The Most Dangerous Forklift Training Mistakes—and How to Fix Them

Posted by: admin on April 29, 2025

Every year, forklift accidents send thousands to the hospital—many of them avoidable.

Most of these injuries come down to one thing: poor training. Whether you’re a safety manager, supervisor, or business owner, knowing these common forklift training mistakes—and how to fix them—can save lives and protect your bottom line.

🚩 1. Rushing Through the Basics

A forklift is not a tool to take lightly. Skipping over fundamentals creates dangerous blind spots for new operators. Teaching the basics slowly and clearly isn’t just helpful—it’s essential.

The Fix: Provide detailed, step-by-step instruction and allow time for questions. Never assume a worker already “gets it.”

🚩 2. Ignoring the Daily Safety Check

Skipping daily inspections might save time—but it risks everything else. Brakes, tires, controls, and warning lights all need a look before each shift.

The Fix: Make daily safety checks part of your routine. Catching a small issue early prevents major accidents later.

🚩 3. Skipping Hands-On Evaluations

Watching a training video doesn’t prove a thing. OSHA requires hands-on, performance-based evaluations for a reason.

The Fix: Evaluate every operator on actual equipment. They must demonstrate skill—not just click through a quiz.

🚩 4. Letting “Experienced” Operators Skip Training

“I’ve driven forklifts for years” doesn’t mean someone is safe on your site. Experience doesn’t replace formal training.

The Fix: No exemptions. Everyone trains, no matter their background. Refresher training keeps veterans sharp and informed.

🚩 5. Overlooking Pedestrian Safety

Many forklift accidents hurt bystanders—not drivers. And too few training programs cover how to safely operate around people on foot.

The Fix: Set clear rules for pedestrian zones. Train operators to be constantly aware of their surroundings.

🚩 6. Poor Record-Keeping

When an incident happens, OSHA will ask for documentation. Missing or messy records could lead to heavy fines—even if you did everything else right.

The Fix: Keep organized, digital records of all training sessions, evaluations, and certifications.

🚩 7. Delaying Certification Renewals

OSHA requires forklift certification renewal every three years. Forgetting to renew means you’re officially out of compliance.

The Fix: Set automated reminders and recertify your team early. Stay ahead of deadlines to avoid penalties.

🚩 8. Using Generic Training for All Equipment

Not all forklifts are the same. An operator trained on one type may not safely handle another.

The Fix: Train your team on the specific models used at your job site. Always include hands-on evaluations for each piece of equipment.

🚩 9. Assigning Unqualified Trainers

Training isn’t just about knowing how to drive—it’s about knowing how to teach. OSHA requires trainers to be qualified in both.

The Fix: Choose instructors who meet OSHA’s standards for knowledge, skill, and training ability.

🚩 10. Skipping Refresher Training After an Accident

After an incident, OSHA expects action. Too many businesses fail to retrain after a near-miss or accident.

The Fix: Conduct refresher training immediately after any incident. Prevent future mistakes by reinforcing correct procedures.

✅ The Bottom Line

Forklift accidents are preventable—when you train the right way. Cutting corners, skipping evaluations, or assuming experience is enough can put lives at risk and expose your company to massive fines and lawsuits.

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