Standard Operating Procedure for Forklift Operations

Purpose

The purpose of this SOP is to establish guidelines for the safe operation of forklifts and other material handling equipment in the warehouse to prevent accidents, injuries, and property damage.

Scope

This SOP applies to all personnel authorized to operate forklifts and other powered industrial trucks within the warehouse facility.

Responsibilities

• Warehouse Manager: Overall responsibility for implementing and enforcing forklift operation procedures and ensuring compliance with safety regulations.
• Operations Supervisor: Responsible for conducting forklift operator training, monitoring operator performance, and enforcing safety rules.
• Forklift Operators: Responsible for operating forklifts safely, conducting pre-operation inspections, and reporting any equipment defects or safety concerns.
• Health and Safety Officer: Responsible for providing guidance on forklift safety practices, conducting periodic inspections, and investigating accidents or near misses.

Procedure

1. Pre-Operation Inspection:
   • Conduct a pre-operation inspection of the forklift to check for any visible damage, leaks, or malfunctions that could affect safe operation.
   • Inspect tires, brakes, steering, lights, horn, and other essential components according to the manufacturer’s specifications and recommended inspection checklist.
   • Do not operate the forklift if any defects or safety hazards are identified during the inspection. Report issues to the supervisor or maintenance personnel for corrective action.
2. Safe Operating Practices:
   • Wear appropriate personal protective equipment (PPE), including a seatbelt, hard hat, safety shoes, and high-visibility vest, while operating the forklift.
   • Observe speed limits and traffic regulations within the warehouse, maintaining a safe distance from pedestrians, obstacles, and other vehicles.
   • Use designated travel routes and avoid sharp turns, sudden stops, or abrupt maneuvers that could cause the forklift to tip over or lose stability.
   • Ensure proper load handling and securement techniques, including centering the load, tilting the forks slightly backward, and securing the load with straps or pallets as needed.
   • Keep the forklift mast tilted slightly backward when traveling with a loaded pallet to improve stability and visibility.
3. Pedestrian Safety:
   • Be aware of pedestrian traffic in the vicinity and use horns, signals, or other warning devices to alert pedestrians of approaching forklifts.
   • Yield the right-of-way to pedestrians at intersections, blind spots, and congested areas, slowing down or stopping as necessary to avoid collisions.
   • Establish designated pedestrian walkways, barriers, or safety zones to separate pedestrian traffic from forklift operations and minimize the risk of accidents.
4. Emergency Procedures:
   • Know the location and proper use of emergency stop buttons, fire extinguishers, and emergency exits in the event of an accident, fire, or other emergency situation.
   • Immediately stop the forklift and safely dismount in the event of an emergency, following established evacuation procedures and assembly points.
   • Report any accidents, injuries, or near misses involving forklifts to the supervisor or health and safety officer for investigation and corrective action.

Abbreviations

• SOP: Standard Operating Procedure
• PPE: Personal Protective Equipment

Documents

• Forklift Operator Training Manual
• Forklift Pre-Operation Inspection Checklist
• Warehouse Traffic Safety Plan
• Emergency Response Procedures

SOP Version

Version 1.0