11 Aug Forklift Operation – JSA

JOB SAFETY ANALYSIS (JSA) – FORKLIFT OPERATION

JOB / TASK

Forklift Operation – Material Handling, Loading, Unloading, and Transport

 

PURPOSE

This Job Safety Analysis (JSA), also known as a Job Hazard Analysis (JHA), identifies hazards associated with forklift operation and establishes safe work practices and controls to prevent struck-by incidents, tip-overs, falls, caught-between injuries, property damage, and other incidents.

 

PERSONNEL QUALIFICATIONS

Only employees who have been properly trained, evaluated, and authorized by the company may operate a powered industrial truck.

• Understand the controls, operating characteristics, and limitations of the forklift.
• Understand the hazards associated with the work environment.
• Demonstrate the ability to safely operate the specific type of forklift authorized for use.
• Follow manufacturer requirements and company procedures.
• Complete required refresher or additional training when required.

Unauthorized employees shall not operate forklifts.

 

REQUIRED PPE

PPE shall be based on the hazards of the work area and may include:

• Safety glasses with side protection.
• Safety footwear with slip-resistant soles.
• High-visibility apparel where required.
• Hard hat where required.
• Hearing protection where required.
• Gloves appropriate for the material-handling task.

PPE does not replace safe forklift operation or other required hazard controls.

 

JSA – JOB STEPS, HAZARDS, AND CONTROLS

Step 1 – Review the Work Area and Task

Potential Hazards:

• Pedestrians
• Other mobile equipment or vehicles
• Uneven, wet, slippery, damaged, or obstructed surfaces
• Poor lighting or visibility
• Overhead obstructions
• Dock edges, ramps, platforms, or floor openings
• Electrical hazards
• Changing site conditions
• Unstable storage or stacked materials

Required Controls:

• Review the work area before operating.
• Identify pedestrian routes, vehicle traffic, loading areas, docks, ramps, and other hazards.
• Follow designated forklift travel routes.
• Keep unauthorized personnel out of operating areas when practical.
• Ensure adequate lighting and visibility.
• Remove or control obstructions.
• Maintain required overhead and electrical clearances.
• Do not operate where surface conditions are unsuitable.
• Follow site traffic-control requirements.

 

Step 2 – Conduct the Pre-Operation Inspection

Potential Hazards:

• Mechanical failure
• Brake or steering failure
• Defective tires or wheels
• Damaged forks or attachments
• Hydraulic leaks
• Inoperative warning devices
• Defective restraint
• Damaged overhead guard
• Defective lights, alarms, or safety equipment

Required Controls:

• Perform the required pre-operation inspection.
• Inspect in accordance with manufacturer requirements and company procedures.
• Check tires/wheels, forks/attachments, mast/lifting components, hydraulics, steering, brakes, restraint, horn, lights/warnings, overhead guard, fluids, battery/charging or fuel system, safety devices, and gauges as applicable.
• Do not operate unsafe equipment.
• Remove defective equipment from service and notify the appropriate person.
• Do not make unauthorized repairs or modifications.

 

Step 3 – Mount and Start the Forklift

Potential Hazards:

• Falls while entering or exiting
• Unexpected movement
• Contact with controls
• Failure to secure the operator

Required Controls:

• Use designated steps and handholds.
• Maintain secure footing and three points of contact where appropriate.
• Keep the operator compartment clean.
• Fasten the seat belt or operator restraint.
• Start only from the designated operator position.
• Confirm controls are properly positioned before starting.
• Check the surrounding area before moving.

 

Step 4 – Pick Up the Load

Potential Hazards:

• Falling or shifting materials
• Overloading
• Unstable loads
• Damaged pallets
• Load exceeding capacity
• Striking employees or objects
• Poor visibility

Required Controls:

• Know the load weight when practicable.
• Verify rated capacity.
• Inspect pallets, containers, and loads.
• Position forks correctly and fully engage the load as appropriate.
• Keep loads centered and stable.
• Do not handle unstable or improperly stacked loads.
• Secure loads when necessary.
• Keep personnel clear of the load area.

 

Step 5 – Travel With the Load

Potential Hazards:

• Tip-over
• Falling loads
• Striking pedestrians
• Collision
• Limited visibility
• Excessive speed
• Uneven surfaces
• Sharp turns
• Elevated loads
• Ramps or inclines

Required Controls:

• Operate at a safe speed.
• Maintain control at all times.
• Keep the load as low as practical.
• Maintain visibility in the direction of travel.
• When the load blocks forward visibility, travel in the direction providing the safest visibility as permitted by the equipment and conditions.
• Slow down at intersections, blind corners, doorways, and congested areas.
• Sound the horn when appropriate.
• Maintain safe distances.
• Avoid sudden stops, starts, and turns.
• Do not race or engage in horseplay.
• Maintain overhead clearance.

 

Step 6 – Travel on Ramps, Grades, or Sloped Surfaces

Potential Hazards:

• Tip-over
• Load sliding or falling
• Loss of control
• Excessive speed
• Insufficient traction

Required Controls:

• Follow manufacturer requirements.
• Use controlled speed.
• Maintain appropriate load orientation for the equipment and conditions.
• Do not turn sharply on grades.
• Do not exceed operating limitations.
• Keep the load stable.
• Verify ramps and surfaces can support the forklift and load.
• Maintain clearance from edges.

 

Step 7 – Interact With Pedestrians

Potential Hazards:

• Struck-by injuries
• Pedestrians entering the travel path
• Blind spots
• Unexpected movement
• People behind or beside the forklift

Required Controls:

• Separate pedestrian and forklift traffic when practical.
• Establish exclusion zones in high-risk areas.
• Follow site traffic rules.
• Maintain visual contact when appropriate.
• Do not move when a person could be struck or crushed.
• Use a spotter when necessary.
• Never assume pedestrians can see or hear the forklift.
• Use extra caution at doorways, corners, intersections, and blind areas.

 

Step 8 – Load or Unload Trucks, Trailers, and Dock Areas

Potential Hazards:

• Forklift falling from a dock
• Trailer movement
• Unsecured trailer
• Dock plate failure
• Uneven surfaces
• Falling loads
• Limited clearance
• Pedestrians or equipment

Required Controls:

• Verify trucks and trailers are properly positioned and secured.
• Confirm dock plates, ramps, and bridge plates are properly positioned and rated for the intended load.
• Inspect trailer floors.
• Verify overhead and side clearance.
• Keep personnel clear when practical.
• Maintain control entering and exiting trailers.
• Do not drive toward an unprotected dock edge.
• Follow site-specific procedures.

 

Step 9 – Place and Remove Loads

Potential Hazards:

• Falling materials
• Collapsing stacks
• Struck-by or caught-between injuries
• Overloaded racks
• Overhead contact
• Unstable storage

Required Controls:

• Ensure storage areas and racks can support the load.
• Keep loads stable and properly positioned.
• Do not exceed rack capacity.
• Maintain clearances.
• Keep personnel away from placement areas when practical.
• Raise and lower loads smoothly.
• Do not block exits, fire equipment, electrical panels, emergency equipment, or access routes.
• Do not leave elevated loads unattended.

 

Step 10 – Park and Shut Down

Potential Hazards:

• Unattended movement
• Forks creating hazards
• Unauthorized use
• Contact with pedestrians or equipment

Required Controls:

• Park only in an authorized location.
• Lower forks or attachment completely.
• Place controls in neutral.
• Set parking brake.
• Turn off power before leaving the operator position.
• Secure the forklift against unauthorized use when required.
• Do not obstruct exits, fire equipment, aisles, doorways, emergency access, or pedestrian routes.
• Do not leave an unattended forklift with an elevated load.

 

Step 11 – Refueling or Recharging

Potential Hazards:

• Fire or explosion
• Fuel or battery-acid exposure
• Chemical burns
• Hydrogen accumulation
• Spills
• Improper charging

Required Controls:

• Refuel or recharge only in designated areas.
• Follow manufacturer instructions and company procedures.
• Shut down before refueling unless manufacturer procedures specify otherwise.
• Keep ignition sources away.
• No smoking or open flames.
• Wear required PPE.
• Clean spills promptly.
• Ensure adequate ventilation in charging areas.
• Follow battery-charging procedures.
• Report damaged batteries, chargers, fuel systems, or electrical components.

 

Step 12 – Unsafe Condition or Incident

Potential Hazards:

• Continued operation of defective equipment
• Additional employee exposure
• Uncontrolled damaged loads or equipment

Required Controls:

• Stop operation when unsafe conditions develop.
• Lower the load and place the forklift in a safe condition when practical.
• Isolate or barricade the area when necessary.
• Notify supervision.
• Do not operate damaged equipment until inspected and released.
• Report incidents, near misses, property damage, and significant unsafe conditions.
• Participate in investigations and corrective actions.

 

PROHIBITED PRACTICES

• Operating without required authorization and training.
• Carrying passengers unless the forklift is specifically designed for passengers.
• Allowing unauthorized persons to operate the forklift.
• Using forks, loads, or equipment as a personnel platform unless specifically designed and approved.
• Standing or allowing others to stand beneath an elevated load or lifting mechanism.
• Placing body parts outside the designated operator compartment while operating.
• Excessive speed, horseplay, or reckless operation.
• Exceeding rated capacity.
• Carrying unstable or improperly secured loads.
• Leaving an unattended forklift with forks or load elevated.
• Operating known defective or unsafe equipment.
• Unauthorized modifications.
• Using unapproved attachments.
• Lifting or transporting people except where specifically permitted by an approved procedure and suitable equipment.

 

EMERGENCY PROCEDURES

• Stop operations when safe.
• Warn personnel in the immediate area.
• Move to a safe location as conditions require.
• Notify supervision and emergency personnel as appropriate.
• Do not stabilize or recover a load unless trained and authorized.
• Do not restart damaged equipment until inspected and released.
• Report and investigate incidents in accordance with company procedures.

If a forklift tips over, the operator shall remain within the operator compartment and follow the manufacturer’s emergency procedures unless remaining in the compartment presents a greater immediate danger.

 

TRAINING REQUIREMENTS

Forklift operators shall receive training appropriate to the type of powered industrial truck and the conditions in which it will be used.

• Operating controls and instrumentation.
• Forklift limitations and rated capacity.
• Stability and load handling.
• Inspection and maintenance.
• Safe travel and maneuvering.
• Pedestrian awareness.
• Loading and unloading.
• Ramps and grades.
• Dock and trailer operations.
• Refueling or battery charging.
• Workplace-specific hazards.
• Company procedures.
• Manufacturer requirements.

Operators shall be evaluated as required and retrained when changes in equipment or conditions, unsafe operation, incidents, or other circumstances indicate additional training is necessary.

 

JSA REVIEW

Review this JSA with affected employees before work begins. Revise or supplement it when:

• The work activity changes.
• A different forklift or attachment is used.
• Site conditions change.
• New hazards are identified.
• An incident or near miss occurs.
• Existing controls are ineffective.
• Employees identify additional hazards.

 

EMPLOYEE ACKNOWLEDGMENT

 

By signing below, employees acknowledge that they have reviewed this JSA/JHA, understand the hazards and required controls, and have had an opportunity to ask questions.

Employee NameSignatureDate

 

JSA Reviewed / Revised ByDate

Supervisor	Date