Common Mistakes in Forklift Operations and How Training Prevents Them
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- Common Mistakes in Forklift Operations and How Training Prevents Them
When forklift operations are handled incorrectly by an untrained or inadequately trained operator, they can lead to accidents, costly damages, and disruptions. Whether it involves reckless driving or a lack of spatial awareness, many companies unknowingly overlook the importance of proper forklift training, which is essential in preventing these operational issues.
At HGVC, we understand that training is the key to reducing errors and ensuring that all drivers operate vehicles like forklifts safely and efficiently. Today, we will explore common mistakes in forklift operations and highlight how professional training can mitigate them, showcasing how you can improve your operations.
Common Mistakes and How to Prevent Them
- Inadequate Load Handling
One of the most frequent forklift mistakes is improper load handling. Forklift operators may incorrectly position loads, leading to imbalance, instability, and even tipping over of the forklift. This not only endangers the operator but can also cause severe damage to goods and infrastructure.
How Training Prevents This: At HGVC, our comprehensive forklift training ensures that operators fully understand how to correctly load, balance, and transport materials. They are trained to assess the weight of a load, place it securely, and move it without jeopardising safety. This crucial skill reduces accidents and boosts the overall efficiency of your logistics operations. - Poor Forklift Maintenance
Another common mistake is neglecting regular maintenance checks. Operators often assume that the forklift is in good working condition, overlooking potential mechanical issues. This can lead to unexpected breakdowns and accidents caused by faulty brakes, worn tires, or malfunctioning hydraulics.
How Training Prevents This: HGVC’s training programs emphasise the importance of daily maintenance checks. Operators learn to spot early warning signs of mechanical failure and are trained in conducting essential pre-shift checks. This proactive approach ensures that your forklifts are always in top condition, preventing costly repairs and downtime. Maintenance checks include battery checks, hydraulic fluid checks, machine capacity management, load assessment and more. This also ensures that all trucks are operating in line with PUWER regulations and certified in line with LOLER regulations. - Speeding and Reckless Driving
Speeding is another major issue with forklift operators. In a rush to meet deadlines, drivers often ignore safe speed limits, increasing the risk of accidents. Forklifts are not designed for high speeds, and even a minor collision can result in significant damage.
How Training Prevents This: Our training focuses on the importance of speed control and careful manoeuvring. Operators are taught to drive at appropriate speeds based on the environment they are working in, whether indoors in tight spaces or outdoors in open yards. HGVC’s training promotes a culture of safety over speed, ensuring that deadlines are met without compromising the safety of the operator and others around. - Lack of Proper Communication
Forklift operations require coordination with other workers in the warehouse. Miscommunication or lack of signalling can lead to dangerous accidents, especially in busy environments. Operators might move forklifts without warning, creating blind spots for other workers. This is, in fact, one of the most common forklift accidents – around 67% of all those hospitalised in a forklift accident are pedestrians.
How Training Prevents This: HGVC emphasises effective communication during forklift operations. Our training covers hand signals, forklift zones, the use of horns, light signals, reversing sounder, and proper eye contact with co-workers to ensure that everyone is aware of the forklift’s movements. This significantly reduces the risk of accidents involving other workers and equipment. - Failure to Understand Load Limits
Operating forklifts without knowing the vehicle’s load limit is a recipe for disaster. Overloading a forklift can cause the machine to tip over or fail to lift properly, risking both operator safety and damage to the load.
How Training Prevents This: HGVC provides in-depth training on the load capacity of different forklifts and the dangers of exceeding those limits. Operators are taught to calculate load weights accurately and always adhere to the manufacturer’s guidelines. This reduces the likelihood of overloading incidents and keeps both the operator and the
load safe. - Improper Parking and Shutdown Procedures
Many operators fail to follow proper parking and shutdown procedures, leading to unintended
movements or accidents when forklifts are left in unstable positions. Forklifts should be parked in designated areas with the forks lowered and the engine turned off.
How Training Prevents This: HGVC’s forklift training covers all aspects of forklift operations, including correct parking and shutdown procedures. Operators learn how to secure the forklift when not in use, ensuring it doesn’t pose a risk to other workers or equipment. This simple yet crucial habit helps maintain a safe working environment. - Ignoring Colleague Safety
In a busy warehouse, it’s not uncommon for operators to focus solely on the task at hand, ignoring their colleagues. This can lead to collisions and injuries. A lack of attention to walkways or blind spots is a significant hazard in any warehouse setting.
How Training Prevents This: Our forklift training ensures that operators remain aware of colleague safety. At HGVC, we train operators to constantly scan their surroundings, use horns at intersections, and avoid colleague-heavy areas whenever possible. This vigilance dramatically reduces the risk of collisions between forklifts and workers on foot. - Overconfidence and Complacency
Experienced operators sometimes become overconfident, believing they don’t need to follow all safety guidelines. Complacency leads to shortcuts, such as skipping safety checks or ignoring proper procedures or operating without a qualified signaller, which increases the likelihood of accidents.
How Training Prevents This: HGVC’s training programs are designed to reinforce the importance of consistent safety practices, regardless of experience level. Our training emphasises the dangers of complacency and encourages operators to always follow the correct procedures, no matter how routine the task may seem. This includes refreshing forklift operators regularly on best practice and updated safety procedures and working with a qualified signaller to avoid entirely avoidable collisions. - Failing to Adjust for Environmental Conditions
Operating a forklift in various environmental conditions, such as on wet or uneven surfaces, requires adjustments in technique. Many operators fail to adapt, leading to accidents caused by slipping or tipping over on unstable ground.
How Training Prevents This: Our courses teach operators how to adjust their driving techniques based on the environment. Whether it’s working in wet conditions or navigating uneven surfaces, HGVC-trained operators know how to modify their approach to maintain control and ensure safety in any situation. - Accidents When Mounting/Dismounting
RIDDOR reports show that 1 in 25 forklift accidents occur when an operator is entering or exiting a truck. This is because some operators try to dismount or mount as the truck is still in motion, they jump on, they are not aware of environmental hazards, or they jump off.
How Training Prevents This: Our training teaches operators the importance of maintaining three points of contact when entering or exiting a truck and the correct locations to dismount into. - Inadequate Training and Certification
Perhaps the most significant mistake is a lack of proper training and certification. Many companies assume that once an operator has basic forklift skills, they are good to go. However, without formal training and certification, operators are more likely to make mistakes, leading to accidents and even legal liability for employers.
How Training Prevents This: HGVC offers comprehensive training and certification programs that go beyond the basics. Our courses are designed to meet industry standards and regulations, ensuring that operators not only learn the skills but also receive the necessary certifications to operate forklifts legally and safely. By partnering with HGVC, you ensure that your team is fully compliant and capable of operating forklifts in any environment.
Why HGVC’s Training is Essential
At HGVC, we take pride in offering industry-leading forklift and HGV training solutions. Our experience as the UK’s largest provider of licence acquisition programmes means we understand the unique challenges companies face when it comes to driver training. By choosing HGVC, you’re not just getting a training provider; you’re partnering with a team that manages the entire process, from onboarding to post-training audits. This holistic approach ensures that your drivers are not only certified but equipped with the skills to avoid common mistakes and enhance your operational safety and efficiency.
Prevention is Better than Cure
Forklift accidents are often the result of avoidable mistakes, many of which can be prevented with proper training. At HGVC, we’ve made it our mission to provide top-tier training that equips forklift operators with the knowledge and skills they need to operate safely.
By addressing the common mistakes outlined above and ensuring that all operators are properly trained and certified, companies can minimise risks and improve their overall efficiency. If you’re looking to enhance your forklift operations, HGVC is here to help with professional training solutions designed to fit your needs.
Contact us today to learn more about how we can support your forklift operations and driver training needs.
Jonathan is a distinguished NRI HGV Instructor accredited by RTITB, with certifications in IOSH Managing Safely, RTITB Lift Truck Instruction, and ROSPA Assured PAT Testing. His expertise extends to EdI Level 3 NVQ Assessing, Btec Level 2 in Transportation of Goods by Road, and he is a skilled Trainer in Driver CPC and Incident Investigation from GH Safety.
