Policy

PROGRAM ADMINISTRATION – RESPONSIBILITIES

Department 

Each operating department is responsible for the proper training and compliance with the criteria set forth in this program.  

Sr. Benefits and Safety Specialist

• Overall program coordinator.
• Provide employees with video training and information on powered industrial vehicles in the workplace.
• Maintain a copy of all training records in Workday.
• Audit divisions for compliance with this policy.

Departmental Managers

• Responsible for the implementation and enforcement of the Powered Industrial Vehicle policy.
• Responsible for the scheduling of preventative maintenance on all forklifts and powered pallet trucks in their division.
• Provide employees with hands-on training and information on powered industrial vehicles in the workplace.
• Provide the Sr. Benefits and Safety Specialist with an updated listing of trained personnel and dates of training.
• Responsible for ensuring that only trained and certified operators are allowed to operate powered industrial vehicles.

Employees

• Responsible for conducting a pre-use inspection on the powered industrial vehicle at the start of their shift.
• Responsible for reporting any defects of the powered industrial vehicle to their manager immediately.
• Must wear proper PPE (safety glasses, safety shoes) while operating forklift in addition to the Proper PPE for changing propane tanks or charging batteries.
• Must wear seatbelt at all times while operating a forklift.
• Must adhere to all safety rules, procedures, and regulations

NOTE:  Contractors and temporary employees are not allowed to operate St. Norbert College powered industrial vehicles.

Procedures

Pre-Use Inspection:

An inspection must be done prior to every shift.  The Forklift Inspection form must be filled out while conducting this inspection. The following includes a list of items to be checked at a minimum (other items may be included on the forklift inspection form):

Visual Inspection:

Overhead guard

Propane cylinder

Engine oil level

Tires

Fuel level

Hydraulic oil

Cylinders                

Fire extinguisher

Lift chains

Carriage

Battery Connectors

Battery vent caps

Mast

Operational Inspection:

Start forklift

Lights

Listen for unusual sounds

Horn

Check service and parking brakes

Gauges

Check lifting control

Oil spots on floor

Forward driving (accelerator, steering, backing)

Reverse driving (accelerator, steering, backing)

If the inspection reveals a problem with the forklift, the unit must be placed out of service until repairs have been made.  The inspection form shall be turned in to the manager so the items can be fixed.

Training

• All operators of any powered industrial vehicle must successfully complete training and evaluation of driving skills. Only those who are trained and certified can operate a forklift on company property.   
• Training will be completed in the environment in which the powered industrial vehicle will be operated.  Training will be completed on each type of powered industrial vehicle that the employee will be expected to operate.  It will consist of classroom training, written test and a hands-on operational test.  Training will be conducted by a qualified instructor.

Training will include the following:

Truck-related topics:

• Operating instructions, warning, and precautions for the types of truck the operator will be authorized operate.
• Types of powered industrial vehicles used at the location.
• Truck controls and instrumentation, where they are located, what they do, and how they work.
• Engine and motor operation.
• Steering and maneuvering.
• Visibility (including restrictions due to loading).
• Fork and attachment adaptation, operation, and use limitations.
• Vehicle capacity and vehicle stability.
• Any vehicle inspection and maintenance that the operator will be required to perform.
• Refueling and/or charging and recharging of batteries.
• Operating limitations.
• Any other operating instructions, warning, or precautions listed in the operator’s manual for the types of vehicle that the employee is being trained to operate.

Workplace-related topics:

• Surface conditions where the vehicle will be operated.
• Composition of loads to be carried and load stability.
• Load manipulation, stacking, and unstacking.
• Traveling with a load.
• Parking a vehicle.
• Changing propane tanks and/or charging batteries.
• Pedestrian traffic in areas where the vehicle will be operated.
• Narrow aisles and other restricted places where the vehicle will be operated.
• Hazardous (classified) locations where the vehicle will be operated.
• Ramps and other sloped surfaces that could affect the vehicle’s stability.
• Other unique or potentially hazardous environments.

Refresher training of each powered industrial vehicle operator will be conducted at least once every three years.

Remedial or refresher training will be completed when the employee is involved in any type of accident/injury involving a powered industrial vehicle or as near misses/unsafe driving indicate.  If there is a change in the vehicle or the plant/warehouse design or use, refresher training may also be required.

Safe Lift Truck Operation

• Do not park on or drop off products where exits, sprinkler systems, or aisles are located.
• Stop and sound the horn at the end of aisle ways or while going through doorways.
• Do not carry any product or material on the overhead guard at any time.
• Travel at a safe speed for the environment the vehicle is driven.
• Unattended vehicle is any vehicle that you are standing more than 25 feet away from, when you cannot see the entire vehicle from any distance or whenever your path of travel to the vehicle is blocked.
• The parking brake shall be set each and every time you dismount from an industrial forklift.
• When loading and unloading trucks and trailers, the truck brakes must be set and wheel chocks in place or dock lock hook engaged before entering the vehicle.
• Before driving into a trailer inspect the flooring for damage and to ensure the trailer floor can support the weight of the PIV.
• A seat belt must be worn at all times.
• Arms and legs should be kept inside the vehicle at all times.
• Pallets shall not be used as improvised working platforms.
• If the truck starts to tip, don’t jump.  Grip the wheel, brace your feet and stay with the truck.
• Never let anyone walk or stand under the raised forks of a truck.
• Never lift anyone without using an approved man basket designed for lifting people safely.
• Always remove the key when leaving the truck unattended.
• Never operate a lift truck when you are ill or under the influence of alcohol or drugs.
• Do not eat, talk on your cell phone, listen to music through headphones, etc. while driving a lift truck.

Load Handling 

Picking Up a Load:

• Make sure the load does not exceed the capacity of the forklift.
• Center the forks to evenly distribute the weight of the load.
• Make sure the load is balanced and secure.
• Check for overhead obstructions such as pipes, sprinklers, and door beams.
• Lower the forks to the floor.
• Drive into the load as far as possible.
• Tilt the load back slightly and then lift it. 
• Back out slowly to clear racks or other obstacles.
• Lower the load to the safe traveling height (usually 4 – 6”above the floor) before moving.
• The forklift should be completely stopped before the load is raised or lowered.

Traveling With a Load:

• Pedestrians always have the right-of-way.
• Keep the load tilted back slightly.
• Keep the forks low, four and six inches (8” maximum) above the floor if possible.
• A forklift operator’s visibility is always restricted, even without a load.  Before moving, always check behind and around the unit for pedestrians and other traffic.
• If the load is large and blocks the operator’s view, travel in reverse.
• Drive at a safe speed (5mph maximum), slowing down when going around corners.
• Sound the horn when approaching aisles, corners or other blind spots.
• On ramps and inclines always drive a loaded forklift with the load “uphill”; driving up the ramp or incline and backing down it.
• Avoid sudden braking.
• Lift or lower the load only when completely stopped, never when traveling.

Placing a Load:

• Stop the forklift in front of the desired location.
• Slowly raise the load to the required height.
• Move forward slowly with load raised.
• Never walk or stand under a raised load.
• Position the load for placement, tilting the load forward to level it.
• Place the load square and straight.
• Once the load has settled, back up slowly.
• Make sure the forks clear the pallet before turning or changing the fork height.
• Before backing, check behind and on both sides for pedestrians or other traffic.
• Unusually shaped loads may require special stacking considerations.  Operators must be aware of the requirements before picking up these loads.

Parking:

• Always park PIV in a safe area away from traffic.
• No not park PIV on an incline or ramp.
• Do not block aisles, doors, exits, fire extinguishers, electrical panels, or access to stairs.
• Before leaving a PIV unattended:
  • Place controls in neutral.
  • Engage the parking brake.
  • Lower the forks all the way to the floor and tilt the tips forward.
  • Turn power off and remove key.
  • Chock wheels if on uneven surface.
• When parking at the end of the day turn off the propane tank.

Fueling the Unit

• Propane
  • Park, engage parking brake and leave the engine running.
  • Select proper PPE (i.e. safety goggles/face shield and gloves).
  • Turn off valve.
  • When engine stops running, turn off ignition switch.
  • Uncouple hose from valve.
  • Uncouple the strap from around cylinder and remove cylinder.
  • Install full cylinder with pressure relief valve up.
  • Secure cylinder with strap.
  • Open valve.
  • If a leak is detected, remove the forklift from use until the leak is repaired
    • Propane tanks should be stored in an open area to prevent leaking propane from accumulating.
    • Place empty propane tanks into the storage cage valve side inward (full tanks should be stored valve side outward)

• Batteries – Charging
  • Always wear the proper personal protective equipment when charging the battery (safety goggles, face shield, apron and gloves).
  • Know the location of the nearest eye wash/shower, flushing station (within 10 seconds).
  • Make sure that the building’s ventilation system is working properly before charging a battery.
  • If charging the battery on the forklift, uncover the battery compartment to prevent a build-up of heat or hydrogen gas.
  • Make sure the vent caps are not plugged.
  • The battery charger must be turned off before connecting it to the battery
  • Make sure that metal objects do not come in contact with the terminals on the battery.
  • Always use proper safety procedures when cleaning up any spilled electrolyte.

Powered Pallet Trucks

• Check the load capacity plate to ensure the load rating is not exceeded.

• Never lift or transport co-workers on the pallet truck.

• Be aware of obstacles and hazards – move slowly and cautiously.

• Always walk in front and to the side of the pallet truck pulling the truck behind you.

Man Baskets

• A man basket is an attachment that allows a person to be lifted safely.  It must be weight rated and approved by the vehicle manufacturer.
• Assure the man basket is properly secured to the forklift, before an employee enters it.
• Make sure that the operator is properly secured using safety devices that meet OSHA standards (such as a full body harness and 3’ lanyard).  If safety devices are not present, the unit must not be operated.
• Communication between the operator on the ground and the person in the lift must be maintained at all times.
• The unit must not travel with the employee elevated in the man basket.

Attachments

Whenever an attachment is used that could affect the capacity or safe operation of a forklift, its use must be approved by the forklift manufacturer. The employer must mark the forklift to show the new weight limit with attachment. The maximum capacity at the highest elevation must also be shown.

Modifications and additions which affect the capacity and safe operation of the vehicle shall not be performed by the user without manufacturers’ prior written approval. Capacity, operation, and maintenance instruction data plates, tags, or decals shall be changed accordingly.

Using an unapproved attachment could alter the forklift’s lifting and balance characteristics and lead to a forklift overturning.

• Types of approved attachments:

• Booms: Converts a forklift truck into a mobile crane for handling unstable awkward loads.  OSHA regulations require that extensions are no more than 150% of the existing fork length.
• Clamps: specialized arms, pads or fork carriers that can be used to clamp and lift palletized or unpalletized loads.
• Push arms:  a hydraulic attachment used for depositing or retrieving numerous loads without pallets, without side clamping. Uses include warehouse operations where the products being handled are too fragile for conventional side squeezing, or where the load consists of uneven or unstable stacks.

Contractors

Contractors working on St. Norbert College properties will not be allowed to use St. Norbert College leased or owned powered industrial vehicles to perform their work.  The contractors will need to provide their own equipment.  Contractors must provide proof of training to the St. Norbert College representative or project manager they are working with.

Definitions:

• Powered Industrial Vehicle is any mobile power-propelled truck used to carry, push, pull, lift, stack or tier materials.  Powered industrial trucks can be ridden or controlled by a walking operator.  (Earth moving and over the road haulage trucks are not included in the definition.)
• Man Basket is a platform designed specifically for elevating personnel. 
• Powered Pallet Truck is a motorized tool used for lifting and moving of heavier and stacked pallets.
• Overhead guard is a metal cage that fits around the cab of the forklift to protect the operator from falling objects.