Category: Forklifts

How Often Does OSHA Inspect?

The Occupational Safety and Health Administration (OSHA) is responsible for ensuring the safety and well-being of workers across the United States. One of the agency’s most effective tools is annual inspections that identify and address hazards and risks.

OSHA’s mandate is to ensure that employers maintain a workplace free from hazards that cause or are likely to cause physical harm to employees. These OSHA inspection requirements apply to all workplaces, including warehouses, and aim to create safe working environments.

How often does OSHA inspect?

All worksites can expect an OSHA inspection at least once every year. These inspections occur during work hours so inspectors can witness the worksite’s daily routines. OSHA standard 1960.25(c) states: “All areas and operations of each workplace, including office operations, shall be inspected at least annually. More frequent inspections shall be conducted in all workplaces where there is an increased risk of accident, injury or illness due to the nature of the work performed. Sufficient unannounced inspections and unannounced follow-up inspections should be conducted by the agency to ensure the identification and abatement of hazardous conditions.” 

Does OSHA do random inspections?

Yes, typically the annual OSHA inspection is random and could occur at any time throughout the year. However, even if a business has already experienced an annual inspection, there are events, such as an accident or suspicion of imminent danger, that can prompt additional inspections. Some examples that could trigger more frequent OSHA job site inspections include:

  • High-hazard industries and workplaces with high injury or illness rates.
  • OSHA receiving an employee complaint about hazards or violations.
  • An incident that involves the death or the hospitalization of three or more employees.
  • OSHA suspecting a workplace hazard that could lead to a serious injury or death. 

Who can conduct OSHA inspections?

 OSHA inspections are performed by experts trained in health and safety regulations, known as compliance officers. These are the professionals who conduct annual inspections in all workplaces, including warehouses. 

How are OSHA inspections conducted?

While every inspection is unique, there is a general outline to an OSHA inspection: 

  1. Opening conference: During an OSHA inspection what happens first is the inspectors inform the employers about the purpose, scope and procedures of the inspection.
  2. Walkaround inspection: Next, inspectors walk through the workplace, inspecting all work areas for potential hazards.
  3. Employee interviews: Employees may be questioned about workplace conditions, safety practices and any concerns or complaints they may have.
  4. Records review: Inspectors then review all documents relevant to the inspection, such as safety plans, training records and injury logs.
  5. Closing conference: After the inspection, a closing conference is held to discuss the findings.
  6. Citations and penalties: If hazards or violations are identified, OSHA may issue citations and penalties.  

During the inspection, employers can request that certain information be treated as a trade secret and not disclosed to the public. However, this does not exempt them from correcting any hazards connected to those trade secrets. Employers are also encouraged to discuss the investigation’s findings, proposed penalties and corrective actions during the closing conference.  

What happens during an OSHA inspection?

The walkaround portion of an OSHA inspection typically involves several stages. During an OSHA inspection, the compliance officer evaluates many aspects of a workplace, including:

  • Physical conditions: This includes the overall state of the facility, the condition of equipment and the presence of hazards like blocked exits, inadequate lighting or faulty machinery.
  • Machine guarding: The compliance officer will check that all machinery and equipment have proper guarding devices installed to prevent employee injuries.
  • Ergonomics: Compliance officers may evaluate workstations to identify ergonomic issues that could lead to musculoskeletal disorders.
  • Chemical exposure: If employees regularly handle hazardous substances, the compliance officer will check that appropriate protective measures, such as personal protective equipment and proper labeling, are being followed.
  • Documentation: Employers are required to maintain records related to safety and health, and the compliance officer will review these documents to verify compliance with OSHA regulations.

Throughout the inspection, employers are encouraged to actively participate and address any concerns raised by the compliance officer. This collaborative approach fosters a better understanding of potential issues and allows for prompt corrective actions. 

How long is an OSHA inspection?

 An OSHA inspection process can take up to several weeks. The duration of an inspection varies based on the size and complexity of the workplace, as well as the nature of the hazards identified. While some inspections are completed in a day, others may last days or even weeks. The time it takes is influenced by the:

  • Size of the workplace: Larger facilities with more employees and complex operations may require an extended inspection period.
  • Nature of the hazards: If the compliance officer identifies serious hazards that require immediate attention, additional time may be necessary.
  • Cooperation from the employer: Employers who actively cooperate and promptly address concerns raised during the inspection can speed up the process.
  • Documentation review: The volume of records reviewed is a significant factor.

Truthfully, what’s more important than how often does OSHA inspect is being ready for an OSHA inspection anytime. As long as your worksite operates safely and productively, you should not experience too many complications during an OSHA inspection.  Speaking of safety and productivity, do you know if your forklift batteries are operating at their peak performance? If not, let our complimentary forklift fleet performance analysis provide the answers you need. Please give us a call at (888) 316-2459 or fill out this form to begin a service request and discover how Texas Motive Solutions can improve your forklift fleet’s efficiency.

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What Is a Reach Truck?

What Is a Reach Truck

Warehouse space becomes more valuable every year. One way to get the most from an existing space is to add more shelving and narrow the aisles. However, many forklifts cannot navigate these new, smaller passages. That’s where a reach truck swoops in to save the day. 

However, size is not the only significant difference between reach trucks and forklifts. It’s the vehicle’s namesake. A reach forklift can literally “reach” into the shelves to place and retrieve pallets.

Is a reach truck considered to be a forklift?

Yes; however, officially, a forklift isn’t a forklift. It’s a powered industrial truck. At least, that’s how they are classified by the Occupational Safety and Health Administration (OSHA). OSHA has seven classifications of powered industrial trucks. What most people think of when they picture a forklift is a counterbalanced forklift, which falls under the first classification: electric motor rider trucks.

Reach trucks are found in the second classification: electric motor narrow aisle trucks. Class II trucks are designed to handle small spaces and narrow aisles with efficiency and speed. Many Class II vehicles are highly specialized or include attachments that adapt them for specific work. Other vehicles, in addition to the forklift reach truck, that are considered class II powered industrial trucks include order pickers (aka, cherry pickers) and side loaders. 

How is a reach truck different than a counterbalanced forklift?

While there are obvious visual differences between a reach lift and a counterbalanced forklift, one of the most important distinctions is less apparent: how they remain balanced while lifting a load.

When a forklift is referred to as counterbalanced, it means that the heavy battery that powers the machine and other weights in the vehicle’s rear help the forklift remain level as it lifts a load and its center of gravity shifts. Counterbalanced forklifts have a three-point suspension system that helps distribute the vehicle’s weight. The area between those three points is known as the stability triangle. When not carrying a load, the forklift’s center of gravity is safely located in the middle of the stability triangle. However, once a forklift picks up a load, its center of gravity moves forward. The heavy weight in the vehicle’s rear helps counterbalance this shift, so the forklift remains steady. 

Reach trucks are too small to utilize counterbalancing. They would be too heavy to efficiently move throughout a warehouse. Instead, a reach truck has two stabilizing legs (also known as outriggers or base legs) that extend parallel to the forks. The stabilizing legs create a secure base when lifting loads that prevent the machine from tipping forward. This design allows reach trucks to operate in narrow aisles and lift loads at high elevations without the need for a counterbalance weight.

A reach truck has forks attached to a mast at the front of the truck similar to a counterbalanced forklift, but reach trucks are much smaller. As a result, the reach truck operator either sits sideways or stands. In a stand up reach truck, the operator either faces forward or parallel to the direction of travel, depending on the design of the stand up reach forklift. Reach trucks commonly have two large rear wheels and two or four smaller front wheels nestled inside the base legs that extend from the front of the vehicle.

The average reach truck can raise a load approximately 40 feet. However, a specialized high reach forklift may be able to reach up to 60 feet.  

What are the different types of reach trucks?

Single-reach trucks

Single-reach trucks are the most common type of reach truck. These machines can load a single pallet into racking, which means they are designed for lower to medium-height storage racks that are one pallet deep.

A single-reach truck has a compact and slender design, allowing it to navigate through aisles that are typically around eight to ten feet wide.

Double-reach trucks

A double-reach truck is similar to its single-reach brethren, except it can extend two pallets deep into storage racks. To accomplish this task, the forks are attached to a telescoping scissor mechanism.

The double-reach mechanism allows the reach truck to place and access pallets in very narrow aisles and reach greater depths in storage racks, making it suitable for high-density warehouse environments.

Moving mast reach trucks

A moving mast reach truck is pretty much what the name implies. Instead of using a scissor mechanism to reach into the racks, the entire mast on these trucks literally moves forward to place cargo. Because these trucks do not need to drive into the racks, they may have the same large wheels on the front as the back. 

Multidirectional reach trucks

A multidirectional reach truck, also known as a side-loader, is a specialized type of forklift designed for handling long and bulky loads in narrow spaces. The distinguishing feature of a multidirectional reach truck is its wheels, which can rotate 90 degrees. This ability enables the reach truck to move in multiple directions, including forward, backward and sideways. This capability allows for increased maneuverability in tight aisles and facilitates the handling of long and awkward loads, like planks of wood or stacks of pipes.

Does a reach truck operator need training to drive a reach truck?

Yes. The operator of any forklift must complete training on their specific model of powered industrial truck before they operate it without supervision. An employer must ensure their employees are certified to operate the forklifts at their job site. 

According to the Texas Department of Insurance. “It is the sole responsibility of the employer to certify that each operator has been trained and evaluated as required by the standard. Outside sources may be used to deliver training or even develop the PIT (powered industrial trucks) program, but only the employer is allowed to certify their PIT operators.”

Also, a reach truck operator does not need a valid class C driver’s license to operate a reach truck (for example, someone with a suspended driver’s license can still do their job as a forklift operator). However, companies can establish policies stating that forklift operators must have a state-issued driver’s license in addition to their forklift certification.  

A final key component of the solution to “What is a reach truck?” is the battery used to power the vehicle. Are you certain that you have the best batters for your fleet? Texas Motive Solutions can help. We provide a complimentary forklift fleet performance analysis to guarantee you have the correct batteries for your needs. Plus, we have the forklift batteries and accessories you need to keep your fleet running. Give us a call at (888) 316-2459 or fill out this form to begin a service request and discover how we can keep your fleet running at peak efficiency.

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What Is a Walkie Rider?

What Is a Walkie Rider

The walkie rider forklift: it’s an extremely useful machine with a kind of silly name.

Words can be extremely silly. Some silly words are onomatopoeias, which sound like what they mean, for example, “buzz” and “gargle.” Some are just silly and fun to say, like “onomatopoeia.” Some words are so silly that they don’t even seem silly anymore because we’re so familiar with them that we overlook their silliness.

Take, for example, the walkie-talkie, developed during World War II so soldiers in the field could communicate with their commanders. These were men in some of the most extreme conditions of their lives as bullets and artillery shells rained around them. They looked at the device formally known as the “handheld transceiver” and agreed on “walkie-talkie” because they could walkie with it and talkie into it at the same time. Even better, the term “walkie-talkie” referred to a backpack radio. What most people tend to think of as a walkie-talkie today was originally called (and we’re not kidding) a “handie-talkie.”

That brings us to the useful dual functionality and silly moniker of the walkie rider pallet jack.

What is a pallet jack?

A manual pallet jack was one of the earliest types of forklifts. This device is relatively simple, consisting of two forks on wheels and a lever the operator uses to steer. To lift cargo, the operator guides the forks through a pallet and then pulls the lever back and forth, using it like a jack.

Most of these vehicles only lift loads a few inches off the ground. Pallet jacks are great for moving pallets a short distance or around a small warehouse as long as the intent is to store them low or on the floor.

Manual pallet jacks take a physical toll on operators because they need to push and pull loads. This is less of an issue over a short distance. However, as goods required transport over extended distances, manual pallet jacks became inefficient and needed to be modernized.

What is a walkie rider?

A walkie rider, also known as a Class III forklift (electric motor hand trucks and rider trucks), is an evolution of a manual pallet jack because an electric motor powers it. In addition to being able to travel longer distances, the electric motor enables a walkie rider pallet jack to navigate through tight spaces. It also contributes to smoother and more controlled movements, especially when transporting loads over longer distances. The front and load wheels (located at the back of the forks) also help to ensure stability, responsiveness and precise control.

A walkie rider pallet jack is an interesting machine because the name can be a little misleading. Some walkie riders are exclusively a pallet rider (also known as a rider jack) designed with a platform in the middle of the machine where the operator stands. Some walkie riders are exclusively walkies with electric propulsion and lifting but no platform, so the operator walks behind the machine. Finally, some are genuinely walkie riders (also adorably known as a ride on walkie) with the ability to steer while walkie-ing and the option to hop on a small platform and rider.

A walkie rider pallet jack is equipped with a hydraulic lifting mechanism, which allows the machine to lift heavier loads than many manual pallet jacks. To raise a pallet, the operator uses controls on the handle to engage the hydraulics. The load wheels provide stability and help distribute the weight of the load. The hydraulics also allow the operator to control the descent and smoothly lower the load.

Benefits of a walkie rider

By offering either walk-behind or ride-on capabilities (and sometimes both), the walkie rider pallet jack provides many material handling benefits.

Increased efficiency

The versatility of the walkie rider streamlines loading and unloading trucks, transporting goods through a warehouse and maneuvering through narrow aisles and tight turns. The machine’s ability to quickly adapt to a variety of needs can help to increase and improve overall operational productivity.

Versatility

A walkie rider is suited for a variety of applications, from easily maneuvering in confined spaces to convenient longer-distance transport. This adaptability is exceptionally valuable in warehouses where equipment needs to adjust to various material handling requirements.

Reducing operator fatigue

A walkie rider improves operator comfort and helps to reduce fatigue. The electric motor and ride-on platform (when available) minimize the physical strain on operators, especially over extended distances. This enhances the operators’ well-being and contributes to sustained productivity throughout the workday.

Make mine a double, a walkie double pallet jack, that is

Some of the walkie riders used in busy or large warehouses and distribution centers include a design variation that dramatically changes their functionality.

A double walkie is designed to lift and transport not one but two pallets simultaneously. A walkie double pallet jack has longer forks that can fit two pallets end-to-end. This essentially doubles operational efficiency and is a significant advantage when you need to move a large volume of goods quickly.

However, when you really want to move some cargo, a triple walkie may be the solution. A walkie triple pallet jack can handle three pallets at once, which is one more than two and three times as many as one. Double and triple walkie rider pallet jacks are typically electric-powered to effectively handle the increased load capacity. They are valuable tools in warehouses dealing with high volumes of goods, where reducing the number of trips is necessary to improve overall productivity.

Walkie rider safety precautions

It is essential to follow proper safety procedures to help ensure a secure and productive work area.

Inspect the equipment before using  

Even a manual pallet jack is designed to carry pallets that are beyond the capacity of most humans to lift. This means any equipment failure could cause an accident and severe injury. It is crucial to carefully inspect the machinery before using any forklift. When inspecting a walkie rider pallet jack, look for loose prongs, unbalanced wheels, leaks, etc. It is advisable to use a pre-op checklist to ensure that nothing is missed during the inspection.

Check and double-check the route

Even with a walkie rider that does not lift pallets too high, cargo can obstruct the operator’s view and cause them to miss obstructions. Be sure to check the route for possible obstacles and clear them before advancing. You should also check the terrain and look for uneven surfaces that could impede your progress. If the surface is bad enough, you may need to find an alternate route.

Operator certification

The Occupational Safety and Health Administration (OSHA) requires that all manual or electric walkie rider operators complete a certification course before using the machine. It is the employer’s responsibility to ensure their workers are certified on the specific machines they use. Those who fail to acquire the appropriate certification can face significant fines and penalties.

Restrict access to the machines

In addition to confirming that all operators are certified, employers should also ensure that those are the only people operating the machines. One method is to restrict access to the walkie riders by storing them in a secure area. It is also recommended to have a check-out and check-in procedure. Even a paper sign-in sheet can provide a safeguard and ensure that only authorized users can access these machines.

At Texas Motive Solutions, we can help ensure that your walkie riders and all electric forklifts remain running at their peak performance. We have the forklift batteries and accessories to keep your fleet purring, and we provide a complimentary forklift fleet performance analysis to guarantee you have the correct batteries for your needs.

Give us a call at (888) 316-2459 or fill out this form to discover everything Texas Motive Solutions can do for you.

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OSHA Forklift Attachment Regulations Guide

OSHA Forklift Attachment Regulations Guide

Forklifts are capable of impressive feats the minute they roll off the assembly line. However, there are some industries where they need to do more. That’s why a wide range of attachments can expand a forklift’s capabilities and versatility. However, just as many regulations must be followed to ensure that a modified forklift remains safe. 

The Occupational Safety and Health Administration (OSHA) officially categorizes all classes of forklifts as industrial trucks. These machines can do a wide variety of tasks, and those duties can be further expanded with specialized attachments.

Fork truck attachments for lifting

There are many (many, many) OSHA regulations regarding the safe operation and maintenance of industrial trucks. While many of these machines are massive, they are also delicately balanced, which is why they are so heavily regulated. Improper operation or an unbalanced load can easily upset a forklift and cause an accident and injury.

Not upsetting this delicate balance is also the goal regarding OSHA forklift attachment regulations.

Forklift attachments OSHA regulations

The primary OSHA regulation regarding forklift attachments is 1910.178(a)4. It states that “modifications and additions which affect capacity and safe operation shall not be performed by the customer or user without manufacturer’s prior written approval. Capacity, operation and maintenance instruction plates, tags or decals shall be changed accordingly.”

The forklift owner is responsible for obtaining the manufacturer’s written approval to comply with OSHA requirements. You must contact the original attachment manufacturer. A forklift dealer cannot supply approval for a forklift attachment.

To obtain a manufacturer’s written approval, you must develop guidelines establishing why you need the attachments and how they will be used. Once you show these to the manufacturer and receive their written approval, you must update the forklift’s instruction plates, tags and decals with their new weight and lifting limits. This is to stay in accordance with OSHA regulation 1910.178(a)5, which states, “If the truck is equipped with front-end attachments other than factory installed attachments, the user shall request for the truck to be marked to identify the attachments and show the approximate weight of the truck and attachment combination at maximum elevation with load laterally centered.”

Finally, after installing the attachment, you need to train all operators on the safe use of the attachments and their potential new risks. This training must include how to operate the machine at all times following OSHA regulation 1910.178(o)4, “Trucks equipped with attachments shall be operated as partially loaded trucks when not handling a load.”

Types of forklift attachments (and some potential risks associated with them)

Interested in a forklift fork hook attachment for lifting? Wondering, “How does the boom extension affect your lifting capacity?” Concerned about OSHA man basket requirements forklift specifications?

Before you can effectively use any lifting device attachment for forklift operations, it is essential to understand its benefits the potential risks associated with its misuse.

Fork extensions

Fork extensions are a lifting attachment for forklift forks that increases their length to handle longer loads. These attachments are steel, come in varying sizes and widths and mount directly on the machine’s factory-installed forks.

The potential hazards of fork extensions include:

  • Overloading: Fork extensions increase the forklift’s load capacity, but operators still need to follow the attachment’s load limit guidelines or risk instability, tipping or damage to both the forklift and the load.
  • Reduced visibility: Longer forks may cause the load to obstruct the operator’s view, which increases the risk of collisions with obstacles, other equipment or personnel.
  • Balance issues: Extended forks change the machine’s center of gravity, affecting the forklift’s stability. Operators must adapt their driving and lifting techniques to avoid accidents.

Side shifters and fork positioners

A side shifter attachment lets an operator move the forks laterally left and right. The benefit of this attachment is that the operator can nudge the forks into an ideal position to grab cargo without repositioning the entire forklift.

A fork positioner adjusts the distance between the forks to easily accommodate various pallet sizes. The forks can move closer together or further apart, either individually or at the same time.

The potential hazards of side shifters and fork positioners include:

  • Pinch points: A side shifter’s or fork positioner’s moving parts can create possible pinch points and injure nearby personnel.
  • Load stability: Laterally moving forks make it easier for cargo to shift accidentally, which can lead to uneven weight distribution and accidents.
  • Misuse: Improper use of side shifters and fork positioners, such as abrupt movements or exceeding weight limits, can damage the attachment or the forklift itself.

Clamps and rotators

Clamps allow forklifts to easily handle irregularly shaped loads, such as barrels, drums and items that don’t fit on pallets. Specific examples include paper roll clamps, drum clamps, bale clamps, carton clamps and multi-pallet handlers.

Rotators let forks turn to transfer loads into other containers. Industries that commonly use this attachment include food and beverage processing, waste and recycling and agriculture.

The potential hazards of clamps and rotators include:

  • Load integrity: Clamps and rotators place pressure on loads and misuse or excessive force can lead to load damage or spillage.
  • Tipping: Handling unbalanced loads with clamps or rotators can increase the risk of forklift tipping. Operators must adjust accordingly.
  • Accidents: Clamps and rotators alter a forklift’s profile, increasing the likelihood of collisions with racking systems, walls and other obstacles.

Buckets and platforms

A bucket attachment for forklift enables the machine to load, scoop or sweep loose debris for quick, easy clearing. There are also buckets, platforms and cages that transform forklifts into mobile elevated work platforms. These OSHA approved man baskets for forklifts can generally lift between two to four people, depending on the forklift’s capacity.

The potential hazards of buckets and platforms include:

  • Load spillage: Handling loose material with a bucket increases the likelihood of a spill, which creates risks for both the forklift operator and other personnel in the vicinity.
  • Limited visibility: Adding a bucket or platform can obstruct the operator’s view, requiring extra caution when maneuvering the forklift to avoid collisions.
  • Falls: What goes up…, elevating personnel always introduces a fall risk, so proper fall protection measures, such as guardrails and personal protective equipment, are crucial.

Fork hooks

Instead of lifting cargo on top of the forks, a fork hook attachment allows a forklift to carry items under the forks. Fork hook attachments secure onto the forklift’s forks using pins or locking mechanisms. This attachment is used to transport loads that might not fit on standard forks, such as containers or machinery that have eyelets, straps or other designated lifting points.

The potential hazards of fork hooks include:

  • Inadequate load distribution: Incorrect positioning can result in uneven weight distribution and upset stability during lifting and transport.
  • Obstructed visibility: Because the forks are raised when using the attachment, the load may hang directly in an operator’s line of vision.
  • Improper attachment: If the fork hook is not secure, it may detach during lifting or transport and cause an accident.

Telescoping booms

A telescoping forklift boom attachment extends the reach of a forklift. Like fork hooks, telescoping boom attachments also use a hook to lift and transport cargo. The boom is operated hydraulically and is extended or retracted to reach heights and distances previously impossible for the machine to achieve. Telescopic booms are versatile and can be used for various applications, including construction, agriculture and warehouse material handling.

The potential hazards of telescoping booms include:

  • Tip-over risk: Extending the boom to its maximum capacity can affect the forklift’s stability.
  • Overloading: Operators must be very careful to stay within the boom’s weight capacity, or the structure could break.
  • Visibility issues: The extended boom may obstruct the operator’s view.

Now that you better understand the OSHA forklift attachment regulations, you may have questions about other OSHA requirements, such as the 1910.178(g) category regarding the safe changing, charging and storage of forklift batteries. Texas Motive Solutions has the answers you need. We can also help with all your forklift battery or forklift battery cell replacement needs. Call us at (888) 316-2459 or fill out this form to discover how our complimentary forklift fleet performance analysis can ensure your fleet runs at its peak perfection.

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Best Practices in Preventing Forklift Accidents

Best Practices in Preventing Forklift Accidents

Forklifts weigh several thousand pounds, can travel up to 20 miles per hour and frequently have obstructed views and uneven weight distribution. Operating these machines can be risky. Fortunately, with careful caution, most forklift accidents are avoidable.

From Oct. 1, 2021, through Sept. 30, 2022, the Occupational Safety and Health Administration (OSHA) gave out nearly 2,000 violations for forklift infractions. Forklifts (or powered industrial vehicles) rank seventh on OSHA’s list of top 10 most frequently cited standards. OSHA updates its fines each calendar year and adjusts for inflation. For 2023, OSHA’s maximum penalty for serious and other-than-serious violations is $15,625 per violation, and the maximum penalty for willful or repeated violations is $156,259 per violation.

The main forklift violations are:

  • Unsafe operation, such as driving with an elevated load, going too fast and not following loading dock safety procedures.
  • Employers failing to provide refresher training.
  • Missing or inadequate forklift operator certification.
  • Failure to remove unsafe trucks from service.
  • Failing to perform a daily pre-operation inspection.

Interestingly, every one of these violations is easily avoidable. If you’ve ever seen a forklift meme, you know that some of the worst forklift accidents are caused by poor decisions or operator error. The most recent OSHA statistics list approximately:

  • 85 fatal forklift accidents per year.
  • 35,000 forklift accidents with serious injuries.
  • 62,000 non-serious forklift accidents.

What are the main causes of injuries when using forklifts?

According to OSHA, the most common forklift accidents are:

Forklift rollovers

Not only are rollovers a significant cause of forklift accidents, but according to the CDC, they are “the leading cause of fatalities involving forklifts.” Rollovers result in “about 25% of all forklift-related deaths.”

The leading cause of rollovers is when the machine becomes imbalanced. Forklifts are counterbalanced by heavy weights in the back that offset the heavy load in the front. However, that delicate stability can be disrupted by:

  • Driving with the load raised too high.
  • Carrying an uneven or unbalanced load.
  • Driving too fast.
  • Turning too quickly.
  • Turning on an incline.
  • Driving on uneven surfaces.

Pedestrian accidents

Collisions with pedestrians are one of the most dangerous warehouse forklift accidents. Forklifts consistently operate in the same vicinity as roving workers. If the forklift operator or a pedestrian loses focus, the risk of a severe accident increases. After rollovers, the three leading causes of a fatal forklift accident are:

  • Crushed between the forklift and a surface.
  • Crushed between two vehicles.
  • Struck or run over by a forklift.

Falling containers

Improperly loaded cargo, which means the load is uneven or contains more than one container, creates a dangerous situation for the operator and anyone nearby. A falling load can injure someone, and the contents could become dislodged and cause harm.

Falling to a lower level

Uneven loading platforms and tractor-trailer thresholds are dangerous locations for forklifts. The leading causes of lower-level falls are:

  • Trucks or trailers rolling away.
  • Slippery floors.
  • Worn or damaged floors.

Driving into storage racks or knocking a pallet loose

Driving carelessly, speeding or turning too fast are the leading causes of knocking into a pallet rack. This action can damage a forklift or knock down a shelving unit, and smacking into a rack is a leading cause of falling pallets.

Inadequate operator training

OSHA estimates that proper safety training could prevent approximately 70% of all fork truck accidents. Fortunately, training and certification are mandated for every forklift operator before stepping into a vehicle. However, the issue typically isn’t that operators are not initially trained. The problem typically arises through a lack of refresher training.

What is the forklift speed limit?

OSHA allows employers to determine the speed appropriate for their specific worksites. However, while there is no single forklift speed limit OSHA has listed guidelines that employers can use to determine what is safe. “These factors include, but are not limited to, the type of truck itself, the manufacturer’s limitations on the truck, the load being carried, adequate stopping distances, operating surface conditions, pedestrian traffic and other safety issues.”

Also, don’t let the fact that a posted speed limit is nonexistent trick you into believing that a worksite can operate like the lawless Wild West. OSHA will issue a citation if they believe an operator is driving at an unsafe speed. “OSHA would consider the totality of the circumstances surrounding the operation of the powered industrial truck in determining whether safe travel speeds are practiced at a workplace.”

When is it acceptable to carry a pedestrian on a forklift?

OSHA has set two standards for when it is safe to carry a pedestrian on a forklift, and both must be met for the practice to be acceptable. According to the Powered Industrial Trucks (Forklifts) eTool on pedestrian traffic, pedestrians should “never ride on a forklift unless authorized and the forklift is designed for riders.”

What areas on a forklift can cause injuries?

Well, if someone is careful, the ideal answer is none of the areas can cause forklift accidents. Unfortunately, we don’t live in a world of make-believe with flowers, and bells, and leprechauns and magic frogs with funny little hats. So, when operators and pedestrians do not exercise the appropriate level of caution, pretty much any area on a forklift can cause an accident.

  • Forks: improperly secured loads can dislodge, injuring operators or bystanders.
  • Tires: moving wheels can flatten feet and toes.
  • Operator’s compartment: not wearing a seat belt or standing while in motion may cause the driver to fall or be tossed from the forklift.
  • Mast: the uprights can obstruct visibility and cause a collision with an object or pedestrian.
  • Pedals: feet can get caught and smooshed, especially if wearing inappropriate footwear.
  • Battery compartment: leaking or improperly maintained batteries can be hazardous to operators and other employees.
  • Hydraulic systems: hands or clothing could become caught in lifting and tilting mechanisms.
  • Exhaust: poorly ventilated areas or enclosed spaces can lead to exhaust exposure.
  • Steps: if a surface becomes slippery, climbing on it may cause a fall.
  • Attachments: improper use of clamps, side shifters or booms can result in load instability and accidents.

How can you decrease the likelihood of injuries while using forklifts?

OSHA has many valuable suggestions to help operators and worksite managers avoid forklift accidents.

Forklift operations

  • Always operate the vehicle according to the manufacturer’s instructions.
  • Always wear a seat belt.
  • Never exceed the rated load and ensure it is stable and balanced.
  • Do not raise or lower the load while traveling.
  • Keep a safe distance from platform and ramp edges.
  • Be aware of other vehicles in the work area.
  • Have clear visibility of the work area and ensure you have enough clearance when raising, loading and operating a forklift.
  • Use proper footing and the handhold, if available, when entering the lift.
  • Use horns at cross aisles and obstructed areas.
  • Watch for pedestrians and observe the speed limit.
  • Do not give rides or use the forks to lift people.

Safety training

  • Only trained and certified workers may operate a forklift.
  • Ensure operators are trained on the types of trucks in use.

Forklift maintenance

  • Remove from service any forklift found to be in unsafe operating condition.
  • Keep forklifts in clean condition, free of excess oil and grease.
  • Repair and maintain according to the manufacturer’s recommendations.

In addition, workplaces should establish a regular forklift maintenance schedule. Routine inspections can identify potential issues before they become safety hazards. Also, operators need to train in responding to emergencies, such as tip-overs, stuck loads and other hazardous situations.

Designate pedestrian zones and walkways by painting yellow traffic lines on the floor or installing permanent protective barriers. In addition, operators and pedestrians should wear appropriate personal protective equipment, such as high-visibility vests, helmets and steel-toed boots.

Creating a safe work environment and preventing forklift accidents is everybody’s responsibility. Maintaining your forklift fleet, including forklift battery maintenance, is essential to workplace safety. That’s why Texas Motive Solutions provides a complimentary forklift fleet performance analysis to ensure your fleet operates at peak efficiency. Give us a call at (888) 316-2459 or fill out this form to learn about our services and discover everything we can do for you.

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The History of Forklifts: A Journey Through Time

The History of Forklifts: A Journey Through Time

The history of warehouse forklifts extends back more than 100 years. Its evolution from simple hand truck to industrial machine is a fascinating part of our evolution from an agricultural to industrial culture.

It is safe to say that today’s supply chain would not—could not—be the same without the modern forklift. The ability to quickly unload a truck, move the cargo through a warehouse, store it on a shelf 25 feet high and reverse the process for shipping is invaluable.

So, when was the forklift invented? Well, to arrive at a machine as large as a forklift, it was necessary to start small.

The first forklift ever made—mid-1800s

The forklift background begins in industrial revolution era England, which started in the mid-1700s and lasted through the mid-1800s. It was a time of massive upheaval, change and invention.

Shipping was an indispensable part of the industrial revolution, bringing much-needed materials and goods from other parts of the world to the island nation. Naturally, people needed to load and unload materials from these ships. It was hard, grueling labor, and eventually, someone created a device to make transporting sacks of goods off and onto ships easier: the sack truck.

The sack truck was manually operated. Like today’s hand truck, a sack truck had two handles at the top of a device, an extended back to rest cargo and a base to lift goods securely. Also, many sack trucks had a hand crank attached to uprights that could lift heavy items up to five feet high.

While this relatively simple machine may not be what you think of as a forklift, it had the necessary components: a pair of forked tines utilized to make lifting heavy objects easier. Hence: the first forklift.

Unfortunately, who invented the forklift, the first one anyway, is lost to time. As to when was the forklift truck invented? Well, we don’t have an exact date on that either. All we know is that during the mid-1800s, some lucky people stopped having to lug heavy sacks on their shoulders thanks to the sack truck.

Late 1800s-early 1900s

The next few decades saw a scattering of inventions that would contribute bits and pieces to the development of the forklift.

The first was a portable elevator patented in 1867. The device was stationary but could be loaded on a cart and moved around a worksite. It consisted of an upright frame, a hand-cranked hoist, and a platform. By loading cargo on the platform and turning the crank, it became much easier to lift heavy goods. Also, the device greatly resembles today’s forklift mast.

Jump forward a few decades, and we arrive at the next invention to impact the forklift (it would also revolutionize the entire world, but that’s someone else’s article): the automobile. On January 29, 1886, Karl (who also went by Carl) Benz (yes, he of Mercedes Benz) secured patent number 37435 for a “vehicle with gas engine operation.” July of that same year saw him tooling around the streets of Mannheim in his three-wheeled “Motorwagen” (that’s 13 years before Henry Ford cruised Detroit in his creation).

Skip another couple decades, and we arrive in the coal-dust-filled air of the Altoona Train Station, specifically, the luggage area where workers lug heavy, four-wheeled luggage carts to and fro. However, their job became incrementally easier when, in 1906, the Pennsylvania Railroad added a battery to help propel the vehicle. Not only did this addition save some workers’ backs, but it also came to be known as the first industrial truck.

Then in 1917, Eugene Clark at Clark Equipment Company developed the Tructractor. If you’re imagining a Bigfoot-esque monster truck, we don’t blame you. In reality, it was the first seated, counterbalanced, internal combustion-powered industrial truck. The Tructractor featured a flatbed or a cargo box that was manually loaded and unloaded, and Clark used it to haul heavy parts around his plant.

Some (like the Logistics Hall of Fame) consider the Tructractor (that name is so cool, it should be a dinosaur’s name) the first forklift. While we appreciate its counterbalanced aspect (and amazing name), the Tructractor (which was also known as the Clarktor—and yes, those two facts are the best things that will happen to you all day) was missing one key component of a forklift. It had no forks.

Affordable hydraulic systems—mid-1900s

Let’s pause our mid-20th century exploration to head back a couple of millennia to 6,000s B.C.E. Imagine you’re a Mesopotamian or Egyptian farmer. You want to grow some crops, but the stupid water is way over there while your stupid field is way over the other way. What can you do? The answer: move the water—a couple of ditches, maybe a rudimentary aqueduct or two, and voilà, the first hydraulics.

Fast-forward to 1650. A couple of smarty-pants, Blaise Pascal and Daniel Bernoulli, were hanging out thinking about water (maybe they were thirsty, we don’t know). However, what they discovered is known as Pascal’s principle (also called Pascal’s law), and it forms the basis of every hydraulic system today.

According to the Encyclopedia Britannica, Pascal’s principle “states that pressure in a liquid is transmitted equally in all directions; i.e., when water is made to fill a closed container, the application of pressure at any point will be transmitted to all sides of the container.” Imagine slapping your hand into a bowl full of water, which sends the liquid everywhere, versus slowly lowering your hand into the bowl, which just gently displaces the fluid.

Now, picture a hydraulic press with a small piston at one end, an enclosed container filled with liquid and a piston 10 times the size of the first at the other end. By pressing down on the small piston, you can lift a very heavy object placed on the larger piston. The reason is that, even though the pressure on the smaller piston may be slight, that pressure is transmitted equally throughout the liquid in the container. So, the larger piston, which is 10 times bigger than the first piston, also receives 10 times the pressure. That’s how a hydraulic fluid system works.

Most hydraulic systems require intricate planning and complex machinery, and for decades they were simply too expensive to be produced on a large scale. However, during World War II, hydraulic systems were widely used in military applications, such as aircraft control systems and heavy machinery. As the military refined its large-scale production of hydraulic systems, it led to manufacturing improvements that significantly reduced assembly costs.

Once the war ended and the global economy began its recovery, industrial production kicked into high gear, which drove demand for hydraulic systems across many industries. This spurred further innovations in hydraulic technology and manufacturing processes, making the production of hydraulic systems even more affordable.

Forklift invention—1920s

Now we’re back to our friend, Eugene Clark and his Tructractor. While hauling this and that around the factory, the vehicle often caught the attention of visitors (because it was called the Tructractor!) who often requested one for their businesses. This happened so frequently that, in 1919, Clark opened the Clark Tructractor Company.

In 1922, the company (with the amazing name) introduced the (less fantastically named) Truclift. The Truclift’s innovation was that it used hydraulics, not mechanical gears, to lift a load. Still no forks, though.

In fact, Clark would not introduce our beloved forks to what would become known as the forklift. That honor belongs to the Yale & Towne Manufacturing Company. In 1923, Yale introduced a machine that anyone today would instantly recognize as a vintage forklift. In addition to forks, the machine also featured a hydraulic mast and another, perhaps even more critical, innovation. The Yale forklift featured an electric motor and a battery pack for power storage, setting the stage for the widespread adoption of electric forklifts in various industries.

Standardization of pallets—1930s-1950s

The main benefit of forks—and the reason they eventually became industry standard—is that they significantly reduce (or eliminate) the need to manually load cargo onto a vehicle. Unfortunately, while the forklift was in its infancy, the cargo made this impossible. Not only were there multiple boxes of varying sizes, but cargo was also shipped in sacks. Sacks and forks are not a great combination, unless the goal is to have grain scattered across the floor from a torn bag. All of this cargo needed something for the forks to lift: a pallet.

One of the earliest pushes for pallet standardization occurred during World War II. Always looking for a way to streamline processes, the U.S. Department of Defense needed more efficient handling and transportation of military supplies. This led to the invention of the “four-way entry” pallet design, which allowed forklifts to lift a pallet from any side.

Following the war, economic recovery, the growth of industrialization and the expansion of international trade further emphasized the importance of pallet standardization. While there still are some variations in pallet sizes based on industry, country and regional preferences, they are all forklift compatible.

New storage needs—1950s

Warehouse needs began to change in the mid-20th century with the growth of the manufacturing, distribution and retail sectors. Warehouses had to adapt to handle larger volumes of goods.

Soon warehouse space was at a premium, and warehouse owners and operators had to make a choice. They could grow out, which meant building new structures and additions dependent on available space, or they could grow up by installing taller shelving.

The decision was a relatively easy one. As shelving rose, forklifts needed to adapt their masts with improved stability and higher lift heights. The aisle widths also became narrower to accommodate more shelving units. However, the older forklift models were too big to fit and couldn’t make the sharper turns. So, narrow aisle forklifts, such as reach trucks and order pickers, were introduced with specialized features like articulated masts, side-stance operator positions, and advanced navigation systems.

Battery improvements—now

Forklift batteries have significantly improved, driven by technological advancements and the need for more efficient and sustainable energy sources.

Modern forklift batteries have higher energy density, meaning they can store more energy within a given volume or weight. This allows for longer operating times between charges and increased productivity. Improved energy density also contributes to the overall efficiency of forklifts.

Traditional lead-acid batteries have been enhanced with maintenance-free designs, reduced water consumption and improved charge acceptance. Additionally, lithium-ion batteries have gained popularity in recent years due to their higher energy density, faster charging capabilities, longer lifespan and reduced maintenance requirements. Lithium-ion batteries also produce fewer greenhouse gas emissions compared to traditional lead-acid batteries.

Rapid charging solutions have become more prevalent, allowing forklift batteries to be charged quickly during scheduled breaks or shift changes. Fast charging technologies, such as high-frequency chargers and opportunity charging systems, reduce downtime and maximize productivity by minimizing battery charging time.

Standing on the shoulders of giants

The modern forklift is an impressive machine. However, it took over 100 years of innovation and drive to develop the individual pieces that combine to create this lifting marvel.

If you’d like to discuss the history of forklifts or the evolution of forklift batteries, Texas Motive Solutions wants to hear from you. Don’t forget that we also offer a complimentary forklift fleet performance analysis to ensure you have the correct batteries for your needs to keep your fleet running at its highest performance.

For all your forklift repair and maintenance needs, give Texas Motive Solutions a call at (888) 316-2459. Please fill out this form to learn about our services and discover everything we can do for you.

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Best Forklift Memes: Lifting Spirits

Forklift Meme

In the fascinating and baffling cyberspace of the internet, one of the most interesting (and surprising?) trends is the longevity of funny forklift memes. So, let’s dive into, as our friend the internet might say, “Ermahgerd, firclift mehms!”

While most people associate memes exclusively with internet culture, the idea of a meme predates the widespread adoption of the net by several years. The term meme was conceived in 1976 by the evolutionary biologist Richard Dawkins in his work, “The Selfish Gene.” Dawkins’s theory is that memes are constructs that spread through the population in a cultural way, such as a melody, a catchphrase, a fashion trend or slang.

Quoting from the Encyclopedia Britannica, “Within a culture, memes can take a variety of forms, such as an idea, a skill, a behavior, a phrase, or a particular fashion. Memes carry information, are replicated, and are transmitted from one person to another, and they have the ability to evolve, mutating at random and undergoing natural selection. The replication and transmission of a meme occurs when one person copies a unit of cultural information comprising a meme from another person.”

However, what most people think of as a meme—an internet meme—differs from Dawkins’s original conception. An internet meme is a cultural item that spreads online and through social media. While Dawkins’s memes spread and evolve naturally, an internet meme is deliberately reproduced and altered. They also tend to be funnier (or, at least, funnier to someone) than Dawkins’s notion of memes as a “cultural parallel to biological genes,” which doesn’t seem that funny at all.

The forklift meme explained

Forklift memes began in 2016 with the creation of a Facebook group dedicated to forklifts and forklift jokes. We don’t know who created the Facebook page, but one of its most popular features is memes. These memes often depict humorous workplace situations, common forklift mishaps or the agility and capability of forklift operators.

One possible explanation for why these memes became and continue to be popular is that forklift operators face unique workplace challenges, such as maneuvering through narrow spaces, carefully lifting heavy loads and navigating crowded warehouse floors. Forklift memes give those in the know a way to blow off steam. Another possible explanation is that these memes help those outside of the profession to gain some (often highly embellished) insight into the world of forklift operators by shedding light on the risks and quirks of the job.

While all forklift memes try to be entertaining and funny, the subject matter ranges from benign to bawdy. (Since this is a family-friendly website, we’re sticking with the benign.)

Types of forklift memes

The forklift certified meme explained

The Occupational Safety and Health Administration (OSHA) requires anyone who operates a lift to be forklift certified meaning they are trained on the specific machine they use on their job site. Because there are many different types of forklifts, there is no universal forklift certification. Instead, forklift certification is both machine-specific and site-specific. The employer is responsible for certifying that each forklift operator is trained on the exact machine they use at their daily workplace.

A forklift certification meme plays on the notion that once someone becomes forklift certified, they become somewhat superhuman. These memes often indicate that being certified to operate a forklift implies that someone is now hyperbolically experienced.

Forklift driver meme

Forklift operator memes differ from the forklift certified meme by featuring an image of a forklift in an awkward or impossible position. Some forklift operator memes play on forklifts getting stuck or tangled in unusual situations and the ingenuity and problem-solving abilities of operators, while others boast of the all-around awesomeness of being a forklift driver.

Forklift safety awareness meme

Forklift safety awareness memes serve as a (sometimes not-so-) gentle reminder of proper safety protocols. By infusing humor into safety messages, these memes help remind forklift operators to remain vigilant, follow safety guidelines and prioritize their and others’ well-being while operating forklifts. They also help to reinforce the repercussions when drivers act without enough care and caution. By using humor to convey serious messages, these forklift memes help highlight safe forklift practices.

Celebrity and pop culture forklift memes

Forklift memes frequently venture into the realm of celebrity and pop culture references. These memes feature images of pop culture figures or iconic movie scenes modified to include or reference forklifts. Some examples include:

“Aliens”
“The Matrix”
Sasquatch
“Zoolander”
“Taken”

“SpongeBob SquarePants” (So many SpongeBob SquarePants memes.)

It’s important to remember that forklift memes are created to be humorous and often rely on exaggeration or absurdity for comedic effect. While these memes may not accurately represent the seriousness of forklift certification in a real-world occupational setting, they allow the internet to revel (and chuckle) at the awesomeness of the average forklift operator.

At Texas Motive Solutions, we love a good laugh, but we also know that workplace safety and keeping your fleet up and running is no joke. That’s why we offer our complimentary forklift fleet performance analysis. For all your forklift repair and maintenance needs, give us a call at (888) 316-2459, or you can fill out this form to learn about our services and discover everything we can do for you.

Disclaimer: No copyright infringement intended. All rights and credits to respective owner(s).

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