safe handling of forklift truck training (basic program)

BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849

SAFE HANDLING OF FORKLIFT TRUCK TRAINING

(BASIC PROGRAM)

FOR INTERNAL/EXTERNAL (PUBLIC)

TRAINING


Fakhruddin @ Farud Bin Esa

I/C No.: 741214-01-6613

Home Town: Batu Pahat, Johor

Portfolio; S.H.E(W.W.T.P)/Building Maintenance/ Industrial

Engineering/Kaizen Practitioner/Manufacturing/Construction /Aviation

Working Experience: 23 years

Certified Green Book Holder and RPO

Completing PhD paper, UTHM Batu Pahat, Johor

Presented and Published Journal in International Conference

and was recently awarded as the best paper in ICMEIM 2017,

organized by WASET.

Trainer Profile


STEP 1

STEP 2

Ice Breaking, Fold & Write Your ID


TIME TOPIC

8.30 ~ 10.30 (2 hours) Theory;

Fundamentals of forklift

Model coding system

Data plate and serial number

Forklift stability triangle

Load capacity charts

10.30 – 10.45 am (15 min) Break

10.45 – 1.00 pm (2 hours

15 min)

Theory;

Driving control and instrument panel

Safe driving technique

Maintenance diagram

Pre-operation check and maintenance

Re-fueling and re-charging

Video : Forklift safety operation

1.00 – 2.00 pm (1 hour) Lunch

Session Plan & Table of Content


TIME TOPIC

2.00 – 3.00 pm (1 hour) Practical;

Walk around inspection

Visual inspection on the machines

3.00 – 3.15 pm (15 min) Break

3.15 – 5.00 pm (1 hour 45

min)

Practical;

Forklift operating technique

Driving the machine in confined area

Picking up the load

Loading and unloading

Ramps and gradients

Session Plan & Table of Content


Objectives

Understand how forklifts work

Operate a forklift safely and skillfully

Identify operating hazards

Apply general principles of safe operation

Properly inspect and maintain a forklift


THEORY


Fundamental of Forklift

SeatBelt

LiftControl

OverheadGuard

TiltControl

Forks

Carriage

Backrest

LiftChains

LiftCylinder

Mast

BASIC PROGRAM PREPARED BY: FAKHRUDDIN BIN ESA HQ/16/SHO/01/00849

Truck Body


Overhead Guard


Hydraulic Lift


Tire Types

X > 10 Tonne; Pneumatic

X < 10 Tonne; Solid


Types of Forklifts

Different types of forklifts are

available, mainly for different

environments/usage:

•Diesel powered

•Electric powered

•Gasoline powered

•LP-Gas powered


JPJ License for Forklift; F


Forklift Operation

OSHA 1910.178 states “Only

trained and authorized operators

shall be permitted to operate a

powered industrial truck.”


•Forklifts weigh thousands of

pounds.

•Are extremely powerful.

•Use rear wheel steering.

•Can turn in a very tight circle.

•Are not very wide for use in

aisles.

Interesting Facts


Model Coding System


Data Plate & Serial Number• OSHA requires a

legible nameplate

• It includes information about the forklift and attachments

• It lists the maximum load capacity

• It describes the load center


Forklift Stability TriangleVehicle Center of

Gravity (unloaded)

Stability Triangle

Center of Gravity of

Vehicle and Maximum

Load (Theoretical)


Forklift Stability Triangle


Load Capacity Chart


Driving Control & Instrument Panel


Safe Driving Technique

Rear Wheel Steering

Unlike a car or truck, lift trucks

use the rear wheels for

steering.



Load Capacity



Load Centering


Speed

KEEP

YOUR

SPEED

DOWN!

05 KM/hour (max) – Outdoor Driving

15 KM/hour (max) – Indoor Driving



Quick Turns



The 8 Inch Rule



If Your View is Blocked

If a load

blocks your

view, travel in

reverse.



Overhead Clearance



Center Your Loads



Loose Loads



Wide and Long Loads



Driving on Ramps

Unloaded



Driving on Ramps

Loaded



Driving Across Ramps



Driving on Various Surfaces



Loading Docks

Will the floor of the trailer

support your load?



Loading Docks



Parking

Always park your truck away from

traffic and on a level surface.



Parking

Lower forks flat

on the floor.

Set directional

control in

neutral.



Parking

Turn engine off

and remove

key.

Set parking

brake.



As you drive, watch out for people walking, and at intersections, slow down, look for

traffic, and sound your horn frequently.

Remember, ALWAYS come to a complete stop before changing direction.

Intersections



Raised Forks

Never let anyone, including yourself, walk or stand under the forks

when they are raised

Keeping Work Area Clear



Keep in mind that you are a lift truck operator, not a taxi service.

You should never allow anyone to ride on your lift truck.

No Riders



Safety Devices

Seat Belt - Most lift trucks are equipped with a

seat belt.

Use it!

Wear Your Seatbelt



Safety Devices

Horn - Sound your horn:

* Before backing up

* At intersections

* When traveling through doors

* Anywhere your vision is limited

or blocked

Using Your Horn Often



Safety Devices

Backup

Backup Alarms



Safety Devices

Warning Light - Some trucks are

Warning Light




Maintenance Diagram



Pre-Operation Check & Maintenance


Daily Inspection

The safety equipment you must

inspect daily is:

•Seat Belt

•Warning Light

•Backup Alarm

•Horn



Daily Inspection


inspect daily is:

•Steering

•Brakes

•Carriage, chains, forks

•Hydraulic hoses



Daily Inspection


inspect daily is:

•Hydraulic lift/tilt controls

•Tires

•Hour Meter

•Leaks



Daily Inspection


inspect daily is:

•Fuel level

•Oil level and pressure

•Water level

•Fan Belt



Refueling and Recharging

*

•Park in designated refueling or

recharging area.

•Do not block emergency equipment.

•Make sure area is well ventilated.

•Have extinguisher nearby.*

*

*


Refueling and Recharging

*

*

*

*

•Turn off engine and lights.

•Do not smoke.

•Do not spill fuel.

•Use only approved cans.

•For LP, shut off valves.

•When charging, remember

gases.


Forklift Safety Operation

*

*

*

*

•Video 1

•Video 2

•Video 3

•Video 4

•Video 5

•Video 6


Sample of “Authorized Driver ID”


Forklift Service Centre


CASTING PLANT (CLASS II ACCIDENT) – 01/02/2016

Root Cause Corrective Action

When? 01st February 2017 at 05:45 p.m.

Where? Casting Machine #18’s Holding

Furnace

Who? Abu Ghulam

What? Holding furnace on fire

How? Caught on fire after molten

aluminum spilled over from the

holding furnace right to the oily

floor.

MC N/A

LWD N/A

First Aid Accident

- Briefed to all related

personnel on safe work

procedures prior

implementing the same task

in the future.

- Introduce “DO” and “DON’T”

visual control at site.

Unsafe Act & Unsafe Condition

1

Preventive Action

- Review on safe work

procedure at the work

station during charging

process.

- Lesson learnt session

with everyone at Casting

Div. Carried out

explanation on things

that need to be followed

(information alert) prior

carrying out the similar

process in the future.

CHRONOLOGY

Case Study


CASTING PLANT (CLASS II ACCIDENT) – 01/02/2016 Chronology

1 2 3

Abu Ghulam charging out molten aluminum at

Casting Machine #18 around 5.45 pm.

He keep charging out the balance of molten aluminum into the

Casting Machine #17’s holding furnace while at the same time

fire start ignited

He immediately stopped the charging

operation at Casting Machine #17 right

after he noticed on the fire existence.

He used the ABC fire extinguisher

(Powder type) attached to the post next

to Casting Machine #18 and managed

to extinguish it less than 3 minutes.

Oily floor was intentionally in contact

With molten aluminum

ROOT CAUSE 4

A minute later, he went to Casting Machine #17 to charge out

the balance without notice that the molten aluminum in the

holding furnace spilled over and was in contact with oil

residue on the floor.

Oil

Residue

Molten

Aluminum

Mirror

Visual Control

Oil

Residue

Spilled over

molten aluminum

Fire ignited at

DCM#18’s holding furnace

Smoke appears right after the fire extinguished

ABC Powder fire

extinguisher

Sprayed & aimed at the

fire soure

Case Study


PRACTICAL


Forklift is properly disengaged

Walk to both sides

Check front

Walk to rear

Inspection Walkaround


Visual Inspection on the Machine

• Propane-powered• Check all oil and

fluid levels

• Check cables

• Check fan belt, fan, and radiator

• Check tank, and hose attachments

• Electric-powered• Check the battery

condition


Forklift Operating Technique

• Authorized operators only

• Quickly report accidents

• Always wear seat belts

• No person under the forks

• Operate controls only from driver’s seat

• Never block exits or emergency equipment


Driving the Machine in Confined Area


Picking up the Load

• Working around loading docks

• Loads that block the forward vision

• Stacking and unstacking on racks


Loading / Unloading

• Never overload forklift

• Check load weight • Locate load’s

center of gravity

• Inspect the load

• Restack or secure unstable loads

• Be sure forks are under load

• Tow from rear towing pin


Ramps / Gradient

• No turns on a ramp

• Load facing upgrade

• Go slow

• Cross railroad tracks diagonally

• Never park within 8 feet of the center of railroad tracks

What’s Wrong Here?

Forklift parked on sloped surface

Forks not fully lowered


Ramps / Gradient


REMEMBER TO DRIVE SAFELY.....

END OF PRESENTATION

safe handling of forklift truck training (basic program)

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