IADC - Forklift Safety Operation Training Course

1. Introduction to Forklift Operations

1.1 Forklift Types and Classifications

• Overview of forklift categories including (counterbalance forklifts, reach trucks, order pickers)

• Specialized equipment types including (side loaders, rough terrain forklifts, pallet jacks)

• Powertrain variations including (electric, diesel, LPG, and hybrid systems)

• Attachments and accessories including (extension forks, rotators, clamps, and specialized grips)

1.2 Forklift Components and Functions

• Main structural components including (mast, forks, carriage, overhead guard)

• Control systems including (hydraulic controls, steering mechanisms, braking systems)

• Operational mechanisms including (lift/lower, tilt, side-shift functions)

• Safety devices including (warning lights, horns, reverse alarms, and stability systems)

2. Pre-Operational Procedures

2.1 Equipment Inspection

• Daily inspection protocols including (visual checks, functional tests, documentation requirements)

• Critical safety components including (forks, chains, hydraulic systems, tires)

• Powertrain inspection including (battery/fuel levels, fluid checks, mechanical connections)

• Documentation requirements including (inspection logs, maintenance records, and certification verification)

2.2 Operational Area Assessment

• Workspace evaluation including (aisle widths, clearance heights, floor conditions)

• Traffic pattern analysis including (pedestrian areas, crossing points, blind corners)

• Surface conditions including (slopes, transitions, loading docks, and ramps)

• Environmental considerations including (lighting conditions, noise levels, and ventilation factors)

3. Load Calculations and Technical Considerations

3.1 Load Weight Determination

• Direct measurement techniques including (scale usage, load markings interpretation)

• Standard weight calculations including (volume × density formulas, pallet weight tables)

• Center of gravity determination including (balanced loads, uneven weight distribution)

• Maximum capacity assessment including (consulting load charts, derating factors)

3.2 Load Capacity Calculations

• Load center distance effects including (horizontal load center calculations, capacity reduction factors)

• Stability triangle principles including (counterbalance calculations, tipping point determination)

• Elevation capacity adjustments including (capacity reduction with height, mast extension factors)

• Attachment effects including (derating calculations for various attachments, and load moment considerations)

4. Safe Operation Practices

4.1 Operational Controls and Techniques

• Control familiarization including (function identification, response characteristics)

• Proper operating posture including (seating position, visibility maintenance, ergonomic considerations)

• Starting and stopping procedures including (safe mounting/dismounting, parking procedures)

• Speed management including (appropriate speed selection, braking techniques, and cornering principles)

4.2 Communication and Workplace Protocols

• Standard signals according to industry practices including (directional signals, warning signals)

• Verbal communication protocols including (standardized terminology, clarity techniques)

• Visual awareness practices including (load visibility, path clearance verification)

• Pedestrian interaction including (right-of-way rules, horn usage, and proximity management)

5. Load Handling Techniques

5.1 Load Assessment and Preparation

• Load characteristics evaluation including (weight distribution, stability, stacking configuration)

• Fork positioning including (proper spacing, insertion depth, load balancing)

• Load stability considerations including (secure stacking, wrapping requirements)

• Special load requirements including (fragile materials, hazardous contents, and oversized items)

5.2 Basic Maneuvering Techniques

• Forward and reverse travel including (proper positioning, visibility maintenance)

• Turning techniques including (swing radius awareness, pivot point understanding)

• Maneuvering in restricted areas including (aisle navigation, clearance assessment)

• Ramp and incline operation including (approach techniques, grade management, and load positioning)

5.3 Advanced Load Handling

• Stacking and unstacking including (proper approach, vertical alignment, precision placement)

• High-level racking including (vertical guidance, load clearance considerations)

• Double-deep racking including (extended reach techniques, alignment methods)

• Special load handling including (long loads, awkward shapes, and sensitive materials)

6. Operational Safety

6.1 Hazard Identification and Risk Assessment

• Common operational hazards including (tip-overs, collisions, falling loads)

• Risk assessment methodology including (hazard recognition, severity evaluation, control measures)

• Pedestrian safety including (separation systems, crossing points, visibility enhancements)

• Critical decision-making including (operation refusal criteria, alternative methods, and contingency planning)

6.2 Accident Prevention

• Human factors including (fatigue management, situational awareness, attention maintenance)

• Environmental considerations including (adverse conditions, workspace changes, operational adaptations)

• Near-miss reporting including (documentation procedures, corrective actions, lessons learned)

• Safety culture development including (peer observation, positive reinforcement, and continuous improvement)

7. HSE in Forklift Operations

• Personal protective equipment including (safety footwear, high-visibility clothing, gloves)

• Battery/fuel handling safety including (charging procedures, spill prevention, ventilation)

• Emergency response including (equipment malfunction, load drops, vehicle tipping)

• Environmental protection including (emissions management, fluid leaks, and waste handling)

8. Quality Assurance in Material Handling

• Procedural compliance including (standard operating procedures, work instructions)

• Product integrity including (damage prevention, proper handling techniques)

• Inventory accuracy including (proper placement, location management)

• Continuous improvement including (efficiency techniques, safety enhancements, and best practice implementation)

9. Maintenance Awareness

• Operator-level maintenance including (daily checks, cleaning, minor adjustments)

• Common operational issues including (control response, unusual noises, operational anomalies)

• Reporting procedures including (defect documentation, communication protocols)

• Service coordination including (scheduled maintenance awareness, condition monitoring, and component lifecycle)

10. Case Studies & Group Discussions

• Regional case studies from Middle East operations including (warehouse operations, manufacturing facilities)

• Incident analysis including (tip-over scenarios, collision events, load handling failures)

• Problem-solving exercises including (operational challenges, decision-making scenarios)

• Best practice sharing including (efficiency techniques, safety enhancements, and operational improvements)

• The importance of proper training in preventing forklift-related incidents