating instructions, warnings, limitations, and precautions specific to the type of powered industrial truck to be utilized by the operator

Differences between the powered industrial truck and a vehicle

Equipment controls and instrumentation, including their location and proper operation

Operating the motor/engine

Steering and maneuverability

Visibility, including limitations when loading/unloading

Fork use and attachment adaptation, operation, and limitations (when applicable)

Vehicle capacity and stability limitations

Completing equipment pre-use inspections

Refueling and/or battery changing/charging

Specific workplace operation of the powered industrial truck, including the following:

Handling loads specific to the operation of the powered industrial truck

Operating in narrow aisles and/or around pedestrian traffic

Operating on sloped surfaces

Ventilation while using powered industrial trucks

Use restrictions based on hazardous locations

Practical evaluation includes a demonstration performed by the competent evaluator and operational exercises performed by the trainee. Practical evaluation shall be conducted utilizing PIT(s) that the operator will utilize in their job tasks and simulating typical work. Practical application should consist of the following:

Performing pre-use inspections

Safe operation of the industrial truck

Handling a load

Maneuverability

A competent evaluator must supervise trainees at all times while being allowed to operate. Evaluators must assure:

Trainees never operate without supervision

Trainees only operate after:

They have successfully completed the classroom instruction and evaluation process

They have completed the hands-on PIT familiarization, e.g., controls locations

A safe space, clear of pedestrians, has been identified

Practical evaluations are documented

Employees are only certified after they show a clear demonstration of necessary skills and abilities

Refresher Training

Refresher training may be necessary due to certain circumstances, such as:

The operator is observed operating in an unsafe manner

The operator is involved in an accident or near miss incident

The operator receives an evaluation revealing unsafe practices

There is a change in workplace conditions affecting operation of an industrial truck

There is a change in the type of industrial truck being utilized in the workplace

There is a change in forklift attachments being used

Certification

Certification must be documented and include the following:

Operator name

Date of training

Date of evaluation

Equipment evaluated on

Trainer name

Rules and Safe Operating Procedures

Daily inspection: Prior to the use of a PIT, an operator must complete an operational inspection to assure his/her safety while operating. Pre-use applies to each shift when multiple shifts are in place utilizing the equipment. The daily inspection checklist must include the following general items:

Identification of the PIT

Name of person conducting the inspection

Date/time of inspection

Inspection of equipment condition when not powered on

Inspection of equipment operation and controls when powered on

Appendix II provides a pre-shift inspection checklist. If at any time a deficiency is noted during the pre-shift inspection, the powered industrial truck must be removed from service and repaired by an authorized repairperson prior to being placed back into operation. Inspection documents shall be maintained by the department supervisor, or their designee, for recordkeeping purposes.

Operation

Operators must wear seat belts at all times.

Operators must sound the horn and use extreme caution when meeting pedestrians, making turns, and cornering.

Passengers are not allowed to ride on an industrial truck, unless the truck has an extra seat that allows the passenger to buckle-up while riding.

Arms or legs may not be placed between the uprights of the mast or outside the running lines of the truck.

Persons are not allowed to stand or pass under any elevated portion of a truck.

Travel-ways must be maintained, free from obstructions. Aisles must be marked, and wide enough for vehicle operation.

Sufficient headroom must be maintained under overhead installations such as lights, pipes, sprinkler systems, etc.

An overhead guard must be used as protection against falling objects.

Lift capacity must be marked on all powered industrial trucks. Operators must assure the load does not exceed rated weight limits.

When a powered industrial truck is left unattended (more than 25 feet away or out of sight), load-engaging means must be fully lowered, controls neutralized, power shut off, and brakes set. Wheels must be blocked if the truck is parked on an incline.

All modifications must be approved by the manufacturer, and new rated load capacities determined and posted on the truck. Written approval is required prior to modifying equipment.

Operators must report all accidents, regardless of fault and severity, to their supervisor.

Loading

Only handle loads within the rated capacity of the truck.

Loads should be safely arranged, stable, and centered – always use caution when handling loads.

Adjust long or high (including multiple-tiered) loads that may affect capacity.

Trucks equipped with attachments must be operated as partially loaded trucks, even when not handling a load.

A load-engaging means must be placed under the load as far as possible. The mast must be carefully tilted backward to stabilize the load.

Use extreme care when tilting the load forward or backward, particularly when high tiering. Tilting forward with load-engaging means elevated is prohibited except to pick up a load. An elevated load may not be tilted forward except when the load is in a deposit position. When stacking or tiering, use only enough backward tilt to stabilize the load.

Traveling

The driver must slow down and sound the horn at cross aisles and other locations where vision is obstructed.

If the load being carried obstructs forward view, the driver must travel with the load trailing.

Loads must be tilted back and carried no more than four inches above the ground.

The driver must look in the direction of and keep a clear view of the path of travel.

Grades must be ascended and descended slowly. Position the load uphill relative to the operator when ascending or descending grades.

Stunt driving and horseplay are prohibited.

While negotiating turns, reduce speed and turn the hand steering wheel in a smooth, sweeping motion.

Fueling

Fuel tanks may not be filled while the engine is running. Avoid spillage.

Spillage of oil or fuel must be absorbed using Oil-Dri or vermiculite, the affected area carefully washed, and the fuel tank cap replaced before restarting engine.

Any spill cleanup debris must be disposed of properly.

No truck can be operated with a leak in the fuel system.

Open flames are not to be used when checking electrolyte levels in storage batteries, or gasoline levels in fuel tanks.

Changing and Charging Batteries

Battery charging installations must be located in areas designated for that purpose.

Facilities must provide for flushing and neutralizing spilled electrolyte, fire protection, protection of charging apparatus from damage by trucks, and adequate ventilation for dispersal of fumes from gassing batteries.

Precautions must be taken to prevent open flames, sparks, or electric arcs in battery charging areas.

Employees charging and changing batteries shall be authorized to do the work; trained in the proper handling; and required to wear protective clothing, including face shields, long sleeves, rubber boots, aprons, and gloves.

Recordkeeping

Documentation of the following shall be kept for a minimum of two years:

Training certifications for all PIT operators, including names and dates of training, and the equipment they are certified to operate

Pre-use inspection checklists

Maintenance records for each powered industrial truck

Accident reports involving powered industrial trucks

Log of program reviews and revisions

Appendix I: List of Authorized Personnel

Employee Name	Position/Department	PIT Brand and Model
<Operator1>	<Position1>	<Equipment1>
<Operator2>	<Position2>	<Equipment2>
<Operator3>	<Position3>	<Equipment3>
<Operator4>	<Position4>	<Equipment4>
<Operator5>	<Position5>	<Equipment5>
<Operator6>	<Position6>	<Equipment6>
<Operator7>	<Position7>	<Equipment7>
<Operator8>	<Position8>	<Equipment8>
<Operator9>	<Position9>	<Equipment9>
<Operator10>	<Position10>	<Equipment10>

Appendix II: Pre-shift Inspection Checklist

<INSERT YOUR CHECKLIST HERE>

Employee Acknowledgement

I have received information on <CompanyName>’s PIT Safety Program. By signing below, I agree to abide by the procedures in this document and bring to the attention of my supervisor any questions or concerns had.

Employee Name:
Employee Signature:
Date:

icwgroup.com ICW Group is the marketing name for ICW Group Holdings, Inc. For a list of all ICW Group Holdings, Inc. subsidiaries, please visit our website www.icwgroup.com.
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