Forklifts

Name:
Professor:
Course:Date:
Like with any other machine, there are a vast number of hazards that can occur in the life cycle of a forklift; starting from its production, through its use and maintenance to the disposal of the machine, machine parts or its other components. All parties involved at all stages should take precautions to ensure their working environment is safe for everyone present. This paper seeks to highlight the various hazards associated with the forklifts at different stages of its life cycle and how the risks can be managed or avoided entirely. It is imperative that the employees that are operating the forklift as well as other persons in the area to stay safe. Therefore, it is mandatory that all the workers and employees of a given forklift company should always brainstorm and establish precautions to observe when using or handling the forklifts (Horberry et al., 575).
The hazards in the life cycle of a forklift can be categorized depending on the stage that the hazard may occur. The main categories of the hazards include production hazards, operation hazards, maintenance hazards, operation hazard and disposal hazards.
Production hazards
Production hazards include all the dangers faced by the workers and other personnel during the production of the forklifts. Forklifts are manufactured at different stages that is, some different parts of the machine are manufactured differently and then later they are assembled. During the production of the different parts and the assembly of the machine, employees face different risks, and different safety measures should be put in place to avoid or manage hazards (Horberry et al.

, 575). Below are some of the hazards and precautions during the production stage.
The metal cutters have rotating parts that revolve at a very high speed. If one of the rotating parts comes off accidentally, there is a high likelihood that the operator might sustain serious injuries. To control the prevalence of such hazards, all rotating pieces of different metal cutting equipment should be kept in concealed states with the help of guards (Hagan, Krieger, and Montgomery 23).
Welding emits fumes and very bright light. The fumes contain toxins that can affect one’s eyesight and the respiratory system if inhaled in large volumes. Welders need to operate in well-ventilated areas. The welders should also wear protective eye gear as well gas masks to stay out of harm’s way.
Painting is an essential process in manufacture. The paint fumes can pose a threat to the respiratory system if inhaled in large quantities. Caution should be taken to eliminate such cases. Through the use of gas masks during painting and proper ventilation, the problem can be mitigated.
Cutting tools are standard in the production process. The chips and removed from the metals being cut usually flies out at a very high speed and may enter into the eyes of the person undertaking the operation. It is important to wear helmets or any other form of protective wear that shall enable them to stay safe from the flying metal chips (Hagan, Krieger, and Montgomery 23).
High-pressure leakages can happen in factories. Since the gas is under high pressure, it may gush out with so much force that it may cause serious injury. Routine checks and servicing of the hydraulic system of the lifts should be done, and any leaks/cracks fixed at the earliest time possible (Horberry et al., 575).
To fit springs into tight spots or parts in the forklifts, it’s usually necessary to compress them. If the pressure that compresses them is suddenly released through say a slip, the spring may jump into the air and ram anything its path. Cautiousness should be observed to make sure that all compressed springs are correctly in place by sound confinements.
Some fluids and sprays that are used in the painting and maintenance of the plants for manufacturing the forklifts like oil and paint are flammable. They could cause a massive fire in a short time. If left unattended or exposed to triggers such as welding sparks, the gases and oils may explode hence posing a risk to the plant’s safety.
As a way to control time wastage, engineers usually put tools and equipment they need as near to their workstation as possible. This sometimes may result in the blockage of the emergency exits temporarily. The doors should always be kept open and free from clutter so that they are accessible in case of a fire or any other accident.
Poorly Insulated electric wires are a significant cause of injury and even death in many factories. Insulation on high voltage wires for welding and often wears out quickly, and they can electrocute people who unknowingly touch them with their bare hands or feet. Precautions to make sure that the wires are reinsulated once they wear and tear, should be taken.
Rust can amass in the iron-based parts of the production factory if exposed to steam and or vapor and air. The parts that rust may malfunction and experience higher amounts of friction and resistance. As a result, the forklift might cause an unexpected problem and may result in accidents in the manufacturer’s warehouse.
Maintenance hazards
To ensure that the forklift operates correctly and its shelf life is prolonged, proper maintenance is necessary. The persons carrying out the maintenance, however, face some dangers when working. Below is a list of hazards and precautions during the maintenance of a forklift.
Forklifts have a very complicated engine and operating mechanism. It is therefore mandatory to allow only the adequately qualified staff to service or perform any maintenance procedure on forklifts. This precaution shall improve the chances of proper and up to standard repair and service to keep the forklift in perfect working condition.
When removing wheels from the forklift because they have become worn out or developed a leak/puncture, proper balance and stability are paramount. The workers performing the maintenance should be encouraged to countercheck and ensure that the truck is correctly locked in place before implementing any wheel change.
If the maintenance team or engineer is working in an enclosed building or room, proper lighting is mandatory. Lack of appropriate light when performing essential procedures can cause incidents like the pouring of flammable oils and diesel on the ground. The poured oils can be a disastrous mistake if they accidentally catch fire. Poor lighting also makes it difficult to see what the engineer is working on hence increasing chances of injury.
Loose hanging equipment and tools can fall off and maybe injury people if the engine is started. Repairs or services often require the technician to start the engine and ensure the truck is working correctly. They should, therefore, ensure that all the tools used in the maintenance procedure are duly removed from the forklift truck before starting the engine.
Missing bolts and nuts often cause many forklift accidents. The maintenance teams might forget to replace a single crucial nut or replace it without tightening correctly. This may lead to imbalance and breakage of critical components of the truck. Technicians should ensure all nuts and bolts are present and tightened before leaving the station.
Refuelling is a standard maintenance procedure in many forklift firms. Given the high flammability of gasoline and petrol, activities such as smoking and welding may trigger a fire hazard in the maintenance booth or building. Technicians should actively ensure that the refueling areas are smoke-free and spark free.
LPG and diesel forklifts emit a lot of smoke when running. The smoke is predominantly composed of carbon monoxide that is very toxic and can lead to suffocation. Technicians should avoid testing forklifts in poorly ventilated locations for long. If they need to leave the engine running for long, open spaces would be the best place to do it.
Elevated forklifts usually depend solely on hydraulic systems to remain in place. Working under high forklifts requires extra support to ensure the weight does not fall on a technician should the hydraulic system fail. This additional support should be obtained from standard quality blocks, and lack of them is a recipe for injury or even death.
Cracks in the engine or hydraulic cylinders can be potentially hazardous. If technicians fail to use magnet particle testing equipment in checking for cracks, the forklift might fail at a very critical moment thus endangering property and the lives of people around the truck.
Working on forklifts without protective wear can be very dangerous. Falling equipment and parts are standard. Technicians need to be prepared for the worst and in that sense wear steel toe boots as well as helmets (Strelec 117).
Operation Hazards
During the operation of the forklift, there are dangers also faced by the operators and other personnel present at the site. It is, therefore, necessary to take certain safety measures to avoid to avoid the dangers or to minimize the impacts in case of any incident at the site (Horberry et al., 577). Below is a list of operational hazards and the safety measures.
Operation of forklifts is a reserve of the licensed and authorized operators only. People who do not have sufficient or any training may not know how to deal with specific occurrences hence leading to accidents and injury.
A slight malfunction of a forklift can lead to immense loss of property carried, injury or death of the workers or other people. Operators should check crucial parts like tires, steering wheels, brakes and lift mechanism before the commencement of trips. Any anomaly should be reported to the supervisor or mechanic for immediate resolution.
Forklift trucks usually lift high tonnage loads. This phenomenon dramatically strains the balance and stability of the truck. Operators who are in a rush and tend to over speed risk destabilizing the truck hence endangering both property and human life.
Forklifts have a high center of gravity and are thus harder to control when negotiating corners. If the operator attempts to make a sharp turn in either direction, they have to reduce the speed to the bare minimum to prevent the truck from toppling over.
Given that they carry hefty loads, the capacity of elevators in which forklifts are driven into is of great interest to operators. If the elevator had already lifted the truck before snapping, an injury might be sustained by the operator.
Passengers on board the trucks add unnecessary weight while also limiting the space that the operator has for their use. The operator should be aware that visibility is of prime importance in the when operating forklifts and they should maximize it to guarantee proper control and operation of the forklift truck.
Tilting loads for any reason whatsoever significantly destabilize the truck. It may cause the truck to overturn even if the load appears to be moderately heavy. In cases where tilting is inevitable, the operators need to be careful.
Just like any other automobile and machine, the operator should ensure that all their body parts are away from parts that are subject to shear forces. This way crushing hazards can be minimized (Strelec 118).
Failure in the lift system often occurs unprecedented. All employees should not work or pass below elevated sections of the forklifts.
Lifted loads in unattended forklifts are potentially hazardous because they could be disturbed by external parties. All unattended loads should be lowered, and the brakes of the forklift engaged to be safe
Disposal Hazards
Disposal hazards include all the hazards caused by improper disposal of dysfunctional forklifts, machine parts and other components such batteries used by the forklift. The disposal should not pollute the environment or cause harm to people or animals.
Improper disposal of the batteries may lead to an explosion or even fires in the area they are thrown. Some cells store a small amount of charge for long and may create a fire hazard.
Reckless disposal of flammable fluids like transmission oil and other petrol-based fluids that can burn when ignited.
Cleaners are disposed into rivers and lakes. They contain harmful chemicals such as phosphates that encourage the growth of green algae thus endangering aquatic life
Piling of tires at different designated places leads to the creation of habitats for rodents and dangerous animals such as snakes.
Inappropriate disposal of antifreeze containers with toxic substances such as ethylene glycol endangers the life of animals and children as they are attracted by its sweet scent. Ingestion can lead to death. (Tsydenova, Oyuna, and Magnus 48).
Old lead-acid batteries may contain some sulphuric acid in them at the time of disposal. The acid can pose a threat to innocent children and pet animals (Duan et al. 224). The batteries should, therefore, be disposed of in the appropriate place.
Broken glasses and remains of old forklifts may be sharp and pierce innocent children who could be playing near the dump sites.
The old retired forklifts usually create an eyesore in previous aesthetic environments. Proper disposal like recycling is mandatory to restore the beauty of the disposal location.
Burning of the old tires can cause a significant amount of carbon to enter the ecosystem. This carbon worsens the issue of global warming.
Storage space for the retired dysfunctional forklifts can be a headache. If found, space will remain unused for a prolonged period leading to wastage of space and money in consequence.
Other Hazards and Safety Measures
The tines of the forklift should be lowered, parking brake engaged and controls put in neutral before getting off the truck (Victoria 10). This will ensure that the truck does not unexpectedly move when parked causing accidents. The forklifts should also be fitted with grab rails and anti-slip surfaces to avoid accidental slips that might cause injuries, loss of properties or lives.
Remove the ignition key from the forklift whenever you park and get off the truck. This will ensure that unqualified and unauthorized persons do not access the truck hence avoiding unnecessary accidents.
Do not jump when getting off the forklift. Always face the forklift while minting three points of contacts to avoid slipping and injuring yourself. Also, the number of times that the operator gets out of the truck should be minimized to reduce the chances of gliding or sliding that might lead to injuries (Victoria 10).
The forklifts should be parked in a well-lit area so that it can be seen by other traffic hence avoiding accidents. Also, the parking should be away from doorways and other passages so that the track does not block other traffic including the pedestrians.
Do not carry unauthorized persons in the forklifts to minimize the affected persons in case the truck is involved in an accident such as overturning. An extra footrest or seat is provided when the truck is designed to carry more than one person.
The forklifts should be used only for its designed purpose to avoid unnecessary accidents that might be costly to both the company and the victim.
Use work cages to raise workers doing short-term tasks. The work cages, however, should be safely attached to the truck to avoid failing to cause injuries to the workers or even deaths. In some cases, the cages should be designed-approved.
Report any unsafe surface conditions to the superior immediately. The obstructions and hazards such as debris and spilled liquid should be cleared instead of driving over or around them. This will ensure that accidents are minimized or avoided entirely. Understand that driving over powder or spilled liquid affects traction of the tires, braking as well as stability.
Goggles should be worn to protect one’s eyes, especially when moving loads from overhead shelving. This will prevent eye injuries from debris or dust.
Be conscious of the surroundings including people around you as well as other traffic. Being aware of will help minimize accidents since the operator is alert and will mind others when operating the forklift truck.
Works Cited
Duan, Huabo, et al. “Hazardous waste generation and management in China: A review.” Journal of Hazardous Materials 158.2-3 (2008): 221-227.
Hagan, P., G. R. Krieger, and J. F. Montgomery. “Accident prevention manual: engineering and technology.” Chicago: National Safety Council (2001).
Horberry, Tim, et al. “Forklift safety, traffic engineering and intelligent transport systems: a case study.” Applied Ergonomics 35.6 (2004): 575-581.
Strelec, Frank. “OSHA Compliance Issues: Health Hazards in a Feed Mill.” Journal of occupational and environmental hygiene 3.11 (2006): D116-D119.
Tsydenova, Oyuna, and Magnus Bengtsson. “Chemical hazards associated with the treatment of waste electrical and electronic equipment.” Waste Management 31.1 (2011): 45-58.
Victoria, WorkSafe. “Forklift Safety: Reducing the Risk.” (2003).