7 Strategies for Improving Forklift Fleet Safety

Implementing practical safety strategies for forklift fleets can reduce accidents, protect workers and enhance operational efficiency in growing industrial sectors.

• By Tom Ryder
• Nov 29, 2024

The scale of forklift operations in U.S. manufacturing and fulfillment centers has reached unprecedented levels, with major e-commerce facilities now operating fleets exceeding 200 units per location. Industry projections indicate a 25 percent increase in deployment over the next year. And with this growth comes heightened safety concerns.

The statistics are sobering. OSHA reports that nearly 100,000 forklift operators sustain injuries annually, with each collision carrying an average cost of $180,000. More troubling still, 10 percent of all forklifts will be involved in an accident each year. Yet 70 percent of these incidents are preventable through proper training and procedures. These figures don't capture the full picture, as they exclude accidents involving reach trucks, scissor lifts, order pickers and other mobile material handling equipment.

With the stakes this high, organizations must implement comprehensive safety measures. The following seven strategies provide a framework for fostering a proactive safety culture that protects both workers and operational efficiency.

1. Conduct a thorough risk assessment.This is a baseline determination of the risks operators face each day, along with comprehensive countermeasures to proactively prevent accidents from occurring. OSHA estimates that 90 percent of forklifts in use today will experience an accident over the course of their deployment. Cutting that percentage in half is an achievable goal for the organization.
2. Foster a culture of safety. Let each employee know that safety comes first. When workplace safety is rewarded, it improves, and so does productivity.
3. Track every incident.Thoroughly document not just forklift accidents but all the “near misses” that could have resulted in serious injuries. Post the results in a visible location like a break room or KPI metrics communication area.
4. Prioritize daily per-shift safety checklists and monitor asset utilization.Implement a systematic approach to OSHA-compliant operator safety checklists as a daily commitment, not a one-time exercise. This daily practice enhances worker safety while reducing legal and compliance risks. Assign a dedicated supervisor with direct authority over the process to ensure consistent compliance and accountability.
5. Conduct scheduled maintenance and equipment inspections.Regular maintenance ensures optimal forklift performance and reduces accident risks through early problem detection. Documented maintenance records are crucial for warranty claims and OSHA compliance. When accidents occur, regulatory officials scrutinize these records to verify proper equipment care and checklist adherence. Consider both routine inspections and long-term equipment lifespan when developing maintenance schedules.
6. Establish a real-time feedback loop. Build a system for immediate communication between operators, maintenance teams and supervisors regarding equipment issues. When a non-compliant forklift shouldn’t be in use, it’s important to quickly share that information with team members managing the equipment and those responsible for restoring it to peak performance.
7. Incorporate safety telematics and reward employee achievement. The objective here isn’t to be “Big Brother” at the facility but to reinforce and reward positive actions. Create a rewards system for operators who achieve outstanding safety metrics, perhaps through paid time off or gift cards celebrating their success or non-monetary items like a parking spot. This type of program recognizes individual operators' accomplishments and sends the company-wide message that safety is valued and rewarded.

The continued expansion of forklift operations in manufacturing and fulfillment centers demands a renewed commitment to safety excellence. While the strategies outlined above provide a framework for improvement, success ultimately depends on consistent execution and measurement of results. By making safety the cornerstone of operations, businesses not only protect their workers but also position themselves for sustainable growth in an increasingly automated industry. Tracking incidents, creating real-time feedback loops, and rewarding safe practices empower employees and enhance productivity. The adage, “if you measure it, it will improve,” holds true. By measuring results from these strategies, businesses can create a safer work environment that supports long-term success.