Table of Contents
A. Forklift Condition and Equipment
Ensure the forklift is in safe operating condition before each use.
- Daily Inspection:
- Brakes are functional and responsive.
- Steering mechanism operates smoothly.
- Horn, lights, and alarms are working.
- Tires are in good condition (no excessive wear, damage, or improper inflation).
- Forks and mast are free from cracks, bends, or other defects.
- Hydraulic systems show no leaks or malfunctions.
- Seatbelt and other safety restraints are intact and functional.
- Battery (if applicable) is charged and connections are secure.
- Daily Inspection:
- Safety Devices:
- Overhead guard is in place and undamaged.
- Backup alarm and warning lights are operational.
- Anti-collision systems (e.g., sensors, auto-braking) are installed and functioning (required as of 2024 update).
- Fire extinguisher (if required) is present and accessible.
- Safety Devices:
- Capacity and Rating:
- Data plate is legible and matches the forklift’s configuration.
- Forklift is rated for the loads being handled (weight and size).
- Capacity and Rating:
Operator Training and Certification
Ensure operators are properly trained and certified to operate forklifts.
- Training:
- Operator has completed OSHA-compliant training for the specific type of forklift.
- Operator is familiar with the forklift’s controls, capabilities, and limitations.
- Operator understands workplace-specific hazards (e.g., uneven surfaces, pedestrian traffic).
- Training:
- Certification:
- Operator holds a valid certification (refreshed every 3 years or after an incident).
- Certification records are up-to-date and accessible.
- Certification:
- Performance:
- Operator demonstrates safe driving practices (e.g., speed control, load stability).
- Operator uses seatbelt at all times during operation.
- Operator follows proper procedures for parking and shutting down the forklift.
- Performance:
C. Workplace Environment
Ensure the workplace is designed and maintained to minimize hazards.
- Aisles and Pathways:
- Aisles are wide enough for safe forklift operation.
- Pathways are clear of obstructions (e.g., debris, spills, or stored materials).
- Pedestrian walkways are clearly marked and separated from forklift zones.
- Aisles and Pathways:
- Lighting and Visibility:
- Adequate lighting is provided in all operating areas.
- Mirrors are installed at blind spots or intersections.
- Warning signs are posted in high-traffic or hazardous areas.
- Lighting and Visibility:
- Ventilation:
- Indoor areas are properly ventilated, especially when using fuel-powered forklifts.
- Carbon monoxide levels are monitored (if applicable).
- Ventilation:
- Surface Conditions:
- Floors are even, free from potholes, and capable of supporting the forklift’s weight.
- Ramps and inclines have appropriate grading and non-slip surfaces.
- Surface Conditions:
D. Load Handling
Ensure loads are handled safely and within the forklift’s capacity.
- Load Stability:
- Load is stable and securely positioned on the forks.
- Load does not exceed the forklift’s rated capacity.
- Center of gravity is maintained within safe limits.
- Load Stability:
- Load Securing:
- Use of straps, chains, or other securing devices when necessary.
- No overloading or unbalanced loads.
- Load Securing:
- Lifting and Transporting:
- Forks are fully inserted under the load.
- Mast is tilted back to secure the load during transport.
- Operator maintains clear visibility or uses a spotter when necessary.
E. Maintenance and Inspection Records
Ensure regular maintenance and inspections are performed and documented.
- Maintenance Schedule:
- Forklift is serviced according to the manufacturer’s recommendations.
- Preventive maintenance (e.g., oil changes, brake checks) is performed on schedule.
- Maintenance Schedule:
- Inspection Records:
- Daily pre-use inspections are documented.
- Any defects or issues are reported and addressed immediately.
- Records of repairs and maintenance are kept for at least 3 years.
- Inspection Records:
- Battery and Fuel Handling (if applicable):
- Battery charging areas are well-ventilated and equipped with safety measures.
- Fuel storage and refueling procedures comply with OSHA standards.
- Battery and Fuel Handling (if applicable):
F. Collision Prevention Measures (2024 Update)
Ensure compliance with OSHA’s new requirement for verifiable collision prevention measures.
- Anti-Collision Systems:
- Forklift is equipped with OSHA-recognized anti-collision technology (e.g., proximity sensors, auto-braking).
- Systems are tested and calibrated regularly.
- Anti-Collision Systems:
- Collision Risk Audits:
- Monthly audits are conducted to identify and address potential collision risks.
- Audit results are documented and reviewed with operators.
- Collision Risk Audits:
- Training and Awareness:
- Operators are trained on the use of anti-collision systems.
- Workplace signage reinforces collision prevention protocols.
G. Emergency Procedures
Ensure emergency protocols are in place and understood by all personnel.
- Emergency Stops:
- Operators know how to activate emergency stop mechanisms.
- Emergency stop buttons are accessible and functional.
- Emergency Stops:
- Incident Reporting:
- Procedures for reporting collisions, near-misses, or equipment failures are established.
- All incidents are documented and investigated to prevent recurrence.
- Incident Reporting:
- First Aid and Fire Safety:
- First aid kits are available and stocked.
- Fire extinguishers are inspected and accessible in case of fire.
Instructions for Use
- Frequency: Complete this checklist:
- Daily (for forklift condition and load handling).
- Monthly (for workplace environment and collision prevention audits).
- Annually (for operator certification and maintenance records).
- Documentation: Keep all completed checklists and related records for at least 3 years.
- Corrective Action: If any item is unchecked, take immediate action to address the issue before operating the forklift.
Additional Notes
- OSHA Reference: This checklist is based on OSHA 1910.178 and the 2024 update requiring verifiable collision prevention measures.
- Customization: Tailor this checklist to your specific workplace hazards and forklift types (e.g., electric vs. fuel-powered).
- Training: Ensure all operators and supervisors are familiar with this checklist and OSHA’s requirements.
This OSHA 1910.178 Checklist provides a structured approach to maintaining compliance with federal safety standards while promoting a safer workplace. Regular use will help you stay audit-ready and reduce the risk of accidents or fines.
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