Do Your Operators Need Refresher Training?

It's been more than a decade since OSHA mandated that all lift truck operators throughout the U.S. complete formal safety training. So, it's no surprise that lift truck safety programs have become standard operating procedure in material-moving environments.

Comprehensive lift truck safety programs from lift truck manufacturers have undoubtedly reduced accidents and injuries caused by unsafe lift truck practices. They have also helped to boost operator confidence, reduce product damage, minimize costly equipment repairs and increase overall lift truck uptime and productivity.

While most manufacturing facility and distribution center managers provide extensive, formalized programs for new hires, there are circumstances in which a full-blown regimen is not necessary. Refresher training is an option for existing employees who only need educational updates for certain aspects of lift truck operation. Brush-up programs target specific areas for improvement and assume an operator is competent in other aspects of lift truck operation.

Formal Evaluations

According to OSHA, employers must evaluate and recertify all lift truck operators — novices and veterans alike — at least once every three years. However, OSHA leaves the details up to the employer. Specific criteria that operators must meet for certification are not formally available, so the employer must use its own discretion to determine whether or not an employee is fully prepared to operate a lift truck in the facility.

An evaluation can involve discussing performance with operators; observing employees using the trucks; administering written or performance-based tests; or documenting previous training that meets current requirements.

Because employers are responsible for certifying their lift truck operators and documenting that the operators have been properly trained and evaluated on their performance, it is imperative that employers conduct thorough evaluations.

Some lift truck manufacturers offer appraisal checklists that list items to consider when determining whether a lift truck driver has been appropriately trained. These checklists include items that were covered in training sessions and then further practiced by the trainee. The checklist can serve as a guideline to help an employer document lift truck training and conduct a thorough evaluation of an operator's performance. Many lift truck dealers also conduct training sessions tailored to a company's specific needs.

According to OSHA, if an operator has been evaluated and determined to be competent on a specific topic that was previously taught, duplicate training is not required. Therefore, an evaluation should reveal the need for refresher training. Lectures, videos, demonstrations or practice sessions can all be used for refresher training.

Informal Red Flags

There are other signals that more education is needed, but certain red flags are rarely identified through formal evaluations. Simple observation is the best test. If an employee is seen violating safety policies or has been involved in an accident or near miss, the response from management should be obvious. The operator should be briefed on what went wrong to prevent a similar incident from happening again.