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Table of Contents
Introduction: Why Forklift Safety Cannot Be Ignored
Forklifts are essential in industrial operations but are equally dangerous when not managed correctly. On November 2, 2024, a tragic accident at a waste treatment facility in Dongguan, China, claimed the life of a forklift driver. The case serves as a painful reminder that forklift safety is not optional—it is critical. This article dissects the accident and offers practical safety solutions to help warehouses and factories avoid similar incidents.
Accident Overview: What Went Wrong?
At approximately 3:27 PM, two forklift operators, Zhao and Li , were moving discarded transmission belts at a slag yard. One forklift dragged the belt while the other lifted it, attempting a tandem maneuver without formal planning, supervision, or approval.
As Zhao attempted to lift and turn with the belt, the forklift overturned, ejecting him from the vehicle. With no seatbelt fastened, he fell to the ground and was crushed by the protective overhead guard of the machine. Despite emergency response, Zhao was declared dead at the scene.
Accident Cause Analysis
Direct Causes
- Lack of Safety Protocol Compliance: No work plan was filed or approved for the tandem forklift operation.
- Seatbelt Not Used: Zhao was not wearing a seatbelt, which could have prevented ejection.
- Improper Fork Usage: The belt was lifted with a single left fork, causing load imbalance.
- Combined Side Forces: The load’s side pull (from the front forklift) and the centrifugal force of the turn created a tipping point.
Technical Factors
- The forklift mast was raised beyond the overhead guard height (2.18m).
- The forklift was turning while under lateral stress from both the load and the towing force of the front forklift.
- A single fork provided insufficient support for a long and heavy object like a transmission belt.
Indirect Causes
- Lack of Effective Forklift Safety Management by the company:
- Inadequate enforcement of forklift operation protocols.
- Failure to monitor or stop unsafe behavior.
- No technical or managerial intervention to correct the unsafe method used.
Key Lessons and Solutions
To prevent similar forklift accidents, companies must improve both technical practices and safety culture. Here’s how:
Enforce Strict Forklift Operating Procedures
- Develop and mandate written work plans for non-standard operations like tandem forklift use.
- Require managerial approval for complex lifting or coordination tasks.
- Implement a pre-task safety briefing for every unusual forklift job.
Mandatory Seatbelt Use with Audible Alarms
- Install seatbelt sensors with alarms that prevent engine start without the operator buckling in.
- Conduct daily checks and penalize non-compliance with safety gear usage.
Forklift Load Handling Guidelines
- Never use a single fork to lift long, heavy, or unbalanced objects.
- Use appropriate attachments or lifting equipment designed for non-standard loads.
- Ensure the load stays within the forklift’s center of gravity during movement.
Avoid Forklift Tandem Operations Unless Approved
- Do not use two forklifts to coordinate lifting unless:
- Operators are trained in tandem operation,
- A supervisor is present,
- Loads are evaluated by a qualified safety engineer.
Conduct Routine Safety Audits and Training
- Schedule monthly forklift safety drills.
- Use real-life forklift accident cases as training tools.
- Create a checklist-based safety inspection system for every shift.
Implement Forklift Telemetry or Monitoring Systems
- Install onboard forklift monitoring devices that track speed, mast height, seatbelt status, and turning behavior.
- Use data to flag risky behaviors in real-time.
Hold Managers Accountable for Safety Enforcement
- Make supervisors personally responsible for safety rule violations under their watch.
- Tie safety performance to managerial evaluations and bonuses.
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Conclusion: Forklift Safety is a Shared Responsibility
The Dongguan accident was preventable. It resulted not from one single error, but from a systemic failure of management, training, and compliance. Forklift safety is a joint effort between workers and leadership. Implementing structured procedures, using proper equipment, and maintaining vigilance can save lives and protect businesses from tragic losses.
Call to Action
Are your forklift operations truly safe? Don’t wait for an accident to take action. Start by reviewing your forklift safety protocols today—and make every workday a safe day.
