7 Steps to Effective Forklift Training

At any distribution center, lift trucks are essential to operation. However, they are only as safe and productive as their operators. So how can you ensure your drivers are competent to safely operate a forklift? What sort of training should you provide?

Any training program has to meet Occupational Safety and Health Administration (OSHA) requirements. OSHA’s regulations what topics must be covered by a driver training program and how instruction should be provided. Topics covered during training usually consist of a bend of “how-to” operating basics and safety information tailored to the specific site.

Training is available from a variety of sources, including packaged training programs, training from dealers, third-party consultants, and in-house instructional programs. Employers interested in hiring an outside party to provide its training must remember that they are ultimately responsible for ensuring drivers receive proper training. Customer Service Representative and Operator Trainer Specialist, Dave Medley of Shoppa’s Mid America says there are a number of steps companies can take to assure they are offering a sound program. Here are a few pointers:

1. Check the credentials. Before bringing in an outside firm, make sure the trainer is qualified, both by experience and on paper. Medley urges customers to check trainers’ credentials to ensure that they are certified. Most major lift truck manufacturers and a number of third-party training organizations offer to certify trainers who complete their programs. Be wary of a training company that offers a one-size-fits-all training program, Medley warns. Since OSHA regulations require training to be both specific to the vehicle and the application, it is unlikely any one-size-fits-all program would meet OSHA requirements, he says.
2. Start with a site visit. Medley emphasizes that the first step for any trainer developing a program for a specific client is a site visit. Because conditions can vary from one operation to the next, it is important for the trainer to visit with the customer to get an idea of the challenges he or she faces. Site visits also offer an opportunity for the trainer to gather information on the composition of the fleet, what shifts it operates, and the qualifications of operators already working in the facility so it can design a program that addresses the customer’s specific needs. “Shoppa’s offers a variety of training programs including on-site training, train the trainer programs, video training, operator permits, and e-learning courses to fit the varying needs of our customers.”
3. Ensure the program is thorough. Lift truck operator training is about more than just starting, driving, steering, and manipulating forks. An effective program should also cover “off the truck” activities like pre-shift inspections and safe battery handling. For example, Shoppa’s Mid America promotes its “Train the Trainer” program that consists of one-on-one instruction and includes such topics as lift truck fundamentals, balance, stability and capacity, pre-operation inspections, safety guidelines, load handling, proper fueling, and battery charging, as well as an overview of OSHA regulations.
4. Provide time for classroom instruction. Classroom instruction can vary from a few hours to a full day, depending on the specific requirements of an operation, the size of the class, and the experience of the operators. Classes typically contain both new operators and experienced drivers taking instruction for the mandated recertification. Shoppa’s Mid America provides a monthly training session open to new and experienced operators alike, and provides instructional material in a variety of formats including videos, PowerPoint presentations, lectures, printed materials, and e-learning courses.
5. Provide the time, space, and vehicles for hands-on training. Although the basics can be covered in the classroom, there are some things that can only be learned on the equipment, such as safe load handling and maneuvering. “Give trainees the opportunity to observe an experienced person, then some time to operate on their own,” Medley says. While hands-on training can be conducted off-site or after hours, many companies end up doing it in a relatively quiet portion of an active distribution center. As for the equipment used in the training, Medley emphasizes that it is not enough to simply train drivers to operate a specific class of vehicle. Because variations in design from one make of vehicle to the next, it is important that they receive training on the specific brand of truck they will be operating. And it is not just the make and type of truck that matters; the model matters too. Even within brands, new or upgraded models of existing trucks may require some vehicle-specific training.
6. Evaluate and certify. “You need to have some kind of evaluation of the operator’s skill,” Medley says. That requires an evaluator who is not shy about stating that a would-be lift truck operator is not up to the job. It is important to note that while professional trainers will offer all of the components of a program, including a formal evaluation, the actual certification is up to the employer.
7. Train pedestrians, too. Lift truck operators are not the only workers at risk in a busy distribution center. People working around these vehicles face hazards as well. To reduce the risk of accidents and pedestrian injuries, some programs, like the one offered at Shoppa’s Mid America, include specific safety training for dockworkers and others who work around lift trucks but do not operate them.

Shoppa's Mid America is proud to help you with all of your forklift and safety training needs. For more information, visit our Training page on our website.