Fine-Tuning Operator Training

Studies have shown that effective forklift operator training programs can improve safe performance by as much as 70 percent. Safety advantages and special features and options included in newer models of lift trucks are operator friendly. These features include  

Operator training is the one area that continues to lack focus in the workplace. 

The statistics involving operator injury and death in the United States are alarming. Many of these statistics were identified earlier in this chapter. In Canada, 19 lift truck-related deaths occurred in 1995. Many of these deaths were attributed to a lack of operator training. To help reduce the toll of injuries and incidents, both the U.S. Department of Labor—OSHA and Ontario Province have developed extensive requirements for operator training. 

The training of operators must include classroom interaction and the use of visual aids. Many of the various details of lift truck movement such as tipover, tip forward, counterbalance, stability triangle, lateral and longitudinal stability must be discussed. Trainees must know each model s specific details for operation. Couple this with the different kinds of lift trucks counterbalance, narrow-aisle, walkies, stock-chasers, etc., and it s obvious that there are many details involved in operating a powered industrial truck. 

Training in the daily evaluation of the lift truck is necessary. Every lift truck must be inspected prior to the start of the shift. A detailed form is required to assist the operator. Supervisors can easily evaluate the correct procedure involved in daily inspections by observing each operator at the beginning of a shift. This serves as a reminder that the process is important and that it must be done correctly. 

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Typically, the first full-scale events are demonstrations. Some scale-up studies may be performed at full scale just before the formal demonstrations are initiated, however. This would be true in those cases in which the results of the development-ranging studies do not provide sufficient confidence or assurance. In addition to providing assurance that the process can be duplicated at full scale, demonstrations provide a platform for operator training, SOP development, laboratory method fine-tuning, equipment cleaning, and most important, site experience with the demonstrated process. It should be noted that most companies are constrained by a budget for product development, which means that they cannot afford doing a battery of demonstrations. 

It takes years to develop and fine-tune a prooftest program. Time is required to identify all of the instrument loops that need to be included, and more time is needed to systematically collect or develop data sheets containing basic operational information for each device or loop. During the development stage, test methods need to be defined, and the appropriate personnel responsible for testing must be identified and trained. Finally, test frequencies must be decided. 

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