Skip to content
Free sample
Español

FREE JHA TEMPLATE

Forklift operation job hazard analysis (JHA) template

Forklift work combines tip-over, pedestrian strikes, falling loads and dock-edge hazards. OSHA requires each operator to be competent, as shown by completing the training and evaluation in the standard (29 CFR 1910.178(l)(1)(i)), and trucks to be examined before being placed in service. Check the truck, check the load, then move.

Open in the generatorDownload PDF

The task

Picking up, carrying and placing palletized loads with a powered industrial truck in a warehouse, yard or dock, including a daily truck check.

Steps, hazards and controls

Controls run from most effective to least. A citation beside a control means an OSHA paragraph requires it; with no citation it is good practice.

StepHazardControls
1. Inspect the truck before useTruck with a defect goes into service
  1. Administrative control: Examine the truck before it is placed in service, and do not use it if the exam shows a condition that hurts safety. (29 CFR 1910.178(q)(7))
  2. Administrative control: Take any truck that needs repair, is defective or is unsafe out of service until it is fixed. (29 CFR 1910.178(p)(1))
  3. Administrative control: Check horn, brakes, steering, forks, mast chains, lights and tires, and make sure the nameplate and markings are legible.
Operator not trained for this truck
  1. Administrative control: Let only operators who have completed the required training and evaluation drive the truck. (29 CFR 1910.178(l)(1)(ii))
  2. Administrative control: Give refresher training and evaluation as the standard requires. (29 CFR 1910.178(l)(4)(i))
2. Plan the route and check the loadUnstable or too-heavy load
  1. Eliminate: Re-stack or re-wrap a load that is not stable or safely arranged before you lift it. (29 CFR 1910.178(o)(1))
  2. Administrative control: Handle only loads within the rated capacity of the truck. (29 CFR 1910.178(o)(2))
  3. Administrative control: Use a load backrest extension where needed to keep the load from falling rearward. (29 CFR 1910.178(m)(10))
Low overhead obstacles in the route
  1. Engineering control: Make sure there is enough headroom under overhead lights, pipes and sprinkler systems. (29 CFR 1910.178(m)(8))
  2. Administrative control: Walk the route first for floor damage, wet spots and blind corners.
3. Pick up the loadLoad shifts, tips or the forks pierce a package
  1. Administrative control: Adjust long or high loads, including multi-tiered loads, that may affect capacity. Handle off-center loads with caution. (29 CFR 1910.178(o)(3))
  2. Administrative control: Never put your arms or legs between the mast uprights or outside the running lines of the truck. (29 CFR 1910.178(m)(4))
  3. Administrative control: Tilt back slightly and lift only high enough to clear the floor for travel.
4. Travel with the loadCollision or tip-over while turning or on a grade
  1. Engineering control: Use the overhead guard as protection against falling objects. (29 CFR 1910.178(m)(9))
  2. Administrative control: Observe traffic rules and keep a safe distance from the truck ahead. (29 CFR 1910.178(n)(1))
  3. Administrative control: Slow down and sound the horn at cross aisles and where vision is blocked. (29 CFR 1910.178(n)(4))
  4. Administrative control: Look in the direction of travel, and keep a clear view of the path. (29 CFR 1910.178(n)(6))
  5. Administrative control: Go up and down grades slowly, and keep a speed that lets you stop safely. (29 CFR 1910.178(n)(8))
5. Share space with pedestriansStruck or crushed by a moving truck
  1. Eliminate: Separate truck routes and walkways with barriers or painted lanes, where layout allows.
  2. Administrative control: Do not drive up to anyone standing in front of a bench or other fixed object. (29 CFR 1910.178(m)(1))
  3. Administrative control: Do not allow anyone to stand or pass under the elevated part of a truck, loaded or empty. (29 CFR 1910.178(m)(2))
  4. Administrative control: Do not allow unauthorized riders on the truck. (29 CFR 1910.178(m)(3))
6. Work at the dock and trailerTruck or trailer moves, or the truck drives off the dock edge
  1. Engineering control: Set brakes and place wheel blocks to prevent movement of trucks and trailers while loading or unloading. (29 CFR 1910.178(m)(7))
  2. Engineering control: Secure dockboards or bridgeplates before driving over them, and never exceed their rated capacity. (29 CFR 1910.178(n)(11))
  3. Administrative control: Stay a safe distance from the edge of ramps and platforms. (29 CFR 1910.178(m)(6))
7. Park, shut down and report problemsUnattended truck rolls or the forks drop onto a person
  1. Administrative control: When leaving the truck unattended, fully lower the forks, neutralize the controls, shut off power and set the brakes. Block the wheels if parked on an incline. (29 CFR 1910.178(m)(5)(i))
  2. Administrative control: If the truck is found defective or unsafe during use, take it out of service until it is restored to safe condition, and report the defect. (29 CFR 1910.178(p)(1))

Required PPE

  • Hard hat where overhead hazards exist
  • High-visibility vest
  • Safety shoes
  • Seat belt or operator restraint, where fitted
  • Hearing protection in loud areas

What the standard says

  • Examine the truck before it is placed in service. (29 CFR 1910.178(q)(7))

    “Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle.”

  • Only handle loads within rated capacity. (29 CFR 1910.178(o)(2))

    “Only loads within the rated capacity of the truck shall be handled.”

  • No one may stand or pass under the elevated portion of a truck. (29 CFR 1910.178(m)(2))

    “No person shall be allowed to stand or pass under the elevated portion of any truck, whether loaded or empty.”

  • Slow down and sound the horn where vision is blocked. (29 CFR 1910.178(n)(4))

    “The driver shall be required to slow down and sound the horn at cross aisles and other locations where vision is obstructed.”

  • Set brakes and block wheels when loading or unloading. (29 CFR 1910.178(m)(7))

    “Brakes shall be set and wheel blocks shall be in place to prevent movement of trucks, trailers, or railroad cars while loading or unloading.”

  • Keep arms and legs out from between the mast uprights and inside the running lines of the truck. (29 CFR 1910.178(m)(4))

    “The employer shall prohibit arms or legs from being placed between the uprights of the mast or outside the running lines of the truck.”

  • Operators must be competent, as shown by completing training and evaluation. (29 CFR 1910.178(l)(1)(i))

    “The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph (l).”

Training

Each powered industrial truck operator must complete the training and evaluation in the standard before operating the truck (29 CFR 1910.178(l)(1)(ii)). Refresher training and evaluation are required as the standard sets out (29 CFR 1910.178(l)(4)(i)). On construction sites the same requirements apply (29 CFR 1926.602(d)).

Frequently asked questions

Does OSHA require a JHA for forklift operation?
OSHA does not require a written JHA for forklift work. It does require operator training and evaluation, truck examinations and safe operating rules (29 CFR 1910.178). A JHA helps a site plan routes, loads and pedestrian separation.
What goes in a forklift operation JHA?
Include the pre-use check, route and load planning, pickup, travel, pedestrian interaction, dock work and shut-down. For each hazard list controls from strongest to weakest and name the authorized operators.
How often must a forklift be examined?
The standard says trucks must be examined before being placed in service. The full paragraph sets the interval at least daily, and after each shift on round-the-clock use (29 CFR 1910.178(q)(7)).

Related toolbox talks

PRINT AND EDIT

JHA template pack, $29

All 20 task templates as editable Word and Excel files and as PDF, in English and Spanish, plus a blank master form. Change them for your site and your equipment and use them inside your company.

  • 20 task JHA templates, editable Word (DOCX)
  • The same 20 as Excel (XLSX) and PDF
  • English and Spanish versions
  • A blank master JHA form
  • Hazards, ranked controls, PPE and the OSHA paragraphs for each task

Instant download. 30-day refund, no questions.

See the JHA generator and all tasks