The core is to build a six-level prevention and control system consisting of "source selection + standard implementation + full-life-cycle maintenance + site management + personnel empowerment + emergency closed-loop management", covering risks in both static and dynamic operating conditions. Below is a structured and actionable implementation guide.
I. Source Prevention and Control: Optimization of Selection and Basic Configuration (Hardware Safety Baseline)
1. Operation Condition-Matched Selection
The rated load and load center distance must match the actual operation requirements. For long/wide cargo and eccentric load conditions, prioritize forklift models with long wheelbase, wide track width and low center of gravity, and equip them with side shifters and adjustable forks.For slippery/low-temperature sites, select anti-slip solid tires and anti-tip brackets; for narrow aisles, use three-way stackers or reach trucks; for heavy-load/high-lifting operations, give priority to counterbalance forklifts. Overloading operations with electric pallet trucks are strictly prohibited.
2. Enhancement of Core Safety Components
Standard configuration shall include Electronic Stability Program (ESP), load-sensing steering, and speed/height/tilt angle limit control systems. Additional devices such as rollover alarms, load indicators, overload protection, rack collision prevention and Hill-Start Assist Control (HAC) should be installed.For electric forklifts, prioritize rear-mounted or bottom-mounted battery layouts to lower the overall center of gravity of the vehicle. The specifications, air pressure and tread patterns of coaxial tires must be consistent.
3. Compliance Verification
All forklifts must obtain special equipment certification; modification and assembly of forklifts are strictly prohibited. Explosion-proof forklifts that meet the corresponding explosion-proof level requirements must be used in explosion-proof areas.
II. Core Implementation: Standardized Operating Procedures (Core of Human Risk Control)
1. Load Preprocessing Standards
Verify the weight and dimensions of goods; overloading, eccentric loading and single-fork operation are strictly prohibited. Place goods in the center and secure them with straps or pallets. For overlong/overwide goods, calculate the offset of the load center distance, and reduce the lifting height and traveling speed.
2. Key Safety Points for Operating Actions
| Operating Actions | Safe Operation Requirements | Strictly Prohibited Behaviors |
|---|
| Lifting/Lowering | Confirm that the forks are fully inserted into the pallet before lifting; lower the forks to 10–15 cm above the ground when traveling; lift and lower the goods smoothly and slowly | Sharp turns and acceleration when the forks are lifted to a high position |
| Traveling/Steering | Slightly lift the forks when the forklift is unloaded; keep the forks as low as possible when carrying heavy loads; travel straight at a constant speed; overspeeding, sudden acceleration and sudden braking are strictly prohibited; reduce speed to below 5 km/h when turning; do not brake while steering | Failing to slow down on slippery/sloped roads, which may cause skidding risks |
| Slope Operation | Drive forward when going uphill (forks facing forward); reverse when going downhill (forks facing backward); steering, parking, and heavy-load lifting/lowering are strictly prohibited when the slope exceeds 5% | Sliding, steering or parking on slopes |
| Stacking/Picking | Operate perpendicular to the shelves; oblique forking is strictly prohibited; confirm that the shelves are stable; do not adjust goods when the forks are suspended | Oblique forking, rack collision, and goods falling |
3. Additional Restrictions for Special Operating Conditions
- Eccentric load/long cargo operation: Lifting height ≤ 1.5 m, traveling speed ≤ 3 km/h;
- Slippery/snowy/icy sites: Do not use sudden braking or sharp turns; install anti-skid chains; prioritize four-wheel-drive models;
- Night/low visibility conditions: Illuminance in the operation area ≥ 100 lux; turn on warning lights and turn signals; assign dedicated personnel to direct operations when necessary.
III. Support Layer: Full-Life-Cycle Vehicle Maintenance (Guarantee of Equipment Safety Status)
1. Daily Inspection (Mandatory Before Each Shift)
- Tires: Normal air pressure, no damage, consistent specifications for coaxial tires;
- Braking: Sensitive brakes, no drag, effective handbrake;
- Steering: No looseness or jamming;
- Hydraulics: No leakage, effective safety valve;
- Stability devices: Rollover alarm and load indicator functioning normally.
2. Regular Maintenance (Implemented in Accordance with the Manufacturer's Manual)
- Monthly: Inspect the frame, forks and suspension for deformation/cracks; calibrate the load indicator and rollover alarm;
- Quarterly: Replace hydraulic oil and filters; check the steering/brake clearance and wear;
- Annually: Conduct static rollover tests and dynamic braking tests to evaluate the overall stability of the vehicle.
3. Fault Handling
Immediately stop operation and conduct maintenance if abnormalities such as tire defects, brake failure or steering jamming are found; operation with faults is strictly prohibited. Establish a fault record and ensure closed-loop rectification.
IV. Auxiliary Control: Site and Environment Optimization (Elimination of External Risks)
1. Site Planning
- Aisle width = forklift turning radius + safety margin;
- The ground shall be flat, free of potholes, oil stains, accumulated water, snow and ice; the slope shall be ≤ 5%; the concrete grade of heavy-load areas shall be ≥ C30;
- Set up speed limit, turning warning, slope identification and no-parking zone signs; separate pedestrian and forklift aisles (physical isolation is preferred).
2. Environmental Control
- Ensure sufficient lighting (≥ 100 lux) to eliminate blind spots;
- Timely clear the ground in rainy and snowy weather; suspend outdoor operations when necessary;
- Promptly remove debris in aisles; ensure that shelves and equipment are firmly fixed.
V. Long-Term Mechanism: Personnel Training and Management System (Implementation of Safety Culture)
1. Certified Operation
All operators must receive professional training and obtain a special equipment operation certificate; unlicensed operation is strictly prohibited. Establish operator files and conduct regular re-examinations.
2. Specialized Training and Assessment
- Training content: Load calculation, slope operation, special condition operation, emergency handling (rollover self-rescue, evacuation in case of goods falling);
- Conduct regular practical assessments to evaluate the standardization of operations, and link assessment results with performance; set up on-site supervision posts to correct irregular operations.
3. Emergency Plans and Drills
Formulate emergency plans for forklift rollover, goods falling, fire, electric shock, etc.; organize regular drills, clarify emergency division of labor, evacuation routes and rescue procedures to improve emergency response capabilities.
VI. Closed-Loop Management: Safety Effect Evaluation and Continuous Improvement
- Regularly count accidents/near-miss incidents and analyze the root causes (human factors, equipment, environment, systems);
- Evaluate the effectiveness of safety measures based on equipment detection data and operation records;
- Dynamically optimize the selection scheme, operating procedures, maintenance plan, site planning and training content to form a PDCA closed loop.
Supplementary: Key Points for Emergency Handling of Forklift Rollover
- Do not jump off the vehicle; firmly grasp the steering wheel with both hands and move your body in the opposite direction of the tilt to lower the center of gravity;
- Apply the brake slowly to avoid skidding;
- When goods fall, immediately evacuate to a safe area and contact professional personnel for disposal
