Forklift Operation JSA – Job Safety Analysis
1. Introduction
Forklifts are widely used in warehouses, construction sites, manufacturing plants, shipping yards, and logistics hubs for material handling and load transport. While efficient, forklifts are among the leading causes of industrial accidents, often resulting in fatalities or severe injuries.
Common forklift-related incidents include:
- Tip-overs due to overloading or unstable surfaces.
- Struck-by accidents involving pedestrians or other equipment.
- Falling loads from improperly secured pallets.
- Operator ejection during sudden stops or crashes.
- Carbon monoxide exposure from poorly ventilated areas (internal combustion forklifts).
A Job Safety Analysis (JSA) for forklift operation ensures hazards are identified, risks assessed, and preventive measures implemented to protect operators and other site workers.
2. Purpose of This JSA
The objectives are to:
- Prevent forklift-related accidents and injuries.
- Establish safe driving, loading, and unloading practices.
- Ensure proper inspection and maintenance of forklifts.
- Comply with OSHA, ISO, and company safety requirements.
- Foster a culture of safe material handling and traffic management.
3. Applicable Standards & References
- OSHA 29 CFR 1910.178 – Powered Industrial Trucks
- ISO 3691-1:2011 – Safety Requirements for Industrial Trucks
- ANSI/ITSDF B56.1 – Safety Standard for Low Lift and High Lift Trucks
- IS 7218 – Code of Practice for Forklift Safety
- Company Forklift Safety Program
4. Scope of Work
This JSA applies to:
- Forklift operation in warehouses, factories, and construction sites.
- Loading and unloading materials.
- Transporting loads within site premises.
- Stacking pallets and racking operations.
- Refueling or battery charging of forklifts.
5. Job Breakdown (Step-by-Step)
- Pre-operational inspection of forklift.
- Pre-job planning and route selection.
- Mounting/dismounting the forklift safely.
- Driving and maneuvering forklift.
- Picking up loads.
- Transporting loads.
- Stacking and unloading.
- Refueling or battery charging.
- Parking and securing forklift after use.
6. Hazard Identification
- Tip-over accidents from unstable loads or sharp turns.
- Struck-by hazards involving pedestrians.
- Load falling due to improper stacking or damaged pallets.
- Poor visibility causing collisions.
- Carbon monoxide poisoning in enclosed spaces.
- Electrocution when working near overhead power lines.
- Pinch points during pallet handling.
- Fire hazards during refueling or charging.
7. Risk Assessment Table
| Task | Hazard | Consequence | Risk Level | Control Measures |
|---|---|---|---|---|
| Pre-use inspection | Faulty brakes, hydraulics | Loss of control | High | Daily inspection checklist |
| Driving forklift | Speeding, poor visibility | Collision, injury | High | Speed limits, mirrors |
| Picking loads | Improper load center | Tip-over | High | Follow load chart |
| Transporting | Load shift | Falling load | High | Secure loads, use straps |
| Stacking | Elevated loads | Falling objects | High | Stack evenly, maintain clear zone |
| Refueling/charging | Fire, explosion | Burns, fatalities | High | No smoking, proper ventilation |
| Parking | Forklift left on incline | Roll-away accident | Medium | Park on level ground, apply brake |
8. Control Measures
A. Engineering Controls
- Seat belts and overhead guards on forklifts.
- Reverse alarms and warning lights.
- Load backrests to prevent shifting.
- Speed limiters for site-specific control.
- Ventilation systems for indoor forklift use.
B. Administrative Controls
- Forklift operator certification and training.
- Traffic management plan with marked pedestrian routes.
- Toolbox talks and refresher training.
- Permit system for hazardous area operations.
- Regular forklift maintenance and inspection schedule.
C. PPE Requirements
- Hard hat.
- Safety shoes with steel toes.
- High-visibility vest.
- Seat belt (mandatory for operators).
- Gloves (for pallet handling).
- Safety glasses (for dusty environments).
9. Roles & Responsibilities
- Forklift Operator: Safe operation, load handling, daily inspections.
- Supervisor: Authorize operations, monitor compliance.
- Pedestrian Workers: Stay clear of forklift zones, use designated walkways.
- Maintenance Team: Ensure regular servicing and immediate repair.
- Safety Officer: Conduct inspections, enforce PPE, and investigate incidents.
10. Emergency Preparedness
- Tip-over incidents: Operators trained to stay seated, hold steering wheel, and lean away from impact.
- Fire emergency: Fire extinguishers available at fueling/charging stations.
- Spill response: Spill kits available at refueling areas.
- First aid stations: Accessible for quick response to injuries.
- Emergency evacuation routes: Clearly marked and unobstructed.
11. Best Practices for Forklift Safety
- Always wear a seatbelt when operating forklifts.
- Do not exceed Safe Working Load (SWL).
- Never allow passengers unless forklift is designed for two.
- Maintain three points of contact when mounting/dismounting.
- Sound horn at blind intersections.
- Keep forks lowered when traveling.
- Never leave forklift running unattended.
- Stop operations in poor weather, low visibility, or high pedestrian traffic.
12. Sample JSA Form – Forklift Operation
Job Title: Forklift Operation
Location: ____________________
Date: ____________________
Supervisor: ____________________
| Task Step | Hazard | Control Measure | PPE Required | Responsible Person |
|---|---|---|---|---|
| Pre-use inspection | Faulty brakes/tyres | Daily checklist | Gloves | Operator |
| Driving | Speeding, poor visibility | Speed limits, mirrors | Vest, helmet | Operator |
| Picking load | Overloading | Follow SWL | Gloves, boots | Operator |
| Transporting load | Falling loads | Secure load, use straps | Gloves | Operator |
| Stacking | Falling objects | Stack evenly, exclusion zone | Helmet | Operator |
| Refueling/charging | Fire hazard | No smoking, ventilation | Gloves, goggles | Operator |
| Parking | Roll-away | Apply brake, park on level ground | None | Operator |
13. Conclusion
Forklifts are indispensable for material handling but present serious hazards when operated unsafely. By following a structured JSA, enforcing operator training, conducting inspections, and maintaining clear pedestrian separation, companies can ensure forklift operations remain safe and efficient.
✅ Final Safety Reminder:
“A forklift can lift loads — but safety lifts lives. Always drive safe, load safe, and stay alert.”
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