Crash course in forklift driver training

One in four workplace transport-related accidents involves a forklift truck. And, in the wider world of occupational health and safety, the highest rates of workplace injury occur in less experienced individuals. Combined, these two facts are proof enough – if proof were needed – that training forklift truck operators is crucial, not only from the point of view of compliance, but also to put the brakes on forklift truck accident statistics. The Fork Lift Truck Association (FLTA) held its annual safety conference in September and, this year, the focus was fixed firmly on training. The theme, 'It's no accident: training saves lives', ran throughout two full days of presentations which aimed to show what the forklift truck industry is doing – and what individuals can do – to drive training further up the management agenda. John Spanswick, non-executive director of the Health and Safety Executive, told delegates they should think long and hard about competence, not just training. "If someone is technically qualified to operate a piece of equipment, does that mean he or she will operate it safely?" he asked. "Technical training is important, but we also need to understand responsibility and accountability." In some circumstances, he added, learning interpersonal skills can have as much impact as technical training, particularly for supervisors. "I believe industry has addressed the issue of technical training pretty well over the last 10 years, but we need to address the personal approach of supervisors and managers and ensure they are taking responsibility for their people." HSE's head of workplace transport, Peter Lennon, told delegates that HSE is looking at the role of accrediting bodies – there are six in the UK – and how they collaborate with each other. In the mid 1980s, he explained, HSE established the accrediting bodies scheme "to assess training for forklift truck operators, and the scheme went hand in hand with our guidance and Approved Code of Practice," he said, more of which later. The accreditation scheme, he was keen to point out, remains just one way for employers to check that training providers are competent – employers are under no legal obligation to use accredited courses or providers. And recognition of the organisations within the scheme is not the same as approval, he added. In addition, "there was no benchmarking of the accrediting bodies against each other," said Lennon, "which HSE recognises has been a failing." Each accrediting body was assessed during 2010/11. Although the results were not made public, Lennon told the FLTA conference delegates that the evaluation proved the scheme does work, with 75% of criteria being met. HSE has arranged follow-up visits to ensure the organisations are working to correct procedures including, for example, how they assess trainers. However, Lennon added that room for improvement lay at his organisation's door, too. "We need to improve or role and regulation of this scheme," he said. "Ultimately, we'd like to hand responsibility back to the accrediting bodies along with a third party auditor, with HSE playing a governance role as regulator." The overall aim is to improve the standards of the accrediting bodies which, in turn, should spark improvement in the organisations they accredit. Some of the bodies have been less effective than their counterparts in terms of promoting competence and a standardised offering. "It is important that all the accrediting bodies share best practice," said John Spanswick. "Safety is not a competition." Practice makes perfect As reported previously in WM, HSE has been revisiting its guidance for forklift truck training with a view to removing duplication and improving clarity. Peter Lennon told delegates that two publications, L117 (Rider operated lift trucks: Operator training, Approved Code of Practice and Guidance) and HSG6 (Safety in working with lift trucks), were to be combined to deliver a revised L117 publication for the employer on what's needed to ensure operators are trained and can safely operate lift trucks. That main document is to be supported with a shorter leaflet (aimed at smaller businesses) and a pocket card for operators. Delivery is planned for spring 2012. The Löfstedt report, commissioned by employment minister Chris Grayling earlier this year, was due to publish in October but was delayed to the end of November (it is due to publish as we go to press – WM will report the findings online at www.worksmanagement.co.uk). If Löfstedt recommends that improvements are needed to HSE Approved Codes of Practice (ACoPs) and guidance, then the current work to revise guidance will come to a halt. On 24 November, Lennon told WM: "Professor Löfstedt's report could mean we stop the work we're doing and have a radical rethink of what an employer might need to know to ensure operators are trained. Whether that's an ACoP, or an ACoP and guidance, or something else entirely, we just don't know." Lennon explained that one of the key concerns for government is that HSE should not overstep its mark as a regulator. Industry feedback has said that sometimes guidance goes beyond the minimum standards required to comply with the law. "The law says an individual must be trained; the ACoP says this is the type of training required – but then we offer additional best practice guidance. That could be seen as confusing, putting pressure on employers and going beyond what's required by law," said Lennon. "My view is that the specifics of forklift truck training are best left to industry organisations such as sector skills councils, accrediting bodies and others who are better placed to come up with best practice guidance. HSE's remit is a regulator, to ensure people go to work, work safely and come home." Well positioned Some of those organisations well placed to offer best practice guidance are, of course, the forklift truck suppliers – a few of which have their own training divisions. Toyota Material Handling UK has a training academy, for example, offering driver training, manual handling courses and more. The company's customer campaign this year has been 'driving down costs' and, as operations director Tony Wallis points out, it's not only equipment developments that contribute to lower running costs: "Providing adequate training for your operators is not only a legal requirement, it's a process to help reduce overall operating costs. It helps minimise damage to equipment, to goods and to the surrounding areas well as reducing fuel consumption." Indeed, less truck damage is an important side effect of good training – not least because the cost of such damage is usually borne by the customer during forklift truck contract hire periods. As with other aspects of health and safety around the factory and warehouse, manufacturers know that building the right culture will reap rewards, and this is often achieved by way of carrot rather than stick. A good example is Toyota's Pride in Performance scheme, an awareness programme which provides customers with resources, including a supervisor handbook and posters, to promote safety, publicise tips and best practice guidance around the site, and encourage a greater sense of accountability among forklift operators. For Briggs Equipment, UK distributor of Yale trucks, training programmes must be relevant and, well, even entertaining. "Much of the training becomes a tick-box exercise," says engineering standards manager Dean Mansell. "The operator may have a certificate saying they are competent to operate the trucks and the employer may have fulfilled its legal obligations, but there is so much more that can be done." More fun, as it happens. Making training fun will make it stick, says Briggs. Being lectured or instructed can be dull; Briggs mixes it up and encourages interaction with break-out sessions for video, hands-on practice, Q&A as well as formal examinations. Operations director Gavin Wickham adds: "For anyone to get the most out of training, it must be enjoyable as well as relevant to their day-to-day experiences and this is central to our approach. If operators enjoy the training, they will learn more and remember what they have learned." Making learning relevant is something on which all providers agree. And Barloworld Handling, distributor of Hyster forklift trucks, makes the point that uppermost in terms of relevance is language – particularly relevant to those manufacturers employing foreign workers. "In today's work environment, not all workers speak English," says Barloworld's national training manager Garry Fillingham. "For these businesses, training materials should be available in various languages." High demand has led to Barloworld producing its forklift truck operator safety guides in Polish, for example. driver training: the law Chris Hopkins, barrister at Pinsent Masons, provides an overview for employers of the legal requirements and considerations relating to forklift driver training Employers must ensure that forklift drivers receive adequate health and safety training regardless of whether they drive full-time or just occasionally. Forklifts are work equipment and the Provision and Use of Work Equipment Regulations 1998 require employers to ensure everyone driving forklifts on their premises and their supervisors have received training covering safe systems of work; any risks that using the forklift may entail; and precautions to be taken. As well as work equipment, forklifts are lifting equipment so the Lifting Operations and Lifting Equipment Regulations 1998 apply. These require employers to ensure that operations involving forklifts are properly planned by a competent person; appropriately supervised; and carried out in a safe manner. In reality, most forklift operations are routine and planning will be done by the driver. This is fine provided the driver has been adequately trained and possesses the necessary knowledge and expertise to properly plan the lifting operation. Where supervision is necessary then employers must ensure the supervisor is also appropriately trained. Self-employed drivers are responsible for ensuring they have adequate training and proof is likely to be required by the organisations they work for. The HSE has published an Approved Code of Practice (ACoP) on operator training for rider-operated lift trucks (available from www.hse.gov.uk). While not legally binding, employers will often avoid enforcement action where they can demonstrate compliance with the ACoP so it is a useful guide. The ACoP provides guidance on who should be selected for driver training and to deliver training, including the bodies recognised by HSE to accredit and monitor training courses. Employers must ensure they check the competence of new employees and visiting drivers before authorising them to drive on their premises. Accurate training records should be kept for all authorised drivers, which may prove vital in demonstrating levels of compliance should a workplace accident occur. Although outside the scope of the ACoP, employers may wish to consider enforcing driver authorisation requirements through the disciplinary process or by barring non-employed, unauthorised drivers from site. Strict enforcement of training and authorisation requirements is often key to ensuring legal compliance. The ACoP suggests how driver training should be structured and recommends that drivers should receive ongoing refresher training. This should be provided not just from time to time but also following changes in working practices. For example, the introduction of new forklifts or other equipment to the workplace, accidents and near misses may all give rise to the need for further training. Employers must ensure that agency or visiting delivery drivers also fit in with the overall work scheme. Drivers must be made aware of the site layout and approved traffic routes. Employers should check these drivers are adequately trained and should ask to see documentary proof. If unsure, employers may wish to supervise the driver to assess their competence. Employers may wish to consider introducing licensing schemes to control visiting or agency drivers. Licences may be issued for defined periods, for example, and only renewed upon proof of satisfactory performance.