Are you worried about forklift safety at work? You should be. From 2011 to 2017, forklift-related incidents claimed the lives of more than 600 workers while causing over 7,000 nonfatal injuries with days away from work annually.

The safety problem isn’t getting better. OSHA’s top 10 citations for fiscal year 2024 reveal that powered industrial trucks (forklifts) rank sixth, with 2,248 violations

Let’s break down what these citations mean for your workplace safety and how you can protect yourself and your workers.

Last year, OSHA cited 2,561 forklift-related violations, compared to 2,248 violations this year. While this shows some progress, it’s a reminder for companies and employers to stay proactive with comprehensive forklift training and certification for your operators.

What Are the Most Common Forklift-Related OSHA Violations?

According to OSHA’s 2024 data, the top five most frequently cited sections for forklifts include:

1 – 1910.178(l)(1): Safe Operation – 531 violations. Employers failed to ensure operators adhered to safe operational practices, putting workers and equipment at risk.

2 – 1910.178(l)(4): Refresher Training and Evaluation – 305 violations. Companies neglected to provide required refresher training and evaluation after accidents, near misses, or observed unsafe practices.

3 – 1910.178(l)(6): Certification Requirements – 286 violations. Many employers did not certify operators, failing to document that training and evaluation had occurred.

4 – 1910.178(q)(7): Daily Inspections – 172 violations. Daily inspections of forklifts before use, as required by OSHA, were often overlooked, allowing unsafe vehicles to remain in operation.

5 – 1910.178(p)(1): Unsafe Equipment Removal – 153 violations. Powered industrial trucks found to be defective or unsafe were not removed from service until repaired.

Why Should You Care About OSHA Citations?

Beyond the immeasurable human toll, forklift accidents can profoundly impact a company’s financial health and overall productivity. Consider these eye-opening statistics:

Financial Impact

Forklift-related violations resulted in over $8 million in penalties in 2024 alone. The manufacturing industry faced the highest number of citations (937) and penalties ($2,700,552). Retail trade, with 145 citations, incurred the second-highest penalties at $1,472,268.

Moreover, these violations can trigger enhanced scrutiny from OSHA, potentially leading to more frequent inspections and additional compliance requirements.

Legal Consequences

Non-compliance with OSHA standards can lead to legal actions, including lawsuits from injured workers or regulatory enforcement actions. In severe cases, company executives may face personal liability for willful violations of safety standards.

Hidden Costs

The true cost of non-compliance goes beyond fines. It can damage your business reputation, increase insurance premiums, and lead to low staff morale due to accidents or investigations. Additionally, high turnover rates among employees due to safety concerns can result in increased recruitment and training costs.

Productivity Losses

Forklift accidents often lead to significant downtime and reduced operational efficiency. An injured operator may require time off work to recover, while damaged equipment may need repairs or replacement. All these disruptions can hinder production schedules and impact your company’s bottom line.

A Tire Company Tragedy: The Risks of Ignoring Forklift Safety

An incident at a tire distribution center in Elm Mott, Texas, illustrates the severe consequences of inadequate forklift safety training.

In June 2024, a forklift operator suffered fatal injuries when a pallet of industrial truck tires fell from a damaged storage system. OSHA’s investigation revealed multiple safety failures, including:

Providing OSHA Compliant Training

Forklift training must cover various topics, such as,

• Operating instructions, warnings, and precautions
• Differences between the forklift and the automobile
• Vehicle controls and instrumentation
• Steering and maneuvering
• Visibility
• Fork and attachment adaptation, operation, and use limitations
• Equipment capacity and stability
• Inspection and maintenance
• Refueling and/or charging batteries
• Operating limitations

Consider incorporating online forklift training into your safety program. Online courses offer:

• Flexibility for employees to complete training at their own pace
• Consistent delivery of training material
• Easy tracking of completion and certification status
• Cost-effective solution for theoretical portions of training

Implementing Daily Equipment Inspections

Establish a routine of daily pre-shift inspections for all forklifts. These inspections should cover the following:

• Tire condition and pressure
• Fork condition and positioning
• Fluid levels (oil, hydraulic, battery)
• Brakes and steering
• Safety devices (lights, horn, backup alarm)
• Seat belts and other operator restraints
• Load-handling attachments
• Battery charge and connections

Following Regular Maintenance Programs

Develop a maintenance program that includes:

• Scheduled preventive maintenance based on manufacturer recommendations
• Prompt repair of any identified issues
• Documentation of all maintenance activities
• Training for maintenance personnel on forklift-specific systems and components

Take Action for Forklift Safety

OSHA data shows that 70% of forklift accidents are preventable with adequate training.

When you invest in comprehensive forklift training, you create a safer work environment, protect your employees, and ensure regulatory compliance.

Don’t wait for an accident or OSHA citation to prioritize forklift safety. Take action today to implement OSHA-compliant forklift classes and ensure all your operators are properly certified.

For OSHA forklift training and certification programs tailored to your specific needs, visit ForkliftTraining.com. Our courses combine theoretical knowledge with practical skills to ensure your operators are fully prepared for safe forklift operations.

Protect your workers, your business, and your peace of mind. Get started with proper forklift certification today.