Frequency breeds severity. It’s an old saying in insurance that rings true across the lumber and wood products industries, especially when it comes to forklift safety.

Forklift accidents consistently rank among the most common claims we see each year at Pennsylvania Lumbermens Mutual insurance Company (PLM). While most are small in nature, every now and then, a forklift accident can create serious injuries—even fatalities—and multi-million dollars’ worth of damage. And that doesn’t even include the additional negative impacts that a mishap can have on your business’ reputation.

Let’s explore why every lumberyard, every furniture manufacturer, cabinet maker, millwork company, assembly and distribution facility be they small or large companies should emphasize forklift safety and examine 12 best practices to protect your company and your drivers.

Inside the numbers
When I talk with insured companies, I like to share some data about forklift safety. Statistics compiled by McCue Corporation, a safety solutions provider, show that:

•    Eleven percent of forklifts are involved in some kind of accident every year. So, if you have nine forklifts in your shop, you’re likely to experience one accident annually.
•    Roughly 1% of all forklift accidents result in deaths, leading to about 87 deaths a year.
•    About 36% of forklift accidents involve pedestrians.

While these numbers hit home with many business owners, here’s the most important stat of all: 70% of forklift injuries could be avoided with better training policies.

12 best practices
Many wood shops believe they are doing everything they can to eliminate forklift injuries. But often, business owners, warehouse managers and other personnel may not know all of the optimal mitigation strategies. So, take time to implement and follow these 12 best practices.

1. Institute a formal forklift training program. It should combine classroom and practical training. Document your program so it is repeatable and consistent. Make sure it includes:

• Processes for daily pre-operational forklift inspections. These can include checking the brakes, tires, steering, battery charge level, warning lights and other key items.
• Procedures for near-miss and post-accident investigation. Spell out how you will conduct each type of incident review and how you will take steps to avoid similar incidents in the future.

2. Get your drivers certified. All forklift drivers must be trained and certified on each piece of equipment they operate. If your shop includes both counterbalanced and truck-mounted forklifts, your drivers will need separate certifications for each one. The same is true if you have a mix of propane-powered and gas-powered forklifts. Certification should include best practices for refueling.

3. Keep driver certifications up-to-date. Certify forklift operators at hire and then once every three years. Certifications from previous employers are not valid. Your company must certify that operators have been trained and supervisors need to certify that they have personally trained and observed every driver operating in a safe manner at their place of business.

4. Integrate forklift safety into your regular processes. Does your shop have regular toolbox talks or Monday morning meetings? If so, then make forklift safety a regular topic of discussion. Offer refresher training and remind everyone in your facility how dangerous forklifts can be.

5. Provide in-the-moment feedback. If you see any unsafe acts—such as carrying extra riders or backing up without looking over their shoulder—address them as soon as they happen. This top-of-mind training reinforces the importance of safe behaviors and prevents future incidents.

6. Always use a spotter. Spotters are not just for big box stores or large warehouses. Every yard should use them. They help to keep loading and unloading zones clear of pedestrian and customer traffic. Spotters also allow forklift operators to focus on driving and balancing their load while someone else watches for passersby.

7. Know where truck drivers are at all times. When loading and unloading vehicles, forklift operators should stay aware of the truck drivers’ location. We recommend that the driver be instructed to stand far away or next to the wheel of their cab. It is not safe to stand on the opposite side of where you’re loading. We have seen serious injuries result when loads fall on top of a driver who is standing alongside a flatbed. If you cannot see the truck driver, stop what you’re doing until you can.

8. Create a designated forklift area. As space permits, set aside a dedicated loading and unloading zone. Keep customers and other unauthorized personnel out of the area to enhance safety. This can be trickier in smaller lumberyards and manufacturing facilities, but it is no less important.

9. Minimize forklift cross-traffic. If space permits, implement a one-way traffic pattern—such as forklifts only going clockwise around the yard—to prevent forklifts from crossing paths. Use floor markings to designate traffic lanes and safe pedestrian walkways.

10. Ban headphones and hoodies. Forklift operators wearing headphones won’t hear others urging them to stop in an unsafe situation. Hoodies, meanwhile, can block a driver’s peripheral vision, creating dangerous blind spots.

11. Look over your shoulder—always. Although many forklifts have mirrors today, it remains a best practice for drivers to look over their shoulder while backing up. This will ensure that the area behind you is clear.

12. Empower your operators. Let your drivers know they should stop whenever they feel unsafe. If a customer won’t get out of a loading zone, encourage drivers to ask a manager for help in clearing the area.

What to do if an accident happens
Nearly all forklift accidents are just that—accidents—and they can happen in even the safest of environments. If one occurs, conduct a thorough incident report immediately. Write down pertinent facts: Did the victim get up right away? Did they need an ambulance? Did they refuse treatment? Collect statements from all witnesses and collect witness contact information. Take and store pictures and videos. Then, report the claim to your insurance company.

Driving a forklift is a repetitive activity, and when you do the same thing over and over, you’re bound to make mistakes. By instituting these 12 best practices, you’ll keep safety top of mind and reduce your forklift-related risks significantly.

About the author: Marco Gulino is a senior loss control specialist at Pennsylvania Lumbermens Mutual Insurance Company (PLM). PLM is a nationally recognized property and casualty insurance carrier serving the lumber, woodworking and building materials industries. Marco can be reached at [email protected].