Operating a forklift is not just a skill that you can pick up overnight. It takes practice and training to become an expert. It is important that the operator of a forklift knows the safety regulations and they should be aware of all the risks associated with operating one, hence OSHA requirements for forklift training are in place.
OSHA requirement for forklift training is contained in the latest 29 CFR 1910.178 - Powered Industrial Trucks standards and in 29 CFR 1926.602 - Material Handling Equipment for construction industry.
To mention, here are the related regulations under above-mentioned OSHA standards:
- The employer has the obligation to ensure that their workers (new hires and current ones) is knowledgeable and capable to operate the forklift equipment prior to commencing work. This can be done by completing the forklift training and the certification process. Please see 1910.178(l)(1)(i) regulation.
- Unexperienced worker can only operate the equipment under the supervision of the trainer; which means he can only operate the forklift during a training course with the guidance of the instructor. Refer to the 1910.178(l)(2)(i)(A) regulation.
- The 1910.178(l)(2)(ii) regulation states that the training course must consist of these three (3) important aspects: classroom training, practical training, and operator performance assessment. To explain these further, please refer below.
- Classroom training – it is the theoretical part of the course; this training consists of lectures, discussion, interactive video and computer presentations, and other modes of teaching necessary for the acquisition of knowledge of the trainees. This part of the training course can be taken online as there are a number of training providers nowadays for such a course. If you’re looking for online training, here’s what we can suggest, get your forklift certificate here.
- Practical training – is perhaps the most important part of the course, if you are going to ask someone. This is when the trainer will do the actual forklift operation and the trainee will perform the hands-on exercises. This is when the trainees must pay attention to acquire the skills needed and to be able to perform the assessment.
- Performance assessment/evaluation – this is the actual certification process. This is composed of a written test and a demonstration test. To further expound on what the trainees are going to do in the assessment, please read below.
- Written Test: This test is designed to measure the applicant's knowledge and understanding of OSHA regulations, safety practices, equipment controls, and operational techniques. The applicant must answer 50 questions in 30 minutes and the passing rate is 80% depending on the standard of the training instructor. There is no cost involved in taking the written as this is part of the training course.
- Demonstration Test: This test evaluates the applicant's ability to perform specific tasks related to their job duties, such as using a forklift, and handling and transporting materials. Applicants are given 1 hour to demonstrate their skills with the equipment they will be using in their work environment. The demonstration test is the most important of the certification process because the instructor will rate the performance and certify the trainee based on the skills exhibited.
- Classroom training – it is the theoretical part of the course; this training consists of lectures, discussion, interactive video and computer presentations, and other modes of teaching necessary for the acquisition of knowledge of the trainees. This part of the training course can be taken online as there are a number of training providers nowadays for such a course. If you’re looking for online training, here’s what we can suggest, get your forklift certificate here.
- OSHA doesn’t specifically state who is the person qualified to conduct the training course. But under 1910.178(l)(2)(iii), it states that the operator performance assessment and training must be conducted by a competent person who has the capacity (knowledge, training and experience) to supply the training and assess the trainees’ operational performance. The company can hire an external trainer or designate an internal instructor to provide the training.
- 1910.178(l)(3) states what should the training program should contain. The program should contain truck-related topics to enable trainees to learn the basics of the equipment; the program should also contain workplace-related topics to familiarize them with the road condition, pedestrian traffic, load maneuvering and manipulation, narrow aisles, and restricted areas, hazardous places, and other dangerous locations.
- Refresher training is a necessity, and under 1910.178(l)(4) there are situations that prompt the trainee/employer to undergo refresher training. In the instances such as when the worker has been observed operating the truck in an unsafe manner if the operator is involved in a near-miss incident or accident if the operator has undergone evaluation but failed it if the operator is designed to drive a different type of forklift, he’s not accustomed to using when the workplace setup changes that could affect the safe operation of the equipment.
- The employer has the responsibility to assess their operators’ performance at least once every three (3) years as stated in the 1910.178(l)(4)(iii). The more frequent, the better.
- In the circumstance when the operators have already received training on a specific topic, and if the topic is appropriate to the type of workplace setup and forklift equipment, those topics can be excluded to avoid duplicate training as per 1910.178(l)(5) regulation.
- To provide the trainees have undergone training and evaluation, the employer shall provide certification. Many people refer to this as a certificate or operator license. But it is a document proving that the holder is properly certified to operate the equipment. The certification bears the name of the trainee, the date of the training and evaluation, and the identity of the instructor who conducted the evaluation, please refer to 1910.178(l)(6).
Ways to Comply with the Requirements
- Understand the Current Compliance Requirements - When it comes to safety training for compliance with OSHA standards there are two types of training that are required: General Industry Training or Construction Training. General Industry Training is required for all employees who work in a general industry job, such as manufacturing, logistics, and logging operation. Construction Training is required for all employees who work in the construction industry, including general contractors and subcontractors. Most employers have their own safety regulations they follow based on their industry. Determine where your company belongs to be able to know what OSHA requirements to comply.
- Train Your Employees on Proper Safety Procedures and Proper Behavior at the workplace - Developing a knowledge base for safety training is an efficient way to make sure that employees are compliant with OSHA forklift training requirements. Training should be conducted on a regular basis, as well as when changes in the workplace occur.
- Monitor Employee Behavior Regularly to Ensure Compliance Continues Throughout Employment Periods - Monitoring employees can help you to ensure that they are complying with company policy and procedures and importantly OSHA requirements as well. Monitoring employees’ behavior on a regular basis can also help you to identify any potential issues before they escalate. This is because the earlier you identify a problem, the easier it will be to resolve it.
- Some of the ways in which OSHA compliance can be achieved are: hiring an OSHA consultant, having a written safety program and other policies in place, training all employees on the health and safety policies, and conducting a workplace risk assessment.
- Know which OSHA Violations Constitute Fines and Penalties - OSHA violations are so common that they are the norm in many industries. It is important for employers to be aware of what constitutes an OSHA violation and what the fines and penalties are for each violation. The fines and penalties for OSHA violations vary on a case-by-case basis but can be as high as $130,000 per offense.
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How to Ensure Your Operators Receive Safe & Effective Fork Lift Operator's Training?
Forklift operators are at risk of serious injury or death if they don't receive the proper training. The following are some safety tips for forklift operator training:
- The best way to know if your employee is receiving effective forklift operator training is to conduct a pre-test. This will help you identify potential gaps and fix them before the employees start operating the forklifts.
- When conducting a pre-test, make sure that you ask all of the questions in the course material, both on paper and orally. This will help you identify any gaps in learning that need to be addressed before they operate the forklifts.
- Ensure your employees are comfortable with all of their safety equipment and understand how to use it properly. Make sure that they are wearing their safety glasses, hard hats, and hearing protection when operating a forklift.
- There are many ways to ensure that your employees are receiving safe and effective forklift operator's training, including: hiring a qualified trainer, conducting an audit, training all new hires on the job, providing refresher courses
Forklift training is a crucial part of any warehouse’s safety policy. Employees who are trained in the use of forklifts are much less likely to be injured on the job. Employers must ensure that each operator receives the proper training.
How to Choose Between In-House & External Training?
The decision between in-house or external training for a forklift operator depends on the needs of the company. External training is usually less expensive, and it is worth it if the company needs to train multiple people quickly and doesn't have enough space for in-house training. The company also needs to consider the fact that there will be an interruption in business operation because the operators will be sent away to the outside training facility to take the training there.
In-house training, on the other hand, is more expensive but provides an opportunity to customize the course according to company needs and standards. It also gives employees a chance to learn from their own colleagues who have experience in similar tasks. In-house forklift training can be done by a member of the organization such as a safety offer, a warehouse supervisor, or a manager who has the knowledge to perform such task on the topic.
Companies should consider their needs, budget, and the availability of resources before deciding which type of training to use. If they need to train forklift operators quickly and are on a tight budget, then they should opt for external training. If they have the resources to invest in internal training, then it's better to do so because it will be more cost-effective in the long run.
The Benefits of Forklift Training: Reaping Advantages from This
Forklift training is a must for anyone who wants to be in the business of operating a forklift. It makes sense to go through the training process because it will help you avoid accidents and save your company from liability.
- There are many benefits that come with receiving forklift training. For example, you will be more confident in your abilities as a forklift operator which can lead to better performance and fewer accidents on the job site.
- Employees who are trained to operate a forklift have more job opportunities, more money, and fewer accidents. Companies are in the continuous process of looking for qualified employees who are certified in this area.
- There will be increased safety awareness and compliance with the company’s safety procedure, forklift operators are among the safest workers out there.
- Forklift training is also an opportunity for you to learn about all of the different types of forklifts and what they are used for. You will be able to choose which type suits your needs best, or which one your company needs most.
- It will teach you how to use the equipment correctly, which will make you safer on the job and around others. You will have the opportunity to learn how to operate different types of trucks, which can help you find a new career if your current one becomes unavailable.
- Employer’s provision of forklift training is in compliance with the OSHA requirements. Employers can avoid fines and penalties by providing this to their operators.
Forklift training is beneficial for both the company and the employee. The company will have increased productivity, fewer accidents, and improved safety measures thanks to their trained employees.
And the employee will have increased job satisfaction, more opportunities for advancement, better pay, more respect from co-workers and supervisors, and a sense of accomplishment at work.
Can You Take the Forklift Training Online to Comply with OSHA Requirements?
The short answer is yes. You can take and complete online training from an online provider. But let me remind you that it only covers the classroom part or the theoretical part of the course. You still have to undergo the hands-on exercises and be evaluated by a competent instructor to receive your certification.
Be aware that many online providers give the option of printing your own certificate upon completion of the training course. But that doesn’t promise you that you are skilled to operate the truck if you only completed the classroom training.
What you can do perhaps is to attend an actual training. You can easily find a training facility that provides such a course near your location. Browse our listing of training schools by clicking the menu below or beside the screen, click your state, and there you can find the one you prefer.
The Dangers of Using a Forklift Without Being Trained
Forklift accidents are on the rise. OSHA statistics show that there were over 17,000 forklift-related injuries in 2023 alone. The majority of these injuries occurred because the person operating the forklift was either not trained or was not following safety procedures.
Some accidents that have occurred due to improper use of a forklift include:
- Property damage caused by turning too quickly with a truckload on the forks, which can cause the load to shift or tip over, leading to injury or death;
- Injuries caused by driving into an object such as a wall or another vehicle;
- Injuries caused by operating the forklift by hitting pedestrian in the workplace.
The dangers of operating a forklift without proper training are well documented. Operating a forklift is much more complicated than it looks and requires knowledge of how to operate it safely and how to handle various types of loads and situations.
Penalties for Not Following OSHA Forklift Certification Requirements
The penalty for non-compliance can be a fine or a penalty. In the United States, employers are required to follow the Occupational Safety and Health Administration (OSHA) regulations. Failure to comply with these forklift training regulations can result in a hefty fine.
OSHA fines can range anywhere from $5,000 to $130,000. The penalty also depends on whether it is a repeat violation, willful or not. These penalties vary as well depending on the severity of the violation and the number of violations. The penalties for not following the regulations can include imprisonment as well.
To avoid fines and penalties, employers are encouraged to supply the training to their forklift operators. The laws say that training must be given at least once every three (3) years, but it is necessary to provide the training in a much more frequent interval to ensure workers are equipped with practical knowledge in the safe operation of the equipment.
As an employer, you are also encouraged to maintain safety training records. The employer can keep a photocopy of the forklift operator certificate to track the dates when each operator previously received training so that employer will enable to determine when each operator has to go to refresher training. The training attendance sheet is also important to keep, and the trainer’s background profile.
Keeping records prevent the employer from receiving a citation from OSHA. In the event of an accident and the OSHA inspector conducting an investigation, the company can show the records to prove that they’ve done their part, thus preventing receiving fines or citations.
To Make a Conclusion
OSHA forklift training requirements for every industry and environment are different. The safety of the workers should be the top priority when it comes to forklift operations. The challenge for every employer to comply has been challenging in the past years, this year in 2023 and in the coming years.
It can be difficult for companies to stay compliant with regulations, but it is important to do so in order to avoid fines and violations.
OSHA compliance is necessary for every company that has employees, regardless of the size. At the end of the day, it is the company and the employees will benefit from complying with the OSHA forklift training requirements.
