The ABC of FLT training

You've just bought a shiny new silver Range Rover. It's your pride and joy. You purr up the drive and through the factory gates. The door makes a satisfying clunk as you close it. You walk away, looking back, admiring the paintwork as it sparkles in the sun. You enter your office. "There you go", you say, tossing the keys to a colleague who's never sat behind a steering wheel in his life. "Enjoy your drive, but make sure you bring her back in one piece." An unlikely scenario? Of course. But hang on a minute; couldn't you be doing something like this every day of the working week? Forklift trucks (FLTs) are not only expensive – a £20,000-£25,000 pricetag is not unusual – but they can also be lethal in untrained hands. FLTs are responsible for around a quarter of all injuries involving workplace transport . And yet, too many are being driven around by poorly trained people. The question is, where do you start when it comes to training drivers? Here is a brief A to Z guide: A ACOP – The best source of advice on operator training can be found in the HSE Approved Code of Practice (L117) 'Rider-operated lift trucks: Operator training and safe use'. L117 covers the training requirements for operators of stacking rider-operated lift trucks. B Basic training (plus specific job and familiarisation training) – The Health and Safety Executive (HSE) says operator training should be in three stages: Basic, specific job and familiarisation. Basic training covers skills and knowledge needed to safely operate the FLT and handling attachments. It should take place 'off the job'. Instructors continuously assess trainees' progress to ensure they meet the required standards. Trainees should then pass a test(s) to demonstrate competence. Specific job training normally follows basic training and includes knowledge and understanding of the operating principles and controls of the lift truck; inspection and servicing; using the truck in work conditions; training in the work to be carried out; and safe work systems. Familiarisation training, the third stage, should be carried out on the job under supervision by someone with the right knowledge. It might include applying the skills learned in basic and specific training under normal working conditions; becoming familiar with the FLT activities of the employer; and familiarisation with the site layout, local emergency procedures and other features of the work. C Conversion training – This enables trained and experienced operators to extend the range of lift trucks they are qualified to drive. Although there is no legal requirement for drivers to receive routine refresher training, the Forklift Truck Association (FLTA) recommends that if it is required – say, because the driver has not operated an FLT for some time, is an occasional user or appears to have developed unsafe practices – it should be designed to overcome weaknesses highlighted through monitoring and assessment rather than following a set programme. D Driver licencing – There is no such thing as a lift-truck driver's licence and no central licensing authority exists. However, after employees have successfully completed all three training elements (see 'B' above), you need to give them written authorisation to operate the type or types of lift truck they have been trained to use. E Employee consultation – You, as an employer, are legally required to consult all your employees, and listen to what they say, on health and safety matters, including the best ways to provide information and training. F Forklift safety – During basic training, state the responsibilities of operators to take reasonable care of their own and others' health and safety and to co-operate with employers and others to help them comply with their legal duties. It might also be necessary to state the purpose of, and demonstrate how to use, safety devices such as stabilisers, level indicators and load indicators, if fitted, as well as the importance of using seat restraints. Find out more in 'Consulting employees on health and safety: A brief guide to the law' – leaflet INDG232 (rev1) www.hse.gov.uk/pubns/indg232.pdf Stuart Taylor of Mentor Performance Risk Management believes a "dangerous lie" is jeopardising forklift safety. He says: "Every day materials handling workers are being hospitalised pointlessly because they, or their manager, think of safety as a cost to be minimised. "The tragic truth is, these compromises are being made for no good reason. Improving safety saves on day-to-day damage like racking damage, forklift repair bills and damaged stock – instantly making you more profitable." In one example cited by Taylor, a major UK company recently invested £50,000 in operator training and immediately cut its stock damage costs by £130,000 per year. G Guiding principles – These can be found in the 'Use lift trucks safely: Advice for operators' Pocket card INDG457 www.hse.gov.uk/pubns/indg457.htm H Hand-operated pallet trucks – Regulation 9 of the Provision and Use of Work Equipment Regulations 1998 (PUWER) demands that employers adequately train everybody using work equipment. As well as FLTs, this includes hand controlled pallet trucks from simple manual pump trucks to complex electric counterbalance stackers. The FLTA says that, for basic equipment, you can provide in-house training provided it is properly organised and formally recorded. However, it suggests that, if you are in doubt, seek professional advice. I Increasing productivity – Effective FLT training will result in greater output because fewer accidents mean less downtime and learning more efficient working practices will increase yields. J Judging success – As well as boosting productivity, effective FLT training also offers you greater peace of mind because you will not be leaving yourself open to legal action, and potentially crippling fines. You will also have the satisfaction that you are protecting your workforce. K Keeping records – You must maintain adequate records for each employee who has completed any stage of lift-truck training (including conversion and refresher training). The record needs to include the identity of the employee and what training he or she has had. You should also record how they perform in associated tests. L Law. The legislation governing FLT training is PUWER (see 'H' above). Regulation 9 of this law says: "Every employer shall ensure that all persons who use work equipment have received adequate training…" The Management of Health and Safety at Work Regulations 1999 also place duties on employers to provide training. And there is a general duty under section 2 of the Health and Safety at Work Act 1974 to provide information, instruction, training and supervision to ensure the health and safety of employees. M Monitoring and assessment – You are required to routinely monitor FLT operators, even those who are trained and experienced. Where necessary, retest or refresher train them to make sure they continue to operate lift trucks safely. You can, says HSE, identify the need for further training using a formal monitoring and assessment process carried out by a suitably competent person, such as an instructor: "Formally timetable this assessment, eg a retest, to make sure it is done at reasonable intervals. Where an operator fails this assessment, arrange further training for them. You may find it useful to record these assessments in operators' personnel records." N Nominating instructors – As an employer. You are obliged to assess the competence of any training organisation you choose. So, ask instructors for evidence of their training and post-training experience on the type of truck to be used, both as instructor and operator, along with documentation such as a valid certificate of training as an instructor; an insurance certificate; and proof they can train on the vehicles concerned. O Overseas licences – Since there is no such thing as an FLT driver's licence, it follows that a licence issued in another country is invalid in the UK. However, as an employer, you are required to give written authority for any employee to operate the equipment. You alone will determine how long this authority remains in place. P Power sources – Most lift trucks are powered by electric batteries or internal combustion engines (liquefied petroleum gas – LPG, petrol or diesel). There are risks associated with each, so you need to take proper precautions and that means safety training in specific power sources. For example, the person responsible for changing batteries on electric trucks should have suitable training on how to change them safely. Q Quality – High quality operator training is critical to ensure your working environment is safe, that your machinery operates efficiently and that you run your business efficiently. R Refresher training – Regular refresher training will ensure operators maintain good driving habits; learn new skills where appropriate; and reassess their abilities. There is no specific time period after which you need to provide refresher training or formal assessment. However, you may decide that automatic refresher training or a retest after a set period of time (for example, three to five years). S Supervisors – The law requires you to provide adequate supervision, so it is essential that supervisors have enough training and knowledge to recognise safe and unsafe practices. T Testing – Instructors should continuously assess a trainee's progress during basic training to ensure they achieve the required standards throughout training. U Useful information – You can download a free copy of the ACOP and guidance to L117 – www.hse.gov.uk/pubns/books/l117.htm • Accrediting Bodies Association for Workplace Transport Training – www.abawt.co.uk • Association of Industrial Truck Trainers – www.aitt.co.uk • British Industrial Truck Association – www.bita.org.uk • Forklift Truck Association – www.fork-truck.org.uk • HSE – http://bit.ly/VyPyRu • Independent Training Standards Scheme and Registrar – www.itssar.org.uk • National Plant Operators Registration Scheme – www.npors.com • Lift-truck training: Advice for employers (HSE) – www.hse.gov.uk/pubns/indg462.htm • RTTITB – www.rtitb.co.uk V Visiting operators and drivers – See 'O' above. W Who to train – Lift-truck operators should be reasonably fit, both physically and mentally; reliable, with a responsible attitude to their work; physically capable; and over 16 (see www.hse.gov.uk/youngpeople/index.htm). James Clark, secretary general of the British Industrial Truck Association, adds: "Each person's fitness for operating a lift truck should be judged individually, with an emphasis on matching the requirements of a particular task with the fitness and abilities of the driver." X (E)xpertise – The most critical attributes in FLT training instructors are expertise and experience. Y Yearning for learning – Encourage your employees who are to be trained as FLT operators to be eager to learn to improve their own abilities. Z Zzzzzzz – Don't fall asleep on the job. As the FLTA points out, as well as your moral responsibility there are also sound commercial reasons to ensure operators are properly trained: "Lost time due to injury has financial implications, as do damaged goods, buildings and trucks. Skilled operators have fewer accidents." Basic training objectives On completion of training, the trainee should, according to the HSE, be able to: • State the reasons for operator training, the risks associated with lift-truck operations and the causes of lift-truck accidents. • State the responsibilities of operators to themselves and others, including their duties under the Health and Safety at Work etc Act 1974 to take reasonable care of their own health and safety and that of other people, and co-operate with employers and others to help them comply with their legal duties. • Identify the basic construction and main components of the lift truck, stating its principles of operation and load-handling capabilities and capacities. • Identify, as appropriate, handling attachments which may be used with the lift truck. • Locate and state the purpose of all controls and instruments and how to use them. • Place the forks or other handling attachment in predetermined positions using the appropriate controls. • Identify various forms of load, and state the procedures for their stacking, destacking and separation; assess the weight, and, where relevant, the load centre of a load; and decide if the load with its known weight and load centre is within the truck's actual capacity (safe working load). • State the factors which affect machine stability, including: turning, especially the speed and sharpness of turn; load security and integrity; rated capacity and rated load centres; centres of gravity; ground conditions; and speed and smoothness of operation. • Follow correct procedures when loading and unloading vehicles. • Make visual checks to ascertain the safety, soundness and rating of structures designed to receive loads, and place and remove loads on and from those structures at various heights. • Pick up and place loads, and drive and manoeuvre the machine forward and in reverse, laden and unladen, on inclines, in restricted spaces and on level ground (including rough terrain as applicable), following correct procedures and precautions. • Park the machine, following correct procedures and precautions. • Where applicable, state the purpose of, and demonstrate how to use, safety devices including stabilisers, level indicators, and load indicators, if fitted, including the importance of using seat restraints. • Carry out inspection and maintenance tasks appropriate to operators as required by the machine manufacturers (including pre-shift checks) and any relevant legislation. • State what to do in an emergency while in control of a lift truck, for example, if there is a tipover. • State why it is essential to have vehicle key custody arrangements.