FOX Corporation makes extensive use of forklifts in the performance of its operations. Because improper use of forklifts can result in severe hazards to
personnel and equipment, only trained personnel may operate these vehicles.
1.0 SCOPE
This Procedure applies to all uses of forklifts, during FOX Corporation (FOX) activities, whether on the Fox Studio Lot or at remote locations.
2.0 Definitions
Forklift:
an industrial truck fitted with a lifting device (mast) and holders (forks), which enable the lifting, transport/movement, and precise placement of heavy
loads.
3.0 Responsibilities
In addition to required Environmental, Health and Safety (EHS) Program responsibilities discussed in EHS001, EHS Policy, the responsibilities
described below are necessary to ensure the effectiveness of the procedure.
3.1 Department Heads
Affected Department Heads will:
- Ensure that only properly trained employees are permitted to operate the specific forklift to be used (see Section 4.1.1)
- Ensure that employees are aware of and follow FOX’s requirements for use of forklifts
- Maintain records for operator training and operator’s daily forklift inspections.
3.2 Employees
All FOX employees will:
- Only operate a forklift if they have received training in its safe operation (see Section 4.1.1)
- Always wear a seat belt when working in a forklift
- Observe the applicable operational requirements specified in Section 4.2.
3.3 Environmental, Health and Safety Department
The EHS Department will:
- Develop appropriate standards for use of forklifts in all FOX activities
- Review and update this Procedure annually, or as necessary, to comply with regulatory changes.
4.0 Procedure
The following requirements pertain to all uses of forklifts.
4.1 Operator Requirements
4.1.1 Operators
Operators of forklifts must possess a valid state drivers license and meet the training requirements detailed below.
Training documentation must be maintained by each affected FOX Department.
Initial Training
– Potential operators of any forklift must receive initial operator training by an authorized training source.
This training must address the following elements:
1. Method for properly performing a daily pre-operational forklift inspection
- Rules for operating powered industrial trucks and an explanation of why these rules exist
- Emphasis on loading and unloading, center of gravity, stability, and mechanical limitations
- Combination of oral, written, and operational performance tests, which adequately demonstrate the operator’s ability to safely use a forklift.
In addition, personnel who operate any forklift on unpaved terrain must complete additional specialized training.
Training from other sources must be reviewed and approved by the EHS Department.
On-Site Training
– Before initial operation of a forklift for FOX, the employee’s supervisor must instruct each new operator on:
- The nature of hazards associated with the FOX operating location (studio lot or other site)
- Any special requirements or hazards of the operator’s particular work area
- The local guidelines for performing work safely.
Periodic Refresher Training
– Refresher training must be provided for each forklift operator at least once every three (3) years, or when a supervisor is presented with a reason to
believe that an unsafe operation has occurred.
Examples of unsafe operation include, but are not limited to:
- When an accident or a near-miss occurs
- When an evaluation indicates that the operator is not capable of performing the assigned work.
Training from other sources must be reviewed and approved by the EHS Department.
4.2 Operations Procedures
Forklift operators must observe the following requirements in their use of forklifts.
4.2.1 Pre-Operational Inspection
- Inspections must be documented, using the Forklift Pre-Operation Inspection Checklist found in Attachment 1. Each Checklist is valid for a
one-week period, and must be maintained with the forklift. - At the end of each week, all Checklist forms must be collected and submitted to the Department Head, or designated alternate, for review and filing.
- If any malfunctions or defects are found during the inspection, the forklift must be parked (with the keys removed) and the forklift must be taken out
of service.
4. The Department Head must be notified to arrange servicing and repair.
Prior to the first use of any forklift on any work shift, the operator must conduct a pre-operational inspection to ensure the following parts, equipment,
and accessories (as applicable) work, and/or are free of apparent damage:
- General condition and cleanliness
- Fire extinguisher – present and charged
· Engine oil level, fuel level, radiator water level (LPG, gas, and diesel forklifts)
· Battery – fully charged; check cables for exposed wires; battery plug connections not loose, worn or dirty; vent caps not clogged; electrolyte levels in
cells (Holddowns or brackets keep battery securely in place.)
· Bolts, nuts, guards, chains, or hydraulic hose reels not damaged, missing, or loose
· Wheels and tires – if pneumatic tires, check for wear, damage, and air pressure
· Forks – forks not bent; no cracks present; positioning latches in good working condition; carriage teeth not broken, chipped or worn
- Chain anchor pins – not worn, loose, or bent
- Fluid leaks – no damp spots or drips
· Hoses – held securely; not loose, crimped, worn, or rubbing
· Horn – working and loud enough to be heard in working environment; other warning devices operational
· Lights – head lights and warning lights operational
- Foot brake – pedal holds, unit stops smoothly
· Parking brake – holds against slight acceleration
· Deadman seat brake – holds when operator rises from seat
· Clutch and gearshift – shifts smoothly with no jumping or jerking
· Dash control panel – all lights and gauges are operational
- Steering – moves smoothly
- Lift mechanism – operates smoothly
· (Check by raising forks to maximum height then lowering forks completely.)
- Tilt mechanism – moves smoothly, holds
(Check by tilting mast all the way forward and backward.)
· Cylinders and hoses – not leaking after above checks
- Listen for any unusual sounds or noises.
4.2.2 Operating Rules
The requirements below apply to all forklift use.
4.2.2.1 Driving a Forklift
- Operators will wear seat belts at all times during forklift operation.
- Operate forklifts only in designated areas with adequate ventilation.
- Do not exceed the floor load rating.
- Secure (i.e., tie down) unstable loads before starting the vehicle.
- Decrease speed at all corners, sound horn, and watch the swing of both the rear of the lift truck and the load.
- Keep arms and legs inside the forklift structure, except when signaling for turns or stops.
- Do not jump from or out of a moving forklift.
- Make sure that adequate clearance is afforded before passing under or between structures.
- Maintain indoor speed under five (5) mph (8 km/hr) and outdoor speed under fifteen (15) mph (24 km/hr).
- Yield to pedestrians.
- Do not carry passengers, except when factory-installed seats are provided.
- Tilt the mast back before traveling.
- Stay at least three (3) vehicle lengths back when following another forklift.
- Maintain forks about four (4) to six (6) in. (10 to 15 cm) above the driving surface when traveling.
- Do not attach slings, cables, or chains to the forks to lift objects from underneath them.
- When forward vision is obscured, drive in reverse.
- Do not leave a forklift parked with an elevated load.
18. Do not park a forklift without turning OFF the power, placing all the controls in the neutral position, and setting the parking brake. A forklift is
considered unattended if the operator is more than twenty-five (25) ft (8 m) away, or out of sight of the forklift.
- Observe all traffic signals.
- Do not use a forklift to tow or push other forklifts, other vehicles, or other equipment.
- Use pneumatic-wheel forklifts when traveling on irregular terrain and on surface streets.
- Use hard-wheel forklifts indoors only.
- Maintain at least a ten (10) ft (3 m) clearance between forklift/load and overhead power lines at all times.
- When crossing rails or other irregular areas, slow down and approach diagonally.
- Move to the right side of the lane when traveling on roads to allow passing vehicles adequate clearance.
Pull over and stop when necessary.
- Mount a “Slow Moving Vehicle” sign (triangle) on the rear of forklifts, which are approved for road use when traveling off site.
4.2.2.2 Handling Loads
- Keep the mast of the forklift in an upright position before inserting the forks into a pallet.
- Level the fork before inserting it into the pallet.
- Insert the fork all the way under the load.
- Adjust the fork as wide as possible to fit the load and to provide a more even distribution of weight.
- Space the fork evenly from the center stringer of the pallet to balance the load.
- Do not protrude the fork past the back of a pallet when stacking in tight areas.
- Place tines as wide as possible for the load, and lock them in place to prevent sideways movement.
- Never add a counterweight to balance an overload; know the weight of the load.
- Do not exceed the forklift’s rated capacity.
- Do not lift material or equipment you are unfamiliar with.
- Ensure that the load is secured before moving. If it is not, realign the load, or strap the load to skid.
- Ensure that loads on pallets are stable, neat, cross-tied, if possible, and evenly distributed.
- Remove damaged pallets from service.
- Do not raise or lower the fork, unless the lift truck is stopped and braked.
- Lift loads straight up or tilt back slightly.
- Do not lift a load that extends above the load backrest, unless no part of the load can possibly slide back toward the operator.
4.2.2.3 Parking
The requirements below apply when parking forklifts:
- Park on level surfaces.
2. Lower the forks to the ground.
- Tilt the mast forward.
- Set the parking brake.
- Place the controls in the neutral position.
- Turn OFF the engine.
- Chock the wheels, if the truck must be parked on a slope.
4.2.2.4 Loading Docks
When operating a forklift on a loading dock, the driver will:
- Ensure at least one trailer wheel is chocked before driving onto, or into, a truck trailer.
- Drive the forklift slowly on wet and slippery docks.
- Slow down and sound the horn when proceeding through doorways.
- Stay clear of edges of docks, rail cars, or ramps. Clearly mark edges.
- Do not operate forklifts inside vehicles without ventilation for long periods of time.
- Make sure that the dock plate is properly secured and can support the load before driving over it. (Load weight must be clearly marked.) Drive
carefully and slowly over the plate. Do not spin wheels.
4.2.2.5 Ramps
When operating a forklift on ramps, the driver will:
- Point the forks up the ramp when carrying a load, regardless of the travel direction.
- Drive unloaded forklifts with the forks pointing downhill for added stability.
- Obtain help to guide you when going up a ramp with a load and your vision is blocked.
- Never turn a forklift sideways on a ramp.
4.2.2.6 Refueling
Refuel gasoline, diesel, and propane fuel-powered forklifts outdoors only.
- Close the valve for the propane bottle while the engine is running to consume all gas in the line.
- The engine must be turned OFF whenever refilling fuel tanks, and must not be restarted until the fuel cap is replaced.
Recharge electric forklift batteries only in designated, posted, and well-ventilated areas.
- Do not conduct spark-producing operations while batteries are being charged.
2. Operator personnel will not perform battery maintenance.
Employees are not permitted to smoke during refueling/recharging.
4.2.3 Indoor Operations
The following requirements apply where forklifts are operated indoors:
- Use adequate ventilation for forklifts powered by internal-combustion engines.
- Only use forklifts with the appropriate classification in areas with explosives or flammable gases.
- Sound the horn when approaching intersections, pedestrians, doors, or corners. Slow down and sound the horn anywhere vision is blocked or impaired.
- Electric forklifts are preferred for indoor operations and required when working in confined spaces.
4.2.4 Pedestrian Areas
Pedestrians working nearby must keep a safe distance from forklifts. This means staying clear of the forklift’s turning radius and making sure the operator
knows where all pedestrians are.
The operator will:
- Yield the right-of-way to pedestrians.
- Prevent anyone from walking or standing under elevated forks.
- Sound the horn as a warning when approaching personnel.
4.3 Maintenance Activities
4.3.1 Semi-Annual Inspection
- Every six (6) months, a manufacturer-certified service provider must inspect each forklift to ensure that it is properly functioning and maintained.
- A qualified inspector must also inspect all new, altered, modified, or extensively repaired forklifts prior to initial use.
- Records of the annual inspections must be maintained by each Department and will indicate:
a. The date the inspection was performed
b. The name of the service provider
c. Any items identified for corrective action
d. Dates corrective actions were completed and the forklift returned to service.
4.3.2 Maintenance Safety
- Permit only qualified persons to service and maintain forklift equipment.
- Disconnect all batteries before doing any work.
- Before servicing LPG forklifts:
a. Shut OFF the tank fuel valve.
b. Run the engine until it stops.
c. Disconnect the tank from the hose.
- Block the forklift securely when removing wheels.
- Support the forklift hood in upright position or remove to do work.
- Keep the work area clean and well lit.
7. Clean spilled oil or hydraulic fluid immediately.
- Remove all tools and parts before starting the engine.
- Handle batteries with care. Avoid contact with battery terminals with hoisting chains, tools, and metal objects.
Cover the battery top with insulating material.
- Attach a chain hoist to the counterweight before removing it from a forklift.
- Check the bolts holding the counterweight to the body and replace any worn or missing bolts.
- Do not leave parts, creepers, cans, tools, or other obstacles lying around.
- Do not start a forklift if it is on a lift hoist or wheel stands.
- Do not work on forklift attachments unless you are familiar with their operation.
- Do not work beneath elevated forklift trucks or forks, unless approved blocks securely support them.
- Do not run LPG, gas, or diesel forklifts in unventilated areas.
4.4 Nonpowered Forklifts/Lifts (Pallet Jacks)
These units are treated differently, and the operator is not required to meet Section 4.1 requirements to operate these types of lifts.
- Department Heads will ensure that only trained personnel operate these units.
- At the start of each work shift during which the unit will be used, the operator will conduct a pre-operation visual inspection.
- If any malfunctions or defects are found during this inspection, the forklift must not be used.
Only special lifting attachments, approved by the respective forklift manufacturer, may be used.
5.0 REFERENCES
EHS 001, EHS Policy
6.0 ATTACHMENTS
Attachment 1 – Forklift Pre-Operation Inspection Checklist.