Proper forklift operator training to meet OSHA requirements consists of classroom instruction by a credible source, hands-on evaluation and equipment- and facility- specific training. Most companies have a handle on the first two components. In many cases, employers also follow up with specific training using the equipment in their facilities. However, all too often, companies ignore the final aspect of ensuring full compliance with OSHA requirements. 

Each facility, be it warehousing, assembly or manufacturing, is unique and has its own set of potential hazards. These potential hazards must be addressed in terms of operating the lift equipment in them. To ignore this is to put your operation and finances in jeopardy, because an accident can occur as a result of one of these hazards. OSHA offers specific guidelines to help guide you through your facility inspection and to identify these potential hazards.  

Workplace Layout & Hazards

• Aisle Width & Traffic Patterns – Ensure operators are trained on navigating tight spaces and avoiding collisions.
• Pedestrian Safety – Identify high-traffic pedestrian areas and enforce safety protocols.
• Loading Dock Safety – Train operators on loading/unloading techniques and dock-specific hazards (e.g., dock edges, trailer creep).
• Ramps & Inclines – Address safe travel on slopes, including weight distribution and braking techniques.
• Blind Spots & Mirrors – Ensure operators are aware of areas with limited visibility.
• Overhead Clearances – Are there low-hanging items that an upright could damage, or doorways. Be sure your operators are aware of these.

Equipment-Specific Training

• Type of Forklifts Used – Cover differences in controls, stability, and lifting capacity for various forklift types (counterbalance, reach truck, order picker, etc.).
• Attachments – Train operators on attachments like clamps, rotators, or extensions and how they affect load handling and stability.
• Pre-Use Inspections – Ensure daily checklists include site-specific concerns, such as dust, debris, or temperature extremes.

Load Handling & Material Storage

• Types of Loads – Address how to handle materials specific to your site (e.g., pallets, bulk materials, fragile items).
• Storage Racking & Stacking Rules – Train operators on proper stacking height, weight limits, and load stability.
• Hazardous Materials – If applicable, cover handling and storage of hazardous materials per OSHA regulations.
• Floor Loading Limits – Be sure your operators do not take heavy loads on to floors not rated to handle them.

Environmental & Seasonal Considerations

• Floor Conditions – Address potential hazards like wet floors, debris, or uneven surfaces.
• Outdoor Operation – Train for weather-related factors (rain, snow, extreme heat).
• Ventilation Needs – If using propane or diesel forklifts indoors, ensure proper ventilation and CO monitoring.

Emergency Procedures & Compliance

• Accident & Incident Response – Train operators on what to do in case of an accident, spill, or equipment failure.
• Evacuation Plans – Ensure operators know exit routes and emergency shutdown procedures.
• Regulatory Compliance – Training must align with OSHA’s Powered Industrial Truck standard (29 CFR 1910.178) and any local safety laws.

Hands-On Training & Evaluation

• Practical Demonstration – Have operators practice on-site tasks under supervision.
• Site-Specific Evaluations – Conduct hands-on skill assessments in the real work environment.
• Refresher Training – Provide ongoing training for new hazards, equipment, or changes in workflow.

Visit our Training Page to learn more about our Forklift Operator Training and Train the Trainer training programs, and see our Training Schedule. There you will also find useful downloads like IC and Electric forklift inspection forms as well as a Forklift Operator Questionnaire. For more information on our training, or to schedule, please contact us at 804-233-0051.