EP.1 – Prevention First! How to Avoid Accidents from Forklift Use in Warehouses and Factories

Workplace environments, particularly in warehouses and factories, are inherently prone to operational risks. It is the responsibility of warehouse managers to ensure the safe and efficient operation of material handling equipment, including forklifts. This article outlines key risk factors associated with forklift use and offers practical prevention strategies to mitigate potential hazards.

Forklifts that are old, heavily used, or poorly maintained pose serious safety risks. Neglecting routine maintenance, especially for critical components such as batteries and distilled water levels, can lead to equipment failure and workplace accidents. To ensure operational reliability, businesses are encouraged to implement a preventive maintenance program. Operators should immediately stop using any forklift that exhibits unusual signs—such as abnormal sounds, vibrations, or erratic performance—and report the issue for inspection and repair.

For electric forklifts, proper battery care is essential. Batteries must be charged correctly and topped up with distilled water to maintain optimal performance. Poor battery maintenance can lead to rapid deterioration, increased downtime, and operational delays.

These maintenance considerations also apply to other equipment such as hand pallet trucks and AGVs (Automated Guided Vehicles). In the event of any issues, personnel should consult their supervisors or authorized distributors for appropriate support and servicing.

• Inability to stop the vehicle properly or delayed braking (potential brake system wear)
• Difficult or heavy steering (may indicate steering system issues)
• Abnormal acceleration delay (possible engine or transmission fault)
• Slow or uneven mast lifting or lowering (indicates possible hydraulic malfunction)
• Hydraulic oil leakage
• Malfunctioning or insufficient safety systems (e.g., missing seat belts or broken lights)
• Excessive or unusual noise, smell, or smoke during operation
• Inoperative or unreadable control panels or display instruments

Using a forklift inappropriately—for instance, lifting personnel instead of goods—can lead to serious accidents. If workers need to be lifted to elevated heights, a man lift or aerial work platform with secure guardrails should be used instead, along with proper fall protection equipment.

Additionally, misuse of forklifts can cause damage to the equipment itself. For example, forklifts designed to lift loads vertically should not be used for pushing or dragging items. Such misuse may bend or deform the forks, rendering the forklift inoperable. Operators must always review the equipment specifications and ensure the machine is suited to the task at hand. Using the correct equipment not only enhances safety but also prolongs equipment lifespan.

Accidents often occur when forklifts are used to lift loads that exceed their rated capacity or intended lifting height. Overloading can cause the rear wheels to lift off the ground, affect balance, damage the machine, or even result in a tip-over incident.

Before operating a forklift, the operator must ensure the total load—including the pallet—does not exceed the forklift’s rated capacity. This information is clearly stated on the Nameplate, typically attached to the forklift, which specifies maximum lifting capacity, lift height, and other critical data. If the nameplate is missing or unreadable, it must be replaced immediately by contacting the authorized dealer.

Poor visibility is a leading cause of collisions in warehouse environments. In an effort to maximize efficiency, operators may attempt to carry multiple or oversized loads that obstruct their line of sight. In some cases, aftermarket attachments or modifications—such as solid load backrests—may further block the forward view. (Note: standard backrests are usually open-frame designs to allow forward visibility.)

Workplace policies must be in place to ensure drivers maintain clear visibility at all times. If the load obstructs the forward view, a spotter should be assigned to assist, maintaining communication via radio and directing movement while the forklift is operated at minimal speed.

• Maintain a safe distance from moving forklifts at all times.
• Use hand signals or radios to communicate clearly with forklift drivers.
• Ensure adequate lighting and remove obstructions from work areas.
• Use audible signals when approaching intersections, doorways, or blind spots.
• Wear high-visibility safety vests to improve driver awareness.
• Never walk underneath or too close to the forklift or its attachments.

In some operations, the absence of suitable attachments—such as drum handlers for transporting oil drums—can compromise safety. The use of appropriate accessories not only improves handling efficiency but also enhances safety during specific tasks.