For safety's sake
May 1st 2007

Michaela Dann, marketing communications manager at Linde Material Handling (UK) looks at truck safety in materials handling

Modern mobile material handling equipment, whether engine or electric counterbalance, or warehouse trucks, incorporates many advanced features in terms of safety, performance, economy and ergonomics to meet the demands of commerce and industry in an intensely competitive environment.

Operating an efficient supply chain is an essential element in the overall success of most businesses and mobile handling equipment plays a major role.

Technological advances have made materials handling equipment faster, safer, more energy efficient, quieter, cleaner and more comfortable to operate.

Designers have to pay great attention to the ergonomic aspects of the trucks as well as the safety and operational features.

This ensures a comfortable and intuitive interface between the operator and the machine, with minimal physical demands placed on operators so that they maintain high levels of efficiency and alertness throughout the working shift.

This has two benefits, because a comfortable and efficient operator is more productive and an alert operator is more aware of the surrounding environment, resulting in safer handling operations.

When considering the advanced technology used in modern handling equipment, a good analogy is the development of private road vehicles, which have an array of ergonomic and safety features.

In spite of this, accidents still continue to happen because, ultimately, however good the equipment or vehicle might be, good performance and safety depends on the human element and nothing involving human endeavour is totally risk free.

The question is: do some design innovations and technological advances lull the fork lift operator into a false sense of security and does modern equipment require a different type of operator training? Certainly, modern handling equipment is more stable and moves and lifts loads faster and more smoothly to meet the high productivity demands of modern businesses. This in turn places greater responsibility on the operator who has to achieve these objectives safely.

The basic skills required to operate material handling equipment today are largely unchanged, while power steering, fingertip hydraulic controls and ergonomic seating are just some of the features that have made the task so much easier and requiring very little physical effort.

Smoother and quieter equipment has also eliminated the stress factor when working through an eight-hour shift.

More efficient braking systems offering both hydraulic and electrical combinations and in some models automatic speed reduction when cornering, have also contributed to higher levels of operational safety.

For managers responsible for ensuring that operators do use the handling equipment safely and efficiently, there are some key issues that have to be addressed to minimise any potential risks.

These are: Selection and recruitment of forklift operators with the right attitude and aptitude.

Specifying the right equipment so that it is matched to the task in hand.

Ensuring that operators receive professional training, ideally from a provider accredited by the Health & Safety Commission on the specific type of equipment they are required to work with.

Setting in place a strict supervisory regime that constantly monitors and ensures that defined safety standards are maintained and working practices are adhered to in the overall working environment, and not just those related to mobile equipment.

Other staff working in the vicinity of fork truck operational areas must also be trained and made aware of the potential hazards posed by mobile handling equipment, as well as their individual responsibilities to comply with defined safe working practices within the company.

The working environment should be designed for the safe operation of mobile equipment with adequate precautions taken to protect pedestrians and other operators on the site.

Regular risk assessments to identify and take precautions where any existing or new factors could adversely affect safety and efficiency should be undertaken.

Regular equipment maintenance is a key element in any safety regime.

Statutory legislation states that 'every employer shall ensure that all persons who use work equipment have received adequate training for the purposes of health and safety, including training in the methods which may be adopted when using the work equipment, any risks which such use may entail and precautions to be taken'.

A similar 'adequate training' clause also applies to those employees who supervise or manage the use of work equipment.

An excellent HSE publication entitled Rider-operated lift trucks: Operator training contains the Approved Code Of Practice and Guidance (ACOP) regarding the requirements of regulation 9 of the Provision and Use of Work Equipment Regulations as they relate to the basic training of operators of rider-operated lift trucks.

To summarise: modern materials handling equipment is inherently safe in design and function and provides higher levels of productivity and comfort.

Operating costs are lower and because operators enjoy a better working environment, they are motivated and more efficient. For more information on HSC publications and for details of accredited training suppliers and operator training courses, contact Jo Beattie at:

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